HS350ATV HS400ATV PART ONE.p65
Contents
1. during a service qoeratian requiring ae take your machine toa ATV dealer to dx te 98 A WARNING POTENTIAL HAZARD Operating this AT V with improper modi WH AT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in same situ ations could lead to an accident HO WTO AVOID THE HAZARD Never modify this ATV through improper installaticn or use of accessories All parts and accessories added to this vehicle should be genuine ATV ar equivalent components designed for use qn this ATV and should be installed and used according to instructions If you have questions consult an authorized AT V dealer E 3 e 6 12 ROUTINE 4 800 SECUS 3 000 mur ewuesseszgewemama Engine oil filter cartridge emegace O Q gre cii cain Final gear oil Check for oil leakage Differential gear oil Replace every 12 months Front brake Correct Rear brake Select lever safety system cable V belt e Check operation e Check for cracks or damege Wheel Check balance damage runout Repair if necessary Check bearing asserblies for losseness damege Wheel bearing e Replace if damaged LN Front and rear Check operation m suspension Correct if necessa Steering system e Check operaticn Replace if damaged e Check toe in Adjust if necessary Drive shaft universal joint e Lubricate with li2. POTENTIAL HAZARD Turning improperly id and lean your ugper body into the tum WH AT CAN HAPPEN Use the throttle to maintain an even speed trau AT V cauld go at c antral asiy 8 ch tre tum This maneuver will let the wheel the ingide of the tum slip sligatly allowing tre ATV to meke the tum praoerly collisim ar overtum CLIMBING UPHILL Use gor riding tedmugues to avoid vehicle overtums hills Be sure that you can maw er yor ATV well flat ground before atat ing any ircline ard thn practice riding first cattle slgos Try nore dif fiait clints aly after you have develqoed your skill In all cases aid inclines with slippery ar loose surfaces ar dostacles that might cause you to lose como WARNING POTENTIAL HAZARD Qoerating excessively steep hills WHAT CAN HAPPEN The vehicle can overturn more easily extremely steep hills than level sur faces or small hills HOWTO AVOID THE HAZARD Never qoerate the AT V an hills too steep for te AT V a fx your abilities Practice on smaller hills befare attempting large hills It is important when climbirg a hill to meke sure that your weight is transferred forward on the AT V This can be accomplished by leaning forward and stesoer inclines standing an the footboards and leaning forward overthe handlebars If you are climbing a hill and you find that you have not properly judged your ability to make it to the t you tald t
3. 27 PTE E 28 EIDA E 2 dM NR MU CEU 29 Cs dd Re eRe ET 3 02 405 da TR 3 Front shock absorber adjgmet 3 Rear dock dereer eee cece eee 31 PRE OPE RATION ORKIS 3 soscacexc ced erac 33 Bir ua Hes oct ae 34 lcm n 36 y en e me RM Cm 113 DNIFS z 38 eria EPE pro 113 116 119 V 119 120 Eie 1 121 Ne Sree aE soU EUM 12 Vabheclezxaveadygmet 2 cece cece cece eee 122 123 1 125 Bate Thi level dek eeeeee 125 127 Hort babe lege Bee play cc 127 Rear rake pedal ard lever adjgmet 128 Adjusting the reser eke lidt switch 131 Ghe tnggection ad TICS eee ee eee 132 Tuloricating the brake levers and ra en 13 ke 225 ot TA Poet EY 0e
4. AED T Eh m xs ca i Hor dE t y r P m a fal ry ess gt IN 1 Jr mT j Lu e n RC j Lu J in 47 F s ks P c 1 oa 9 Es p ks 1 Four wheel drive switch 2WD 4WD 2 Emergency light switch 19 fit On Command four wheel drive switch 2WD AWD To change from two wheel drive 2WD to far wheel drive D st the ATV and set the switch to the 4WD position To change from four wheel drive 4WD to two wheel drive WD st the ATV ads the switch to the 2WD positian 19 A WARNING POTENTIAL HAZARD Changing from 2WD to 4WD or from AWD to 2WD while the ATV is movirg H AT CAN HAPPEN e ATV handles differently in 2WD than in 4WD in some circumstances ently This could distract the cperator and increase the risk of losing control and an accident OWTO AVOID THE HAZARD Always stop the ATV before changing from 2WD to 4WD or vice versa Emergency light switch When ATV hagosns to be troublesare or other cantitions db reed st the vehicle ridi away to wmn cther drivers Speed limiter The speed limiter keeps the throttle from fully cpenirg even when the throttle lever is pushed to the meximum Tuming in the adjusting screw limits the meximum engine power available and decreases the mximm speed of the ATV 1 Todt 2 Adjusting screw a 12 m 0 47 in 21 POTENTIAL HAZARD Improper adjustment of the
5. ENERGY CONSERVING II or higher 5 Make sure that no foreign material en ters the crankcase 9 10 Start the engine and warm it up for seve ral minutes While warming up check for oll leakage If oil leakage is ford tum the engine off immediately and check for the cause Tum the engine off and then check the ail level ard aret it if necessary Firal gear Final gear oil measurement 1 Place the mhire ma level surface 2 Rowe the ail filler bolt acd thn dx te ail leel in te Grel oer Gee NOTE Tre ail level dod ke at the bom cf tte filler role 4 Roe th al filler bolt ard tbe drain bolt to 5 Install tte drain bolt ard thn tid ten it to tte Tightening torque Firal r al drain belt 23 Nn 2 3m kof 16 ft 158 6 Add the recomended final gear oil to the bom of the filler tole Recommended oil CAF 80 API GL 4 Hypoid gear oil Qu qatity 0 23 L 0 20 mp at 0 24 UB at CAUTION Be sure ro foreign material enters the final gear case 7 Install te al filler bolt ad thn tidten it to 8 Check for al leskace oil leskage is ford d k for the case 9 Install th firal gear cese cover bolts ad thn taghten them to the specified tace Tightening torque Final gear case cover bolt 16 Nn 1 6 m kf 11 ft 8 5 Fill the differential g r case with the soeci fied amount of the reocuamerced oil NOTE o nx exceed the specified differential gear oil quantit
6. THE HAZARD Always check the brekes at the start of every ride Do mx ride the AT V if yu find any prcblem with the brakes If a problem cannot be corrected by the adjustment procedures provided in this manual have a dealer check for the cause Gasohol There are two types of casdwl caschol containing ethanol and that containing methanol Gaschol containing ethanol can be used if ethanol content does not exceed 10 Gasohol containing methanol is not reconmended by ATV because it may cause fuel system damage or vehicle performance problems 1 Rel leal 2 Rel tak filler the POTENTIAL HAZARD Improper care when refuelirg WH AT 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 cut due to h t fram the engine or tte an HOWTO AVOID THE HAZARD Do not overfill the fuel tank Be careful not to spill fuel especially cn the engine or exhaust pipe W ipe up any spilled fuel immediately Be sure the fuel tank cap is closed securely Do no refel rigt after the engine has been ruming and is still very I Mke sure the dif ferarial r al is at te soecified level Add oil as necessary Sese peces 110 111 for dais Recommended oil SAE 80 API GL 4 Hypoid gear oil Thratle lever Check to see that the throttle lever qerates correctly It must smoothly and soring back to the idle positicn when released Have a ATV d
