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SAE5W30:Suitable for the ambient temperature(0 or below)

Recommended engine oil classfication: SE,SF,SG type or higher.

Oil quantity:

Periodic oil change:2.9L

With oil filter replacement:3.0L

Total amount:3.5L

Lubrication oil of gear case

Make sure the lubrication oil of gear case is at the specified lever. Add oil as

necessary.

Recommended oil

SAE80 API GL Hypoid gear oil.

Throttle lever

Check to see that the throttle lever operates correctly. It must open smoothly and spring

back to idle position when released. Repair as necessary for proper operation.

Fittings and Fastenerns

Always check the tightness of chassis fittings and fasteners before a ride. Refer to the

Service. Manual for correct tightening torque.

Light

Check the headlight and taillight to make sure they are in working condition . Repair as

necessary for proper operation.

Switches

Check the operation of the headlight. Switch, engine stop switch and any other

switches. Repair as necessary for proper operation.

Battery

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12
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16
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Содержание XT400ATV

Страница 1: ...use inuries and deaths Warning Read this manual carefully and follow the operating procedures and methods described in this manual Never operate an ATV without proper training or instruction A child under 16 years old should never operate an ATV Never allow drive of an ATV by and individal person if he or she does not have the abilites to operate it safely Warning Injury or death could be result f...

Страница 2: ... go slowly and pay extra attention when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV Never operate on excessively rough slippery or loose terrain unless you have learned and practiced the skills necessary to control the ATV on such terrain Always be especially cautious on these kinds of terrain Always follow proper procedures for turning as ...

Страница 3: ...teep hill if possible Avoid crossing the steep hills Always use proper procedures if you stall or roll backwards when climbing a hill To avoid stalling se proper gear and maintain a steady speed when climbing a hill If you stall or roll backwards follow the special procedure for braking described in this manual Always check for obstacles before operating in a new area Never attempt to operate over...

Страница 4: ...ual for carrying cargo or pulling a trailer Allow greater distance for braking Improper handling of gasoline can cause fire and can cause jnjruies and deaths and other serious accident So do not refuel right after the engine has been running and is still every hot Never refuel while smoking or while in the vicinity of sparks open flames or other sources of ignition When transporting the machine in...

Страница 5: ... wheel 3 Mirror 4 Main switch 5 2WD 4WD transforming lever 6 Fuel cock 7 Taillight 8 Rear wheel 9 Rear luggage carrier 10 Exhaust silencer 11 Cushion 12 Fuel tank cover 13 Brake pedal 14 Front luggage carrier 15 Gear bar ...

Страница 6: ...brake lever Key identification number The key identification number should be stamped on the key as shown in the following drawing This number can be used for ordering a new key Vehicle identification number The vehicle identification number is stamped on underside of seat ...

Страница 7: ...tch positions are as follow ON Engine can be started only at this position and the headlight and taillight come on when the light switch is on OFF All electrical circuits are switched off The key can be removed in this positio Handlebar switch ...

Страница 8: ...e break level Throttle lever Once the engine is running movement of the throttle lever will increase the engine speed Adjust the speed of the machine by changing the throttle position Because the throttle is spring loaded the machine will decelerate and the engine will return to an idle and time the hand is removed from the throttle lever Before starting the engine check the throttle to be sure it...

Страница 9: ...ially on a slop Use the parking brake Apply the rear brake lever and push down the lock plate to apply the parking brake Squeeze the rear brake lever to release the parking brake Caution The ATV could start moving unexpectedly if the parking brake is out of fuction before starting the engine This could cause loss of control or a collision The brake could overheat if you ride the ATV without releas...

Страница 10: ...hicle might be damaged due to this reason 2WD 4WD shift lever To shift the 2WD to 4WD stop the ATV and shift the shift lever to 4 WD position To shift the 4WD to 2 WD stop the ATV and shift the shift lever to 2WD position Warning Potential hazard When driving the ATV and shifting 2WD to 4WD or 4WD to 2WD the 2WD is different from 4WD in operation Shifting 2WD to 4WD when driving the ATV will make ...

Страница 11: ...d Low the Throttle lever 2 Use the low speed gear on the rough road 3 if not on the smooth road or the driver has skill don t use the high speed gear Fuel tank cap Remove the fuel tank cap by turning it counter clockwise Fuel cock The fuel cock supplies fuel from the fuel tank to the carburetor The fuel cock has three positions OFF ...

Страница 12: ...t into the receptacle on the frame and push down the seat at the rear You should pay attention to make sure that the seat is securely fitted Front carrier Maximum load limit 40kg Rear carrier Maximum load limit 80kg Front and rear brakes Always check the brakes at the start of every side Do not ride the ATV if you find any problem with the brakes If a problem cannot be corrected by the adjustment ...

