IMPORTANT NOTICEThis machine is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this machineon any public street, road or highway.This machine complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effectat the time of manufacture.Please check your local riding laws and regulations before operating this ATV.

USER'S MANUAL

Congratulations on your purchase of the RD400. This manual will provide you with a good basic under

It also includes basic maintenance and inspection procedures. If you have any questions

regarding the operation or maintenance of your ATV, please consult a dealer.

READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETELY

BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALL 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 ANYONE WHO BUYS A NEW ATV.

THIS ATV, AND ANY OTHER ATV OVER 90cc, SHOULD NOT BE RIDDEN BYANYONE UNDER 16 YEARS

OF AGE.

standing

of the features and operation of this ATV.

This manual includes important safety information. It provides information about special techniques and skillsnecessary to ride your ATV.

AN IMPORTANT SAFETY MESSAGE:

INTRODUCTION

USER'S MANUAL

YOUR SAFETY IS INVOLVED!

Failure to follow warning instructions could result in injury or

FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUALCAN RESULT IN

Particularly important information is distinguished in this manual by the following notations:

A CAUTION indicates special precautions that must be taken to avoiddamage to the machine

A NOTE provides key information to make procedures easier or clearer.

death to the machine operator, a bystander or a person inspecting or repairing

The SafetyAlert Symbol means ATTENTION! BECOME ALERT!

IMPORTANT MANUAL INFORMATION

the machine.

NOTE:

SERIOUS INJURY OR DEATH.

Indicates a potential hazard that could result in serious injury or death.

USER'S MANUAL

CONTENTS

Safety information

Control Functions4.Main SwitchIndicator And Warning Lights

5. peration ChecksPre-o

Handlebar switchesThrottle leverSpeed limiterFront brake leverBrake and rear brake leveleverParking brakeDrive select leverRecoil starterFuel tank capFuel cock

Front And Rear BrakesFuelEngine Oil

1.Location of the warning andspecification labels 1

53.Description and machine identification 11

Vehicle identification number 1213131417202122222324242526

Starter (choke)SeatStorage boxFront carrierRear carrierFront shock absorber AdjustmentRear shock absorber adjustment

27282930303031

33343638

Final gear oilDifferential gear oilThrottle leverFittings and fastenersLightsSwitchesTiresHow to measure tire pressureTire wear limit

383939393939404142

USER'S MANUAL

6.OperationStarting a cold engineStarting a warm engineWarming upDrive select lever operation andreverse drivingEngine break-inParkingParking on a slopeAccessories and loading

Getting to know your ATVRide with care and good judgmentBe careful where you rideTurning your ATVClimbing uphillRiding downhillCrossing a slopeCrossing through shallow waterRiding over rough terrainSliding and skidding

43434545

46495051525658597177798587899293

7.Riding Your ATV

What to do ifWhat to do

Owner’s manual and tool kitPeriodic maintenance/lubricationPanel removal and installationEngine oil and oil filter cartridgeFinal gear oil

9596

979799

101102107

8.Periodic Maintenance AndAdjustment

Differential gear oil replacementAxle bootsSpark plug inspectionAir filter element cleaningV-belt cooling duct check hoseV-belt case drain plugSpark arrester cleaningCarburetor adjustmentIdle speed adjustmentValve clearance ad just mentThrottle lever adjustmentFront brake pad check

110113113116119119120121122122123124

USER'S MANUAL

Rear brake shoe inspectionBrake fluid level checkBrake fluid replacementFront brake lever free playRear brake pedal and lever adjustmentAdjusting the rear brake light switchCable inspection and lubricationLubricating the brake levers andbrake pedalWheel installationBattery

10.Specifications

11.Noise Regulation

125125127127128131132

133134136

Battery maintenanceFuse replacementReplacing a headlight bulbHeadlight beam adjustmentTail/brake light bulb replacementTroubleshootingTroubleshooting chart

137137139142143143145

150

156

9.Cleaning And StorageA. CleaningB. Storage

146146148

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12.Warranty Information 158

LOCATION OF THE WARNING ANDSPECIFICATION LABELS

1

USER'S MANUAL

Read and understand all of the labels on your machine.They contain important information for safe and properoperation of your ATV.Never remove any labels from your ATV. If a labelbecomes difficult to read or comes off, a replacementlabel is available from your dealer.

2

USER'S MANUAL

2

IMPROPER TIRE PRESSURE OR OVERLOADING CANCAUSE LOSS OF CONTROL.LOSS OFF CONTROL CAN RESULT IN SEVERE INJURYOR DEATH.OPERATING TIRE PRESSURE: Set with tires cold• Recommended : FRONT : 25kPa, (0.25kgf/cm²), 3.6psi

REAR : 25kPa, (0.25kgf/cm²), 3.6psi• Minimum : FRONT : 22kPa, (0.32kgf/cm²), 3.2psi

REAR : 22kPa, (0.32kgf/cm²), 3.2psi• Never set tire pressure below minimum. It could cause the

tire to dislodge from the rim.

• Cargo or a trailer can affect stability and handling.Read owner’s manual before loading or towing.

• When riding with cargo or lowing a trailer: Reduce speedand allow more room to stop. Avoid hills and rough terrain.

• Maximum Vehiele Load:220kg, (485lbs) includes weightof operator, cargo and accessories(and if applicable, trailerongue weght).

LOADING/TRAILER TOWING

! WARNING

USER'S MANUAL

3

NEVERride with passengers.

Riding with passengescan cause a loss of control,resulting inSEVERE INJURY orDEATH

! WARNINGImproper ATV use can result in SEVERE INJURYor DEATH,

NEVER

ALWAYS:

LOCATE AND READ OWNER,S MANUAL.FOLLOW ALL INSTRUCTIONS AND WARNINGS.

operate:• without proper training or instruction.• at speeds too 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 control.

• use proper riding techniques to avoid overtuming thevehicle on hills and rough terrain and while turning.

• avoid paved surfaces-pavement may seriously affecthanding and control.

ALWAYS USEAN APPROVEDHELMET ANDPROTECTIVEGEAR

NEVER USEON PUBLICROADS

NEVER CARRYMORE THANONE PASSENGER

NEVER USEWITH DRUGSOR AL COHOL

! WARNING⑤

3

4

USER'S MANUAL

Operating this ATV if you are underthe age of 16increases your chanceof severe injury or death.NEVER operate this ATV if lyou areunder age 16.

! WARNING⑨

DRIVE SELECT LEVER• Read owner’s manual carefully before operating.• ATV MUST be stopped before shifting select lever.• Shifting info or from reverse or park is impossible

without applying rear brake.

⑥6 7

An ATV handles differently ther vehicles including motorcycles and cars. Acollision or rollover can occur quickly,even maneuvers such as turning and riding on hills or over obstacles, if you fail to take

from oduring routine proper

precautions.

SEVERE INJURY OR DEATH can result if you do not follow these instructions:

Read this manual and all labels carefully and follow the operating procedures described.Never operate anATV without proper training or instruction. Take a Training Course. Begin receive trainingfrom a certified instructor. Contact an authorized dealer .

ners shouldATV

Always follow the age recommendation: Achild under 16 years old should never operate anATV with engine sizegreater than 90cc.Never allow a child under age 16 to operate an ATV without adult supervision, and never allow continued use of anATVby a child if he or she does not have the abilities to operate it safely.Never carry a passenger on an ATV.Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets.

Never operate an ATV on any public street, road or highway, even a dirt or gravel one.

SAFETY INFORMATION

5

USER'S MANUAL

Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You should also wear eyeprotection (goggles or face shield), gloves, boots, a long-sleeved shirt or a jacket, and long pants.Never consume alcohol or drugs before or while operating this ATV.Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is proper for the terrain,visibility, operating conditions, and your experience.Never attempt wheelies, jumps, or other stunts.Always inspect yourATV each time you use it to make sure it is in safe operating condition. Always follow the inspectionand maintenance procedures 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 on unfamiliar terrain. Always be alert to changing terrainconditions when operating the ATV.Never operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessaryto control the ATV on such terrain. Always be especially cautious on these kinds of terrain.Always follow proper procedures for turning as described in this manual. Practice turning at low speed beforeattempting to turn at faster speed. Do not turn at excessive speed.Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills beforeattempting larger hills.

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USER'S MANUAL

Always follow proper procedures for climbing hills as described in this manual. Check the ter before youstart up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Neveropen the throttle suddenly. Never go over the top of a hill at high speed.

rain carefully

Always follow proper procedures for going down hills and for braking on hills as described in this manual. Checkthe terrain carefully before you start down any hill. Shift your weight back ward. Never go down a hill at high speed.Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side. Go straight down the hillwhere possible.

Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid hills with excessivelyslippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV aroundon any hill until you have mastered the turning technique described in this manual on level ground. Avoidcrossing 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 whenclimbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual.Dismount on the uphill side or to a side if pointed straight up-hill. Turn theATV around and remount, followingthe procedure described in this manual.

Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles such aslarge rocks or fallen trees.Always follow proper procedures when operating

,over obstacles as described in this manual.

7

USER'S MANUAL

Always be careful when skidding or sliding. Learn to safely control skidding or sliding by practicing at low speedsand on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order toreduce the chance of skidding or sliding out of control.Never operate an ATV in fast flowing water or in water deeper than that recommended in this 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.Always be sure there are no obstacles or people behind you when you operate in reverse.When it is safe to proceed in reverse, go slowly.Always use the size and type of tires specified in this manual.Always maintain proper tire pressure as described in this manual.Never modify an ATV through improper installation or use of accessories.Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached.Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater distancefor braking.

8

USER'S MANUAL

POTENTIAL HAZARDImproper handling of gasoline.WHAT CAN HAPPENGasoline can catch fire and you could be burned.

HOW TO AVOID THE HAZARDAlways turn off the engine when refueling.

Do not refuel immediately after the engine has been runningand is still very hot.

Do not spill gasoline on the engine or exhaust pipe/mufflerwhen refueling.

Never refuel while smoking, or in the vicinityof sparks, openflames, or other sources of ignition such as the pilot lightsof water heaters and clothes dry-ers.

When transporting theATV in another vehicle, be sure itis kept upright and that the fuel cock is in the FF position.Otherwise, fuel may leak out of the carburetor or fuel tank.

"O "

WHAT CAN HAPPENGasoline is poisonous and can causeinjuries.

9

USER'S MANUAL

POTENTIAL HAZARD

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

Starting or running the engine in a closed area.

Exhaust fumes are poisonous and may cause loss ofconsciousness and death within a short time.

Always operate your ATV in an area with adequateventilation.

10

USER'S MANUAL

1 Rear shock absorber assemblyspring pre load adjusting ring

2 Spark arrester3 Storage box and tool kit4 Spa k plug5 Front shock absorber a sembly

spring pre load adjusting ring6 Brake pedal7 V-belt case8 uel cock9 Ai rfilter case

FusesTail/ brake ligh t

rs

F

NOTE:The machine you have purchased may differ slightly from those shown in thefigures of this manual.

DESCRIPTION AND MACHIN IDENTIFICATION

11

12 Front Shock absorber assemblySpring Preload adjusting Ring

13 V-belt cooling duct check hose14 Oil Filter cartridge15 Engine oil dipstick16 Rear brake lever17 Left handlebar switches18 Starter(choke)19 Drive select lever20 Main switch21 Fuel tank cap22 Right handle barswitch23 Throttle lever24 Front brake lever

1011

USER'S MANUAL

12

Vehicle identification numberThe 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:

①

USER'S MANUAL

CONTROL FUNCTIONS

Indicates a potential hazard that could result in serious injuryor death.

Main switchFunctions of the respective switch positions are as follows:

Main switch①

13

USER'S MANUAL

ON:

OFF:

The engine can be started only at this position and theheadlights and taillight come on whenthe light switch ison.

All electrical circuits are switched off. The key can beremoved in this position.

14

Indicator and warning lights

Neutral indicator light “N”Reverse indicator light “R”Four-wheel drive indicator light “ ”Oil temperature warning light

①②③③

Neutral indicator light “N”

Reverse indicator light “R”

This indicator light comes on when the drive selectlever is in the “N” position.

This indicator light comes on when the drive selectlever is in the “R” position.

USER'S MANUAL

4

Four-wheel-drive indicator lightThis indicator light comes on when the 2WD/ 4WDswitch is in the 4WD position.

NOTE:Due to the synchronizing mechanism in the differentialgear case, the light may not come on until the ATV startsmoving.

Oil temperature warning light ?