7. cecresse the aire sed Specified idle speed 1 450 1 550 r min 1 Throttle stoo screw Valve clearance adjustment The correct valve clearance changes with use resulting in improper fuel air suly or engine mis To prevent this the valve clearance must be adjusted regularly This adjustment however gald be left to a pofessosel ATV szavice Front brake pad check Check the brake pads for damege ard wear a brake pad thickness is less than 1 mm 0 04 in leve a ATV daler replace te ps as a s a Brake pad thickness OO _ c S IL Ihe wheels need to be removed to check the brake pads See pages 134 135 for rewval ad installaticn proce res CQoserve these precautiqns e Brake fluid may deteriorate painted surfaces ar When checdkdng the brake fluid level mke sure plastic parts Always clean up spilled fluid the tgo of the brake fluid reservoir is level immediately Use cnly the designated quality brake fluid tye a dealer dx the ease if tbe brake fluid otherwise the rubber seals may deteriarate level goes down causing leakage and poor brake performance Recommended brake fluid DOT 4 Refill with the sme type of brake fluid Mix irg fluids may result in a harmful chemical reactian and lead to poor brake perfornence Be careful thet water d s ncc eter te breke ificantly lower the boiling point of the fluid and may result in vapar lock WARNING POTENTIAL HAZARD
8. oo Cd etas 137 FREES PN 5 decks Stank 137 Ro rgalsdidthib e T3 142 Talade lidtbibrplammaet 143 x cern NR 143 Ta DIES E d aE S ode e re pra ed 45 9 CLEANING AND 146 IN CERES dudo ios ede uo dodo eO 16 D S 123 10 SSPEETETCATENES esee desto 1 It NOISE REGU ATEN e CU MO ve 1 i i IGATION OF THE WARNING AND SHIPKATION LABELS i SEPT mL T D n l l 5 3 i A WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH 4 WARNING Overloading this ATV or carrying cargo improperly can change handling stability and braking performance and can lead to an accident Never exceed the maximum rear cargo limit of 80kg 176 Ibs NEVER sit on the carrier Refer to instructions in the Owner s Manual Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER CARRY NEVER USE AN APPROVED PASSENGERS WITH DRUGS HELMET AND OR ALCOHOL PROTECTIVE GEAR Q NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions with a passenger passengers affect balance and steeri
9. shifting into the neutral positian WH AT CAN HAPPEN Ihe ATV could start to move unexpect edly which could cause an accident HOWTO AVOID THE HAZARD Shift the drive select lever into the neu tral position and apply the parking brake before starting the agire 25 Fuel tank cap Remove the fuel tank cap by turning it coun terclockwise Garter due 4 Starting a cold engine requires a rider air fiel mixture A separate starter circuit supplies this mixi e Move in direction 4 amp to tum the starter dicke Move in direction b to tum off the starter dicke Refer to Starting a cold engine for proper eration Gee pece 43 1 Arrow mark pointing to RES Storage box Maximum load limit 2 kg 4 4 10 CAUTION To protect from damage do not put metal products like tools or sharply edged prod ucts directly in the storage box If they must be stored wrap them in appropriate 1 Storage box NOTE There is a check hose at the bottom of the storage box If any water collects in this hese remove the hose empty it and then install it WARNING POTENTIAL HAZARD Improper shock absorber adjustment WH AT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability which could lead to an accidert HOWTO AVOID THE HAZARD Always adjust the shock absorbers on the left and right s
10. which could allow the ATV to tip x roll oe Carefully chose your path and ride no faster than you will be able to react to dostacles which may appear CROSSING A SLOPE Traversing a sloping surface cn your ATV 1e quires you to properly positim your weight to maintain proper balance Be sure that you have leamed the basic riding skills cm flat ground be fare atterpting to cross a sloping surface Avoid slqoes with slippery surfaces ar rough terrain that may upset your balance As you travel across a slope l n your body in the udull directian It may be necessary to arret the steering when riding cn loose surfaces by pointing the fat wels sligtly yhli When riding con sloces be sure to make sharp tums either up or down hill If yor ATV does begin to tip oer gredaally st r in the dwhill directian if there are ro costacles in your path As you regain proper balance gradually steer again in the directian you wish to tael 87 WARNING POTENTIAL HAZARD Impra rly crossing hills ac tuming Hills WHAT CAN HAPPEN Could cause loss of amtrol a cause tre ATV to xer m H O WTO AVOID THE HAZARD Never attempt to tum the ATV arround on any hill until you have mastered the tum ing technique as described in the Owner s Manual on level ground Be very careful when tuming cn any hill Avoid crossing the side of a steep hill if possible When cr sirg the side c a hill Always follow proper procedures as d
11. 10 minutes CAUTION The engine may overheat if the ATV overloaded If this happens reduce the l d to specificatian Restart after making sure that the light is out Continuous use while the light is on may cause damage to the en gire Left tuming indicator Light After open left turning light cntrol left turning indicator light is on Small course demenstraticn Small course table demenstraticn only records course number before closing electrical somce If restart electrical samc after closing it small course derenstraticn will record again Speed demenstration Speed demenstration is moving speed of the ATV Total course demenstration Total course demenstratim is total moving course of ATV and can keeps memory Right tuming indicator light After open turning light cntrol ridit turning indicator light is on Metric English system transfer indicator button Metric English system transfer indicator button can control transfer indicator between meric and English in meter Matic system demenstraticn indicator light Metric system damenstraticn indicator light is it indicates that vehhicle speed demenstratcn is KM h High beam indicator light High beam indicator light is cn it indicates large headlight source English system demenstration indicator light English system darenstratian indicator light is it indicates that vehicle speed demenstraton is mph High and low beam switch Engine fl
