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97

PERIODIC MAINTENANCE AND ADJUSTMENT

POTENTIAL HAZARD

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

Periodic inspection, adjustment and lubrication will keep
your machine in the safest and most efficient condition
possible. Safety is an obligation of the machine owner.
The most important points of machine inspection, adjustment
and lubrication are explained on the following pages.

Servicing an engine while it is running.

Moving parts can catch clothing or parts of the body, causing
injury.
Electrical components can cause shocks or can start fires.

Turn off the engine when performing maintenance unless
otherwise specified.
Have a ATV dealer perform service if you are not familiar with
machine service.

Owner

’

s manual and tool kit

You are recommended to put this owner

’

s manual in

the vinyl bag and always carry it on the bottom of the
seat as shown. Put the owner

’

s tool kit and low-pressure

tire gauge under the seat.
The service information included in this manual is
intended to provide you, the owner, with the necessary
in fo rmat ion fo r co mpl etin g yo ur own p re ven tiv e
maintenance and minor repairs. The tools provided in
the Owner

’

s tool kit are sufficient for this purpose, except

that a torque wrench is also necessary to properly
tighten nuts and bolts.

USER'S MANUAL

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Содержание RD400

Страница 1: ...unsafe to operate this machine on any public street road or highway This machine complies with all applicable OFF ROAD noise level and spark arrester laws and regulations in effect at the time of manu...

Страница 2: ...YOURATV MAKE SURE YOU UNDERSTANDALL INSTRUCTIONS PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION TRAINING IS AVAILABLE TO A...

Страница 3: ...ns A CAUTION indicates special precautions that must be taken to avoid damage to the machine A NOTE provides key information to make procedures easier or clearer death to the machine operator a bystan...

Страница 4: ...ne Oil 1 Location of the warning and specification labels 1 5 3 Description and machine identification 11 Vehicle identification number 12 13 13 14 17 20 21 22 22 23 24 24 25 26 Starter choke Seat Sto...

Страница 5: ...56 58 59 71 77 79 85 87 89 92 93 7 Riding Your ATV What to do if What to do Owner s manual and tool kit Periodic maintenance lubrication Panel removal and installation Engine oil and oil filter cartr...

Страница 6: ...rake levers and brake pedal Wheel installation Battery 10 Specifications 11 Noise Regulation 125 125 127 127 128 131 132 133 134 136 Battery maintenance Fuse replacement Replacing a headlight bulb Hea...

Страница 7: ...LOCATION OFTHE W ARNING AND SPECIFICATION LABELS 1 USER S MANUAL...

Страница 8: ...PRESSURE Set with tires cold Recommended FRONT 25kPa 0 25kgf cm 3 6psi REAR 25kPa 0 25kgf cm 3 6psi Minimum FRONT 22kPa 0 32kgf cm 3 2psi REAR 22kPa 0 32kgf cm 3 2psi Never set tire pressure below mi...

Страница 9: ...fast for your skills or the conditions on public roads a collision can occur with another vehicle with more than one passenger passengers affect balance and steering and increase risk of losing contro...

Страница 10: ...ce of severe injury or death NEVER operate this ATV if lyou are under age 16 WARNING DRIVE SELECT LEVER Read owner s manual carefully before operating ATV MUST be stopped before shifting select lever...

Страница 11: ...ng Course Begin receive training from a certified instructor Contact an authorized dealer nersshould ATV Always follow the age recommendation Achild under 16 years old should never operate anATV with...

Страница 12: ...cedures and schedules described in this manual Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation Always go slowly and be extra careful when operating...

Страница 13: ...escribed in this manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV Never attempt to turn the ATV around on any hill until you have mastered...

Страница 14: ...ving water If necessary apply them several times to let friction dry out the linings Always be sure there are no obstacles or people behind you when you operate in reverse When it is safe to proceed i...

Страница 15: ...l gasoline on the engine or exhaust pipe muffler when refueling Neverrefuel while smoking orinthe vicinityofsparks open flames or other sources of ignition such as the pilot lights of water heaters an...

