BR400 4WD Owner`s Manual
Contents
1. 18 Manual Choke Rocker Switch Shift Stick oo ooo 19 Parking Lever Rear Brake Flagpole holder 20 MC AUIEOGK PPP ON 21 LCD Instrument Panel Adjustment 22 Starting the Engine Electrically ococoncconcconcccncocncanonas 24 When Starting The Engine When the Engine is Difficult to SO D O POR IR ER COR EO E On 25 NOMAS de ESS Re RS A ol erica 26 NORALRIQINOR SES rence an ee ane ed en nn te ca cc 28 On command four wheel drive switch 2W D 4WD 29 On command differential gear lock switch 4WD FLOCK 30 Prolonged Engine Life Depends Upon Correct Riding 32 When Applying Brakes Simultaneously Apply Both Front and Rear Brake Handle Levers nnanannnnennnnennnnnnnnnenennnnnnnnnrnnnnrennne 32 Do Not Apply Emergency Brake and Have a Quick Turn 33 Riding with Particular Attention in Raining Days 33 How to Stop the ATV When The ATV Comes to a Full Stop 34 When parking the ATV a a o e Lao e ao cos 35 When transporting the ATV 39 Checks Before Riding 36 Pre riding Check Oil Check and Refilling 36 Recommended Oil Specification and Grade 37 Snanging Ol surcar delas 39 Differential gear oil Change the differential gear oil 39 Recommended oil specificatio2. Owner s Manual Y ACCESS moror DD BR400 4WD Dear Customers Thank you for purchasing BR400 4WD You will find it easier to start your engine with actuation of the manual choke for 20 30 seconds after you receive your new ATV That is because we have drained out the fuel in the carburetor when we finished assembling the ATV This will ensure ATV performance and safety This manual describes detailed instructions of correct operation maintenance and adjustment of BR400 4WD to ensure durable safe and comfortable riding In order for you to ride more safely and more comfortably please read this manual thoroughly before riding it Have a nice time riding lf data and relevant pictures contained in this manual differ from the real ATV the data of the real ATV shall supersede data contained herein Mportant Message vecinas dianas 1 RICINO PTECAUMON Sara vaterenevesaxesevasouscvesueceegets 3 Attire Check before Riding 4 Particular Attention on Parts That May Cause Burn Load Went iia 5 Looking at The Terrain 6 Making Turns Going Uphill ooccooccccciccncocncccncocncanonas T Going Downhill Riding through Water 8 Naming of Each Component cccccccecceeceeeseeeseeeeeeeeeeeaes 10 Operation of Each Component Ignition switch 14 Headlight Switch Startup Rocker Switch 17 Accelerator Lever Accelerator Limiting Device
3. At this position the headlight comes on and the light is beaming at a short distance The headlight will not come on if the ignition switch is not turned on Elo At this position the headlight comes on and the light is beaming at a far distance The headlight will not come on if the ignition switch is not turned on 20 Startup Rocker Switch When the engine is started electrically be sure to pull tight the front or rear brake handle lever to energize the system Then the engine can be started while pressing the startup rocker switch M Accelerator Lever NW Accelerator Limiting Device The speed of the ATV is controlled via the accelerator To protect a new rider who is not familiar with this ATV lever The ATV speed increases when pressing the from an accident this ATV is fitted with an accelerator accelerator lever using your thumb Press the accelerator limiting device that can adjust the travel of the throttle valve which in turn limits engine power lever slowly When starting the engine or riding uphill press the accelerator lever slowly the engine revs up and produces more power Adjustment Loosen the retaining nut and then turn the adjusting screw with a screwdriver rider Turning clockwise will reduce the travel of the throttle valve while turning counterclockwise will To reduce the speed release the accelerator lever increase the travel and increase the engine power up to its maximum When the ap
4. CVT with reverse H L Gear pushbutton 3 way locking differential 2WD 4WD locked 4WD shaft drive Dual A arm with 5 way preload adjustable shocks 64 DIMENSIONS Overall length Overall width Overall height Wheelbase Ground clearance Claim dry weight Fuel Capacity Battery Lubrication System a 1260 mm 49 6 in 300 mm 11 8 in
5. Ridebelt_ Ti fif R 1f al sion is not seriously Valve gap 4D A A J Jaf AAT oct However it these Ignition e A AA Rt e a system er eee sl in TE AAA A E TT UT tT T T T Gorrective actions will not ne system be conducted until they are reported for approval Maintenance other than planned schedule Item Causeformaintenance Ignition system Ifabnormal ignition engine over heat engine stall are found immediately perform inspection If engine power reduces significantly after operation of ten to fifteen months If power reduces significantly when accelerating after operation of ten to fifteen months If the engine is under severe load in the first month since operation the piston piston rings cylinder may wear or get stuck The engine an should be cleaned or honed Some parts may be renewed 99 Battery Electrolyte Check 1 of refilling battery electrolyte 1 Battery tie band 2 Positive 4 Fuse box 5 Battery 3 The battery for this model is a servicing free type without need 3 Negative 2 Battery stud terminal Remove the seat before cleaning the battery stud terminals If the stud terminal becomes corroded remove the battery and clean it thoroughly After cleaning the stud you may apply a thin layer of grease or Vaseline Then position the battery in place and attach the connecting wires Notes Do not open the cover of the enclosed b