12. 7 s c l Rear dock amwe asemly 12 Frm sock aborer aambly pring pelad adjustirg ring prng pelad adj wtirg ring J 2 Spark mete B Vbelt wo ing dut dhek hose T 0 2 D 3 torge bax ard t l kit 14 0il filter artrde i 4 Spark plug 15 Hgine oil dipstick A E CIE 5 Fort dod aborer ashy b Ra brke lever T el 1 i a M s pring pelad adjustirg rng 17 left hadba switdies YAH RAS BUE Se 6 Bak pal 8B ater dwk eS eh 7 V belt cose 19 Dive seed lever e CON XS 8 Fwuel ok 20 Min switch ra N 9 Air filer cee 2 el tak ap S 10 Fuses 22 Ridit hadlekarswitch 11 Tal bzrke ight 2 Throttle lever 214 Frmt brak lever NOTE The machine you have purchased may dif fer sligtly fram those shown in the figures of this renal 11 CONTROL FUNCTIONS A WARNING Indicates a potential hazard that could result in serious injury or h Main switch Functions of the respective switch positicns are as follow ON The engine can be started ally at this positim 1 Main switch and the headlights and taillight com cn when the lidt switch is OFF All electrical cirauts are switchsd The key can be reroved in this positicn Oil temperature waming light Oi When the oil temperature reaches a specified level this light coms cn to wm that the en gine oil temperature is too hot If the light cames on during operation stop the engine as som as it is safe to so ard allow the en gine to cool dow for about
13. D THE HAZARD Never consume alcohol or drugs before ar while driving thus AT V WARNING Indicates a potential hazard that could result in serious injury ar death Do nct operate at speeds too fast for your skills ar the axuitiass POTENTIAL HAZARD Operating this AT V at speeds too fast far yar skills ar the omditims WHAT CAN HAPPEN Increases your chances of losing ccn trol of tte AT V which can result inan accident HOWTO AVOID THE HAZARD Always go at a speed that is proper for the terrain visibility and qoerating n ditians and your experience Speed limiter Por riders less experienced with this noel this model is eguipped with a speed limiter in the throttle from fully qaim even wen the thraccle lever is pushed to the neximm Tumirg tre adjusting screw in limits the meximum engine power available and decreases the meximum sp d of the AT V Tumurg the adjusting screw in decreases tcp speed and tum rg it aut increases tcp sp d ecu 2 A EA Ca E A CIK i X 1 Iont 2 Adjusting screw During operation Always keep your feet the foctboaras during cperaticn Otherwise your feet may the rear Weels 67 A WARNING POTENTIAL HAZARD Removing hands from handlebars or feet fram footboards during operaticn WH AT CAN HAPPEN Removing even one hand or fot n reduce your ability to amtrol the AT V a could cause you to lose your balance and
14. IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEAIH Particularly important informaticn is distinguished in this manual by the following notations Ihe Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVO LVED Failure to follow warning instructicns could result in aevere A WARNING injury or death to the machine operator a bystander or a persa inspecting or repairing the machine A CAUTION indicates special precautions that must be taken to avoid damage to the machine NOTE A NOIE provides key informaticn to make procedures easier or clearer CAUTION 4 WARNING Indicates a potential hazard that could result in serious injury or death CONTENTS 1 LOCATION OF THE WARNING AND SPECIFICATKNIZPHS 1 2 SAFETY INBFORMATEN ub eet eii 5 3 DESCRIPTION AND MACHINE DEIN TEES CATION i pero we AO ebesicteo edi 11 Vednde j1od8tificardmnnmnte Luuue 12 A OGNIR ORANI debet oseutaus ees 13 DOT Sut ecu ERE E TE E E UE Adde B doctor ad varnrg en nee ny ee eer er pe 14 Haar GUIS Lees Des ese eue SER Eau ro Su OR UEEUS 17 gleia ra SAS am EE 20 TE I 21 e 75 ST 5 Sac CIL 22 Bae peal ad reer Exeleve 22 IE SILBA E S PM 23 DE cadi qe PR A ID UE 72 dU oan eee een E MEN MO 33 PUES CNG RN PET NL 2b ER AT 25 Mid dB c MENU RE NN
15. Operating with improperly serviced or adjusted brakes WH AT CAN HAPPEN You could lose braking ability which could lead to an accident HO WTO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the free play is came e Make sure the brakes do not drag e Make sure the brakes are not spongy All air must be bled from the brake system Replacement of brake components re quires professional knowledge These procedures should be performed by ATV a daler Rear brake pedal and lever adjustment Brake pedal free play adjustment 1 Fully locem the adjusting mut an the brake lever cable at the reer Weel 1 Adjusting nut brake pedal cable 2 Adjusting nut brake lever cable 2 Tum in the adjustirg mut an brake cable to 3 Tum th adjustirg bolt at the bake lever util proide ap of 0 1mm 0 0 04 in b the free play at te bale lever put is 3 5 nm 0 12 0 20 in e Mona L Adjusting nut brake lever cable a Gp 1 Iont 2 Adjusting bolt a Rear brake lever free play 4 Tighten the lockat Cable inspection and lubricatioan A WARNING POTENTIAL HAZARD Damaged control cables WHAT CAN HAPPEN Corrosiaa can result when the outer covering of control cables becomes damaged Cables can also become frayed or kinked Qperaticon of controls could be restricted which could cause H O WTO AVOID THE HAZARD Inspect cables frequently Replace dam ag
16. al 0 87 US gal Carburetar Type quantity Manufacturer DR8EA NGK 0 6 0 7mm 0 02 0 08 in Double wishbone Swi ngar m monocross 160 mm 6 30 in 180 mm 7 09 in DC C D I A C magneto YTX14AH 2 Ah NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing therecf 1 The renwal ar renin imperative by any person other then for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of mis atal prior to its sale ar delivery to the ultimate purchaser or while it is in use 2 the use of the vehicle after ach device ar eleet of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tanpering with the following systems i e modificatim removal etc 156
17. ame out 15 XO Horn switch Electrical starter switch i 8 1 Turning light switch 6 light switch e TX im i When ligat switch is pxned to RE of th first r taillidr Bow lidt ad mter lidt will het When light switch is pushed to 3 of the soad gear taillidi front dt large hesdlidt ard meer When ligt switch is puhd to A of the sa gear and press down the buttm of high amp low beam switch and hich amp low bean of large headlight will shift it Mm A WwW NE 17 comespodingly ad indicata ligt Z0 m the meter plate also will lidt be at aresadirgly CAUTION Do not use the headlights with the engine turned off for more than thirty minutes The battery may discharge to the point that the starter motor will not operate properly If this should happen remove the battery and recharge it Tumin light switch omitrd Press tntg lidt switch left left fat umir lidt left rear tum rg lidt ad meter left tum rg indicata bgt ae lt Press tung lidt switch ridt ridt fat tinig lidt ridt rear tumung lidt and meter night tumung irdica tor lidt ae lit Press tumirg lidt switch middle all tumurg ligt ad tumirg indicator lidt ae at WARNING When change vehicle lines or tum each time cn the move must form the habit of sending sional After frr ishing changing vehicle lines or tuming cperatian must close tuming lidt a REE p a Tu p ra m L n I EF 3 i j P Les nw go wE