Страница 16: ...O AVOID THE HAZARD Starting or running the engine in a closed area Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time Always operate your ATV in an area with...

Страница 17: ...chine you have purchased may differ slightly from those shown in the figures of this manual DESCRIPTION AND MACHIN IDENTIFICATION 11 12 Front Shock absorber assembly Spring Preload adjusting Ring 13 V...

Страница 18: ...dentification number The vehicle identification number is stamped into the frame Vehicle identification number front left side The vehicle identification number is used to identify your machine NOTE U...

Страница 19: ...tch Functions of the respective switch positions are as follows Main switch 13 USER S MANUAL ON OFF The engine can be started only at this position and the headlights and taillight come on whenthe lig...

Страница 20: ...ur wheel drive indicator light Oil temperature warning light Neutral indicator light N Reverse indicator light R This indicator light comes on when the drive select lever is in the N position This ind...

Страница 21: ...ay overheat if the ATV is overloaded If this happens reduce the load to specification Restart after making sure that the light is out Continuous use while the light is on may cause damage to the engin...

Страница 22: ...smission in neutral Oil temperature warning light comes on momentarily Oil temperature warning light does not come on Oil tempera ture is low Oil tempera ture is high Engine oil temperature and electr...

Страница 23: ...he engine stop switch is set to before starting the engine The engine stop switch controls ignition and can be used at all times to stop the engine especially in an emergency The ngine will not start...

Страница 24: ...the engine See page 43 for details On command four wheel drive switch 2WD 4WD Tochange from two wheeldrive 2WD tofour wheel drive 4WD stoptheATVandsettheswitchtothe 4WDposition To change fromfour whe...

Страница 25: ...rently in 2WD than in 4WD in some circumstances Changing from 2WD to 4WD or from theATV to unexpectedly handle diffe ntly This could distract the operator and increase the risk of losing control and a...

Страница 26: ...eck the throttle to be sure it is operating smoothly Make sure it returns to the idle position as soon as the lever is released POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Malfunction of...

Страница 27: ...TV Locknut Adjusting screw a 12 mm 0 47 in POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle WHAT CAN HAPPEN The throttle cable could be damaged Improper throttle operation could...

Страница 28: ...apply the front brake Brake pedal and rear brake lever The brake pedal islocated onthe right sideoftheATVandthe rearbrake leveris located on the left handlebar Push down on the pedal or pull the leve...

Страница 29: ...APPEN The ATV could start moving unexpect edly if the parking brake is not applied before starting the engine This could cause loss of control or a collision The brake could overheat if you ride the A...

Страница 30: ...neutral and reverse positions Refer to page 46 for the drive select lever operation Drive select lever Recoil starter Firmly grasp the handle and pull slightly until engagement can be felt Then pull...

Страница 31: ...D Starting the engine without shifting into the neutral position WHAT CAN HAPPEN TheATV could start to move unexpect edly which could cause an accident HOW TOA VOID THE HAZARD Shift the drive select l...

Страница 32: ...is position With the lever in this position fuel flows to flow Always turn the lever to this position when the engine is not running With the lever in this position fuel will not while riding turn the...

Страница 33: ...mixture Aseparate starter circuit supplies thismixture Moveindirection a toturnon thestarter choke Moveindirection toturnoffthestarter choke a Refer to tarting a cold engine for proper operation See p...

Страница 34: ...up the seat at the rear Seat Seat lock lever To install the seat insert the projections on the front of the seat into the seat holders and push down on the seat at the rear Make sure that the seat is...

Страница 35: ...harply edged products directly in the storage box If they must be stored wrap them in appropriate cushion material Storage box NOTE There is a check hose at the bottom of the storage box If any water...

Страница 36: ...and riding conditions Adjust the spring preload as follows To increase the spring preload turn the adjusting ring in direction a To decrease the spring preload turn the adjusting ring in direction b...

Страница 37: ...tion a To decrease the spring preload turn the adjusting ring in direction b Spring preload adjusting ring Position indicator POTENTIAL HAZARD Improper shock absorber adjustment WHAT CAN HAPPEN Uneven...

