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Rear and Auxiliary Brake

Rear Brake

The rear brake is a hydraulic disc type brake which is activated by the same pedal which activates

the front brake system is self adjusting and requires no maintenance other than periodic checks of

the pads for wear.

Pads should be changed when the friction material is worn to 3/64” (1 mm).

Inspect the brake disc spine and pad wear surface for excessive wear.

Auxiliary Brake Systems

Your ATV’s auxiliary brake system is intended to be used as a backup for the main

brake system. Should the main system fail, the rear brake can be activated by the

brake lever being moving toward the handlebar. The hydraulic brake system will not

require adjustment.

NOTE:

Since this is a rear brake only, it will not be as effective as the all wheel

system.

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Содержание FA-D300

Страница 1: ...ACING BEFORE OPERATING THIS VEHICLE THE OWNER AND EACH OPERATOR MUST HAVE READ AND HAVE AN UNDERSTANDING OF ALL THE INSTRUCTIONS FOR PROPER ASSEMBLY AND SAFE OPERATION AS WELL AS THE INSTRUCTIONS CONC...

Страница 2: ...NS 33 8 STARTING THE ENGINE 46 9 VEHICLE BREAK IN PERIOD 47 10 RIDING GEAR 48 11 CARRYING LOADS 49 12 RIDING 51 13 CVT SYSTEM 63 14 BATTERY 66 15 EXHAUST SYSTEM 69 16 MAINTENANCE 70 17 TROUBLE SHOOTIN...

Страница 3: ...that you understand and follow all Warnings and Instructions in this material If you did not receive any of the material listed above please call your dealer and request to have them sent to you Impor...

Страница 4: ...tional riding laws and requirements Remember Respect your vehicle respect the environment and respect the property of others You are responsible for your safety and the safety of others around you whe...

Страница 5: ...TV without wearing an approved helmet that fits properly You should also wear eye protection goggles or face shield gloves boots a long sleeved shirt or jacket and long pants Never consume alcohol or...

Страница 6: ...Never attempt to turn the ATV around on any hill until you have mastered the turning technique described in this manual on level ground Avoid crossing the side of a steep hill when possible Always use...

Страница 7: ...urning at sharp angles in reverse Always use the size and type of tires specified in this manual Always maintain proper tire pressure as described in this manual Never modify an ATV through improper i...

Страница 8: ...us areas which are being discussed on your machine Operating this vehicle carries with its responsibilities for your personal safety the safety of others and the protection of our environment NOTE Ill...

Страница 9: ...When you see this symbol on your machine or in this manual be alert to the potential for personal injury Your safety is involved WARNING Indicates a potential hazard which could result in severe inju...

Страница 10: ...or your protection Read and follow the instructions on each decal carefully In the event any decal becomes illegible or comes off contact your dealer for a replacement Create PDF with GO2PDF for free...

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Страница 16: ...r free operation and closing 5 Headlight Taillight Brakelight check operation of all indicator lights and switches 6 Engine stop switch check for proper function 7 Wheels check for tightness of wheel...

Страница 17: ...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 TO AVOID THE HAZARD Never carry a passenger Create PDF wi...

Страница 18: ...orized ATV dealer WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet eye protection and protective clothing WHAT CAN HAPPEN Operating without an approved helmet increases y...

Страница 19: ...riveways WHAT CAN HAPPEN Paved surfaces may seriously affect the handling and control of the ATV and may cause the vehicle to go out of control HOW TO AVOID THE HAZARD Avoid operating the ATV on pavem...

Страница 20: ...er consume alcohol or drugs before or while driving this ATV WARNING POTENTIAL HAZARD Operating this ATV at excessive speeds WHAT CAN HAPPEN Increases your chance of losing control of the ATV which ca...

Страница 21: ...her stunts WHAT CAN HAPPEN Increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps Create PDF with GO2PDF for free if you wish...

Страница 22: ...oving hands from the handlebars or feet from the footrests during operation WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your ba...

Страница 23: ...es without enough time to react Could result in the ATV overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain Always be alert...