18. case is excessively gey apoly degreaser with a paint brush Do rcc apgoly degreaser to the wel axles 3 Rinse the dirt ad degreeser cff with a garden hose Use oily enough pressure to cb tre jd CAUTION Excessive water pressure may cause water seepage and deterioration of wheel bearings brakes transmission seals and electrical de vices Many expensive repair bills have result ed from improper high pressure detergent applications such as those available in coin operated car washers 4 Once the majority of the dirt has been hosed off wash all surfaces with warm water and mild detergent type scgp An old tocthbrush or bottle brush is handy forhard to get at places 5 Rinse the machine off immediately with clean water and dry all surfaces with a chamois clean towel ar soft absorbent cloth B STORAGE Iong term storage 60 days or more of your machine will require same preventive proce dures to guard against deterioraticn After thoroughly cleaning the machine prepare for starage as follows 1 Fill the fuel tak with fresh fuel ard add the specified aart of ATVFuel Stabilizer and Conditioner or an equivalent product Specified aart tAili r to ech plo of fuel 7 5 cc c tdili r to ch liter fiel NOTE Use of fuel stabilizer and aatia eliminates the reed to drain the fuel system Grgmult a ATV dealer if the fuel system resckto be drained insted 2 Remove the spark plug pour abou
19. dill side POTENTIAL HAZARD S amp allirg rolling backwards or improperly disrounting while climbing a hill WHAT CAN HAPPEN Could r t ii AT V overtumirg HOWTO AVOID THE HAZARD Maintain steady speed when climbing a hill If you lose all forwerd speed Keep weight yill Apoly the brakes Apply the parking brake after you are stopped RIDING DOWNHILL When riding your AT V dowiull shift your veignt as far to the rear ard yill side cf te ATV possible Move back cn the seat ard sit with your ams straigt Engine compressian will nest of the braking for you For maximum engine c pressicn braking effect change to 4WD before begiming to descend the hill Improper braking may caue a loss of tractim Ube cautim wile desce rdirg a hill with loose or slippery surfaces Brak ing ability and tractian may be adversely af fected by these surfaces Inor braking may also cause a l s c tatio 85 When this ATV is in 4D all weeels fat and rear are Intercomsected by the drive train This means that applying either the front brake or the rear bake will hake all weels When descending hills using either brake lever or the brake pechl will brake the wheels cn the down hill side Avoid sudden agolicaticn of either the front or rear brake because the wheels cn the uhill side could care Gf the gard Apoly both the front and rear brakes gradually Whenever possible ride your ATV straigt dw hil Avoid sharp angles
20. e scribed in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uchill side of the AT V CROSSING THROUGH SHALLOWWATER The ATV can be used to cross slow moving shall ow water of up to a maximum of 35 cm 14 inches in dacth Before entering the water doo se your path carefully Enter were thee is ro sharp drop of f ard avoid rocks or other dostacles which may be slippery or upset the ATV Drive slowly ard carefully a WARNING POTENTIAL HAZARD Operating this AT V through deep or fat flowing water WHAT CAN HAPPEN Tires may float causing loss of tractimn and loss of omtrol which could lead to an accident HOWTO AVOID THE HAZARD Never qoerate this ATV in fast flowing water or in water deeper than that spec ified in your Owner s Manual Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings 1 Drive select lever box check bose 1 V belt cese drain plug SLIDING AND SKIDDING Care should be used when riding loose or slip pery surfaces since the ATV my slide If uee cted and uncorrected sliding could l d to an accidat To reduce the tendency for the frat wheels to slide in loose ar slippery aauditians pogsitianing your weight over the front wheels will sametimes If the wer wels of yor AT V sart to slide g ways Co
21. ealer repair as necessary for proper qoeratian Fittings and fasteners Always check the tughtness of chassis fittings and fasterers befoe a ride Take the mhire to a ATV dealer or refer to the Service Manual for correct taghtening torque Lights Check the headlights and tail orake light to make sure they are in working condition Repair as necessary far por qoeraticn Switches Check the aperaticn of all switches Have a ATV dealer repair as necessary for proper qoeratian How to measuretire pressure Use the low oressure tire gage NOTE The lowpressure tire gauge is included as standard equipment Make two measurements of the tire pressure ard use the seco r dir Dust or dirt in the gare ald causes the first reading to be incorrect Set pressure with tires cold Set tire pressures to th following soecificaciams ak eae Recommended Minimum Maximum OPERATION Starting a cold engine WARNING Indicates a potential hazard that could reault in POTENTIAL HAZARD serious injury ar death Freezing control cables in cold weather A WARNING WHAT CAN HAPPEN You could be unable to contral te AT V which could lead to an accident or colli POTENTIAL HAZARD l Operating AT V without being familiar with all arras WHAT CAN HAPPEN HOWTO AVOID THE HAZARD When riding in cold weather always make sure all catrol cables work smoothly Loss of CEE ON which could cause an acci before you begin riding c
22. ed cables 1 Rer bale lidt switch 2 Adjusting nut Tuloricate the imer cables ard the cable exis If the cables do not operate smoothly aka ATV CEaler to replace them Recommended lubricant dein ard cable lube or SAE 10W30 motor oil Wheel removal 1 loosen the Weel nts 2 Elevate the ATV and place a suitable stand under the frame 3 Revove the nuts from the Weel Remove the wheel TN Battery This machine is eguipped with a sealed type battery Therefore it is nt necessary to dek the electrolyte or add distilled water in the ket tery If the battery seems to have discharced amut a ATV cooler CAUTION Do not try to remove the sealing caps of the battery els You may damage the battery POTENTIAL HAZARD Failure to handle batteries or battery electrolyte carefully WH AT CAN HAPPEN You could be poisoned You could be severely bumed by the sulfuric acid in battery electrolyte Batteries produce explosive gases HOWTO AVOID THE HAZARD Avoid contact with skin eyes or clcth ig Always shield eyes when working near batteries Keep out of reach of chil dren Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of wa ter or milk Follow with milk of magne Sia beaten egg or vegetable oil Get prampt medical attention EYES Flush with water for 15 minutes and get prompt medical attention Keep batteries away fram sparks flames cig arettes ar other sources of i