15

The engine may overheat if the ATV is overloaded. Ifthis happens, reduce the load to specification.Restart after making sure that the light is out. Continuoususe while the light is on may cause damage to the engine.

When the oil temperature reaches a specified level,this light comes on to warn that the engine oil temperatureis too hot. If the light comes on during operation, stop theengine as soon as it is safe to do so and allow the engineto cool down for about 10 minutes.

USER'S MANUAL

Oil temperature warning light checking method

16

Turn the main switch to "ON"andthe engine stop switch to

Oil temperature warninglight does not come on.

Push shart switch with thetransmission in neutral.

Oil temperaturewarning light comeson momentarily.

Oil temperature warninglight does not come on.

Oil tempera-ture is low.

Oil tempera-ture is high.

Engine oil temperatureand electrical circuit areOK.Go a head with riding.

Ask a dealer to inspect theelectrical circuit.

Allow to cool.

Oil temperature warninglight comes on.

Check engine oil temperature.

USER'S MANUAL

Handlebar switches

① Light switch “ / /OFF”② “ /Engine stop switch ”③ ”Start switch “

Light switch / /OFF“ ”Set the switch to “ ” to turn on the low beam and thetaillight.Set the switch to “ ” to turn on the high beam and thetaillight.Set the switch to FF to turn off all the lights.O

Engine stop switch “ / ”Make sure that the engine stop switch is set to“ ”before starting the engine. The engine stop switchcontrols ignition and can be used at all times to stop theengine, especially in an emergency. The ngine will notstart or run when the engine stop switch is set to “ ”

e

17

Do not use the headlights with the engine turned off formore than fifteen minutes.the battery may discharge to the point that the startermotor will not operate properly. If this should happen,remove the battery and recharge it.

USER'S MANUAL

18

Start switch “ ”The starter motor cranks the engine when this switchis pushed.

See starting instructions prior to starting the engine.(See page 43 for details).

On-command four-wheel drive switch “2WD

/4WD”To change from two-wheel drive(2WD)to four-wheel drive

(4WD), stop theATVandset the switch to the 4WD position.

To change from four-wheel drive (4WD)to two-wheel drive

(2WD), stop theATVandset the switch to the 2WD position.

① Four-wheel drive switch “2WD/4WD”

USER'S MANUAL

POTENTIAL HAZARDChanging from 2WD to 4WD or from 4WD to 2WD while the ATV is moving.

WHAT CAN HAPPENTheATV handles differently in 2WD than in 4WD in some circumstances.Changing from 2WD to 4WD or from the ATV to unexpectedly handle diffe ntly. This could distract the operator andincrease the risk of losing control and an accident.

re

HOW TO AVOID THE HAZARDAlways stop theATV before changing from 2WD to 4WD or vice-versa.

19

USER'S MANUAL

20

Throttle leverOnce the engine is running, movement of the throttle leverwill increase the engine speed. Regulate the speed ofthe machine by varying the throttle position. Becausethe throttle is spring-loaded, the machine willdecelerate, and the engine will return to an idle anytime the hand is removed from the throttle lever.

① Throttle lever

Before starting the engine, check the throttle to be sureit is operating smoothly. Make sure it returns to the idleposition as soon as the lever is released.

POTENTIAL HAZARD

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

Malfunction of throttle.

The throttle could be hard to operate, making it difficult tospeed up or slow down when you need to. This could causean accident.

Check the operation of the throttle lever before you startthe engine. If it does not work smoothly, check for thecause.Correct the problem before riding the ATV. Consult adealer if you can’t find or solve the problem yourself.

USER'S MANUAL

Speed limiterThe speed limiter keeps the throttle from fully opening,even when the throttle lever is pushed to the maximum.Turning in the adjusting screw limits the maximumengine power available and decreases the maximumspeed of the ATV.

① ②Locknut Adjusting screwa 12 mm (0.47 in)

POTENTIAL HAZARDImproper adjustment of the speed limiter and throttle.

WHAT CAN HAPPENThe throttle cable could be damaged. Improper throttleoperation could result.You could lose control, have an acci dent or be injured.

HOW TO AVOID THE HAZARDDo not turn the adjusting screw out more than 12 mm(0.47 in).Always make sure the throttle lever free play is adjust edto 3 5 mm (0.12 0.20 in).- -

21

USER'S MANUAL

22

Front brake leverThe front brake lever is located on the right handlebar.Pull it toward the handlebar to apply the front brake.

Brake pedal and rear brake lever. The brake pedal is locatedon the right side of theATV and the rear brake lever is locatedon the left handlebar.Push down on the pedal or pull the lever toward thehandlebar to apply the rear brake.

① Front brake lever

① Brake pedal

① Rear brake lever

USER'S MANUAL

Parking brakeUse the parking brake when you have to start the engineor park the machine, especially on a slope. Apply therear brake lever and push down the lock plate to applythe parking brake. Squeeze the rear brake lever to releasethe parking brake.

① Lock plate

POTENTIAL HAZARDImproper use of the parking brake.

WHAT CAN HAPPENThe ATV could s tart moving unexpect edly if theparking 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 ATV withoutreleasing the parking brake. You could lose brakingperfor- mance which could cause an accident.You could also wear out the brakes pre- maturely.

HOW TO AVOID THE HAZARDAlways set the parking brake before starting the engine.Always be sure you have released the parking brakebefore you begin to ride.

23

USER'S MANUAL

24

Drive select leverThe drive select lever is used to shift your machine intothe forward, neutral and reverse positions.(Refer to page 46 for the drive select lever operation.)

① Drive select lever

Recoil starterFirmly grasp the handle and pull slightly until engagementcan be felt. Then pull forcefully, being careful not topull the rope all the way out.

① Recoil starter

USER'S MANUAL

Fuel tank capRemove the fuel tank cap by turning it counterclockwise.

1 Fuel tank cap

POTENTIAL HAZARDStarting the engine without shifting into the neutral position.

WHAT CAN HAPPENTheATV could start to move unexpect edly, which couldcause an accident.

HOW TO AVOID THE HAZARDShift the drive select lever into the neutral position andapply the parking brake before starting the engine.

25

USER'S MANUAL

26

Fuel cockThe fuel cock supplies fuel from the fuel tank to the carburetor.The fuel cock has three positions.

This indicates reserve. If you run out of fuel thecarburetor. Normal riding is done with the leverin this position.

With the lever in this position, fuel flows to flow.Always turn the lever to this position when theengine is not running.With the lever in this position fuel will not whileriding, turn the lever to this position.

THEN FILL THE FUEL TANK AT THE FIRSTOPPORTUNITY. After refuelling,return the fuel cock leverto the “ON” position.

RES:

ON:

OFF:

① Arrow mark pointing to “ON”

① Arrow mark pointing to “OFF”

USER'S MANUAL

Starter (choke) “ ”Starting a cold engine requires a richer air-fuelmixture. Aseparate starter circuit supplies thismixture.

Move in direction a to turn on the starter(choke).

Move in direction to turn off the starter(choke).a

Refer to tarting a cold engine for proper operation.(See page 43).

① “ ”Starter (choke)

① RESArrow mark pointing to

27

USER'S MANUAL

28

SeatTo remove the seat, pull the seat lock lever upward andpull up the seat at the rear.

① ②Seat Seat lock lever

To install the seat, insert the projections on the front ofthe seat into the seat holders and push down on the seatat the rear.

Make sure that the seat is securely fitted.NOTE:

① ②Projection ( I 2) Seat holder ( I 2)

USER'S MANUAL

Storage boxMaximum load limit: 2 kg (4.4 lb).

To protect from damage, do not put metal products, liketools or sharply edged products directly in the storage box.If they must be stored, wrap them in appropriate cushionmaterial.

① Storage box

NOTE:There is a check hose at the bottom of the storage box.If any water collects in this hose, remove the hose,empty it, and then install it.

① Storage box check hose

29

USER'S MANUAL

30

Front carrier

Rear carrierMaximum load limit: 40 kg (88 lb).

Maximum load limit: 80 kg (176 lb).

Front shock absorber adjustment.The spring preload can be adjusted to suit the rider’sweight and riding conditions.Adjust the spring preload as follows.To increase the spring preload, turn the adjusting ringin direction a .To decrease the spring preload, turn the adjusting ringin direction b .

①②

Spring preload adjusting ringPosition indicator

A special wrench can be obtained at a dealer to make thisadjustment.

NOTE:

Standard position: 21 - Minimum (soft).5 - Maximum (hard).

USER'S MANUAL

Rear shock absorber adjustmentThe spring preload can be adjusted to suit the riderweight and riding conditions.Adjust the spring preload as follows:To increase the spring preload, turn the adjusting ringin direction a .To decrease the spring preload, turn the adjusting ringin direction b .

① Spring preload adjusting ring② Position indicator

POTENTIAL HAZARDImproper shock absorber adjustment.

WHAT CAN HAPPENUneven adjustment can cause poor handling and loss ofstability, which could lead to an accident.

HOW TO AVOID THE HAZARDAlways adjust the shock absorbers on the left and rightside to the same set-ting.

31

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32

NOTE:A special wrench can be obtained at a dealer to make thisadjustment.

Standard position: 21 - Minimum (soft).5 - Maximum (hard).

① Special wrench.

Indicates a potential hazard that could result in seriousinjury or death.

USER'S MANUAL

PRE-OPERATION CHECKSBefore using this machine, check the following points:

USER'S MANUAL

ITEM ROUTINE

Front brake Check operation, free play, fluid level and fluid leakage.Fill with DOT 4 brake fluid if necessary.

Rear brake

Check fuel level.Fuel Fill with fuel 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 and damage.Wheels and tires

Check all fittings and fasteners.Fittings and fasteners

Check for proper operation.Lights and switches

Check for damage.Axle boots

33

Check operation, free play, fluid level and fluid leakage.Fill with DOT 4 brake fluid if necessary.

POTENTIAL HAZARD

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

Failure to inspect the ATV before operating.Failure to properly maintain the ATV.

Increases the possibility of an accident or equipmentdamage.

Always inspect yourATV each time you use it to make surethe ATV is in safe operating condition.Always follow the inspection and maintenance proceduresand schedules described in the Owner’s Manual.

34

Front and rear brakesBrake levers and brake pedal

Check for correct free play in the front brake lever. If thefree play is incorrect, have a dealer adjust it.Check for correct free play in the rear brake lever andbrake pedal. If the free play is incorrect,adjust it. (Seepages 127--129.)Check operation of the levers and pedal.They shouldmove smoothly and there should be a firm feeling whenthe brake is applied. If not, have a dealer in-spect them.

USER'S MANUAL

Brake fluid leakage (All brake)Check to see if any brake fluid is leaking out of the hose, jointor brake fluid reservoir of the front brake. Apply the brakefirmly for one minute. If the levermoves slowly inward, theremay be a leak in the brake system. If there is any leakage,the brake system should be inspected by a dealer.

Brake operationTest the brakes at slow speed after starting out to makesure they are working properly.If the brakes do not provide proper braking performance,inspect the brake pads and shoes for wear. (See page 123.)

POTENTIAL HAZARDRiding with improperly operating brakes.

WHAT CAN HAPPENYou could lose braking ability, which could lead to anaccident.

HOW TO AVOID THE HAZARDAlways check the brakes at the start of every ride.Do not ride the ATV if you find any problem with thebrakes. If a problem cannot be corrected by the adjustmentprocedures provided in this manual, have a dealer checkfor the cause.

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USER'S MANUAL

36

FuelMake sure there is sufficient gasoline in the tank.Recommended fuel:UNLEADED GASOLINE ONLYFuel tank capacity:Total:

13.5 L (2.97 Imp gal, 3.57 US gal)Reserve:

3.3 L (0.73 Imp gal, 0.87 US gal)

Use only unleaded gasoline. The use of leaded gasoline willcause severe damage to internal engine parts, such as thevalves and piston rings, as well as to the exhaust system.

YourATV engine has been designed to use regular unleadedgasoline with a pump octane number ([R+M]/2) of 86 orhigher, or researchoctane numberof 91 or higher. If knockingor pinging occurs, use a different brand of gasoline orpremium unleaded fuel.Unleaded fuel will give you longer spark plug life andreduced maintenance cost.

USER'S MANUAL

GasoholThere are two types of gasohol; gasohol containingethanol and that containing methanol. Gasohol containingethanol can be used if ethanol content does not exceed10%. Gasohol containing methanol is not recommendedby ATV because it may cause fuel system damage orvehicle performance problems.