Страница 24: ...NTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in t...

Страница 25: ...erating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level surfaces or small hills HOW TO AVOID THE HAZARD Never operate the ATV on...

Страница 26: ...down the hill when possible WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn HOW TO AVOID THE HAZARD Never a...

Страница 27: ...stopped If the ATV begins rolling backwards Keep weight uphill never apply engine power Never apply the rear brake while rolling backwards Apply the single lever brake gradually When fully stopped ap...

Страница 28: ...u cannot avoid obstacles always follow proper procedures as described in the Owner s Manual WARNING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN You may lose control of the ATV You may also re...

Страница 29: ...y avoiding sudden turns or stops and do not make sudden throttle changes Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several...

Страница 30: ...ARNING POTENTIAL HAZARD Operating this ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some...

Страница 31: ...raking Always follow the instructions in the Owner s Manual for carrying cargo or pulling a trailer WARNING POTENTIAL HAZARD Riding on frozen lakes and rivers WHAT CAN HAPPEN Severe injury or death ca...

Страница 32: ...e active vehicle requires good judgment and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturns and loss of control which could...

Страница 33: ...a key blank and having it cut by mating it with your existing key Record Key Number The vehicle frame and engine serial numbers are important for model identification when registering your vehicle ob...

Страница 34: ...tches 1 Main Switch This key switch must be turned clockwise to the on position to start the engine 2 Engine Start Button To start the engine Create PDF with GO2PDF for free if you wish to remove this...

Страница 35: ...tion of these lights differs with individual models and not every model is equipped with all the lights The information will help you identify the lights on your machine and their function 1 Transmiss...

Страница 36: ...for free movement and return before starting the engine and occasionally during riding Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle lever The throttle leve...

Страница 37: ...ly brake fade and the possibility of severe injury Front and Rear Brakes The front and rear brakes are located on the inside of the tight floor board and are operated by the right foot The front and r...

Страница 38: ...g the Parking Brake 1 Squeeze the left hand brake lever two or three times and hold it 2 Push the park brake lock 1 into the notches on the master cylinder body Release the brake lever 3 To release th...

Страница 39: ...NG Always check to be sure that the parking brake has been disengaged before operating the ATV An accident could result causing severe injury if the parking brake is left on while the ATV is operated...

Страница 40: ...aster cylinder which is located on the left handlebar should be checked before each side There is an indicator window 1 on the top of the master cylinder This window will appear dark when the fluid le...

Страница 41: ...vehicle is moving could cause transmission damage Always place the transmission in gear with the parking brake locked whenever the vehicle is left unattended Maintaining shift linkage adjustment is i...

Страница 42: ...into the recovery bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the tank past the pressure cap and into the radiator NOTE Some coolant level drop...

Страница 43: ...spected and coolant added if necessary NOTE Use of a non standard pressure cap will not allow the recovery system to function properly If the cap should need replacement contact your dealer for the co...

Страница 44: ...tank neck If you get gasoline on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Gasoline powered engine...

Страница 45: ...ree positions OFF For vehicle storage and whenever transporting ON For normal operation RES No use NOTE Never switch the fuel valve to the RES position Always return valve to on position after refueli...

Страница 46: ...into the oil tank don t screw in it remove it and read the oil level 5 Remove dipstick and check to see that the oil level is between the full and add marks 2 Add oil as indicated by the level on the...

Страница 47: ...he vehicle 4 Turn the engine stop switch to RUN 5 Turn the ignition key to on apply the brake lever and press the starter button 6 Do not press the throttle more than 20 while starting the engine 7 Ac...

Страница 48: ...parts Please set a limit to half throttle during the break in periods 1 Locknut 2 Adjuster 1 Fill the fuel tank 2 Check the oil reservoir level indicated on the dipstick Add oil if necessary 3 Drive s...

Страница 49: ...t can prevent a severe head injury 2 Eye Protection A pair of goggles or a helmet face shield offers the best protection for your eyes 3 Gloves off road style 4 Boots A pair of strong over the calf bo...