23. ent or injury HOWTO AVOID THE HAZARD Read the Owner s Manual carefully If there L Apply the brake peal is a amtrol ar function you do notunder 2 Tum the fuel cock to ON stand ask your AT V dealer 3 Tum the mein switch to ON and the en gie dxp witho O 4 mft the drive select lever into the matral i NOTE A CAUTION e If tee fails to start rel tte start switch then push the start switch again Pare a few ee Hue seconds before the next attenpt Each crark eon a ea ing should be as start as possible to preserve battery exrgy Do not crank the engine mare than 10 seconds an each attempt Starting a warm engine 5 D To start a wm eine refer to the Starting a cold to tart te agire engine secticn The starter dike should nct be 7 Tf the agire is started with the tater dde in used The throttle should be qoened sligtly positim 1 the starter dcdke should ke re turned to position 2 to warm up the engine If the engine is started with the W aming up starter dike Inpositim 2 ke tle starter To get maximum engine life always warm up the choke in this position to warm up the engine before starting of f Never accelerate hard agire with a cold engine To see whether or rot the 8 Gmtins warming up the eine until it idles engine is warm dx if it resan to the throttle arocthly and rean the starter che to nomelly with the starter drke tamed off p itim 3 before ndro Gifting re
24. fall off of tte AT V If you remove a foot from a footboard your foot or leg may care into contact with the rear wheels which could injure you or cause an accident HOWTO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footboards of your ATV your AT V during cperatian Modifications A WARNING POTENTIAL HAZARD Qoerating this AT V with improper modifi cations WH AT CAN HAPPEN Improper installatian of accessories or modification of this vehicle may cause changes in handling which in same situ aticns could lead to an accident HOWTO AVOID THE HAZARD Never modify this AT V through improper installation ar use of accessories All parts and accessories added to this vehicle should be genuine AT V a equivalent com ponents designed for ue mths ATV and should be installed and used according to instructians If you have questians cansult an authorized AT V dealer 69 Know the terrain where you ride Ride cauticusly in unfamiliar areas Stay alert for holes racks arats in terrain ad dhe hidden hazards which may cause the ATV toys WARNING POTENTIAL HAZARD Failure to use extra care when operating ths ATV unfamiliar terrain WHAT CAN HAPPEN You can came upon hidden racks bumps or holes without enough time to react Could result in the AT V overtum ing ar goin at of card HOWTO AVOID THE HAZARD Go slowly and be extra careful when erating on unfami
25. ga itim Ve tilate when charging or using in a closed space Y NT gt mme 2 Remove the h dlidt bulb holder by umiy it camterclockwise 1 adligt bulb holder t f 1 Headlight bulb holder 3 Remove the defective bulb by unhooking the hk dlidt bulb hl r tabs 5 Install the h dlidt bulb Folder by tumirg it clockwise 6 Install the hk dlidt bulb Folder aver at the rear Of the edig Headlight beam adjustment CAUTION It is advisable to have a AT V dealer make this adjustment To raise the beam tum the adjusting screw in To lower the beam tum the adjusting screw in dedin A WARNING POTENTIAL HAZARD Checking the fuel system while smok ing ar near an gpen flame WHAT CAN HAPPEN Fuel can ignite or explode causing se vere injury or property damage HOWTO AVOID THE HAZARD Do not smoke when checking the fuel system Make sure there are no open flames ar sparks in the area including piloc ligats from water fetes cr fumseces CLEANING AND STORAGE A CLEANING Frequent thorough cleaning of your machine will rct aly eterce its appearance ht will improve its rral perfommnoe and extend the useful life of many conporents 1 Before cleanirg the mire a Black off the eu of te etast pipe to prevent water entry A plastic beg and strong rubber band may be used b Moke sure the s rk plug and all filler caps are properly installed 2 If the egie
26. he carburetar and manifold fittings far an airtidtt seal Tidtten all Fittings searely to avoid the possibility of unfilt CAUTION 0 0 Never operate the engine with the air filter element removed This will allow unfiltered air to enter causing rapid engine wear and possible engine damage Additicnally qoera tim without the air filter element will affect carburetor jetting with subsequent poor per formance and possible engine overheating Spark arrester cleaning Be sure the exhaust pipe and nuffler are cool before clesning the s rk arrester 1 Rame the bolts 2 Rame the tailpipe by pulling it at of l Spark arrester 4 Insert the tailpipe into the muffler add align tre bolt roles 5 Install ard tihan tte bolts 1 Bolt 13 2 Tailpipe 3 Tap the tailpipe lidily ard then use a wire brush to remove any carbon depos its from the s rk arrester patim of the d Idle speed adjustment NOTE A diagnostic tachameter must be used for this procedure 1 Start the engine ard warm it up far a few minutes at approximately 1 000 to 2 000 r min Occasianally rev the engine to 4 000 to 5 000 r min The engine is warm when it quickly resomds to the throttle 2 Commect the tachameter to the spark plug lead ard then set the idle to the specified idling speed by adjusting the throttle stop screw Tum the screw in direction 4 to increase the engine speed and in directim to
27. heck for dostacles before operating in a new area Never attempt to operate over lage dostacles such as large rocks ar fallen trees Always follow proper procedures when operating POTENTIAL HAZARD Improper handling of gasoline WH AT CAN HAPPEN Gasoline can catch fire and you could be bumed HOWTO AVOID THE HAZARD _ Always turn off the engine when refiel ig Do not refuel immediately after te e gine has been ruming and is still very I Do not spill gasoline cn the engine or exhaust pipe muf fler when refueling Never refuel while smoking or in tte vi cinity of sparks cpen flames or other sources of ignition such as the pilot lights of water heaters and clothes dry es When transporting te ATV in ancther vehicle be sure it is kept upright and that the fuel cock is in the OFF posi tim Otherwise fuel may leak out of the carburetor a fuel tak WHAT CAN HAPPEN Gasoline is poisonous and can cause 1 I uries HOWTO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot of gasoline vapor or get some gasoline in your eyes see your If you should swallow some gasoline or doctor immediately If gasoline spills your skin wash with soap and water If gasoline spills on your clothing change your clothes DESCRIPTION AND MACHIN IDENTIFICATION Bi 8 q VT 3 IE dE Em r TA t i 1 pi wd J pi x 2 2 ji enn e i d jo ac 6