Страница 38: ...al wrench can be obtained at a dealer to make this adjustment Standard position 2 1 Minimum soft 5 Maximum hard Special wrench Indicates a potential hazard that could result in serious injury or death...

Страница 39: ...if necessary Check oil level Engine oil Fill with oil if necessary Check for leakage Fina l gear oil differential gear oil Check for proper throttle cable operation Throttle Check tire pressure wear a...

Страница 40: ...intenance procedures and schedules described in the Owner s Manual 34 Front and rear brakes Brake levers and brake pedal Check for correct free playinthe front brake lever If the free play is incorrec...

Страница 41: ...starting out to make sure they are working properly If the brakes do not provide proper braking performance inspect the brake padsandshoes for wear See page 123 POTENTIAL HAZARD Riding with improperly...

Страница 42: ...will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system YourATV engine has been designedtouse regularunleaded gasoline with a pump octan...

Страница 43: ...TENTIAL HAZARD Improper care when refueling WHAT CAN HAPPEN Fuel can spill which can cause a fire and severe injury Fuel expands when it heats up If the fuel tank is overfilled fuel could spill out du...

Страница 44: ...lity than specified In addition donot useoilslabeled ENERGYCONSERVING II or higher Make sure that no foreign material enters the crankcase Final gear oil Make sure the final gear oil is at the specifi...

Страница 45: ...en released Have aATV dealer repair as necessary for proper operation Fittings and fasteners Always check the tightness of chassis fittings and fasteners before a ride Take the machine to aATV dealer...

Страница 46: ...the recom mended pressure Recommended tire pressure Front 25 kPa 0 25 kgf cm2 3 6 psi Rear 25 kPa 0 25 kgf cm2 3 6 psi Check and adjust tire pressures when the tires are cold Tire pressures must be e...

Страница 47: ...eading 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 0 25kgf cm Recommended pressure Front Rea...

Страница 48: ...42 Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire a Tire wear limit USER S MANUAL...

Страница 49: ...not understand ask yourATVdealer Starting a cold engine POTENTIAL HAZARD Freezing control cables in cold weather WHAT CAN HAPPEN You could be unable to control theATV which could lead to an accident o...

Страница 50: ...rting the engine 5 Use the starter choke in reference to the figure Position 1 Cold engine start ambient temperature below 5 C 40 F Position 2 Cold engine start ambient temperature at 0 C 30 F 30 C 90...

Страница 51: ...should not be used The throttle should be opened slightly starting a cold Warming up To get maximum engine life always warm up the engine before starting off Never accelerate hard with a cold engine...

Страница 52: ...amaged Shifting forward 1 Bring the machine to a complete stop and return the throttle lever to the closedposition 2 Shift the gear from neutral to forward and vice versa by moving the drive select le...

Страница 53: ...nd vice versa by moving the drive select lever along the shift guide 4 Check behind for people or obstacles then release the brake pedal 5 Open the throttle lever gradually and continue towatch to the...

Страница 54: ...D THE HAZARD Improper operation in reverse You could hit an obstacle or person behind you resulting in serious injury Whenyoushift intoreverse makesure there are no obstacles or people behind you When...

Страница 55: ...y condition which 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 0 10 hours Avoid continuous...

Страница 56: ...throttle Rev the machine freely but do not use full throttle at any time Avoid prolonged full throttle operation Vary speeds occasionally Parking When parking stop the engine and shift into neutral Tu...

Страница 57: ...AN HAPPEN TheATV could roll out of control increas the chance of an accident ing HOW TOA VOID THE HAZARD Avoid parking on hills or other inclines If you must park on an incline place the machine trans...

Страница 58: ...one that is equivalent in design and quality Accessories Accessories should be rigidly and securely mounted An accessory which can shift position or come off while you are riding could affect your abi...

Страница 59: ...kgf 33 lbf 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 with the tongue at hitch height Adjust the loa...

