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Lubricating the knuckle pivots

The knuckle pivots must be lubricated at the intervals specified

in the periodic maintenance and lubrication chart.

Lubricate the pivoting points using a grease gun.

Rear axle

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Lubricating the front & rear coupling gear

The front & rear coupling gear must be lubricated at the intervals

specified in the periodic maintenance and lubrication chart.

Lubricate the pivoting points using a grease gun.

Front

Rear

Содержание AX600 EFI 4x4

Страница 1: ...AX600 EFI 4x4 400 OWNER S MANUAL ...

Страница 2: ...P N 72117 A40 000 ...

Страница 3: ...ent of AX600U 4x4 EFI 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 the real ATV the data of the real ATV shall supersede data contained herein ...

Страница 4: ...k turn 34 Riding with particular attention in raining days 34 How to stop the ATV When the ATV comes to a full stop 35 When parking the ATV 36 6 Checks before riding Pre riding check 37 Recommended oil specification and grade 37 Oil check and refilling 38 To change the engine oil 39 Differential gear oil Change the differential gear oil 41 Recommended oil specification and grade 41 Final gear oil ...

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

Страница 6: ...2 1 2 3 4 5 6 ...

Страница 7: ...an 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 1 You should familiarize yourself with basic operations of this ATV before you try more difficult operational techniques 2 To ensure the r...

Страница 8: ...duct a pre riding check in accordance with Check before riding in user s manual on Page 37 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 9: ...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 10: ...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 11: ...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 12: ... ATV will be affected which may cause unsafely to the rider Notes 1 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 2 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 rear brakes to restore the brake fun...

Страница 13: ... 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: ...10 2 Naming of each component 1 Headlight position light 2 Right front turn signal light 3 Left front turn signal light 4 Front brake handle lever 5 Rear brake handle lever 6 Parking lever 1 2 3 4 5 6 ...

Страница 15: ...11 7 Ignition switch 8 Power Supplier 12V 9 Foot brake 1 for 4 wheel 10 Front brake reservoir 11 Seat 8 7 9 10 11 ...

Страница 16: ...haust pipe 14 Aux liquid bottle 15 Accelerator lever 16 Throttle Bottom Clamp 17 LCD instrument panel 18 Battery ECU Fuse Box Starter Relay Blink Relay Sound Blink Indicator Rely 19 Accompanying tools 15 12 13 14 16 18 19 17 ...

Страница 17: ...rtup rocker switch Warning light switch Turn signal light switch Horn switch Override 21 Fuel tank cap 22 Rear light brake light 23 License plate light 24 Right rear turn signal light 25 Left rear turn signal light 21 20 23 25 24 22 ...

Страница 18: ...omes on 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 Indicator lights and warning lights 1 Hazard Light red light The Hazard Light and the Left right turn signal light comes on when you push on the Warning light switch 2 Rear Fog Light amber light selective equipment When operating the Rear Fog Light this indicator will come on N...

Страница 19: ... light comes on you must stop the engine and let it cool down 5 Left Right signal indicator green light 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 1 8 liters Refuel with 95 unleaded gasoline as early as possible Note There is ...

Страница 20: ...Engine Failure Light red light The Engine Failure Light comes on amber light when you turn on the ignition switch Starting the engine the engine failure light extinguishment 8 Four wheel drive switch 2WD 4WD ...

Страница 21: ...17 9 Warning lamp red light Above rotational speed 7300rpm of the engine ...

Страница 22: ... 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 23: ... 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 t...

Страница 24: ...rear brake handle lever or the engine will stop This serves as a safe interrupting system Parking lever Rear brake How to use it Turn the rear brake lever to the left side tightly How to release it Pull parking lever to the right side it will return automatic to its position the rear brake will be relieved at the same time Notes 1 When starting the engine or parking the ATV apply the parking lever...

Страница 25: ...wise to lock the handlebars Then remove the key How to unlock the handlebars Turn the key counterclockwise to unlock the handlebars and then remove the key Notes 1 After the handlebars are locked verify that they are really locked by slightly turning them 2 After the handlebars are unlocked verify that they are really unlocked by rotating the handle This can prevent risk of hazard when riding LOCK...

Страница 26: ...sert the projections 1 on the front of the seat into the seat holders 2 and push down on the seat at the rear 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 and lead to an accident Seat Unlock 2 1 Type 1 Type 2 Pull ...