28. ide to the same set tig Rear shock absorber adjustment The soring preload can be adjusted to suit the ride s weight and riding oeauditians Adjust the soring prelced as follows To increase the spring preload tum the ad Justirg org in dietin amp To decrease the spring preload tum the ad PRE OPERATION CHECKS Before using this machine check the following points m m e REE Check qoeraticn free play fluid level and fluid lesekece 34339 Fill with DOT 4 breke fluid if necessary 123 126 34 35 perde cperatzin condition and free play Adjust if necessary 124 127 129 Check fuel level Fill with fiel if necessary 36 37 Brune oil Fil withal if 38 102 107 Fira 1 36 37 n xy aum o Brake fluid leakage front brake Check to see if any bake fluid is leakirg at of the bose joint or brake fluid resewvoir of the frat lake Apoly the brake firmly for ane minute If the lever noves slowly inward there may be a leak in tre brake system If there is any lek the bale system should be insted bya dealer Brake operation Test the brakes at slow speed after starting aut to make sure they are working properly If the brakes do nc provide proper braking per formance inspect the brake pads and shoes for wear See pace 123 WARNING POTENTIAL HAZARD Riding with improperly operating brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOWTO AVOID
29. ident is greatly increased if the qoerator does not know how to g r ate te AT V properly in dif frer situatians and on dif ferent types of terrain d amp fered by AT V They should then regularly practice the skills leamed in the course and the qoerating techniques described in this Owner s Manual For more information about the training course contact an author 153 AT V dealer Riding your AT V reguires skills agured through practice over a period of tine Take the time to leam the basic tedm gues well before atterpting mare dif ficult mensuvers Tus AT V is designed to carry operator and cargo aly passengers prdnbited A WARNING POTENTIAL HAZARD Carrying a passenger m this AT V WHAI CAN HAPPEN Greatly reduces your ability to balance and control this AT V Could cause an accident resulting in harm to you and Or your Passenger HOWTO AVOID THE HAZARD Never carry a passenger The long seat is to allow the qerator to shift positian as needed during operation It is not for carrying passengers Do not operate after consuming alcohol or drugs Qoerator s performance capability is reduced by the influence of aladol or drugs WARNING POTENTIAL HAZARD Operating this AT V after consuming alco hol or drugs WH AT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and percecticm Could result in an accidat HOWTO AVOI
30. ighway even a dirt ax gravel Always follow proper procedures for climbing hills as described in this memal Check the ter rain carefully before you start up any hill Never clinb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly Never go over the t of anll at Inch speed Always follow proper procedures for going down hills and for braking cn hills as described in this mmal Check the terrain carefully before you start down any hill Shift your weight back ward Never go down a hill at high speed Avoid going dom a hill at an angle that would cause the vehicle to lean sarply to ce side Go straigt down the hill Were possible Always follow proper procedures for crossing the side of a hill as described in this manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the 1 side of the AT V Never attempt to tum the ATV around cn any hill until you have mastered the tuming technique described in this manual cn level ground Avoid crossing the side of a steep hill if possible Always use proper procedures if you stall or roll backwards when climbing a hill Maintain a steady speed when climbing a hill If you stall or roll backwards follow the special procedure for braking described in this manual Damart cn the upchill side or to a side if pointed straight up Tun tte AT V arom and mart following th procedure described in this renal Always c
31. iler ad arg 500 kof 1 102 Ibf Tage welont vertical weidi trailer hitch point 15 33 lbf Do not exceed the maximum tongue weight You can measure tongue weight with a bathroom scale But the tame of tte l d trailer m tte scale with the tage at hitch height Adjust the lced in the trailer if necessary to mde te weight an hitch If you are carrying cargp and towing a trailer include the tongue weight in the maximum vehicle l d limit Load cargo an the carrier as clase to the carter of the vehicle as possible Put carop at the r r cf the fat carrier and at the fort of the rear carrier Canter the Iced fram s to sice Tie down carcp surely to the carriers Make sure cargo in the trailer can move aard A dif ing load can cause an acidet Mke sure the load does nct interfere with amtrols ar your ability to see where you are cory A WARNING Indicates a potential hazard that could result in serious injury or cesth 57 RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced Begirrers should t training fram a certified iEn Beoqme familiar with this ATV at slow ye first even if you are an experienced qoeratar Do not attempt to aperate at maximum perfor mne until you are totally familiar with the ATV s handling and perfamarce characteristics WARNING POTENTIAL HAZARD Qoerating this AT V without proper ir structicn WH AT CAN HAPPEN The risk of an acc
32. ith the specified plug Specified s rk plug DR8EA NGK Installatian 1 Measure the electrode gap with a wire thick ness gare ard if necessary adjust the p to specificetia l Air filter element cleaning NOTE There is a Check ose at the bottom of the air filter case If dust ax wter collects in this k empty the hose and clean the air filter element 1 Holder gj 4 2 Air filter case cover 3 Rame the air filter elmet assembly 1 Air filter case check hose 1 Remove the seat See page 28 for seat ramwal and installation procedures 2 Remove the air filter case cover by uha ing the holcexs 1 1 Air filter element assenbly 8 Zpply atv f m ar filter al ac aider quality foem air filter ail to the air filter eleet NOTE The air filter element should be wet but nct drigoir m 9 RU tear filter elmet oer its hae ad then install tre lak plate 10 Install the air filter elmer aseanbly 11 Install th air filter case cover by toda 12 Isal tre s t NOTE The air filter element should be cleaned every 20 40 hars It should be cleaned and luni cated more often if the machine is operated in extremely dusty areas Fach time the air filter element maintenance is performed check the air inlet to the filter as far dstnrctias Check the air filter case nidore joint to t