Страница 60: ...efully Added weight affects the stability and handling of the ATV POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Overloading this ATV or carrying or towing cargo improperly Could cause chang...

Страница 61: ...Indicates a potential hazard that could result in serious injury or death 55 USER S MANUAL...

Страница 62: ...56 USER S MANUAL...

Страница 63: ...57 USER S MANUAL...

Страница 64: ...tice over a period of time Take the time to learn the basic techniques well before attempting more difficult maneuvers Riding your new ATV can be a very enjoyable activity providing you with hours of...

Страница 65: ...rse offered byATV They should then regularly practice the skills learned in the course and the operating techniques described in this Owner Manual For more information about the training course contac...

Страница 66: ...mendations for this ATV Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child Achild under 16 should never operate anATV with engine size great...

Страница 67: ...T CAN 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 TOA VOID THE HAZARD Never carry a passenger The lon...

Страница 68: ...in the event of anaccident Operating without an approved motorcycle helmet increases your chances of a severe head injury ordeath in the event of an accident Operatingwithoutprotectiveclothingincreas...

Страница 69: ...ENTIAL HAZARD Operating thisATV after consuming alco ol or drugs h WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and perception Co...

Страница 70: ...e operating condition Always follow the inspection and maintenance procedures and schedules described in the Owner s Manual POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Operating this ATV...

Страница 71: ...iders less experienced with this model this model is equipped with a speed limiter in the throttle lever housing The speed limiterkeepsthe throttle from fully opening even when the throttle lever is p...

Страница 72: ...itch Pulling load 500 kgf 1 102 lbf Totalweightoftrailerand cargo Tongue weight 15 kgf 33 lbf Vertical weight on trailer hitch point POTENTIAL HAZARD Overloading this ATV or carrying or towingcargo im...

Страница 73: ...emoving even one hand or foot can reduce your ability to control theATV or could cause you to lose your balance and fall off of the ATV If you remove a foot from a footboard your foot or leg may come...

Страница 74: ...e ATV or overturn Attempting wheelies jumps and other stunts Increases the chance of an accident includinganoverturn Never attempt stunts such as wheelies or jumps Don t try to show off POTENTIAL HAZA...

Страница 75: ...in some situations could lead to an accident HOW TOA VOID THE HAZARD Never modify thisATV through improper installation or use of accessories All parts and accessories added to this vehicle should be...

Страница 76: ...ATV in a place where others might be likely to touch it POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Hot exhaust system Dry grass or brush or other combustible material accumulated around...

Страница 77: ...ously affect handling and control of the ATV and may cause the vehicle to go out of control HOW TO AVOID THE HAZARD Always avoid paved surfaces including sidewalks driveways parking lots andstreets BE...

Страница 78: ...NTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Operating thisATVon public streets roads or highways You can collide with another vehicle Never operate this ATV on any public street road or highw...

Страница 79: ...ilure to use extra care when operating this ATV on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in theATV overturn ing or...

Страница 80: ...terrain Could cause loss of traction or vehicle control which could result in an accident including an overturn Do not operate on excessively rough slippery or loose terrain until you have learned an...

Страница 81: ...perating in areas where you might not be seen by other off road vehicles WHAT CAN HAPPEN You could be in a collision You could be injured HOW TOA VOID THE HAZARD Always mount a caution flag on theATV...

Страница 82: ...cause the tires to lose traction reducing control and increasing the possibility of an accident Select a large flat area off road to become familiar with your ATV Make sure that this area is free of o...

Страница 83: ...rol causing acollision or overturn HOW TOA VOID THE HAZARD Always follow proper procedures for turning as described in this Owner Manual Practice turning at low speeds before at tempting to turn at fa...

Страница 84: ...ave learned this technique you should be able to perform it at higher speeds or in tighter curves Improper riding procedures such as abrupt throttle changes excessive braking incorrect bodymovements o...

Страница 85: ...to lose control POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN Thevehiclecanoverturnmoreeasilyonextremelysteep hills than on level surfaces or small hills HOW TOA VOID THE HAZAR...