6. Raining Days Using emergency brakes and quickly turning are two major In raining days the condition of road surface differs from causes to lead to skidding and turning over which is very that in clear days The brake distance will be extended dangerous for the rider Ride at a lower speed and apply brakes earlier When going downhill put the accelerator lever back to the OFF position and intermittently apply brakes Ride at a slower speed 38 WE How to Stop the ATV E When the ATV Comes to a Full Stop When approaching the parking space Put the shift stick at the N position and turn the ignition Check that the surroundings are in safe condition and switch to the OFF position then slowly park the ATV Put the accelerator lever back to the original position and pull both front and rear brake handle levers which will activate the brake light to alert coming ATVs in the back 1 Key hole 2 Key Note Turning off the ignition switch and removing the key during riding will cause the electrical system to disable This is a major cause of an accident Do not do that until the ATV comes to a full stop 39 NW When parking the ATV NW When transporting the ATV To prevent the ATV from moving pull tight the brake handle First drain fuel in the tank and the carburetor lever and push the parking lever to the ON position leftward to Loosen the draining screw of the carburetor Use a containe
7. an accident neutral position to avoid any risk of hazard 17 3 High Beam Indicator Light 5 Left Right signal indicator When this light comes on the headlight is using high beam When operating the Left right turn signal light switch this light indicator will come on 4 Temperature Indicator Light 6 Fuel level indicator When this light comes on it means the engine temperature is When the pointer of the fuel level indicator rests near the last too high Stop engine and check the coolant level in the Aux scale the fuel remaining in the tank is about 3 7 liters Refuel Liquid Bottle with 95 unleaded gasoline as early as possible ahh trarin Tt i T LE ns ae l a T i EAR T AA a E LEE N Y BEBE T ma Py i E eee TENSES En j PRA A WA rani ae c IO gt J I ok i ioe ei ms re I j at Ey 7 cn F ieee TEER pamp D La E AA po Note Note When the engine over temperature indicator light comes on There is no need to add any additive to the fuel when refueling you must stop the engine and let it cool down Addition of any additive in fuel may cause engine failure 18 7 Four wheel drive switch 2WD 4WD y 2WD Rear Wheel Drive ODiferential Lock fh ieh a i A ra i Le va AA A mue jf a 1j m Podes GU NL Pech A Er i aA j E ed mt el D Ge 19 by 2WD Rear Wheel Drive NW Headlight Switch Lo
8. following conditions 1 Often riding in rain 2 Often riding on the dusty road surface Note Regularly drain off the accumulated oil in the oil collecting pipe under the air cleaner Do not let accumulated oil exceed two thirds of the pipe length TE Clip Oil collecting pipe Spark Plug Check Dirty pole or too wide a gap will cause incomplete sparking lt How to clean it gt Ideally use a spark plug cleaner to clean it Or use a needle brush to clean it lt Adjustment gt The gap between two poles normally is 0 6 0 7 mm as shown in Figure A NGK CR8E Your ATV comes equipped with a NGK CR8E spark plug Do not use a spark plug other than a recommended one Si Note When the engine stops it is still very hot Be careful not to get burnt First put the spark plug with hand tight and then tighten it using a spark plug spanner 55 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart If there is play in a wheel hub or if a wheel dose not turns smoothly check the wheel bearing Replace the wheel bearings if necessary Checking the stabilizer bushes The stabilizer bushes must be checked for crakes or damage at the intervals specified in the periodic maintenance and lubrication chart Replace the stabilizer bushes if necessary Check