33. liar teram Always be alert to changing terrain conditions when operating the AT V When riding in an area where you might not easily be seen such as desert terrain mrt a atim flag m the ATV DO NOT u tie flag pole bracket as a trailer mita POTENTIAL HAZARD Operating in areas where you might not be seen by other d fr d vehicles WH AT CAN HAPPEN You could ke ina collisim You could be injured HOWTO AVOID THE HAZARD Always mount a caution flag the ATV to make you more visible W atch care fully for cther vehicles Do nct ride in areas posted no trespsssirg Do mot ride private property without getting r missi IURNING YOUR ATV HOWTO AVOID THE HAZARD To achieve maximum traction while riding of Always follow proper procedures for toed the two rear wheels are mounted solidly turning as described in this Owner s cn am axle and tum totter at the same speed Manual MU MEE E CE Practice turning at low speeds before a gt PS Oe eS tempting to tum at faster speeds Do not ATV will resist tumurg A special tumurg tum at speeds too fast for your skills or tedmigue must be used to allow the AT V to MU ES meke tums quickly ad easily It is essential thet this Sall be first at low speed As you approach a curve slow down and begin to tum the hardleers in the desired directi As you do so put your weight cn the footboard to the outside of the tum qite your desired
34. ng and increase risk of losing control ALWAYS use proper riding techniques to aviod vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handing and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS A SAFETY INFORMATION AN ATV IS NOTA TO YAND CAN BE HAZARDOUS TO OPERATE An ATV hele dif feerly from other vehicles including motorcycles and cars A collisim ar rollover can oxur quickly even during routine maneuvers such as tuming and riding m hills or over dostacles if you fail to take proper precautians SEVERE INJURY OR DEATH n result if you nx follow these instunctians Red this manial ard all labels carefully and follow th qoerating procedures described e ever c rate an AT V without proper training or instruction Take a Training Course Begin rers sold recerve training from a certified instructor Gontact an authorized ATV dle e Always follow the age recomandati A child under 16 years old should never aperate an ATV with engine size greater than 90cc e Naver allow a dild under age 16 to aperate an AT V without adult supervisicn and never allow comtined use cf an ATV bya hild if he ar she does nt have the abilities to operate it safely carry a pesexuaroaen ATV e Always avoid operating an ATV cn any paved surfaces including sidewalks driveways park lds ad stets e Beqeaem ATV may ablic street wad ar h
35. ntrol n usually be regaired if there is rom to do so by steering in the directian of the slide Applying the brakes or accelerating is mt recommended until you have corrected the slide W HAT TO DO IF This sxtim is designed to be a reference guide aly Be sure to reed each stim an riding teh niques conpletely WHATTOD TE yor ATV cbesn t tum wen you vert it to Bring the ATV to a sto ad patie tt imig maneuvers again Be sure you are putting yor weight on the footboard to the outside of the tum Positicn your weight over the frant wheels for better awol Ge paces 77 78 TF yor ATV begins to tip while umim Lean more into the tum to regain balance If necessary grednlly let cff the throttle a o steer to the outside of the tum See peses 77 B ATV carts to slice sicbways Steer in the divectim of the slide if you have the rom Applying the brakes or accelerating 1s not recomended until you have corrected the slide See peces 93 94 If yar ATV an t m it up a hU yu ae trying to clinb Tum te ATV anrd if you still hawe forward speed If nx ston daart an tte udull side of the ATV and physically tum the AT V aard If the AT V starts to slip backwards DO NOT USE THE REAR BRAKE the ATV may tip over t of you Damart the ATV m the ynill side See s 79 84 1 Owner s manual 2 Owner s tool kit 3 Low pressure tire gauge NOTE If you do mt have a tange wrench available
36. sp d limit x and thrdtle WHAT CAN HAPPEN The throttle cable could be damaged Improper throttle operation could reat You could lose control have an acci dent or be injure HOWTO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm 0 47 in Always make sure the throttle lever fre play is adjust ed to 3 5mm 0 12 0 20 in See pee 122 Parking brake Use the parking brake when you have to start the engine or park the machine especially cn a slgpge Apply the rear brake lever and push down the lock plate to apply the parking brake Squeeze the rear brake lever to re lease the parking brake 1 Io plate WARNING POTENTIAL HAZARD Improper use of the parking brake WH AT CAN HAPPEN The AT V could start moving unexpect edly if the parking brake is not applied before start ing the engine This could of omtrol ora The brake could overhsst if you ride te ATV without releasing the parking brake You could lose braking perfor mance which could cause an accident You could also wear out the brakes pre maturely H O WTO AVOID THE HAZARD Always set the parking brake before Always be sure you have released the parking brake before you begin to ride Steering load tum the steering ber let ad mscrew the lock cover then insert the key into the lodecitd tum it fora anplete rardwit force then the steering mechanism can be locked POTENTIAL HAZARD Starting the engine without
37. t ane table spoon of SAE 10W30 or 20W40 motor oil in the s rk plug hole ard reinstall the s rk plug Ground the spark plug wire and turn the engine over several times to coat the cylinder wall with ail 3 hixicste all atl cales 4 Block up tte frame to raise all Weels off te ground 5 Tie aplastic keg over the etast pipe atlet to prevent moisture fram entering 6 storing in a hmd ar salt air atmegd ere coat all exposed metal surfaces with a light film of ail Do nt aly ail to any nir parts or the s t cov SPECIFICATIONS sb 1 984mm 78 1in 1 984m 78 1in cs 1 085nm 42 7in 1 085mm 42 71 Overall heidht 1 120mm 44 1in 1 120mm 44 1in Seat height 827m 32 6in 827mm 32 6in Wheel base 1 233mm 48 51in 1 233mm 48 5in Ground clearance 245m 9 65in 245m 9 65in Minimum turing radius 3 000mm 118 111 3 000mm 118 1in Basic weight W ithoilad fill fiel tak 265 kg 267 kg Engine Engine type Air cooled 4 stroke SOHC Air cooled 4 stroke SOHC Cylinder arrangement PForward inclined single cylinder Parward inclired single cylinder Di splacement 348 9 an gt 387cm3 Bore j stroke 83 0 64 5 mm 83 0 71 6 mm Compression ratio 9 20 1 9 50 1 Tubricaticn system W et sum W et sump 150 SAE80 API GL 4 Hypoid gear oil 0 23 L 0 20 Inp qt 0 24 US at SAE80 API GL 4 Hypoid gear oil 0 35 L 0 31 Imp at 0 37 US ct UNLEADED GASOLINE ONLY 13 5 L 2 97 lp gal 3 57 W cal 3 3 L 0 73 mm c