Страница 50: ...t 25 lbs 11 kg Improper loading of the front rack can obstruct the headlight beam reducing night visibility Do not obstruct the headlight beam with cargo Use of low forward gear is recommended in heav...

Страница 51: ...ing conditions LOADS MUST BE CARRIED AS LOW ON THE RACKS AS POSSIBLE Carrying loads high on the racks raises the center of gravity of the vehicle and creates a less stable operating condition When car...

Страница 52: ...starting the engine and allowing it to warm up shift the transmission into gear 3 Check your surroundings and determine your path of travel 4 Release the parking brake 5 Slowly depress the throttle w...

Страница 53: ...ire must slip traction slightly To turn steer in the direction of the turn leaning your weight on the outer footrest This technique alters the balance of traction between the rear wheels allowing the...

Страница 54: ...skid by turning the handlebars in the direction of the skid and shifting your body weight forward 4 Never apply brakes during a skid Complete loss of ATV control can result 5 Do not operate on excess...

Страница 55: ...Whenever traveling uphill always travel straight uphill and 1 Avoid steep hills 15 maximum 2 Keep both feet on the footrests 3 Transfer your weight forward 4 Proceed at a steady rate of speed and thro...

Страница 56: ...ur feet on the footrests 3 Steer slightly into the hill to maintain vehicle directions If the vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side imm...

Страница 57: ...in slowing Familiarize yourself with the auxiliary rear brake pedal and its use in the event loss of normal service brakes occurs WARNING Do not travel at excessive speeds It is dangerous and can caus...

Страница 58: ...e service brake release parking brake lock and slowly allow the ATV to roll around to your right until the ATV is pointing across the hill or slightly downward 6 Lock the parking brake and remount the...

Страница 59: ...akes by applying light pressure to the lever until braking action is normal CAUTION Never operating the ATV through deep or fast flowing water NOTE After running the vehicle in water it is critical yo...

Страница 60: ...the carburetor drain screw 1 Turn the engine over several times with the electric start Dry the spark plug and reinstall or replace it with a new plug Tighten the carburetor drain screw 1 Turn the fue...

Страница 61: ...e constantly alert for hazards such as logs rocks and low hanging branches WARNING Not all obstacles are visible Travel with caution on trails Severe injury or death can occur when vehicle comes in co...

Страница 62: ...topping 4 Avoid turning at sharp angles in reverse 5 Never open the throttle suddenly while backing NOTE This ATV is equipped with a reverse speed limiter Do not operate at wide open throttle Only ope...

Страница 63: ...fuel supply 5 Avoid parking on an incline If it is necessary to park on an incline always block the rear wheels on the downhill side as shown above 6 Do not leave the ATV on a hill depending on the p...

Страница 64: ...recommended maintenance procedures See your dealer The CVT housing must be securely in place during operation Failure to comply with this warning can result in severe injury or death Low Range Use Ma...

Страница 65: ...f the CVT components belt cover etc Adjust the center distance of the CVT 1 Remove crankcase filter cover cover protector and crankcase cover 2 Loosen the left link bolts right link bolts and engine m...

Страница 66: ...sic operation at speeds less than 7 MPH 11 km h Heavy pulling Riding through rough terrain swamps mountains etc at low ground speeds High Range Basic operation at speeds greater than 7 MPH 11 km h Hig...

Страница 67: ...etable oil Call physician immediately Eyes Flush with water for 15minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when chargi...

Страница 68: ...Installation and Connections WARNING To avoid the possibility of explosion always connect battery cables in the order specified Red positive cable first black negative cable last An exploding battery...

Страница 69: ...ge for one month or more the battery should be removed charged to proper level and stored in a cool dry place Before reusing take the battery to your dealer for testing and recharging When installing...

Страница 70: ...ged of accumulated carbon as follows 1 Remove the arrestor screw located on the bottom of the muffler pull out the arrestor the mesh 2 Clean the arrestor or replace it WARNING When cleaning the spark...