9. CK This ATV is equipped with a switch allowing you to lock the differential gear when in four wheel drive Select the appropriate switch position according to the terrain and the conditions 4W D four wheel drive Power is supplied to the rear and front wheel LOCK four wheel drive with differential gear locked Power is supplied to the rear and front wheel and the differential gear locked Unlike in four wheel drive all wheel turn at the same speed To lock the differential gear in four wheel drive make sure the On Command four wheel drive switch is pushed in to the AWD position Stop the ATV move the differential gear lock lever to position 2WD 4WD switch a and then push the differential gear lock switch in to the LOCK position When the differential gear is locked the differential gear lock indicator D will come on along with the caro in the multifunction meter display Bye Differential Lock 35 Warning What can happen The ATV handles differently in four wheel drive than in differential gear lock in some circumstances Changing from four wheel drive to differential gear lock while moving may cause the ATV handle differently unexpectedly This could distract the operator and increase the risk of losing control and of causing an accident How to avoid the hazard Always stop the ATV before changing from four wheel drive differential gear lock to four whee
10. able weight for this ATV is 150 kg two riders The exhaust pipe and the engine become very hot when or When you carry loads on the ATV slow down your speed to after the ATV runs for a period of time To avoid personal injury increase effective braking distance including human and objects etc do not touch these parts When you carry loads on the ATV you should keep loads in When the ATV is parked also note that children or passers by balance to avoid loss of control of the ATV due to imbalance should not touch these parts to avoid injury Max weight 150kg To reduce the risk of fire do not park this ATV near a dry lawn or flammable substances Load weight limit 150 kg Exceeding the maximum load weight for this ATV may cause an accident When using this ATV as a trailer slow down your riding speed E Looking At The Terrain Watch your speed and control technique when you ride on When riding with poor visibility e g riding at night turn on the excessively flat loose and rough surface and keep an eye on headlight and slow down your speed to ensure safety any potential hazards such as pits water puddles rocks root When riding in the area where your viewing angle is limited e g blocks etc to avoid the risk of an accident riding on a rough road in hills it is advisable to attach a flag of some height in the rear of the ATV for warning purposes This can assure Safety for the rider other riders a
11. and Notes easily leads to circuit failure To remove the fuse oa ssembleit Care should be taken when removing the fuse as its holder is Insert the fuse in the holder and position the cover back very small If the fuse does not have good contact after opening the cover it may generate heat and lead to circuit failure in place To assemble the fuse Be sure to gently pull the fuse to ascertain that the fuse Insert the fuse in its holder has good contact A loose fuse will generate heat Be sure to gently pull the fuse to ascertain that the fuse is well in Fuse rating 20A contact A loose fuse will generate heat 61 E Consumer information SERIAL NUMBER Location of Engine Serial Number Location of Frame Serial Number Vehicle Identification Number 62 When Failure Occurs If ATV experiences a malfunction during use please take it to a dealer or service center for inspection lf The Engine Stops If the engine stops during riding first check the following Is fuel available The way to start the engine is correct Any failure occurs on other part 63 E Specifications MODEL NAME ENGINE Type BR400 4WD BEAR 400 4WD Liquid cooled 4 stroke 4 valve Cylinder Arrangement Single cylinder vertical Displacement Carburetor Compression Ratio Iginition Starting System Transmission Final Drive Suspension Front Suspension Rear Brakes Front Brakes Rear Tires Rear
12. attery that contains battery electrolyte If the ATV has not been used for a long period of time the battery may have discharged and reduced its power In this case remove the battery and recharge it to its full power and then put it in a cool and well ventilated place If the ATV will not be used for a long period of time remove the connecting wire at the negative pole Notes While removing or mounting the battery do not allow flammable gas to get close To remove the battery first turn off the ignition switch Then first detach the negative connecting wire However to connect the battery first attach the positive wire and then the negative wire If the terminal screw becomes loose tighten it firmly 60 E Replacing the Fuse Turn off the ignition switch and check if the fuse is blown To replace the battery lamps use only the original components When replacing the fuse always get a fuse of the of the prescribed specification If components are not original or out of specification the fuse can easily be blown and the battery will not be in balanced status specified rating Before replacing the fuse first find out why it is blown Remove the seat The fuse is located behind the battery To remove the fuse jet Open the fuse box and take out the blown fuse When washing the ATV do not wash it with high pressure water If the fuse is not well in contact it will create heat