Страница 86: ...cribed in this Owner s Manual Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the thr...

Страница 87: ...mastered the turning technique as described in the Owner Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill ifpossible If you are climbing a hill...

Страница 88: ...ossing the side of a hill Always follow proper procedures as described in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV USE...

Страница 89: ...nt brake or the rear brake will brake all wheels When descending hills using either brake lever or the brake pedal will brake the wheels on the down hill side Avoid sudden application of either the fr...

Страница 90: ...en fully stopped apply the rear brake as well and then lock the parking brake 4WD Apply both front and rear brakes gradually When fully stopped lock the parking brake Dismount on uphill side or to a s...

Страница 91: ...ing may also cause a loss of traction Whenever possible ride your ATV straight down hill Avoid sharp angles which could allow the ATV to tip or roll over Carefully choose your path and ride no faster...

Страница 92: ...n hills as described in this Owner s Manual Note a special technique is required when braking as you go down a hill Always check the terrain carefully before you start down any hill Shift your weight...

Страница 93: ...yourATV does begin to tip over 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 you wish totravel PO...

Страница 94: ...88 USER S MANUAL...

Страница 95: ...and carefully llow POTENTIAL HAZARD Operating thisATV through deep or fast flowing water WHAT CAN HAPPEN Tiresmayfloat causinglossoftractionandlossofcontrol which could lead to an accident HOW TOAVOI...

Страница 96: ...re to drain the trapped water by removing the check hose at the bottom of the air filter case the V belt cooling duct check hose the drive select lever box check hose and the storage box check hose Al...

Страница 97: ...Drive select lever box check hose V belt case drain plug 91 V belt cooling duct check hose left front side ofATV Storage box check hose USER S MANUAL...

Страница 98: ...the ATV as loss of control and damage to the ATV may result POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Improperly operating over obstacles Could cause loss of control or a collision Coul...

Страница 99: ...for the front wheels to slide in loose or slippery conditions positioning your weight over the front wheels will sometimeshelp If the rear wheels of yourATV start to slide side ways control can usuall...

Страница 100: ...ch as ice since all control may be lost POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Skidding or sliding improperly You may lose control of this ATV You may also regain traction unexpected...

Страница 101: ...ary gradually let off the throttle and or steer to the outside of the turn See pages 77 78 If yourATV starts to slide sideways Steer in the direction of the slide if you have the room Applying the bra...

Страница 102: ...the ATV is going to tip over dismount on the uphill side See pages 87 88 If your ATV encounters shallow water Rideslowlyandcarefullythroughslowmovingwater watching for obstacles Be sure to let water d...

Страница 103: ...rt fires Turn off the engine when performing maintenance unless otherwise specified Have aATVdealerperformserviceifyouarenotfamiliar with machine service Owner s manual and tool kit You are recommende...

Страница 104: ...this ATV with improper modifications Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident Never modify...

Страница 105: ...400 2400 4800 200 750 1500 1500 3000 20 75 15 15 30 Every 20 40hours More often in wet or dusty areas Valves Spark plug Check valve clearance Adjust if necessary Check condition Adjust gap and clean R...

Страница 106: ...eck operation Select lever safety system cable Check operation Adjust if necessary V belt Wheel Check operation Check for cracks or damage Check balance damage runout Repair if necessary Check bearing...

Страница 107: ...re special tools data and technical skills have a HSUNdealer pertorm the sevice NOTE Recommended brake fluid DOT 4 Brake fluid replacement When disassembling the master cylinder or caliper replace the...

Страница 108: ...n this chapter Refer to this section each time the panel has toberemoved or installed Panel A Panel A To remove Remove the bolt and then take the panel off To install Place the panel in the original p...

Страница 109: ...oil filter cartridge replaced at the intervals specified in the periodic maintenance and lubrication chart 1 Place the ATV on a level surface 2 Start the engine warm it up for several minutes and then...