① ②Fuel level Fuel tank filler tube

POTENTIAL HAZARDImproper care when refueling.

WHAT CAN HAPPENFuel 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 due to heat from the engine or thesun.

HOW TO AVOID THE HAZARDDo not overfill the fuel tank. Be careful not to spill fuel,especially on the engine or exhaust pipe. Wipe up anyspilled fuel immediately. Be sure the fuel tank cap is closedsecurely. Do not refuel right after the engine has beenrunning and is still veryhot.

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38

Engine oilMake sure the engine oil is at the specified level.Add oil as necessary. (See pages 102--107).

In order to prevent clutch slippage (since the engine oilalso lubricates the clutch), donotmixanychemical additives.Do not use oils with a diesel specification of “CD” oroils of a higher quality than specified. In addition,donotuse oils labeled“ENERGYCONSERVING II” or higher.Make sure that no foreign material enters the crankcase.

Final gear oilMake sure the final gear oil is at the specified level.Add oil as necessary.(See pages 107--109 for details).

Recommended oil:SAE 80 API GL-4 Hypoid gear oil.

If desired, an SAE 80W90 hypoid gear oil may be used forall conditions.

NOTE:GL-4 is a quality and additive rating, GL-5 or GL-6rated hypoid gear oils may also be used.

USER'S MANUAL

Differential gear oilMake sure the differential gear oil is at the specified level.Add oil as necessary. (See pages 110--111 for details).

Recommended oil:SAE 80API GL-4 Hypoid gear oil.

Throttle leverCheck to see that the throttle lever operates correctly.It must open smoothly and spring back to the idle positionwhen released. Have a ATV dealer repair as necessaryfor proper operation.

Fittings and fastenersAlways check the tightness of chassis fittings and fastenersbefore a ride. Take the machine to aATV dealer or referto the Service Manual for correct tightening torque.

SwitchesCheck the operation of all switches. Have a ATV dealerrepair as necessary for proper operation.

LightsCheck the headlights and tail/brake light to make surethey are in working condition. Repair as necessary forproper operation.

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USER'S MANUAL

40

POTENTIAL HAZARD

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

Operating this ATV with improper tires, or with improperor uneven tire pressure.

Use of improper tires on this ATV, or operationof thisATV with improper or uneven tire pressure, may causeloss of control, increasing your risk of accident.

1. The tires listed below have been approved by MotorCo., Ltd. for this model. Other tire combinations arenot recommended.

Manufacture Size Type

Front

Rear

WD

WD AT25 I 10-12 M912Y

AT25 I 8-12 M911Y

2. The tires should be set to 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 arecold.Tire pressures must be equal on both sides.

specifiedcould cause the tire to from the rim under severeriding conditions.

The following are minimums:Front 22 kPa (0.22 kgf/cm2, 3.2 psi).Rear 22 kPa (0.22 kgf/cm2, 3.2 psi).4. Use no more than the following pressures when seating

the tire beads.Higher pressures may cause the tire to burst. Inflate thetires very slowly and carefully. Fast inflation couldcause the tire to burst.Front 250 kPa (2.5 kgf/cm2, 36 psi).Rear 250 kPa (2.5 kgf/cm2, 36 psi).

3. Tire pressure below the minimum dislodge

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How to measure tire pressureUse the low-pressure tire gauge.

NOTE:The low-pressure tire gauge is included as standardequipment. Make two measurements of the tire pressureand use the second reading.Dust or dirt in the gauge could cause the first readingto be incorrect.

Set pressure with tires cold.Set tire pressures to the following specifications:

(0.25kgf/cm,

Recommendedpressure

Front

Rear

Minimum Maximum

25kPa

3.6psi)

25kPa(0.25kgf/cm,

3.6psi)

22kPa(0.22kgf/cm,

3.2psi)

22kPa(0.22kgf/cm,

3.2psi)

28kPa(0.28kgf/cm,

4.0psi)

28kPa(0.28kgf/cm,

4.0psi)

① Low-pressure tire gauge.

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Tire wear limitWhen the tire groove decreases to 3 mm (0.12 in)due to wear, replace the tire.

a Tire wear limit.

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OPERATION

Indicates a potential hazard that could result in seriousinjury or death.

POTENTIAL HAZARDOperatingATV without being familiar with all controls.

WHAT CAN HAPPENLoss of control, which could cause an accident or injury.

HOW TO AVOID THE HAZARDRead the Owner Manual carefully. If there is a controlor function you do not understand, ask yourATV dealer .

Starting a cold engine

POTENTIAL HAZARDFreezing control cables in cold weather .WHAT CAN HAPPENYou could be unable to control the ATV, which couldlead to an accident or colli-sion.

HOW TO AVOID THE HAZARDWhen riding in cold weather, always make sure allcontrol cables work smoothly before you begin riding.1. Apply the brake pedal.2. Turn the fuel cock to ON.3. Turn the main switch to ON nd the engine stopa

switch to “ ”.4. Shift the drive select lever into the neutral position.

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NOTE:

°

° ° ° °

When the drive select lever is in the neutral position,the neutral indicator light should come on. If it doesnot come on, ask a ATV dealer to inspect the electriccircuit.The engine can be started in any gear if the brake pedalis applied. However, it is recommended to shift intoneutral before starting the engine.5. Use the starter (choke) in reference to the figure:

Position 1 : Cold engine start ambient temperaturebelow 5 °C (40 F).Position 2 : Cold engine start ambient temperatureat 0 C (30 F) 30 C (90 F) and warming upposition.

Position 3: Cold engine start ambient temperatureabove 25 C (80 F) and warm engine start position.° °

AMBIENT TEMP./STARTER(CHOKE)POSITION

a Starter (choke)Fully openHalf openClosed

6. Completely close the throttle lever and start the engineby pushing the start switch.

①②③

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If the engine fails to start, release the start switch,then push the start switch again. Pause a few secondsbefore the next attempt. Each cranking should beas short as possible to preserve battery energy. Donot crank the engine more than 10 seconds on eachattempt.If the battery is discharged, pull the recoil starterto start the engine.

NOTE:

See the ngine break-in?section prior to operating the enginefor the first time.

e

Starting a warm engineTo start a warm engine, refer to theengine section. The starter (choke) should not be used.The throttle should be opened slightly.

starting a cold

Warming upTo get maximum engine life, always warm up the enginebefore starting off. Never accelerate hard with a coldengine! To see whether or not the engine is warm, checkif it responds to the throttle normally with the starter(choke) turned off.

7 If the engine is started with the starter. (choke) inposition 1 , the starter (choke)should be returned toposition 2 to warm up the engine. If the engine is startedwith the starter (choke) in position 2 , keep the starter(choke) in this position to warm up theengine.

8 Continue warming up the engine until it idles smoothlyand return the starter (choke) to position 3 before riding..

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Drive select lever operation and reverse driving.

Before shifting, stop the machine and return the throttlelever to its closed position. Otherwise, the transmissionmay be damaged.

Shifting: forward1. 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 lever along the shift guide.3. Open the throttle lever gradually.

NOTE:Make sure that the drive select lever is completelyshifted into position.

① Drive select lever

USER'S MANUAL

Shifting: reverse1. Bring the machine to a complete stop and return

the throttle lever to the closed position.2. Apply the brake pedal.

3. Shift the gear from neutral to reverse and vice versaby moving the drive select lever along the shift guide.

4. Check behind for people or obstacles, then release thebrake pedal.

5. Open the throttle lever gradually and continue towatchto the rear while backing.

NOTE:When in reverse, the reverse indicator light should be on.If the light does not come on, ask aATV dealer to inspect.

① Drive select lever.

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POTENTIAL HAZARD

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

Improper operation in reverse.

You could hit an obstacle or person behind you, resulting in serious injury.

When you shift into reverse, make sure there are no obstacles or people behind you.When it is safe to proceed, go slowly.

USER'S MANUAL

Engine break-inThere is never a more important period in the life ofyour machine than the period between zero and 20 hours.

For this reason, we ask that you carefully read the followingmaterial. Because the engine is brand new, you must notput an excessive load on it for the first several hours ofrunning.

During the first 20 hours, the various parts in the enginewear and polish themselves to the correct operatingclearances.

During this period, prolonged full throttle operation orany condition which might result in excessive engineheating must be avoided.

However, momentary (2-3 seconds maximum)full throttleoperation under load does not harm the engine.

0-10 hours:

Avoid continuous operation above half throttle.Allowa cooling off period of five to ten minutes after everyhour of operation. Vary the speed of the machine fromtime to time. Do not operate it at one set throttle position.

Each ful l throttle acceleration sequence should befollowed with a substantial rest period for theengine bycruising at lower r/min so the engine can riditself of thetemporary build up of heat If any abnormality is noticedduring this period, consult a ATV dealer.

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10-20 hours:

After break-in:

Avoid prolonged operation above 3/4 throttle.Rev the machine freely but do not use full throttle at anytime.

Avoid prolonged full throttle operation.Vary speedsoccasionally.

ParkingWhen parking, stop the engine and shift into neutral.Turn the fuel cock to “OFF” and apply the parkingbrake.

USER'S MANUAL

1. Bring the machine to a stop by applying the brakes.2. Stop the engine.

3. With the rear brake lever and pedal applied, applythe parking brake, and then lowly release the brakepedal.

POTENTIAL HAZARDParking on a hill or other incline.

WHAT CAN HAPPENTheATV could roll out of control, increas the chanceof an accident.

ing

HOW TO AVOID THE HAZARDAvoid parking on hills or other inclines. If you must park

on an incline, place the machine transversely across the

incline,apply the parking brake, and block the front and

rear wheels with rocks or other objects.

Do not park the ATV at all on hills that are so steep you

could not walk up them easily.

Parking on a slope

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Accessories can affect the handling and control of your ATV.Keep the following in mind when considering anaccessoryor operating anATV which has accessories.Choose only accessories designed for your ATV.YourATV dealer has a variety of genuineATV accessories.

Other accessories may also be available on the market.However, it is not possible for ATV to test all non-ATVaccessories,nor have any control over the quality orsuitabilityof them. Choose a genuine ATV accessory,or 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 whileyou are riding could affect your ability to control theATV.

Do not mount an accessory where it could interferewith your abil i ty to control the ATV. Examplesinclude (but are not limited to) a heavy or bulky objectattached to the handlebars which could make steeringdifficult, an accessory that limits your ability to movearound on the seat, or one that limits your view.

Use extra caution when riding an ATV withaccessories. The ATV may handle differentlythan itdoes without accessories.

USER'S MANUAL

LoadingCargo or a trailer can change the stability and handlingof anATV.You must use common sense and good judgment whencarrying cargo or towing a trailer. Keep the followingpoints in mind:

Never exceed the weight limits shown.An over loadedATV can be unstable.

MAXIMUM LOADING LIMITVehicle loading limit (total weight of cargo, rider andaccessories, and tongue weight):210 kg (463 lb).Front carrier: 40 kg (88 lb).Rear carrier: 80 kg (176 lb).Storage box: 2.0 kg (4.4 lb).Trailer hitch:Pulling load (total weight of trailer and cargo):500 kgf (1,102 lbf).Tongue weight (vertical weight on trailer hitch point):15 kgf (33 lbf).

Do not exceed the maximum tongue weight. You canmeasure tongue weight with a bathroom scale.Put the tongue of the loaded trailer on the scale withthe tongue at hitch height. Adjust the load in the trailer,if necessary, to reduce the weight on hitch.

If you are carrying cargo and towing a trailer, includethe tongue weight in the maximum vehicle load limit.

Load cargo on the carrier as close to the thevehicle as possible. Put cargo at the rear of the frontcarrier and at the front of the rear carrier. Center the loadfrom side to side.

center of

Tie down cargo securely to the carriers.Make sure cargo in the trailer cannot move around.Ashift ing load can cause an accident.

Make sure the load does not interfere with controls oryour ability to see where you are going.

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Ride more slowly than you would without a load.The more weight you carry, the slower you shouldgo.Allow more braking distance. A heavier vehicle takeslonger to stop.Avoid making sharp turns unless at very slow speeds.Avoid hills and rough terrain. Choose terrain carefully.Added weight affects the stability and handling ofthe ATV.

POTENTIAL HAZARD

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

Overloading this ATV or carrying or towing cargoimproperly.

Could cause changes in vehicle handling which could leadto an accident.

Never exceed the stated load capacity for this ATV. Cargoshould be properly distributed and securely attached.Reduce speed when carrying cargo or pulling a trailer.Allow greater distance for braking.