13. ch and check that the high beam or Then screw in or out the adjusting screw to adjust the beaming low beam illuminates distance Check that the headlight housing is clean or damaged y 4 i j 7 Ta De 4 ee My a t k j i J 48 E Tire Check Is tire pressure OK If metal chips or small stones are found in tire grooves remove See the following table when checking tire pressure them before riding If tire crack is found or tire wear exceeds the prescribed limit Recommended immediately change the tire Lower limit Upper limit standard value dd If tire groove depth is less than 3mm immediately change the 0 28 kgf cm 0 25 kgf cm 0 35 kgf cm tire 3 92 PSI 3 5 PSI 5 PSI 0 28 kgf cm 0 25 kgf cm 0 35 kgf cm 3 92 PSI 3 5 PSI 5 PSI Front wheel Rear wheel f d a mi 49 E Front 8 Rear Shock Absorber Check Put your weight on the handlebars and rear hand rest and shake them upward downward to check that the shock absorbers are To ensure riding comfort the spring pre compression of rear OK shock absorber is adjustable Front amp Rear Shock Absorber Adjustment 1 90 To refill coolant normally do not open the radiator cap when the engine is still hot 1 Park the ATV on a flat surface with stand 2 Open the Aux Liquid Bottle and refill coolant until the level reaches the upper limit If the coolant level drops significantly it usua
14. companying tools 13 Accelerator lever 14 Shift stick 15 Front brake reservoir 16 Seat 17 Aux liquid bottle 18 Right footrest 19 Left footrest 20 Foot brake 1 for 4 wheel 15 16 21 LCD instrument panel 22 Rear brake handle lever 23 High low beam switch Startup rocker switch Warning light switch Turn signal light switch Horn switch 24 Fuel tank cap 25 Throttle Bottom Clamp 26 parking lever 27 Manual Choke 28 Power Supplier 12V 3 Operation of Each Component 1 Reverse Indicator Light M ignition switch The reverse indicator light comes on red light when you turn OFF At this position power supply to the ATV is on the ignition switch when the transmission is at the reverse completely cut off The key can be removed The gear engine stops 2 Neutral Indicator Light ON At this position power supply to the ATV is The neutral indicator light comes on green light when you turn connected The key cannot be removed at this on the ignition switch when the transmission is at the neutral position The engine can be started up position At this position power supply to the ATV is connected The key cannot be removed and the position light comes on The engine can be started up 1 Key hole 2 Key Note Do not turn the key to the OFF position while riding This is When starting the engine the transmission should be at the the major cause of
15. e ATV flipping Over Notes Do not ride across a river with fast current or great depth to avoid loss of control of the ATV and cause risk of hazard to the rider After crossing the water area you should check that the brake function is normal If it is not slow down your speed and also intermittently apply both front and rear brakes to restore the brake function If it takes a long period of time to ride through the water area and the brake system submerges in water too long it will lead to loss of brake function Do not ride this ATV any longer and 10 take it to the nearest service center for inspection and servicing 11 Smoking is strictly prohibited when refueling the ATV Functionality of the ATV is dependant upon its structure Any modification without our permission may cause performance Turn off your engine when refueling the ATV degradation and in turn affect the service life of the ATV and riding safety It is illegal to modify this ATV without our permission Do not attempt to make any modification 12 01 Headlight position light 2 Naming of Each Component T 02 Front brake handle lever 03 Right front turn signal light gt m A 04 Left front turn signal light 13 14 05 Right rear turn signal light 06 Rear light brake light 07 Ignition switch 08 Left rear turn signal light 09 Exhaust pipe 10 License plate light 11 Battery 12 Ac
16. els in the reservoirs Fluid level should be 2 Refill brake fluid recommended DOT 4 grade until it reaches between upper and lower limits the upper limit Then position back the cover and tighten two 2 When the fluid level drops to the lower limit check the fixing screws condition of the brake shoe wear 3 Change brake fluid once a year 3 If the brake shoe wear is within the specified limit then it normally represents that there is leakage in the system Ride your ATV to the dealer s workshop or service center for inspection Notes Do not mix brake fluid of different brands or grades which may lead to brake failure and the risk of hazard When changing brake fluid cover the painted area with cloth to prevent painted surface from being damaged by brake fluid 46 Is Brake Performance Good Brake Light Check Ride slowly to verify that the front and rear brake performance is Turn the ignition switch to the ON position Pull both the front and rear brake handle levers to make sure that the brake light illuminates Check that the brake light housing is clean or damaged good amp es 47 Headlight B ing Dist Adjustment Headlight Check Headlig eaming Distance Adju mr Headlight s beaming distance is adjustable 0 How to adjust it Turn the ignition switch to position Turn on the ignition switch and also turn on the headlight switch Operate the headlight swit