Страница 27: ...23 LCD Instrument panel adjustment Speedometer Tachometer ...

Страница 28: ...24 ...

Страница 29: ...l indicator light comes on The gear should be in neutral when the engine is started 2 Pull tight the front or the rear brake handle lever or step on 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 b...

Страница 30: ...ne to high speed while it is idling This can ensure the engine life Notes 1 Once the engine starts to run immediately release the startup rocker switch 2 Do not press the startup rocker switch while the engine is running or it will lead to an adverse effect to the engine 3 Do not press the startup switch for over four seconds when the electric motor is used to start the engine ...

Страница 31: ...ider shall put both of his feet 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 When the engine is idling do not push the accelerator to rev the engine Note Before riding the rear brake handle levers should be kept at braking positions ...

Страница 32: ...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 33: ...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 34: ...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 35: ...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 36: ...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 37: ... 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 1 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 2 Do not attempt to apply emergency brakes during rid...

Страница 38: ... 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 39: ...ndle 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 the ATV...

Страница 40: ...oving pull tight the brake handle lever and push the parking lever to the ON position leftward to lock the rear wheels Note If the play of the rear brake handle lever is incorrect it will not lock the rear wheels which will lead to the risk of hazard ...

Страница 41: ... ATV to the nearest workshop or service center for inspection and repair Recommended oil specification and grade Oil specification SAE 20W50 API SL or above Engine oil grade SL or above certified by API American Petroleum Institute Oil capacity Total amount 2 9 liter Without oil filter cartridge replacement 2 5 liter With oil filter cartridge replacement 2 6 liter Note To prevent using low grade o...

Страница 42: ... 6 If the engine oil is at or below the minimum level mark add sufficient oil of the recommended type to raise it to the correct level 7 Insert the dipstick completely into the oil filler hole 8 Install the panel Notes If the ATV is parked on a tilted surface or the engine just stops the oil level will not be accurate When the engine stops it is still very hot If you check the oil level or replace...

Страница 43: ...e dipstick and then remove the engine oil drain bolt to drain the oil from the crankcase 5 Remove the panel A 6 Remove the oil filter cartridge with an oil filter wrench CAUTION Be sure the engine oil is at the correct level otherwise engine damage may result Note Skip steps 5 9 if the oil filter cartridge is not being replaced Panel Oil filter cartridge Oil filter wrench Panel A Engine oil drain ...

Страница 44: ...mmended engine oil and then insert the dipstick completely into the oil filler hole 12 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause 13 Turn the engine off wait at least ten minutes and then check the oil level and correct it if necessary 14 Install the panel Note Make sure that ...

Страница 45: ...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 15Nm 1 5kgf 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 ...

Страница 46: ...n 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 15Nm 1 5kgf 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 15Nm 1 5kgf m 7 Check t...

Страница 47: ...1 3 Open the fuel cap cover 2 4 Use the key and turning the fuel cap counterclockwise open and remove it 5 Turning the fuel cap clockwise you can close and tighten it while turning counterclockwise you can open and remove the fuel cap 6 When starting the engine turn the ignition switch from the OFF to ON position 1 Key hole 2 Key ON OFF 2 Fuel cap ...

Страница 48: ... 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 Open and remove Close and tighten ...

Страница 49: ...em 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 yea...

Страница 50: ...e front and rear brake performance is good Brake light check 1 Turn the ignition switch to the ON position 2 Pull both the front and rear brake handle levers to make sure that the brake light illuminates 3 Check that the brake light housing is clean or damaged ...

Страница 51: ... beam illuminates 3 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 1 Key hole 2 Key ON OFF ...

Страница 52: ...ight comes on red light 2 Pull tight the front or the rear brake handle lever or step on the brake pedal starting the engine the engine failure light extinguishment 3 After engine starting or while riding if engine failure light is on take it to a dealer or service center for inspection 1 2 ON OFF ...

Страница 53: ...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 54: ...andlebars and rear hand rest and shake them upward downward to check that the shock absorbers are OK Front and Rear shock absorber adjustment To ensure riding comfort the spring pre compression of front and rear shock absorber is adjustable 1 2 3 4 5 Special wrench ...