USER'S MANUAL

Indicates a potential hazard that could result in serious injury or death.

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Indicates a potential hazard that could result inserious injury or death.

GETTING TO KNOW YOUR ATVThis ATV is for recreation and utility use. This section,R i d i ng your AT V, prov i de s gene ra l AT Vr i d i nginst ructions for recreational riding. The skills andtechniques described in this sect ion, however,areappropriate for all types of riding. Riding yourATVrequires special skills acquired through practice overa period of t ime. Take the time to learn the basictechniques wel l before attempting more diff icul tmaneuvers.

Riding your new ATV can be a very enjoyable activity,providing you with hours of pleasure.But it is essentialto familiarize yourself with the operation of the ATVto achieve the skill necessary to enjoy riding safely.Before you begin to ride, be sure you have read this

Owner ’s Manual completely and understand theoperation of the controls. Pay particular attention tothe safety information on pages 5--10 .Please also read all caution and warning labels on yourATV.

USER'S MANUAL

RIDE WITH CARE AND GOOD JUDGEMENT

Get training if you are inexperienced.Beginners should get training from a certifiedinstructor.Become familiar with thisATV at slow speeds first, even ifyou are an experienced operator.Do not attempt to operate at maximum perfor mance untilyou are totally familiar with the handling andperformance characteristics.

ATV

HOW TO AVOID THE HAZARDBeginning and inexperienced operators should completethe certified training course offered byATV. They shouldthen regularly practice the skills learned in the courseand the operating techniques described in this OwnerManual. For more information about the training course,contact an authorized ATV dealer .

Riding yourATV requires skills acquired throughpractice over a period of time.

Take the time to learn the basic techniques well beforeattempting more difficult maneuvers.

POTENTIAL HAZARD

WHAT CAN HAPPEN

Operating thisATV without proper in- struction.

The risk of an accident is greatly increased if the operatordoes not know how to operate theATV properly in differentsituations and on different types of terrain.

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Not recommended for children under 16 years of age.

Failure to follow the age recommendations for this ATV.

Use by children of ATVs that are not recommended fortheir age can lead to severe injury or death of the child.

A child under 16 should never operate an ATV with enginesize greater than 90 cc.

POTENTIAL HAZARD

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

USER'S MANUAL

ThisATV is designed to carry operator and cargo onlypassengers prohibited.

POTENTIAL HAZARDCarrying a passenger on this ATV.

WHAT CAN HAPPENGreatly reduces your ability to balance and control thisATV. Could cause an accident, resulting in harm to youand/or your passenger.

HOW TO AVOID THE HAZARDNever carry a passenger. The long seat is to allow theoperator to shift position as needed during operation.It is not for carrying passengers.

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Apparel

POTENTIAL HAZARD

WHAT CAN HAPPEN

Operating this ATV without wearing an approvedmotorcycle helmet, eye protection and protective clothing.

Operating without eye protection can result in an accidentand increases your chances of a severe injury in the eventof anaccident.Operating without anapproved motorcyclehelmet increases yourchances of a severehead injury ordeathin the event of an accident.

Operating without protectiveclothing increases your chancesof severe injury in the event of an accident.

Alwayswearanapprovedmotorcyclehelmet thatfits properly.You should also wear:eye protection(goggles or faceshield)gloves boots long-sleeved shirt or jacket.

HOW TO AVOID THE HAZARD

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Do not operate after consuming alcohol ordrugs.

Operator performance capability is reduced by theinfluence of alcohol or drugs. POTENTIAL HAZARD

Operating thisATV after consuming alco ol or drugs.h

WHAT CAN HAPPENCould seriously affect your judgment.Could cause you to react more slowly.Could affect your balance and perception.Could result in an accident.

HOW TO AVOID THE HAZARDNever consume alcohol or drugs before or while drivingthis ATV.

c

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Pre-operation checksAlways perform the pre-operation checks l isted onpage 33 before riding for safety and proper care of the ATV.

POTENTIAL HAZARD

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

Failure to inspect the ATV before operating.Failure to properly maintain the ATV.

Increases the possibility of an accident or equipmentdamage.

Always inspect yourATV each time you use it to make surethe ATV is in safe operating condition. Always followthe inspection and maintenance procedures and schedulesdescribed in the Owner’s Manual.

POTENTIAL HAZARD

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

Operating this ATV with improper tires, or with improperor uneven tire pressure.

Use of improper tires on this ATV, or operation of thisATVwith improper or uneven tire pressure, may cause lossof control, increasing your risk of an accident.

Always use the size and type tires specified in the Owner’sManual for this vehicleonpages 40. Always maintain propertire pressure as described in the Owner’s Manual onpage 41.

USER'S MANUAL

Indicates a potential hazard that could result in seriousinjury or death.

Do not operate at speeds too fast for your skills or theconditions.

POTENTIAL HAZARDOperating thisATV at speeds too fast for your skills or theconditions.

WHAT CAN HAPPENIncreases your chances of losing control of theATV whichcan result in an accident.

,

HOW TO AVOID THE HAZARD

Speed limiterFor riders less experienced with this model, this model isequipped with a speed limiter in the throttle lever housing.The speed limiter keeps the throttle from fully opening, evenwhen the throttle lever is pushed to the maximum. Turningthe adjusting screw in limits the maximum engine poweravailable and decreases the maximum speed of theATV.

Turningtheadjustingscrew in decreases top speed and turningit out increases top speed.

Locknut Adjusting screw① ②

65

Always go at a speed that is proper for the terrain, visibilityand operating conditions, and your experience.

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Loading and accessoriesUse extra caution when riding the ATV with additionalloads, such as accessories or cargo. TheATV’s handling maybe adversely affected. Reduce your speed when addingadditional loads.

MAXIMUM LOADING LIMITVehicle loading limit: 210 kg (463 lb).

Total weight of cargo, rider and accessories, and trailerhitch vertical load.Front carrier: 40 kg (88 lb).Rear carrier: 80 kg (176 lb).Storage box: 2.0 kg (4.4 lb).

Trailer hitch:Pulling load: 500 kgf (1,102 lbf) Total weight of trailer andcargo.Tongue weight: 15 kgf (33 lbf).Vertical weight on trailer hitch point.

POTENTIAL HAZARD

Overloading this ATV or carrying or towingcargoimproperly.

WHAT CAN HAPPEN

Could cause changes in vehicle handling which couldlead to an accident.

HOW TO AVOID THE HAZARDNever exceed the stated load capacity for this ATV.Cargo should be properly distributed and securelyattached.Reduce speed when carrying cargo or pulling a trailer.Allow greater distance for braking.Always follow the instructions in your Owner’s Manual forcarrying cargo or pulling a trailer.

USER'S MANUAL

During operationAlways keep your feet on the footboards during operation.Otherwise your feet may contact the rear wheels. POTENTIAL HAZARD

Removing hands from handlebars or feet from footboardsduring operation.

WHAT CAN HAPPENRemoving even one hand or foot can reduce your abilityto control theATV or could cause you to lose your balanceand fall off of the ATV. If you remove a foot from afootboard, your foot or leg may come into contact with therear wheels, which could injure you or cause an accident.

HOW TO AVOID THE HAZARDAlways keep both hands on the handlebars and both feeton the footboards of your ATV yourATV during operation.

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Avoid wheelies and jumping. You may lose control of theATV or overturn.

Attempting wheelies, jumps, and other stunts.

Increases the chance of an accident, including an overturn.

Never attempt stunts, such as wheelies or jumps. Don’t tryto show off.

POTENTIAL HAZARD

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

USER'S MANUAL

Modifications

POTENTIAL HAZARDOperating this ATV with improper modifications.

WHAT CAN HAPPENImproper installation of accessories or modificationof this vehicle may cause changes in handling whichin some situations could lead to an accident.

HOW TO AVOID THE HAZARDNever modify this ATV through improper installationor use of accessories. All parts and accessories addedto this vehicle should be genuine ATV or equivalentcom onents designed for use on this ATV and shouldbe installed and used according to instructions. If youhave questions, consult an authorizedATV dealer.

p

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Exhaust systemThe exhaust system on the ATV is very hot during andfollowing operation. To prevent burns, avoid touchingthe exhaust system. Park the ATV in a place wherepedestrians or children are not likely to touch it.

70

Do not touch the hot exhaust system.Do not park the ATV in a place where others might belikely to touch it.

POTENTIAL HAZARD

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

Hot exhaust system.

Dry grass or brush or other combus t ible materialaccumulated around the engine area could catch fire.Someone touching the exhaust system during or afteroperation could be burned.

Do not operate, idle, or park the ATV in dry grass or otherdry ground cover.Keep the engine area free of dry grass,brush, or othercombustible material.

USER'S MANUAL

POTENTIAL HAZARDOperating this ATV on paved surfaces.

WHAT CAN HAPPENATVs are designed for off-road use only. Pavedsurfaces may seriously affect handling and controlof the ATV, and may cause the vehicle to go out ofcontrol.HOW TO AVOID THE HAZARDAlways avoid paved surfaces, including sidewalks,driveways, parking lots andstreets.

BE CAREFULWHERE YOU RIDEThisATV is designed for off-road use only. Riding onpaved surfaces can cause loss ofcontrol.

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Do not ride on any public road, street, or highway.Riding on public roads can result in collisions with othervehicles.

POTENTIAL HAZARD

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

Operating thisATV on public streets, roads or highways.

You can collide with another vehicle.

Never operate this ATV on any public street, road orhighway, even a dirt or gravel one.In many states it is illegal to operate ATVs on publicstreets, roads and highways.

USER'S MANUAL

Know the terrain where you ride. Ride cautiously inunfamiliar areas. Stay alert for holes, rocks, or roots inthe terrain, and other hiddenhazards which may causethe ATV to upset.

POTENTIAL HAZARDFailure to use extra care when operating this ATV onunfamiliar terrain.

WHAT CAN HAPPENYou can come upon hidden rocks, bumps, or holes,withoutenough time to react. Could result in theATV overturn ingor going out of control.

HOW TO AVOID THE HAZARDGo slowly and be extra careful when operating on unfamiliarterrain. Always be alert to changing terrain conditionswhen operating the ATV.

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POTENTIAL HAZARD

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

Failure to use extra care when operatingon excessivelyrough, slippery or loose terrain.

Could cause loss of traction or vehicle control, whichcould result in an accident, including an overturn.

Do not operate on excessively rough, slippery or looseterrain until you have learned and practiced the skillsnecessary to control the ATV on such terrain. Alwaysbe especially cautious on these kinds of terrain.

USER'S MANUAL

When riding in an area where you might not easily be seen,such as desert terrain, mount a caution flag on theATV.DO NOT use the flag pole bracket as a trailer hitch.

POTENTIAL HAZARDOperating in areas where you might not be seen by otheroff-road vehicles.

WHAT CAN HAPPENYou could be in a collision. You could be injured.

HOW TO AVOID THE HAZARDAlways mount a caution flag on theATV to make you morevisible. Watch care fully for other vehicles.

Do not ride in areas posted o trespassing Do not ride onprivate property without getting per-mission.

"n "

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With the engine idling, return the starter (choke)tothe closed position, shift the drive select lever intothe forward position, and then release the parkingbrake. Apply the throttle slowly and smoothly. Thecentrifugal clutch will engage and you will start toaccelerate. If the throttle is applied too abruptly, thefront wheels may lift off the ground resulting in a lossof directional control. Avoid higher speeds until youare thoroughly familiar with the operation of your ATV.

When slowing down or stopping, release the throttle andapply the brakes smoothly and evenly.Improper use of the brakes can cause the tires to losetraction, reducing control and increasing the possibility ofan accident.

Select a large, flat area off-road to become familiar withyour ATV. Make sure that this area is free of obstaclesand other riders. You should practice control of the throttle,brakes, and turning techniques in this area before tryingmore difficult terrain.

Always avoid riding on paved surfaces: the ATV isdesigned for off-road use only, and handling maneuversare more difficult to perform on pavement.

Set the parking brake and follow the instruction onpage 43 to start the engine. Once it has warmed up youare ready to begin riding your ATV. Remember that theengine and exhaust pipe will be hot when riding andafterwards; do not allow skin or clothing to come in contactwith these components.

USER'S MANUAL

TURNING YOUR ATVTo achieve maximum traction while riding off road, thetwo rear wheels are mounted solidly on one axle and turntogether at the same speed.Therefore, unless the wheel on the in side of the turnis allowed to slip or lose some traction, the ATV willresist turning.Aspecial turning technique must be usedto allow the ATV to make turns quickly and easily. Itis essential that this skill be learned first at low speed.