Страница 71: ...ed in the following chart on the following pages Maintenance intervals are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to se...

Страница 72: ...en replaced Tail Lamp Inspection Daily Daily Check operation daily apply dielectric grease to socket when replaced l Air Filter Main Element Weekly Weekly Inspect Replace if necessary l Transmission O...

Страница 73: ...months Inspect adjust D Drive Belt 50 hrs 6 months Inspect replace if necessary l Steering 50 hrs 6 months Inspect daily lubricate l Rear Axle 50 hrs 6 months Inspect bearings Lube l Front Suspension...

Страница 74: ...onths Inspect D Valve Clearance 100 hrs 12 months Inspect adjust D Shift Selector Box H L R N 200 hrs 24 months Change grease every two years D Brake Fluid 200 hrs 24 months Change every two years Idl...

Страница 75: ...o years or 200 hours 3 Transmission Oil SEA 80W 90GL5 See 16 MAINTENANCE Transmission Lube Change annually or at 100 hours 4 Front Gear Case Oil SAE 15W 40SG See 16 MAINTENANCE Front Gear Case Oil Cha...

Страница 76: ...ry Semi annually 9 Tie Rods Grease Locate fittings and grease Semi annually 10 Shift Linkages Grease Locate fittings and grease Semi annually 11 Ball Joints Inspect Inspect and replace it if necessary...

Страница 77: ...ght lithium soap grease 3 Grease M molybdenum disulfide MoS2 grease water resistant 4 When suspension action becomes stiff or after washing 5 Hours are based on 10 mph 16 Km h average Create PDF with...

Страница 78: ...odic maintenance work Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remark First 5 Hrs 10 Hrs 15 Hrs 20 Hrs 25 Hrs 50 Hrs 75 Hrs 100 Hrs Create PDF with GO2PDF for free if y...

Страница 79: ...ur personal fit 1 Remove the handlebar cover 2 Loosen the four bolts 3 Adjust handlebar to desired height Be sure handlebars do not hit gas tank or any other part of machine when turned fully to left...

Страница 80: ...hat have a cotter pin installed must be serviced by an authorized Dealer Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations Service wo...

Страница 81: ...and remove cover 3 Loosen clamp and remove filter 4 Remove fabric type pre filter from main filter Wash pre filter in soapy water and dry it 5 Reinstall pre filter over main filter Replace main filter...

Страница 82: ...injury or death can result from improper adjustment Contact your dealer He She has the training and tools to make these adjustments Toe Alignment Check The recommended toe alignment is 1 8 to 1 4 3 to...

Страница 83: ...s upon the type of driving that has been done Keep fluid level in the master cylinder reservoirs as described see 7 Control and parts functions Normal functioning of the diaphragm is to extend into th...

Страница 84: ...brake disc spine and pad wear surface for excessive wear Auxiliary Brake Systems Your ATV s auxiliary brake system is intended to be used as a backup for the main brake system Should the main system f...

Страница 85: ...ill raise RPM Turning the screw out counterclockwise will lower RPM 4 The standard idle RPM is 1500 10 Throttle Cable Free Play Adjustment Throttle cable free play is adjusted at the handlebar 1 Slide...

Страница 86: ...park Plug Removal and Replacement WARNING Never attempt to remove a spark plug while the engine is warm The exhaust system or engine could burn you causing severe injury Remove the spark plug by rotat...

Страница 87: ...n most trips are slow speed and less than 5 mph 8 km h Be sure to change the oil filter whenever changing oil CAUTION Oil may be hot Do not allow hot oil to come into contact with skin as severe burns...

Страница 88: ...ded gear case oil as needed to bring the level to the bottom of the fill hole threads 4 Reinstall the fill plug Torque to 14 ft lbs 19 Nm Oil Change 1 Position the vehicle on a level surface and remov...

Страница 89: ...hichever comes first Transmission oil should be changed annually With the ATV on a level surface remove fill plug 1 and check the lubricant level The correct transmission lubricant to use is SEA 80W 9...