Страница 110: ...neoilshouldbebetweentheminimumandmaximum level marks NOTE Maximum level mark Minimum level mark 7 Insert the dipstick into the oil filler hole and then tighten the oil filler cap 6 If the engine oil i...

Страница 111: ...ce an oil pan under the engine to collect the used oil and then remove the engine oil filler cap 3 Remove the engine oil drain bolt to drain the oil from the crankcase NOTE Skip steps 4 6 if the oil f...

Страница 112: ...er wrench is available at a nearby ATVdealer 5 Apply a light coat of engine oil to the O ring of the new oil filter cartridge Make sure the O ring is seated properly NOTE NOTE O ring Oil filter wrench...

Страница 113: ...ng torque Engine oil drain bolt 23 N m 2 3 m kgf 16 ft lbf 8 Add the specified amount of recommended engine oil and then install the engine oil filler cap and tighten it Tightening torque Oil filter c...

Страница 114: ...art the engine and warm it up for several minutes While warming up check for oil leakage If oil leakage is found turn the engine off immediately and check for the cause 10 Turn the engine off and then...

Страница 115: ...ase 4 Install the oil filler bolt and then tighten it tothe specified torque Tightening torque Final gear oil filler bolt 23Nm 2 3m kgf 16ft lbf 2 Place the machine on a level surface 3 Place a contai...

Страница 116: ...m of the filler hole Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity 0 23 L 0 20 Imp qt 0 24 US qt Be sure no foreign material enters the final gear case 7 Install the oil filler bolt and...

Страница 117: ...ear case to catch the oil 3 Remove the oil filler bolt and oil drain bolt to drain the oil Differential gear oil filler bolt Differential gear oil drain bolt 4 Install the oil drain bolt and then tigh...

Страница 118: ...pacity is greater than the recommended oil quantity therefore the oil level cannot be accurately checked from the oil filler cap hole Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity 0 35...

Страница 119: ...Check the protective boots for holes or tears If any damage is found have them replaced by a ATV dealer Axle boot 2 each side Spark plug inspection Removal 1 Remove the spark plug cap Spark plug cap...

Страница 120: ...ormally Do not attempt to diagnose such problems yourself Inspection Instead take theATVtoaATVdealer Youshouldperiodically remove and inspect the spark plug because heatanddeposits will cause the spar...

Страница 121: ...spark plug threads 3 Install the spark plug and tighten it to the specified torque NOTE If a torque wrench is not available when you are installing a spark plug a good estimate of the correct torque i...

Страница 122: ...hose and clean the air filter element and air filter case 1 Remove the seat See page 28 for seat 2 Remove the air filter case coverbyunhook NOTE removal and installation procedures ingtheholders 3 Re...

Страница 123: ...THE HAZARD Using low flash point solvents or gasoline to clean the air filter element Low flash point solvents or gasoline can catch fire or explode Use parts cleaning solvent to clean the air filter...

Страница 124: ...more often if the machine is operated in extremely dusty areas Each time the air filter element maintenance is performed check the air inlet to the filter case for obstructions Check the air filter c...

Страница 125: ...eck hose Left front side ofATV V belt case drain plug After riding in water deep enough to allow it to enter the V belt case remove this plug to drain the water from the case NOTE If water drains from...

Страница 126: ...2 Remove the tailpipe by pulling it out of the muffler 3 Tap the tailpipe lightly and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe Spark arreste...

Страница 127: ...start the engine when cleaning the exhaust system Carburetor adjustment The carburetor is a vital part of the engine and requires very sophisticated adjustment Most adjusting should be left to aATV de...

Страница 128: ...and then set the idle to the specified idling speed by adjusting the throttle stop screw Turn the screw in directiona to increase the engine speed and in direction b to decrease the engine speed Speci...

Страница 129: ...nt however should be left to aATV dealer Select lever safety system cable adjustment Throttle lever adjustment Adjust the engine idling speed before adjusting the throttle lever free play 1 Loosen the...

Страница 130: ...ke pads for damage and wear If a brake pad thickness is less than 1 mm 0 04 in have a ATV dealer replace the pads as a set The wheels need to be removed to check the brake pads See pages 134 135 for r...