-

POTENTIAL HAZARDTurning improperly.WHAT CAN HAPPENATVcould go out of control, causing acollision or overturn.

HOW TO AVOID THE HAZARDAlways follow proper procedures for turning as describedin this Owner Manual.

Practice turning at low speeds before at tempting toturn at faster speeds. Do not turn at speeds too fast for yourskills or the conditions.

As you approach a curve, slow down and begin to turnthe handlebars in the desired direction.As you do so, putyour weight on the footboard to the outside of the turn(opposite your desired direction) and lean your upperbody into the turn.Use the throttle to maintain an even speed through theturn.This maneuver will let the wheel on the inside of theturn slip slightly, allowing the ATV to make the turnproperly.

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This procedure should be practiced at slow speed many timesin a large off-road area with no obstacles.If an incorrect technique is used, yourATV may continue togo straight. If the ATV doesn’t turn, come to a stop andthen practice the procedure again. If the riding surfaceis slippery or loose, it may help to position more of yourweight over the front wheels by moving forward on the seat.

Once you have learned this technique you should be ableto perform it at higher speeds or in tighter curves.Improper riding procedures such as abrupt thrott lechanges, excessive braking, incorrect body movements, ortoo much speed for the sharpness of the turn may causethe ATV to tip.

If the ATV begins to tip over to the outside whilenegotiating a turn, lean more to the inside. It may alsobe necessary to gradually let off on the throttle and steerto the outside of the turn to avoid tipping over.Remember: Avoid higher speeds until you are thoroughlyfamiliar with the operation of your ATV.

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CLIMBING UPHILLUse proper riding techniques to avoid vehicle overturns onhills. Be sure that you can maneuver yourATV well onflat ground before attempt ing any incline and then practiceriding first on gentle slopes. Try more difficult climbs onlyafter you have developed your skill. In all cases avoidinclines with slippery or loose surfaces, or obstacles thatmight cause you to lose control.

POTENTIAL HAZARDOperating on excessively steep hills.

WHAT CAN HAPPENThe vehicle canoverturn more easilyon extremelysteep hillsthan on level surfaces or small hills.

HOW TO AVOID THE HAZARDNever operate the ATV on hills too steep for the ATV orfor your abilities. Practice on smallerhills before attemptinglargehills.

It is important when climbing a hill to make sure that yourweight is transferred forward on the ATV. This can beaccomplished by leaning forward and, on steeper inclines,standing on the footboards and leaning forward over thehandlebars.

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POTENTIAL HAZARD

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

Climbing hills improperly.

Could cause loss of control or cause theATV to overturn.

Always follow proper procedures for climbing hills asdescribed in this Owner’s Manual.Always check the terrain carefully before you start up anyhill.Never climb hills with excessively slippery or loosesurfaces.Shift your weight forward.Never open the throttle suddenly.The ATV could flip over backwards.Never go over the top of any hill at high speed.

An obstacle, a sharp drop, or another vehicle or person couldbe on the other side of the hill.

USER'S MANUAL

POTENTIAL HAZARDImproperly crossing hills or turning onhills.

WHAT CAN HAPPENCould cause loss of control or cause the ATV to overturn.

HOW TO AVOID THE HAZARDNever attempt to turn theATV around on any hill until youhave mastered the turning technique as described in theOwner Manual on level ground. Be very careful whenturning on any hill. Avoid crossing the side of a steep hillif possible.

If you are climbing a hill and you find that you have notproperly judged your ability to make it to the top, you shouldturn the ATV around while you still have forward motion(provided you have the room to do so) and go down thehill.

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When crossing the side of a hill:Always follow proper procedures as described in theOwner’s Manual.Avoid hills with excessively slippery or loose surfaces.Shift your weight to the uphill side of the ATV.

USER'S MANUAL

If your ATV has stalled or stopped and you believe youcan continue up the hill, restart carefully to make sureyou do not lift the front wheels which could cause youto lose control. If you are unable to continue up the hill,dismount theATV on the uphill side. Physically turn theATV around and then descend the hill.

If you start to roll backwards, DO NOT applyeither brakeabruptly. If you are in 2WD, apply only the front brake.When this ATV is in 4WD, all wheels (front and rear)are interconnected by the drive train. This means thatapplying either the front brake or the rear brake willbrake all wheels.When descending hills, using either brake lever or thebrake pedal will brake the wheels on the down hill side.Avoid sudden application of either the front or rear brakebecause the wheels on the uphill side could come off theground. TheATV could easily tip over backwards. Applyboth the front and rear brakes gradually, or dismount theATV immediately on the uphill side.

POTENTIAL HAZARDStalling, rolling backwards or improperly dismounting whileclimbing a hill.

WHAT CAN HAPPENCould result in ATV overturning.

HOW TO AVOID THE HAZARDMaintain steady speed when climbing a hill.If you lose allforward speed:

Keep weight uphill.Apply the brakes.Apply the parking brake after you arestopped.

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If you begin rolling backwards:Keep weight uphill.2WD: Never apply the rear brake while rolling backwards.Apply the front brake. When fully stopped, apply therear 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 side if pointed straightuphill. Turn the ATV around and remount, followingthe procedure described in the Owner’s Manual.

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RIDING DOWNHILLWhen riding yourATV downhill, shift your weight as farto the rear and uphill side of the ATV as possible.Move back on the seat and sit with your arms straight.Engine compression will do most of the braking for you.For maximum engine compression braking effect, changeto 4WD before beginning to descend the hill. Improperbraking may cause a loss of traction. Use caution whiledescending a hill with loose or slippery surfaces. Brakingability and traction may be adversely affected by thesesurfaces. Improper braking may also cause a loss oftraction.

Whenever possible, ride your ATV straight down hill.Avoid sharp angles which could allow the ATV to tip orroll over. Carefully choose your path and ride no fasterthan you will be able to react to obstacles which may appear.

off the ground.Apply both the front and rear brakes gradually.

85

When this ATV is in 4WD, all wheels (front and rear) areinterconnected by the drive train. This means that applyingeither the front brake or the rear brake will brake allwheels. When descending hills, using either brake leveror the brake pedal will brake the wheels on the down hillside.Avoid sudden application of either the front or rearbrake because the wheels on the uphill side could come

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POTENTIAL HAZARD

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

Going down a hill improperly.

Could cause loss of control or cause the ATV to overturn.Always follow proper procedures for going down hillsas described in this Owner’s Manual. Note: a specialtechnique is required when braking as you go down ahill.

Always check the terrain carefully before you start downany hill.Shift your weight backward.Never go down a hill at high speed.Avoid going down a hill at an angle that would causethe vehicle to lean sharply to one side. Go straight downthe hill where possible.

USER'S MANUAL

CROSSING A SLOPETraversing a sloping surface on your ATV re uires youto properly position your weight to maintain properbalance. Be sure that you have learned the basic ridingskills on flat ground before attempting to cross a slopingsurface. Avoid slopes with slippery surfaces or roughterrain that may upset your balance.

q

As you travel across a slope, lean your body in the uphilldirection. It may be necessary to correct the steeringwhen riding on loose surfaces by pointing the frontwheels slightly uphill. When riding on slopes be surenot to make sharp turns either up or down hill.

If yourATV does begin to tip over, gradually steer in thedownhill direction if there are no obstacles in your path.As you regain proper balance, gradually steer again in thedirection you wish totravel.

POTENTIAL HAZARDImproperly crossing hills or turning onhills.

WHAT CAN HAPPENCould cause loss of control orcause the ATVto overturn.

HOW TO AVOID THE HAZARDNever attempt to turn theATV around on any hill until youhave mastered the turning technique as described in the.Owner Manual on level ground. Be very careful when turningon any hill.Avoid crossing the side ofasteephill ifpossible.When crossingthe side of a hill:Always follow proper procedures as described in the OwnerManual.Avoid hills with excessively slippery or loose surfaces.Shift your weight to the uphill side of theATV.

87

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CROSSING THROUGH SHALLOW WATERThe ATV can be used to cross slow moving,sha waterof up to a maximum of 35 cm (14 inches) in depth. Beforeentering the water, choose your path carefully. Enter wherethere is no sharp drop off, and avoid rocks or other obstacleswhich may be slippery or upset theATV. Drive slowly andcarefully.

llow

POTENTIAL HAZARDOperating thisATV through deep or fast flowing water.

WHAT CAN HAPPENTiresmayfloat, causinglossoftraction andlossofcontrol, whichcould lead to an accident.

HOW TO AVOID THE HAZARDNever operate thisATV in fast flowing water or in waterdeeper than that specified in your Owner Manual.

Remember that wet brakes may have reduced stoppingability. Test your brakes after leaving water. If necessary,apply them several times to let friction dry out the linings.

89

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90

Test your brakes after leaving the water. Do not continueto ride your ATV without verifying that you have regainedproper braking ability. After riding yourATV in water, be sure to drain the trapped

water by removing the check hose at the bottom of the airfilter case, the V-belt cooling duct check hose, the driveselect lever box check hose and the storage box checkhose. Also, remove the V-belt case drain plug to drain anywater that may have accumulated. Wash the ATV in freshwater if it has been operated in salt water or muddyconditions.

USER'S MANUAL

① Drive select lever box check hose. ① V-belt case drain plug.91

① V-belt cooling duct check hose (left front sideofATV).

Storage box check hose.①

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RIDING OVER ROUGH TERRAINRiding over rough terrain should be done with caution.Look out for obstacles which could cause damage tothe ATV or could lead to an upset or accident. Be sureto keep your feet firmly mounted on the footboards atall times.Avoid jumping the ATV as loss of control and damageto 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.Could cause the ATV to overturn.

Before operating in a new area, check for obstacles.Never attempt to ride over large obstacles, such aslarge rocks or fallen trees.When you go over obstacles, always follow properprocedures as described in the Owner’s Manual.

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SLIDING AND SKIDDINGCare should be used when riding on loose or slippery surfacessince the ATV may slide. If unexpected and uncorrected,sliding could lead to anaccident.

To reduce the tendency for the front wheels to slide in looseor slippery conditions, positioning your weight over thefront wheels will sometimeshelp.

If the rear wheels of your ATV start to slide side ways,control can usually be regained (if there is room to doso) by steering in the direction of the slide. Applyingthe brakes or accelerating is not recommended untilyou have corrected the slide.

93

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With practice, over a period of time, skill at controlledsliding can be developed. The terrain should be chosencarefully before attempting such maneuvers, since bothstability and control are reduced. Bear in mind thatsliding maneuvers should always be avoided on extremelyslippery surfaces such 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 regaintraction unexpectedly, which may cause the ATV tooverturn.

Learn to safely control skidding or sliding by practicing atlow speeds and on level,smooth terrain.On extremely slippery surfaces, such as ice, go slowly andbe very cautious in order to reduce the chance of skiddingor sliding out of control.

USER'S MANUAL

This section is designed to be a reference guide only.Be sure to readeachsection onriding techniques completely.

If yourATV does no turn when you want it to:Bring the ATV to a stop and practice the turningmaneuvers again. Be sure you are putting your weighton the footboard to the outside of the turn. Positionyour weight over the front wheels for better control.(See pages 77--78).

If yourATV begins to tip while turning:Lean more into the turn to regain balance. If necessary,gradually let off the throttle and/or steer to the outsideof 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 brakes or accelerating is not recommendeduntil you have corrected the slide. (See pages 93--94).

If yourATV can trying to climb:make it up a hill you are

Turn theATVaround if you still have forward speed. If not,stop, dismount on the uphill side of theATV andphysicallyturn theATV around. If theATV starts to slip backwards,DO NOTUSETHE REARBRAKE theATV may tip overon top of you. Dismount theATV on the uphill side.(See pages 79--84.)

WHAT TO DO

WHAT TO DO IF

95

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If your ATV is traversing a sloping surface:Be sure to ride with your weight positioned towards theuphill side of theATVto maintain proper balance. If theATVstarts to tip, steer down the hill ( if there are no obstacles inyour way) to regain balance. If you discover that the ATVis going to tip over, dismount on the uphill side. (See pages87 --88).

If your ATV encounters shallow water:Rideslowlyandcarefullythroughslowmovingwater, watchingfor obstacles. Be sure to let water drain from the ATV andCHECKYOURBRAKESFORPROPER OPERATIONwhenyou come outofthewater. Donotcontinue to ride yourATVuntil you have regained adequate braking ability. (Seepages 89--91).