Страница 13: ...vailable then leaded regular gasoline can be used Caution Fuel can spill causing a fire and severe injury Fuel will expand when it heats up if the fuel tank is overfilled fuel could spill out due to heat from the engine or the sun So do not overfill the fuel tank Be careful not to spill fuel especially on the engine or exhaust pipe Wipe up any spilled fuel immediately Be sure the fuel tank cap is ...

Страница 14: ...eck to see that the throttle lever operates correctly It must open smoothly and spring back to idle position when released Repair as necessary for proper operation Fittings and Fastenerns Always check the tightness of chassis fittings and fasteners before a ride Refer to the Service Manual for correct tightening torque Light Check the headlight and taillight to make sure they are in working condit...

Страница 15: ...ure may increase your risk of accident Use of improper tyres on this ATV or operation of this ATV with improper tyre pressure may Cause loss of control Pay attention to choose the size and type of used tyres according to the description in the above chart and make sure that the tyre pressure is normal The tyres should be set to the recommended pressure Recommended pressure Front 25kpa Rear 25kpa C...

Страница 16: ... Note If the engine fails to start release the start switch then push the start switch again pause a several secords before the next attempt Each cranking should be as short as possible to preserve battery energy Do not crank the engine more than 10 seconds for each starting If the battery is discharged Pull the recoil starter to start the engine Starting a warm engine The throttle should be opene...

Страница 17: ...Vary the speed of the machine from time to time Do not operate it at one set throttle position 2 10 20 hours Avoid prolonged operation above 3 4 throttle revolving the machine can freely through the gears during running of engine but do not use full throttle any time 3 After break in Avoid prolonged full throttle operation Chang speeds properly Parking When parking Stop the engine and shift into n...

Страница 18: ...ering difficult an accessory that limits your ability to move around on the seat or one that limits your view Use extra caution when riding an ATV with accessories Loading Never exceed the weight limits shown an overloaded ATV can be unstable You must use common sense and good judgement when carring cargo or towing a trailor Keep the following points in mind Maximum loading limit Vehicle loading l...

Страница 19: ...ly Extra weight will affects the stability and operation of ATV This machine could be used to carry cargo and passengers is prohibited Ride with care 1 Get training if you are unexperienced Beginners should be trained at the guide of professional person Drive with this ATV with low speeds first to familiar with its performance even if you are an experienced rider fo not attemp to operate at maximu...

Страница 20: ...wheel Never attempt stunts such as wheelies or jumps Don t try to show off 8 Refit Improper installation of accessories or refit of this vehicle may cause changes in harding which in some situations could load to an accident Never refit this ATV through improper installation or use of accessories All parts and accessories added to this vehicle should be genuine or equivalent components designed fo...

Страница 21: ...ht not easy to be seen such as dune and hilly land must mount a caution flag on the machine to remind other vehicles Do not ride in areas of forbidding pass Do not ride on private property Operation course Caution Do not shift gears without releasing the throttle Otherwise may cause damage to the engine or drive gear When slowing down or stopping release the throttle and brake gradually As you bra...

Страница 22: ...arn this technique you can turn your ATV at higher speed The sudden acceleration brake incorrect body position and too high speed will cause the ATV to slip If the ATV slips while passing a curve and the ATV machine leans inward you should release the throttle and move your body gravity center to outside of the carve to avoid tipping over Remember ride at higher speed only after you are thoroughly...

Страница 23: ...ation manual Ensure the ATV not to slip when stop it on slope The shift should be proper and speed should be stable when climbing slope Losing traction force you should transfer the gravity center forward and brake the machine Close the brake closing piece after stopping the machine If the machine slips backward Transfer your gravity center backward Brake by foot pedal Close the brake closing piec...

Страница 24: ...ul and cautious if making a turn on any slope When crossing a slope Always follow proper prouclures in operation manual Avoid slope with slippery or loose surface Lean your gravity center in the slope direction Crossing through shallow water The ATV can be used to cross shallow water of maximum depth of 35cm Check your path carefully before crossing and avoid of ride where there is sharp drop off ...

Страница 25: ...ircumstances Periodic maintenance and adjustment Periodic inspection adjustment and lubrication will keep your machine in the safest and most efficient condition The points of machine inpeciton adjustment and lubrication are detailed in following Note Turn off the engine when maintaining unless specified Have a dealer perform sevice if you are not familiar with maintenance Operation manual and too...

Страница 26: ... minutes and turn off it Wait more than 10 minutes for the oil to drain back into the crankcase before checking the oil level b Wipe the dipstick off with a clean rag Insert the dipstick in the filler hole c Remove the dipstick and inspect the oil level d The oil level should be between maximum and minimum marks if level is low add oil to raise it to proper level 2 Engine oil replacement and oil f...