Страница 55: ...rops 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 1 Use soft water to mix with anti freeze 2 Note that low grade coolant will shorten the radiator service life 3 Under normal conditions coolant should be repla...

Страница 56: ...lant drips on the painted surface immediately rinse it with clean water How to drain coolant 1 First remove the front rack and front panel 2 Push downward the radiator cap and turn counterclockwise to open the cap 3 Remove the L footrest 4 Remove the draining bolt and let coolant drain out Tilting the ATV rightward may facilitate coolant to drain faster 5 Take out the Aux Liquid Bottle and pour ou...

Страница 57: ...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 58: ... to mount it To mount it take the reverse steps as above for replacing it Notes 1 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 2 Do not wet the air cleaner when washing the ATV Wet air cleaner may cause the engine to be difficult to start 3 Check and replace the air cleaner at a short...

Страница 59: ...55 Fixing clips Air cleaner cover Sponge material Mesh ...

Страница 60: ...n it Adjustment The gap between two poles normally is 0 6 0 7 mm as shown in Figure A NGK CR8E Do not use a spark plug other than a recommended one Notes 1 When the engine stops it is still very hot Be careful not to get burnt 2 First put the spark plug with hand tight and then tighten it using a spark plug spanner Tightening torque 12 5Nm 1 25m kgf NGK CR8E A SW B8RTC ...

Страница 61: ...should be checked before each ride and the cables and cable 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 steering shaft The steering shafts must be lubricated at the intervals specified in the periodic maintenance and lubrication chart Lubricating the upper and lower arm pivots...

Страница 62: ...aintenance and lubrication chart Lubricate the pivoting points using a grease gun Rear axle Lubricating the front rear coupling gear The front rear coupling gear must be lubricated at the intervals specified in the periodic maintenance and lubrication chart Lubricate the pivoting points using a grease gun Front Rear ...

Страница 63: ...or 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 Rear axle boots ...

Страница 64: ...duct those operations in accordance with the description in the regular check record Notes Ensure safety when serving the ATV 1 Use suitable tools 2 Make preparation while the engine stops 3 When the engine stops the engine and exhaust pipe are still very hot Care should be taken to avoid getting burnt ...

Страница 65: ...ential gear oil Final gear oil Check oil level oil leakage and correct if necessary Replace every 12 months Spark plug Check condition Adjust gap and clean Replace if necessary Coolant Check coolant leakage Replace if necessary Replace coolant Every 24 months Battery Check specific gravity Check breather hose for proper operation Correct if necessary Spark arrester Clean Air filter element for eng...

Страница 66: ...ck for cracks or other damage Replace brake pad if necessary Moving parts and cables Lubricate Drive select lever safety system cable Check operation and adjust or replace if necessary Throttle lever housing and cable Check operation and correct if necessary Check throttle cable free play and adjust or replace if necessary Lubricate throttle lever housing and cable Steering system Check operation ...

Страница 67: ... we recommend with an asterisk these items should be serviced only by an authorized Access Motor dealer The air filter needs more frequent service if you are riding in unusually wet or dusty areas Hydraulic brake service Regularly check and if necessary correct the brake fluid level Every two years replace the internal components of the brake master cylinders and calipers and change the brake flui...

Страница 68: ...ing the battery do not allow flammable gas to get close 2 To remove the battery first turn off the ignition switch Then first detach the negative connecting wire However to connect the battery first attach the positive wire and then the negative wire 3 If the terminal screw becomes loose tighten it firmly Notes 1 Do not open the cover of the enclosed battery that contains battery electrolyte 2 If ...

Страница 69: ... has good contact A loose fuse will generate heat Fuse rating 5A 10A 15A 30A and 35A Notes 1 To replace the battery lamps use only the original components of the prescribed specification 2 If components are not original or out of specification the fuse can easily be blown and the battery will not be in balanced status 3 When washing the ATV do not wash it with high pressure water jet Notes To remo...

Страница 70: ...66 Consumer information SERIAL NUMBER Location of Frame Serial Number Vehicle Identification Number Location of Engine Serial Number ...

Страница 71: ...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 72: ...D locked 4WD shaft 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 2040 mm 80 3 in Overall width 1200 mm 47 2 in Overall height 1252 mm 49 3 in Seat height 950 mm 37 4 in Wheelbase 1260...

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