Indicates a potential hazard that could result in seriousinjury or death.

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PERIODIC MAINTENANCE AND ADJUSTMENT

POTENTIAL HAZARD

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

Periodic inspection, adjustment and lubrication will keepyour machine in the safest and most efficient conditionpossible. Safety is an obligation of the machine owner.Themost important points of machine inspection, adjustmentand lubrication are explained on the following pages.

Servicing an engine while it is running.

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

Turn off the engine when performing maintenance unlessotherwise specified.Have aATVdealerperformserviceifyouare not familiar withmachine service.

Owner’s manual and tool kitYou are recommended to put this owner’s manual inthe vinyl bag and always carry it on the bottom of theseat as shown. Put the owner’s tool kit and low-pressuretire gauge under the seat.The service information included in this manual isintended to provide you, the owner, with the necessaryinformat ion for completing your own preventivemaintenance and minor repairs. The tools provided inthe Owner’s tool kit are sufficient for this purpose, exceptthat a torque wrench is also necessary to properlytighten nuts and bolts.

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①

②

③

Owner’s manual.Owner’s tool kit.Low-pressure tire gauge.

If you do not have a torque wrench available duringa service operation requiring one, take your machineto a ATV dealer to check the torque settings and adjustthem as necessary.

NOTE:

POTENTIAL HAZARD

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

Operating this ATV with improper modifications.

Improper installation of accessories or modification ofthis vehicle may cause changes in handling which insome situations could lead to an accident.

Never modify this ATV through improper installation oruse of accessories. All parts and accessories added to thisvehicle should be genuine ATV or equivalent componentsdesigned for use on this ATV and should be installed andused according to instructions. If you have questions,consult an authorized ATV dealer.

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PERIODIC MAINTENANCE/LUBRICATIONFor ATVs not equipped with an odometer or an hour meter, follow the maintenance intervals.

For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. However,keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed.

NOTE:

ITEM ROUTINE whichevercomes first

monthkm(mi)hours

1 3 6 6 12320 1200 2400 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.Replace if necessary.

Air fiter element

Crankcase breathesystem*

Exhaust system*

fuel line*

Spark arrester

Clean.Replace if necessary.

Carburetor* Check and adjust idle speed/starter operation.Adjust if necessary.Check breather hose for cracks or damage.Replace if necessary.Check for leakage.Tighten if necessary.Replace gasket(s) if necessary.Clean.Check fuel hose for cracks or damage.Replace if necessary.

EVERY INITAL

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2 0 7 5 150 150 300

3 6 6 1 2320

(200)1,200 1,200 2,400 4,800(750) (1,500) (1,500) (3,000)

1

Replace.(Warm engine before draining).Engine oil

Axle boots*

Engine oil filter cartridge Replace.Engine oil strainer* Clean.Final gear oilDifferential gear oil

Check for oil leakage.Replace every 12 months.

Front brake*Check operation/fuid leakage.(See NOTE page 8).Correct if necessary.

Rear brake* Adjust if necessary.Check operation.

Select lever safety systemcable*

Check operation.Adjust if necessary.

V-belt*

Wheel*

Check operation.Check for cracks or damage.Check balance/damage/runout.Repair if necessary.Check bearing assemblies for losseness/damage.Replace if damaged.Check operation.Correct if necessary.Check operation./Replace if damaged.Check toe-in./Adjust if necessary.Lubricate with lithium-soap-based grease.Check operation.Replace if damaged.

Wheel bearing*

Front and rearsuspension*

Steering system*

Drive shaft universal joint*

ITEMmonth

ROUTINE whichevercomes first

EVERY INITAL

k m(m i)hours

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2 0 7 5 150 150 300

3 6 6 1 2320

(200)1,200 1,200 2,400 4,800(750) (1,500) (1,500) (3,000)

1ITEM

monthROUTINE whichever

comes first

EVERY INITAL

k m(m i)hours

Correct if necessary.Check all chassis fittings and fasteners.

Fittings and fasteners*

Adjust headinght beams.Check operation.

Lights and switches*

Since these items require 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 brake fluid. Normally check the brake fluid leveland add fluid as required.On the inner parts of the master cylinder and caliper,replace the oil seals every two years.Replace the brake ho ses every four years, or if cracked or damaged.

Indicates a potential hazard that could result in serious injury or death.

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Panel removal and installationThe panel illustrated needs to be removed to perform someof the maintenance described in this chapter.Refer to this section each time the panel has to beremoved orinstalled.

Panel A①

Panel ATo removeRemove the bolt, and then take the panel off.To installPlace the panel in the original position and install thebolt.

When installing the panel, be sure not to pinch the cablesor wires.

Panel A Bolt① ②

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Engine oil and oil filter cartridge

To check the engine oil level

The engine oil level should be checked before each ride.In addition, the oil must be changed and the oil filtercartridge replaced at the intervals specified in theperiodic maintenance and lubrication chart.

1. Place the ATV on a level surface.2. Start the engine, warm it up for several minutes, and

then turn it off.3. Wait a few minutes until the oil settles.4. Remove the engine oil filler cap and wipe off the

dipstick with a clean rag.

Engine oil filler cap

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5. Insert the dipstick in the oil filler hole (without screwingit in), and then remove it again to check the oil level.

The engine oil shouldbe between theminimum andmaximumlevel marks.

NOTE:

Maximum level mark Minimum level mark① ②

7. Insert the dipstick into the oil filler hole, and then tightenthe oil filler cap.

6. If the engine oil is at or below the minimum level mark,add sufficient oil of the recommended type to raise itto the correct level.

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To change the engine oil (with or without oil filter cartridgereplacement).1. Start the engine, warm it up for several minutes, and

then turn it off.2. Place 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 filter cartridge is not being replaced.

4. Remove the oil filter cartridge with an oil filter wrench.

① Engine oil drain bolt

① Oil filter cartridge

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An oil filter wrench is available at a nearby ATVdealer.

5. Apply a light coat of engine oil to the O-ring of the newoil filter cartridge.

Make sure the O-ring is seated properly.

NOTE:

NOTE:

① O-ring ① Oil filter wrench

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6. Install the new oil filter cartridge with an oil filterwrench, and then tighten it to the specified torquewith a torque wrench.

Torque wrench①

7. Install the engine oil drain bolt, and then tighten it tothe specified torque.

Tightening 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 tightenit.

Tightening torque:Oil filter cartridge:17 N·m (1.7 m·kgf, 12 ft·lbf)

Recommended engine oil:See page 151.Oil quantity:Without oil filter cartridgereplacement:2.2 L (1.94 Imp qt, 2.33 US qt)With oil filter cartridge replacement:2.3 L (2.02 Imp qt, 2.43 US qt)

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In order to prevent clutch slipppage (since the engineoil also lubricates the clutch), do not mix any chemicaladditives. Do not use oils with a diesel specification of“CD” or oils of a higher quality than specified. In addition,do not use oils labeled “ENERGY CONSERVING II”or higher.Make sure that no foreign material enters the crankcase.

9. Start the engine and warm it up for several minutes.While warming up, check for oil leakage. If oilleakage is found, turn the engine off immediately andcheck for the cause.

10. Turn the engine off, and then check the oil level andcorrect it if necessary.

Final gear oilFinal gear oil measurement

NOTE:

1. Place the machine on a level surface.2. Remove the oil filler bolt, and then check the oil level

in the final gear case.

The oil level should be at the brim of the fillerhole.

Final gear oilFinal gear oil filler boltProper oil level

①②③

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3. If the oil is below the brim of the filler hole,

· ·

add sufficientoil of the recommended type to raise it to the correctlevel.

Be sure no foreign material enters the final gear case.

4. Install the oil filler bolt, and then tighten it tothe specifiedtorque.

Tightening torque:Final gear oil filler bolt:23Nm(2.3m kgf, 16ft lbf)

2. Place the machine on a level surface.3. Place a container under the final gear case to collect

the used oil.

① ②Final gear case cover Bolt ( 2)

Final gear oil replacement1. Remove the final gear case cover by removing the

bolts.

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4. Remove the oil filler bolt and the drain bolt to drainthe oil.

Final gear oil drain bolt

5. Install the drain bolt, and then tighten it to thespecified torque.

Tightening torque:Final gear oil drain bolt:23 Nm (2.3 m·kgf, 16 ft·lbf)

6. Add the recommended final gear oil to the brim ofthe filler hole.

Recommended oil:SAE 80 API GL-4 Hypoid gear oilOil 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 then tighten it to thespecified torque.

8. Check for oil leakage. If oil leakage is found, check forthe cause.

9. Install the final gear case cover bolts, and then tightenthem to the specified torque.

Tightening torque:Final gear case cover bolt:16 Nm (1.6 m·kgf, 11 ft·lbf)

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Differential gear oil replacement1. Place the machine on a level surface.2. Place a container under the differential gear case to

catch the oil.3. Remove the oil filler bolt and oil drain bolt to drain

the oil.

Differential gear oil filler bolt①

Differential gear oil drain bolt4. Install the oil drain bolt, and then tighten it to the

specified torque.

Tightening torque:Didderential gear oil drain bolt:10 Nm (1.0 m·kgf, 7 ft·lbf)

①

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5. Fill the differential gear case with the specified amountof the recommended oil.

Do not exceed the specified differential gear oil quantitywhen filling. Overfilling will cause the oil to seep outof the breather hose during and after riding.

The differential gear oil level cannot bechecked. Thedifferential gear case capacity is greater than therecommended oil quantity, therefore the oil level cannotbe accurately checked from the oil filler cap hole.

Recommended oil:SAE 80 API “GL-4” Hypoid gear oilOil quantity:0.35 L (0.31 Imp qt, 0.37 US qt)

NOTE:

Be sure no foreign material enters the differential gearcase.6. Install the oil filler bolt, and then tighten it to the

specified torque.

Tightening torque:Differential gear oil filler bolt:23 Nm (2.3 m·kgf, 16 ft·lbf)

7. Check for oil leakage. If oil leakage is found, checkfor the cause.

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Axle boots.Check the protective boots for holes or tears.If any damageis found, have them replaced by a ATV dealer.

Axle boot ( 2 each side)①

Spark plug inspection Removal.1. Remove the spark plug cap.

Spark plug cap①

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2. Use the spark plug wrench in the owner’s tool kit toremove the spark plug as shown.

Spark plug wrench

The spark plug is an important engine component andis easy to inspect. The condition of the spark plug canindicate the condition of the engine.The ideal color on the white insulator around the centerelectrode is a medium-to-light tan color for an ATV thatis being ridden normally.Do not attempt to diagnose such problems yourself.

Inspection

①

Instead, take theATVto aATVdealer.You should periodicallyremove and inspect the spark plug because heat anddepositswill cause the spark plug to slowly break down and erode.If electrode erosion becomes excessive, or if carbon andother deposits are excessive, you should replace the sparkplug with the specified plug.

Specified spark plug:DR8EA (NGK)

1. Measure the electrode gap with a wire thick-nessgauge and, if necessary, adjust the gap tospecification.

Spark plug gap:0.6 0.7 mm (0.02 0.03 in)

Installation

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2. Clean the surface of the spark plug gasket

Tightening torque:Spark plug:17.5 Nm (1.75 m·kgf, 12.5 ft lbf)

and its matingsurface, and then wipe off any grime from the sparkplug threads.

3. Install the spark plug and tighten it to the specifiedtorque.

·

NOTE:If a torque wrench is not available when you areinstalling a spark plug, a good estimate of the correcttorque is 1/4 to 1/2 turn past finger tight. Have the sparkplug tightened to the specified torque as soon as possible.

4. Install the spark plug cap.

a Spark plug gap

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Air filter element cleaning.

There is a check hose at the bottom of the air filter case.If dust or water collects in this hose, empty the hose andclean the air filter element and air filter case.

1. Remove the seat. (See page 28 for seat

2. Remove the air filter case cover by unhook

NOTE:

removal andinstallation procedures.)

ing the holders.3. Remove the air filter element assembly.

Holder ( 4) Air filter case cover① ②

① Air filter element assembly

1 Air filter case check hose

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4. Wash the element gently but thoroughly in solvent.

5. Wash the element gently but thoroughly in solvent.

① ②③

Air filter element frame Air filter elementLock plate

POTENTIAL HAZARD

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

Using low flash point solvents or gasoline to clean theair filter element.

Low flash point solvents or gasoline can catch fire orexplode.

Use parts cleaning solvent to clean the air filter element.