Страница 131: ...to replace shoes as a set Brake fluid level check Insufficient brake fluid may let air enter the brake system possibly causing the brakes to become ineffective Before riding check that the brake fluid...

Страница 132: ...fluid DOT 4 Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor brake performance Be careful that water does not enter the brake fluid re...

Страница 133: ...e the following components during periodic maintenance or when they are damaged or leaking Replace the oil seals every two years Replace the brake hoses every four years Front brake lever free play Th...

Страница 134: ...uld lead to an accident After servicing Make sure the brakes operate smoothly and that the free play is correct Make sure the brakes do not drag Make sure the brakes are not spongy All air must be ble...

Страница 135: ...129 Brake lever free play adjustment 1 Loosen the locknut and fully turn in the adjusting bolt at the brake lever Locknut Adjusting bolt USER S MANUAL...

Страница 136: ...between the brake camshaft lever and the pin Adjusting nut brake lever cable a Gap 3 Turn the adjusting bolt at the brake lever until the free play at the brake lever pivot is 3 5mm 0 12 0 20 in Lockn...

Страница 137: ...onal knowledge These procedures should be performed by a dealer Adjusting the rear brake light switch The rear brake light switch which is activated by the brake pedal and rear brake lever is properly...

Страница 138: ...of control cables becomes damaged Cables can also become frayed or kinked Operation of controls could be restricted which could cause an accident or injury Inspect cables frequently Replace damaged ca...

Страница 139: ...d brake pedal Lubricate the pivoting parts To access the brake pedal pivot remove panel A See page 102 for panel removal and installation procedures Recommended lubricant Lithium soap based grease all...

Страница 140: ...134 Wheel removal 1 Loosen the wheel nuts 2 Elevate the ATV and place a suitable stand under the frame 3 Remove the nuts from the wheel 4 Remove the wheel Nut 4 USER S MANUAL...

Страница 141: ...s tapered side towards the wheel The arrow mark on the tire must point toward the rotating direction of the wheel Tapered nut NOTE 2 Lower the ATV so that the wheel is on the ground 3 Tighten the whee...

Страница 142: ...could be poisoned You could be severely burned by the sulfuric acid in battery electrolyte Batteries produce explosive gases Avoid contact with skin eyes or clothing Always shield eyes when working ne...

Страница 143: ...or recharging a sealed type battery Using a conventional battery charger may shorten the battery life 2 Always make sure the connections are correct when putting the battery back in the machine Fuse r...

Страница 144: ...Fuse box Specified fuses Main fuse 30A Headlight fuse 15 A Ignition fuse 15 A Four wheel drive fuse 3 A Signaling system fuse 10 A Headlight fuse Ignition fuse Four wheel drive fuse Signaling system f...

Страница 145: ...e a fuse of the specified rating Never use a material in place of the proper fuse To prevent accidental short circuiting turn off the main switch when checking or replacing a fuse Replacing a headligh...

Страница 146: ...2 Remove the headlight bulb holder by turning it counte rclockwise 3 Remove the defective bulb by unhooking the headlight bulb holder tabs Headlight bulb holder Headlight bulb holder tab 2 USER S MAN...

Страница 147: ...it 4 Insert a new headlight bulb into the bulb holder and then secure the bulb by hooking the tabs onto the bulb Do not touch the glass part of the bulb Do not touch the glass part of the headlight b...

Страница 148: ...ulb holder cover at the rear of the headlight Headlight beam adjustment It is advisable to have aATV dealer make this adjustment To raise the beam turn the adjusting screw in direction a To lower the...

Страница 149: ...an cause poor starting and loss of power The troubleshooting chart describesa quick easyprocedure for making checks If your machine requires any repair take it to a ATV dealer The skilled technicians...

Страница 150: ...l system while smoking or near an open flame Fuel can ignite or explode causingsevereinjuryorproperty damage Do not smoke when checking the fuel system Make sure there are no open flames or sparks in...