Страница 90: ...d side and drain the oil Catch and discard used oil properly 4 Clean and reinstall the drain plug torque to 14 ft lbs 19 Nm 5 Add the correct amount of SEA 80W 90GL5 Lubricant until oil reaches the bo...

Страница 91: ...a level surface 2 Remove the side fill plug and view the oil level through the fill plug hole 3 Add the recommended gear case oil as needed 4 Reinstall the fill plug Torque to 14 ft lbs 19 Nm Oil Chan...

Страница 92: ...oper tires The use of non standard size or type tires may affect ATV handling Make certain the wheels are installed properly If wheels are improperly installed it could affect vehicle handling and tir...

Страница 93: ...ighten them 3 Lower the vehicle to the ground 4 Securely tighten the wheel nuts according to the chart found in 16 MAINTENANCE Wheel Nut Torque Tire Inspection When replacing a tire always use origina...

Страница 94: ...he life of the lamp Lamp Replacement Headlight Lamp Relpacement 1 Use bulb 12V 35W 2 Turn the M4x30 bolt and remove it 3 Dismantle the hoop 4 Remove the lens together with the reflecting mirror 5 Chan...

Страница 95: ...can be adjusted up and down 1 Place the vehicle on a level surface with the headlight approximately 25 ft 7 6 m from a wall 2 Measure the distance from the floor to the center of the headlight and mak...

Страница 96: ...last Rinse with water frequently and dry with a chamois to prevent water spots NOTE If warning labels are damaged contact your dealer for replacement Waxing Your ATV can be waxed with any non abrasive...

Страница 97: ...y contain minerals that reduce battery life Apply dielectric Grease to the terminal bolts and terminals Charge the battery Storage Area Covers Set tire pressure and safely support the ATV with the tir...

Страница 98: ...mbient temperatures Warm engine at least 5 min with the transmission in neutral advance throttle to approx 1 8 throttle in short bursts 5 to 7 times The belt will become more flexible and prevent belt...

Страница 99: ...in this manual for inspection adjustment and replacement of parts Adjustment and replacement must be done by your dealer STARTING FAILURE HARD STARTING FUEL SYSTEM Fuel tank Auto choke Empty Starter p...

Страница 100: ...STOP Wire between terminals broken switch Improper heat range Faulty brake switch Faulty spark plug cap Wiring Ignition coil Loose battery terminal Broken or shorted primary Loose coupler connection s...

Страница 101: ...usted fuel level valve and valve seat Improper carburetor air vent hose Faulty valve timing setting Clutch Refer to CLUTCH SLIPPING DRAGGING section Engine oil Improperly oil level low or over oil lev...

Страница 102: ...ear malfunction bent dowel pin gear Damaged impeller shaft Disconnected fan motor connector FAULTY CLUTCH WHEN ENGINE RUN ATV DOES NOT RUN V belt POOR SPEED PERFORMANCE Worn bent slipping V belt Worn...

Страница 103: ...fluid Damage Faulty master cylinder kit Compressing spring Faulty caliper seal kit Loose union bolt Secondary sliding sheave Broken brake hose Improper operation Oily or greasy brake pad Oily or grea...

Страница 104: ...18 Tool Create PDF with GO2PDF for free if you wish to remove this line click here to buy Virtual PDF Printer...

Страница 105: ...acity Combined Rider Payload 156 kg Tongue Weight 11 kg Tow Capacity 200 kg Drive System Drive System CVT Front Tire 25x8 12 Rear Tire 25x10 12 Tire Pressure front 40 kPa 5 8 PSI Tire Pressure rear 40...

Страница 106: ...Cooled Lubrication System Wet Sump Carburetor CVK052 Ignitions T C I Spark Plug Type DR8EA NGK Electrical Equipment Battery 12V 14AH Head Light 35W 35W Brake Tail Light 21W 5W Reverse Indicator 12V 0...

Страница 107: ...20 WIRING DIAGRAM Create PDF with GO2PDF for free if you wish to remove this line click here to buy Virtual PDF Printer...

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