Do not twist the air filter element when squeezing it.

7. Inspect the air filter element and replace it if damaged.

6. Squeeze the excess solvent out of the air filter elementand let it dry.

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8. Apply atv foam air filter oil or other quality foam airfilter oil to the air filter element.

The air filter element should be wet but not dripping.

9. Pull the air filter element over its frame, and then installthe lock plate.

10. Install the air filter element assembly.11. Install the air filter case cover by hooking the fasteners

onto the air filter case.12. Install the seat.

NOTE:

NOTE:The air filter element should be cleaned every20-40 hours. It should be cleaned and lubricated moreoften 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 case rubber joint to the carburetorand manifold fittings for an airtight seal. Tighten allfittings securely to avoid the possibility of unfilteredair entering the engine.

Never operate the engine with the air filter element removed.This will allow unfiltered air to enter, causing rapid enginewear and possible engine damage.Additionally, operation without the air filter element willaffect carburetor jetting with subsequent poor performanceand possible engine overheating.

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V-belt cooling duct check hoseIf dust or water collects in the V-belt cooling duct checkhose, remove the hose and clean it.

V-belt cooling duct check hose (Left frontside of ATV)①

V-belt case drain plugAfter riding in water deep enough to allow it to enter theV-belt case, remove this plug to drain the water from thecase.

NOTE:If water drains from the V-belt case after removing theplug, have a dealer inspect the ATV as the water mayaffect other engine parts.

V-belt case drain plug①

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Spark arrester cleaning.Be sure the exhaust pipe and muffler are cool beforecleaning the spark arrester.1. Remove the bolts.2. Remove the tailpipe by pulling it out of the muffler.

3. Tap the tailpipe lightly, and then use a wire brush toremove any carbon deposits from the sparkarrester portion of the tailpipe.

Spark arrester

4. Insert the tailpipe into the muffler and align the boltholes.

5. Install and tighten the bolts.

①

① ②Bolt ( 3) Tailpipe

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POTENTIAL HAZARD

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

Improper cleaning of the spark arrester.Hot exhaust system.

Could injure the eyes.Could cause burns.Could cause carbon monoxide poisoning,possibly leadingto death.Could start a fire.

When cleaning the spark arrester:Always let the exhaust system cool prior to touchingexhaust components.Do not start the engine when cleaning the exhaust system.

Carburetor adjustmentThe carburetor is a vital part of the engine and requiresvery sophisticated adjustment. Most adjusting shouldbe left to aATV dealer who has the professional knowledgeand experience to do so. However, the idling speed maybe performed by the owner as a part of the usual maintenanceroutine.

The carburetor was set at the ATV factory after manytests. If the settings are disturbed by someone withoutsufficient technical knowledge, poor engine performanceand damage may result.

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Idle speed adjustment

NOTE:A diagnostic tachometer must be used for this procedure.

1. Start the engine and warm it up for a few minutes atapproximately 1,000 to 2,000 r/min. Occasionallyrev the engine to 4,000 to 5,000 r/min. The engine iswarm when it quickly responds to the throttle.

2. Connect the tachometer to the spark plug lead, and thenset the idle to the specified idling speed by adjustingthe throttle stop screw. Turn the screw in direction a toincrease the engine speed, and in direction b to decreasethe engine speed.

Specified idle speed:1,450-1,550 r/min

Throttle stop screw

The correct valve clearance changes with use,resultingin improper fuel/air supply or engine noise. To preventthis, the valve clearance must be adjusted regularly.This adjustment however,should be left to a professionalATV service technician.

Valve clearance adjustment

①

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The select lever safety system cable streches with use ,resulting in improper function. To prevent this, the cablemust be adjusted regularly.This adjustment, however, should be left to a ATV dealer.

Select lever safety system cable adjustment Throttle lever adjustment.

Adjust the engine idling speed before adjusting the throttlelever free play.1. Loosen the locknut.2. Turn the adjusting bolt until the throttle lever free play

is 3 5 mm (0.12- 0.20 in).3. Tighten the locknut.

Locknut Adjusting bolt

NOTE:

① ②

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a Throttle lever free play

Front brake pad check

NOTE:

Check the brake pads for damage and wear. If a brakepad thickness is less than 1 mm (0.04 in), have a ATVdealer replace the pads as a set.

The wheels need to be removed to check the brake pads.(See pages 134--135 for removal and installationprocedures.)

a Brake pad thickness

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Rear brake shoe inspectionAwear indicator is provided on the rear brake.This indicatorallows checking of brake shoe wear without disassemblingthe brake. Apply the rear brake and check the positionof the indicator.If the indicator reaches the wear limit line, ask a ATVdealer to replace shoes as a set.

Brake fluid level checkInsufficient brake fluid may let air enter the brake system,possibly causing the brakes to become ineffective.Before riding, check that the brake fluid is above theminimum level mark and replenish if necessary.A low brake fluid level may indicate worn brake padsand/or brake system leakage. If the brake fluid level islow, be sure to check the brake pads for wear and thebrake system for leakage.

Minimum level mark

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① Observe these precautions:When checking the brake fluid level, make sure the topof the brake fluid reservoir is level.

Use only the designated quality brake fluid, otherwise,the rubber seals may deteriorate,causing leakage andpoor brake performance.

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Recommended brake fluid: DOT 4

Refill with the same type of brake fluid. Mixingfluids may result in a harmful chemical reaction andlead to poor brake performance.Be careful that water does not enter the brake fluidreservoir when refilling. Water will significantlylower the boiling point of the fluid and may result invapor lock.Brake fluid may deteriorate painted surfaces orplastic parts. Always clean up spilled fluidimmediately.Have a dealer check the cause if the brake fluid levelgoes down.

①

127

Brake fluid replacementComplete fluid replacement should be done only bytrained service personnel.Have a dealer replace the following components duringperiodic 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 playThe front brake lever should have a free play of zero mm(zero in) at the lever end.

a Front brake lever free play

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POTENTIAL HAZARD

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

Operating with improperly serviced or adjusted brakes.

You could lose braking ability, which could lead to anaccident.

After servicing:Make sure the brakes operate smoothly and that thefree play is correct.Make sure the brakes do not drag.Make sure the brakes are not spongy. All air must bebled from the brake system.

Replacement of brake components requires professionalknowledge. These procedures should be performed byATV a dealer.

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Brake lever free play adjustment1. Loosen the locknut and fully turn in the adjusting bolt

at the brake lever.

Locknut Adjusting bolt① ②

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2. Turn in the adjusting nut on brake cable toprovide agap of 0-1 mm (0-0.04 in) between the brakecamshaft lever and the pin.

Adjusting nut (brake lever cable) a Gap①

3. Turn the adjusting bolt at the brake lever until the freeplay at the brake lever pivot is 3-5mm (0.12-0.20 in).

Locknut Adjusting bolta Rear brake lever free play

4. Tighten the locknut.

① ②

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POTENTIAL HAZARD

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

Operating with improperly serviced or adjusted brakes.

You could lose braking ability, which could lead to anaccident.

After servicing:Make sure the brakes operate smoothly and that thefree play is correct.Make sure the brakes do not drag.

Replacement of brake components requires professionalknowledge. These procedures should be performed by aATV dealer.Replacement of brake components requires professionalknowledge. These procedures should be performed by adealer.

Adjusting the rear brake light switchThe rear brake light switch, which is activated by thebrake pedal and rear brake lever, is properly adjustedwhen the brake light comes on just before braking takeseffect. If necessary, adjust the brake light switch as follows.1. Remove panel A. (See page 102 for panel removal and

installation procedures).2. Turn the adjusting nut while holding the rear brake

light switch in place. To make the brake light comeon earlier, turn the adjusting nut in direction a .To make the brake light come on later, turn theadjusting nut in direction b .

3. Install the panel.

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① ②Rear brake light switch Adjusting nut

Cable inspection and lubrication

POTENTIAL HAZARD

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

Damaged control cables.

Corrosion can result when the outer covering of controlcables becomes damaged. Cables can also become frayedor kinked. Operation of controls could be restricted,which could cause an accident or injury.

Inspect cables frequently. Replace damaged cables.

Lubricate the inner cables and the cable ends. If the cablesdo not operate smoothly, ask a ATV dealer to replace them.

Recommended lubricant:chain and cable lube or SAE 10W30 motor oil

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Lubricating the brake levers and brake pedal Lubricatethe pivoting parts.

To access the brake pedal pivot, remove panel A.(Seepage 102 for panel removal and installation procedures).

Recommended lubricant:Lithium-soap-based grease(all-purpose grease)

NOTE:

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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)①

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Wheel installation.1. Install the wheel and the nuts.

Tapered nuts are used for both the front and rear wheel.Install the nut with its tapered side towards the wheel.The arrow mark on the tire must point toward the rotatingdirection of the wheel.

Tapered nut

NOTE:

①

2. Lower the ATV so that the wheel is on the ground.3. Tighten the wheel nuts to the specified torque.

Wheel nut torque:Front: 55 Nm (5.5 m·kgf, 40 ft·lbf)Rear: 55 Nm (5.5 m·kgf, 40 ft·lbf)

①Arrow mark

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Battery

POTENTIAL HAZARD

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

This machine is equipped with a sealed-type battery.Therefore it is not necessary to check the electrolyte oradd distilled water in the battery. If the battery seemsto have discharged, consult a ATV dealer.

Do not try to remove the sealing caps of the battery cells.You may damage the battery.

Failure to handle batteries or battery electrolyte carefully.

You could be poisoned. You could be severely burned bythe sulfuric acid in battery electrolyte. Batteries produceexplosive gases.

Avoid contact with skin, eyes or clothing. Always shieldeyes when working near batteries. Keep out of reach ofchildren.

Antidote:EXTERNAL:INTERNAL:

EYES:

Flush with water.Drink large quantities of water or milk.

Follow with milk of magnesia, beaten egg or vegetableoil. Get prompt medical attention.

Flush with water for 15 minutes and get promptmedical attention. Keep batteries away from sparks,flames, cigarettes or other sources of ignition. Ventilatewhen charging or using in a closed space.

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Battery maintenance1. When the machine is not used for a month or longer,

remove the battery and store it in a cool, dark place.Completely recharge the battery beforereinstallation.

A special battery charger (constant voltage/ampere orconstant voltage) is required for recharging a sealed-typebattery. Using a conventional battery charger may shortenthe battery life.

2. Always make sure the connections are correct whenputting the battery back in the machine.

Fuse replacement1. The main fuse case and the fuse box are located under

the seat.2. If a fuse is blown, turn off the main switch and install

a new fuse of the specified amperage. Then turn onthe switches. If the fuse immediately blows again,consult a ATV dealer.

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① ②③

Main fuse Spare main fuseFuse box

Specified fuses:Main fuse: 30AHeadlight fuse: 15 AIgnition fuse: 15 AFour-wheel drive fuse: 3 ASignaling system fuse: 10 A

①②③④⑤

Headlight fuseIgnition fuseFour-wheel drive fuseSignaling system fuseSpare fuse ( 3)

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POTENTIAL HAZARD

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

Using an improper fuse.

An improper fuse can cause damage to the electricalsystem which could lead to a fire.

Always use a fuse of the specified rating. Never use amaterial in place of the proper fuse.

To prevent accidental short-circuiting, turn off the mainswitch when checking or replacing a fuse.

Replacing a headlight bulbIf a headlight bulb burns out, replace it as follows.1. Remove the bulb holder cover at the rear of the headlight

by pulling it off.

Headlight bulb holder cover①

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2. Remove the headlight bulb holder by turning it counterclockwise.

3. Remove the defective bulb by unhooking the headlightbulb holder tabs.

① Headlight bulb holder ① Headlight bulb holder tab ( 2)

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POTENTIAL HAZARD

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

A headlight bulb is hot when it is on and immediatelyafter it is turned off.

You can be burned, or a fire could start if the bulb touchessomething flammable.

Wait for the bulb to cool before touching or removing it.

4. Insert a new headlight bulb into the bulb holder,andthen 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 bulb to keepit free from oil, otherwise the transparency of the glass,the luminosity of the bulb, and the bulb life will beadversely affected. Thoroughly clean off any dirt andfingerprints on the headlight bulb using a cloth moistenedwith alcohol or thinner.

①

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5. Install the headlight bulb holder by turning it clockwise.6. Install the headlight bulb holder cover at the rear of

the headlight.

Headlight beam adjustment

It is advisable to have a ATV dealer make this adjustment.