Страница 27: ...l the dipstick Caution Be sure no foreign material enters the carnkcase f Warm up the engine for several minutes at idle speed Check for oil leakage when warming up the engine for several minutes at idle speed Check for oil leakage when warming up Caution If oil leakage is found turn off the engine promptly and check for the cause Lubrication oil of final gear case a Measurement of lubrication oil...

Страница 28: ...ar case with oil Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity Periodic oil change 0 25L 0 21 Imp qt Total amount 0 27L 0 23Imp qt Lubrication oil of front drive gear case a Measure of lubrication oil of front drive gear case Place the ATV on a level place Remove the oil filter bolt and check the oil level It should be up to the brim of the hole If the level is too low add oil to ra...

Страница 29: ...u should periodically remove and check the spark plug because heat and deposits will cause slow damage oaderosion of the spark plug If electrode erosion is excessive you should replace the spark plug with one of the proper type D8REA Before installing the new spark plug measure the electrode gap with a feeler gauge and adjust to specification Spark plug gap 0 6 0 8mm When installing the spark plug...

Страница 30: ...est If the setting s are disturbed by someone without sufficient technical knowledge poor engine performance and damage may result Never run the engine with the air element removed This will let unfiltered air enter causing rapid wear and possible damage of engine Additionally operation without the filter element will weak the performance of carburetor and cause overheating of engine Carburetor ad...

Страница 31: ...essary Brake liquid replacement 1 The complete replacement of brake liquid should be done by trained workers of the Group 2 When periodic maintain or damage of block or oil occurs ask the dealer to replace the following components Replace all the rubber seal components every two years Replace all the pipes every four years Wheel remove 1 Left the wheel by placing a suitable support under the frame...

Страница 32: ...ed for both front and rear wheels Install tapered side of the nut towards the wheel 3 Tighten the wheel nut Battery Avoid contact with skin eyes or clothes Always shield eyes when operate battery Keep children away from it to avoid accidents Cleaning and storage A Cleaning Thorough cleaned ATV will has better appearance in general Cleaning improves its running performance and prolongs the service ...

Страница 33: ...e soap Use old tooth brush a bottle brush to wash hard to get at places 5 After cleaning ATV with clean water immediately dry the surface with a chamois clean towel or soft absorbent cloth 6 Clean the seat with a vinylupholstery cleaner to keep the cover pliable and glossy 7 Apply automotive type wax to all chrome plated surfaces Avoid using combination cleaner waxes After using abrasives to prote...

Страница 34: ...evate the engine body to raise all wheels off the ground 5 Seal the exhaust pipe outlet with plastic bag to prevent water in 6 If store ATV in a humid or salt air atmosphere cover all exposed metal surfaces with a light plastic film of oil Do not apply oil to any plastic parts or the cushion 7 Take out the battery and store if in a dry place The battery should be stored in the place where the ambi...

Страница 35: ...ell base 1400mm Minimum ground clearance 210mm Frame minmum turning radius 3200mm Frane type stell tube Basic weight Caster angell 4 With oil and full tank Trail 28mm Engine 1 stroke 4 stroke water cooling Tire Dispiacement 264ml Type Vacuum Cylinder diameter 72mm Size Front AT25 8 12 Compresssion ratio 10 5 1 Size Rear T25 10 10 Starting system Electric Lubricaton system presssure splash ...

Страница 36: ...Center damper Spark plug gap 0 6 0 7mm Shock absorber Front rear Spring hydraulic damper Clutch type shoe automatic centrifuga wet several type Whell travel Transmission Front whell 150mm Primary reduction system Apur gear Rear whell 150mm Primary reduction ratio 2 444 Electrical Secondary reduction ststem Shaft drive lgnition system C D I Secondary reduction ratio 2 61 Generrator system A C Magne...

Страница 37: ...rrester Clean Fuel line Check fuel hose for crcks or damage Replace if necessary Engine oil Repleace warm engine before draining Engine oil filter Clean Engine oil straniner Clean Final gear oil Check oil level oil leakage Replace Brake Check operation Adjust if necessary Clutch Check operation Adjust if necessary Wheels Check balance damage run out Replace if necessary Wheels bearings Check balan...

Страница 38: ...nd indicator limited speed Cool fan Singal controller Brake switch Left hand switch limited speed meter Speed transmission main switch Brake switch Emergency switch Hom button Cool fan Brake switch Currecnt switch Oil temperature switch Front right turn light Head light Four ways fuse Main switch fuse Ignition coils fuse light fuse Cool fan fuse B blue G green Y yellow BL black O orange A azury W ...

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