Страница 151: ...f there is compression There is compression No compression Compression nomal Ignition system is nomal 3 Lgnition Remove thespark plug and check the electrodes Wet Dry Wipe clean with dry cloth Attach...

Страница 152: ...to the wheel axles 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job Excessive water pressure may cause water seepage and deterioration of wheel bearings br...

Страница 153: ...ves which may mar the paint or protective finish When finished start the engine and let it idle for several minutes POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Operation with wet brakes a...

Страница 154: ...minates the need to drain the fuel system Consult a ATV dealer if the fuel system needsto be drained instead 2 Remove the spark plug pour about one tablespoon of SAE 10W30 or 20W40 motor oil in the sp...

Страница 155: ...e it Store it in a dry place and recharge it once a month Do not store the battery in an excessively warm or cold place less than 0 C 30 F or more than30 C 90 F Make any necessary repairs before stori...

Страница 156: ...base Ground clearance Minimum turing radius Basic weight With o il and full fuel tank 577 7 lbs Oil cooling 4 stroke SOHC Forward inclined singlecylinder 387cc 83 71 6 mm 9 50 1 Electronic Ignition wi...

Страница 157: ...Carburetor Type quantity Manufacturer Spark plug Type manufacturer Spark plug gap Clutch type SAE80 API GL 4 Hypoid gear oil 0 23 L 0 20 Imp qt 0 24 US qt SAE80 API GL 4 Hypoid gear oil 0 35 L 0 31 Im...

Страница 158: ...r angle Trail Tire Type Size Brake Front brake Rear brake V belt Shaft dr ive 41 21 24 18 33 9 9 545 V belt automatic Left hand operation 35 20 1 750 26 15 1 733 Steel tube frame 4 21 mm 0 83 in Tubel...

Страница 159: ...ck absorber Wheel travel Front wheel travel Rear wheel travel Electrical Ignition system Generator system Battery type Battery capacity Head li ght type Double wishbone Swingarm monocross Coil spring...

Страница 160: ...t Reverse indicator light Oil temperature warning light Four wheel drive indicator light Fuses Main fuse Headlight fuse Ignition fuse Four wheel drive fuse Signaling system fuse 12 V 30 30 W 2 12 V 5...

Страница 161: ...o the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CO...

Страница 162: ...Y M D Y M D Y M D Y M D Y M D Y M D Y M D Y 1 2 3 4 5 6 7 8 9 10 500 1000 1500 3000 4500 6000 7500 9000 10500 12000 USER S MANUAL 156 Oil Oil Filter All nuts Oil Filter Oil Filter Oil Filter Oil Filte...

Страница 163: ...e Mileage km Items Maintained Dealer M D Y M D Y M D Y M D Y M D Y M D Y M D Y M D Y M D Y M D Y 11 12 13 14 15 16 17 18 19 20 10000 Oil Air Cleaner Spark plug Brake fluid USER S MANUAL 157 MAINTENANC...

Страница 164: ...ONLY by authorized QLINK MOTOR dealers Any warranty work done by an unauthorized QLINK MOTOR dealer will not be covered under the warranty policy Periodic services and inspections can be performed by...

Страница 165: ...crate damage and the unit has not yet been sold Initial dealer pre delivery inspections and set up of the product is very important in ensuring trouble free operation Warranty starts from date of purc...

Страница 166: ...ster 2 Years Unlimited Miles Battery when purchased with new unit Battery 30 Days Unlimited Miles Suspension Shocks Forks 1 Year Unlimited Miles Brake Caliper 2 Years Unlimited Miles Exhaust Header pi...

Страница 167: ...trical Harness CDI Inst Cluster 1 Year Unlimited Miles Battery when purchased with new unit Battery 30 Days Unlimited Miles Suspension Shocks Forks 1 Year Unlimited Miles Exhaust Header pipe Muffler 1...

Страница 168: ...Boards Pegs Oil Fuel Filters Grips Motor Mount Bushing Any damage which results from the following are not covered by warranty Unavoidable natural disasters fire collision theft improper storage or t...

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