To raise the beam, turn the adjusting screw in direction a .To lower the beam, turn the adjusting screw in direction b.

headinght beam adjusting screw①

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Tail/brake light bulb replacementIf the tail/brake light bulb burns out, have a ATV dealerreplace it.

TroubleshootingAlthough ATV machines receive a rigid inspection beforeshipment from the factory, trouble may occur duringoperation. Any problem in the fuel, compression, orignition systems can cause poor starting and loss of power.The troubleshooting chart describes a quick, easy procedurefor making checks. If your machine requires any repair,take it to a ATV dealer. The skilled technicians at a ATVdealership have the tools, experience, and knowhow toproperly service your machine. Use only genuine partson your machine.Imitation parts may look like ATV parts, but they are ofteninferior. Consequently, they have a shorter service lifeand can lead to expensive repair bills.

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POTENTIAL HAZARD

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

Checking the fuel system while smoking or near an open flame.

Fuel can ignite or explode, causing severe injury or property damage.

Do not smoke when checking the fuel system. Make sure there are no open flames or sparks in the area, including pilotlights from water heaters or furnaces.

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1.Fuel turn the fuel cocklever to “OFF”.There is fuel. Remove the fuel hose

from the fuel cock.Check thefuel flow. Nofuel. fuel cock

is clogged.

tuen the cocklever to “ON”.

Restart the engine.Check if there is fuelin the fueltank. Some fuel. Turn the fuel cock

lever to “RES”.

Supply fuel.No fuel.

Ask a ATV dealer to inspect.

2.Compression

Use the electric starterto see if there iscompression

There is compression.

No compression.

Compression nomal.

Ignition system isnomal.

3. Lgnition

Remove thesparkplug and check theelectrodes.

Wet

Dry

Wipe clean with dry cloth.

Attach spark plug cap andground to chassis.

Use the electricstarter.

Spark is good.

Spark is weak.

Adjust the spark

the spark plug.plug gap or replace

4.Battery

Use the electricstarter.

Engine turnsover slowly.

Engine turnsover quickly.

Battery is good.

Check the battery lead connections,and charge the battery if necessary.

No spark.

Ask a ATV dealer toinspect.

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CLEANING AND STORAGEA. CLEANINGFrequent, thorough cleaning of your machine will notonly enhance its appearance but will improve its generalperformance and extend the useful life of many components.1. Before cleaning the machine:a. Block off the end of the exhaust pipe to prevent water

entry. A plastic bag and strong rubber band may beused.

b. Make sure the spark plug and all filler caps are properlyinstalled.

2. If the engine case is excessively greasy,apply degreaserwith a paint brush. Do not apply degreaser to thewheel 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 anddeterioration of wheel bearings, brakes, transmissionseals and electrical devices.Many expensive repair bills have resulted from improperhigh pressure detergent applications such as those availablein coinoperated car washers.4. Once the majority of the dirt has been hosed off, wash

all surfaces with warm water and mild, detergent-type soap. An old toothbrush or bottle brush is handyforhard-to-get-at places.

5. Rinse the machine off immediately with clean waterand dry all surfaces with a chamois, clean towel orsoft absorbent cloth.

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6. Clean the seat with a vinyl upholstery cleaner to keepthe cover pliable and glossy.

7. Automotive type wax may be applied to all paintedand chrome plated surfaces. Avoid combinationcleaner-waxes. Many contain abrasives which may marthe paint or protective finish. When finished, start theengine and let it idle for several minutes.

POTENTIAL HAZARD

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

Operation with wet brakes after washing.

Wet brakes may have reduced stopping ability, increasingthe chance of an accident.

Test the brakes after washing. Apply the brakes severaltimes at slow speeds to let friction dry out the linings.

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B. STORAGE

NOTE:

Long term storage (60 days or more) of your machinewill require some preventive proce dures to guard againstdeterioration. After thoroughly cleaning the machine,prepare for storage as follows:1. Fill the fuel tank with fresh fuel and add the specified

amount of ATVFuel Stabilizer and Conditioner oran equivalent product.

Specified amount:1 oz of stabilizer to each gallon of fuel (or 7.5 cc ofstabilizer to each liter of fuel)

Use of fuel stabilizer and conditioner eliminates the needto drain the fuel system. Consult a ATV dealer if the fuelsystem needsto be drained instead.

2. Remove the spark plug, pour about one tablespoonof SAE 10W30 or 20W40 motor oil in the spark plughole and reinstall the spark plug.Ground the spark plug wire and turn the engine overseveral times to coat the cylinder wall with oil.

3. Lubricate all control cables.4. Block up the frame to raise all wheels off the ground.5. Tie aplastic bag over the exhaust pipe outlet to prevent

moisture from entering.6. If storing in a humid or salt-air atmosphere,coat all

exposed metal surfaces with a light film of oil. Donot apply oil to any rubber parts or the seat cover.

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7. Remove the battery and charge it. Store it in a° ° °

dry place and recharge it once a month. Do not store the battery in anexcessively warm or cold place (less than 0 C(30 °F) or more than30 C (90 F)).

Make any necessary repairs before storing the machine.NOTE:

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SPECIFICATIONS

76.8in41.3in42.9in32.3in48.2in9.6 in118.1in

Model Rd400

Di mensions:Overall lengthOverall widthOverall heightSeat heightWheel baseGround clearanceMinimum turing radius

Basic weight:With o il and full fuel tank

577.7 lbs

Oil cooling 4-stroke, SOHCForward-inclined single cylinder387cc83* 71.6 mm9.50 :1Electronic Ignition with recoilWet sump

Engine:Engine typeCylinder arrangementDi splacementBore I strokeCompression ratioStar ting systemLubrication system

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151Wet, centrifugal automatic

Rd400

Final gear case oil:TypeQuantity:

Differen tial gear case oi l:TypeQuantity:

Air filter :

Fuel:TypeFuel tank capacityFuel reser ve amount

Carburetor:Type/quantityManufacturerSpark plug:Type/manufacturerSpark plug gap

Clutch type:

SAE80 API GL-4 Hypoid gear oil0.23 L (0.20 Imp qt, 0.24 US qt)

SAE80 API GL-4 Hypoid gear oil0.35 L (0.31 Imp qt, 0.37 US qt)

Wet element

UNLEADED GASOLINE ONLY13.5 L (2.97 lmp gal, 3.57 US gal)3.3 L (0.73 lmp gal, 0.87 US gal)

PD33G

DR8EA / NGK0.6 0.7 mm (0.02 0.03 in)

Model

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Transmission:Primary reduction systemSecondary reduction systemSecondary reduction ratioTransmission typeOperationForward gearReverse gear

Chassis:Frame typeCaster angleTrail

Tire:TypeSize

Brake:Front brake

Rear brake

V-beltShaft dr ive41/21 24/18 33/9 (9.545)V-belt automaticLeft hand operation35/20 (1.750 )26/15 (1.733)

Steel tube frame421 mm (0.83 in)

TubelessAT25 8 - 12AT25 10 - 12

Dual disc brakeRigh t han d operationSingle disc brakeLeft hand and r ight foot operation

typeoperationtypeoperation

Rd400Model

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Rd400Model

Krypton bulb

Suspension:Front suspensionRe ar suspension

Shock absorber:Front shock absorberRear shock absorber

Wheel travel:Front wheel travelRear wheel travel

Electrical:Ignition systemGenerator systemBattery typeBattery capacity

Head li ght type:

Double wishboneSwingarm (monocross)

Coil spring / oil damperCoil spring / oil damper

160 mm (6.30 in)180 mm (7.09 in)

DC-C.D.I.A.C. magnetoYTX14AH12 V, 12 Ah

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Rd400Model

Bulb voltage, wattage !A quantity:HeadlightTail/brake lightNeutral indicator lightReverse indicator lightOil temperature warning lightFour-wheel drive indicator light

Fuses:Main fuseHeadlight fuseIgnition fuseFour-wheel drive fuseSignaling system fuse

12 V, 30/30 W 212 V, 5/21 W 112 V, 1.7 W 112 V, 1.7 W 112 V, 1.7 W 112 V, 1.7 W 1

30 A15 A15 A3 A10 A

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Federal law prohibits the following acts or the causing thereof:(1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement

of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to itssale or delivery to 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 anyperson.

“AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW.”These acts include tampering with the following systems; i.e., modification, removal, etc.

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:NOISE REGULATION

Air cleaner caseAir cleaner elementIntake duct

Exhaustsystem

MufflerExhaust pipeSilencer

Intake system

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MAINTENANCE RECORDS

Times Date Mileage 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

1

2

3

4

5

6

7

8

9

10

500

1000

1500

3000

4500

6000

7500

9000

10500

12000

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Oil

Oil/FilterAll nuts

Oil/Filter

Oil/Filter

Oil/Filter

Oil/FilterAir Filter

Oil/Filter

Oil/Filter

Oil/FilterOil/FilterSpark plug/Brake fluid

Times Date 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 CleanerSpark plug / Brake fluid

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MAINTENANCE RECORDS

Warranty RegistrationWithin 7 days dealer must register product warranty after a vehicle is sold. QLINK MOTOR will keep record of allthe registration forms for the warranty policy on all the units.No warranty claim will be processed unless the product warranty is registered with QLINK MOTOR.

Vehicle's owner must properly use, maintain and care for the vehicle as outline in the QLINK MOTOR owner'smanual.Owner of the unit must service and maintain the vehicle according to the Service Schedule and Record Sheet inorder to maintain the warranty.*Any warranty repairs must be performed 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 authorized QLINK MOTOR dealer or any reputable cyclerepair shop.*Periodic service and inspections are considered regular maintenance and not reimbursable.

Warranty repairs will be made at no charge for parts and labor to the consumer or the dealer.Any replacement parts will be replaced with new parts.Warranty terms and rights may vary from state to state.Any implied warranty of merchantability and fitness for a particular purpose shall be limited to the duration of thiswritten warranty.

Vehicle Owner's Responsibilities:

Authorized QLINK Dealer's Responsibilities:

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Limited Warranty

SELLING A UNIT IN THE CRATE OR WITHOUT THE PROPER SET UP WILL VOID ALL WARRANTYCOVERAGE!

All new QLINK MOTOR motorcycles and scooters are covered with 2 YEAR LIMITED WARRANTY, and ATVsare covered with 1 YEAR LIMITED WARRANTY. Only QLINK MOTOR authorized dealers can submit warrantyclaim not consumers. The warranty registration needs to be on file with QLINK MOTOR before a warranty claimcan be processed, unless the claim is due to shipping or 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 purchase by the consumer from their QLINK MOTOR dealer for all QLINK MOTORproducts. During the warranty policy period, QLINK MOTOR will only cover all warranty parts and labor. Thedealer is required to order parts for all warranty work to be performed and once the work is completed, the dealershould submit a warranty claim for full labor reimbursement within 7 days.

The following parts are covered under warranty, along with their warranted period:

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Covered Parts Description Covered Period

Motor Engine & Transmission 2 Years (Unlimited Miles)

Mechanical Components Carburetor 2 Years (Unlimited Miles)

Electrical Harness, CDI, Inst. Cluster 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 pipe, Muffler 2 Years (Unlimited Miles)

Pulleys Moveable Gearshift Pulley 90 days (Unlimited Miles)

Clutch CVT/Manual Clutch 90 days (Unlimited Miles)

Motorcycle / Scooter:

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Covered Parts Description Covered Period

Motor Engine & Transmission 1 Year (Unlimited Miles)

Mechanical Components Carburetor 1 Year (Unlimited Miles)

Electrical 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 Year (Unlimited Miles)

Pulleys Moveable Gearshift pulley 90 day (Unlimited Miles)

Clutch CVT/Manual Clutch 90 days (Unlimited Miles)

ATV:

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Parts Not Covered Under Warranty:

Spark Plugs Throttle Cable, Idle Cable Brake Line Cable, Clutch Cable

Drive Chains, Drive Belts Air Cleaner’s Element & Bracket Rear Brake Shoes

Front / Rear Brake Pads Swing Arm Bushing Light Bulbs

Fuses Rubber Parts Front / Rear Tires & Tubes

Front / Rear Rims Gear / Engine Oil Front / Rear Brake Rotors

Brake / Clutch Levers Steering Stem Bearings Floor 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 transportation, negligence of the periodicmaintenance is not covered, improper repair or adjustment or maintenance, using product as a rental vehicle orcommercial use, unauthorized modification made to the product, keeping riding when the vehicle is overheating,installing performance parts or components on the vehicle that changes the original engineering.

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