38. thium soep based grease Axle boots e Check operation Replace if damaged 100 300 O NUM KJ Panel removal and installation Panel A Ihe panel illustrated needs to be removed to To remove perform same of the maintenance described in Remove the bolt and then take the pel cff this dix To reall Refer to this sectian each tine the panel res to Place the pare in the arigiral position ard install be remwed or installed tre bolt CAUTION When installing the panel be sure not to pinch the cables or wires 1 ael A 5 Insert the dipstick in te ail filler tole With at screwing it in and then rewe it amin to dx te ail level NOTE The engine oil should be between the minimum and maximum level marks 1 Maximum level mark 2 Minimm level mark 6 If the egi oil is at ar below the minimm level mark acd sufficient oil of the recor mened type to raise it to te aret level 7 Insert the dipstick into the al filler hoe aad 1 Oil filter wench NOTE um mal filter wen is available at a rearby AT V daler 5 Zpply a ligt cost cf engine to the O ring of NOTE Make sure the O ring is seated properly 1 Orig CAUTION 6 In order to prevent clutch slipopace since the engine oil also luboricates the clutch do not mix any chemical additives Do not use oils with a diesel specificatian of CD or als of a higher quality than specified In aitim do not use oils labeled
39. um tt ATV arom while you still have forward motion provided you have the roam to cb so and go down tt hill POTENTIAL HAZARD Imprgperly cr sirg hills ac turning Hills WH AT CAN HAPPEN Could cause loss of amtrol a cause the ATV to oertum HOWTO AVOID THE HAZARD Never attempt to tum the AT V acound on any hill until you have mestered the turning technique as described in the Owner s Manual on level ground Be very careful when tuming cn any hill Avoid crossing the side of a steep hill if possible If yor ATV bes stalled ar staqgped and you believe you can atine up the W restart carefully to mke sure you do nd lift the font Weels which could cause you to lose amixol If you are umble to atine up tte hill disront th ATV m te ull side Pysically tum the ATV around and then descadd the mil If you start to roll backwards DO NT apply either broke abructly If you are in 21 apply aly the for bake When this ATV is in 4D all wheels font ad rear are intercorectad by te dene train This means that applying either the tat brake or the rear brake will brake all Weels When desaendirg hills using either brake lever or the brake pedal will brake the Weels the dwn hll s Avoid sudden agolicatim of either the front or rear brake because the wels the u hill side could ome of f tte gard Th ATV could easily tip over backwards Apoly both the Front ad rear brakes gredally or dismount the ATV immediately the u
40. uring this period amsult aATV cmle 0 10 hours Avoid continuous qoeraticn above half throttle Allow a cooling off period of five to ten minutes after every hour of qoeratiqm Vary the speed of the machine fram time to time Do mt qoerate it at ore set thicttle pegsitian Parking a slope 1 Bong the mhir to a stop by agplyirg the baes 3 W ith the r r brake lever ard pedal applied POTENTIAL HAZARD apgoly the parking hae and then lowly Parking an a hill or other inchre WH AT CAN HAPPEN The ATV cauld roll at of aairol imress ing the chance of an accident HOWTO AVOID THE HAZARD Avoid parking hills or other irclires you must park on an incline place the machine transversely across the incline apoly the parking brake and block the frat and rear wheels with rocks or Other dyjects Do nct park the ATV a all an hills trt are so steep you could nct walk up them easily Loading Caro or a trailer n der th scability ard handling of an AT V You must use caman sense and good judgment when carrying cargp or towing a trailer Keep the following points in mind Never exceed the weigat limits shown An Over l d AT V n be unstable MAXIMUM LOADING LIMIT veucle l ding lmt tctal widt c ara rider and accessories amd tamyue weight 210 kg 463 10 Front carrier 40 kg 88 10 Rear carrier 80 kg 176 10 Starece box 2 0 kg 4 4 Ib Trailer hitch Pulling l d tctal weidtt of tra
41. verse 1 Bring the machine to a complete stop and retrum the throttle lever to the clegsd pesitian 2 Apoly the brake pedal 3 Suft the gear fran mual to reverse ard vice versa by moving the drive select lever alag NOTE es When in reverse the reverse indicator ligt should be cn If the lidt does nt ame an ask a ATV cealer to ingoect F Forward N Neutral R Reverse 1 Drive select lever 4 Check behind for people or dostacles then releese the brake hl 5 Open the throttle lever gradually and om tine to watch to the rear wile kedarg Engine bresk in There is never a mare important period in the life of your machine than the period between zero amd 20 hours For this rasa we ask thet you carefully reed the following material Because the engine is brand new you must rct put an excessive load it for the first several hours of rumirg During the first 20 hours the varios parts in te engine wear ard polish themselves to the correct Qoerating clearances During this period prolamged full throttle q r ation ar any ditim which mgt result in ex cessive engine heating must be avoided However momentary 2 3 seconds maximum full throttle aoeratian under losd does not harm the eure Fach full throttle acceleratim sequence should be followed with a substantial rest period for the engine by cruising at lower r min so the egie n rid itself of the temporary hild up of h t If any amomelity is noticed d
42. y when filling Overfilling will cause the oil to seep out of the breather e Tre differential gear oil level amt becheck ed The differential gear case capacity is greater than the recommended oil quantity therefore the oil level cant be acaurately checked fron the oil filler p hale Recommended oil CAF 80 API Hypoid gear oil Qu qatity 0 35 L 0 31 Imp at 0 37 UB CAUTION Be sure m foreign material enters the dif fe ential gear case 6 Install te al filler bolt ad thn tid ten it to Tightening torque Differential r al filler bolt 23 Nn 2 3m kof 16 ft 108 7 Check for ail leekage If oil l ka is ford check far the cause 2 Use the spark plug wrench in the owner s tool kit to remove the spark plug as shown 1 Spark plug wrench Inspection The spark plug is an important engine omo rent amd is easy to inset The oanditian of the spark plug can indicate the omditim of the agire The ideal color the white insulator around the center electrode is a mediumto light tan colar for an ATV thet is being riden romelly Do not attempt to diagnose such problems yourcelf Trstesd tae the AT V toa AT V daler You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If elec trode erosicn becomes excessive or if carbon and other deposits are excessive you should re place the s rk plug w
Download Pdf Manuals
Related Search