17. engine and let the radiator fan run more than two times Then stop the engine Be sure to wait until the radiator cools down before opening the cap to avoid getting burnt Open the radiator cap and check that coolant level is still at the upper limit if not refill coolant and then firmly tighten the cap Start the engine again and let it run for 1 2 minutes Open the radiator cap and check that the coolant level is still at the upper limit if not refill coolant again Keep repeating this procedure until coolant level can retain at the upper limit 93 How to Replace the Air Cleaner A dirty air cleaner is the major causes of engine power drop and high fuel consumption The air cleaner for this model is a wet sponge type Check and replace the air cleaner every three months How to replace it 1 Remove the seat 2 Unclip two fixing clips on the air cleaner cover and remove the air cleaner cover 3 Loosen the screw and take out the cleaner core 4 Replace the air cleaner core How to mount it To mount it take the reverse steps as above for replacing it Notes If the air cleaner is not mounted correctly dirt dust may directly be drawn in the cylinder causing engine wear power drop and resulting in shorter engine life Do not wet the air cleaner when washing the ATV Wet air cleaner may cause the engine to be difficult to start Check and replace the air cleaner at a shorter period under the
18. er to lock the rear wheels to prevent the ATV from moving and causing the risk of hazard If the play of the brake handle level is incorrect the rear wheels may not be locked which may cause the risk of a hazard 23 MW Seat lock The seat can be removed The battery fuses are located under the seat How to remove the seat Pull the locking lever rightward and then lift rear part of the seat backward Now the seat can be removed 24 How to mount the seat Push the retaining tab under the front seat into the holder on the frame Then push downward the rear part of the seat and the seat can be attached on the frame Note After the seat is mounted you need to ascertain that it is firmly attached to the frame by moving it upward downward and forward backward If the seat is not firmly attached it may cause the rider to lose control of the ATV and lead to an accident NW LCD Instrument Panel Adjustment SYMBOL NOTE lP S TIEL C TIOPY Mela You could get he Installation details from the nforma on behind he mark A Some processes musi be followed To avoid the affection caused by wrong Installation 1 BASIC FUNCTION INSTRUCTION Indicator lights OL Turn signal light Green ich beam Blue m hois temperature Reqd E rss Pear Neutral Green N 05 Geor Shift laht Green H L Seor Shiff fight Orange L urn signal light Green gt Oil level Oisoloy range 5 levels Oi starting war
19. ever should be pushed slowly When going uphill slowly push the accelerator lever the engine will rev up and power increases Return to original position the speed decreases 33 E On Command Four wheel drive switch 2WD 4WD This ATV is equipped with a switch to change from two wheel Warning drive to four wheel drive What can happen Select the appropriate drive according to the terrain and the Meade aria thamin four wheel drive in some circumstances Changing from two wheel drive to four wheel drive or from four wheel drive to two wheel drive while moving may cause the ATV to unexpectedly handle differently This could distract the operator and increase the risk of losing control and of ATV and push the switch in to the 4WD position Then the causing an accident conditions 2WD two wheel drive Power is supplied to the rear wheel AWD four wheel drive Power is supplied to the rear and front wheel To change from two wheel drive to four wheel drive stop the F How to avoid the hazard four wheel drive indicator rs comes on in the a Always stop the ATV before changing from two wheel multifunction meter unit display drive to four wheel drive To change from four wheel drive to two wheel drive stop the ATV and push the switch in to the 2WD position 1d 024 0 Rear Wheel Drive 34 E On Command differential gear lock switch a 4WD LO
20. ge If any damage is found please take it to a dealer or service center check or replace it Front axle boots 57 Notes Ensure safety when serving the ATV Use suitable tools Rear axle boots Make preparation while the engine stops When the engine stops the engine and exhaust pipe are still very hot Care should be taken to avoid getting burnt Simple Maintenance If check results show that cleaning adjustment and replacement are required Conduct those operations in accordance with the description in the regular check record 98 Regular Maintenance Table Emission control system checklist for serving items and timetable For riding safety keeping performance prolonging ATV life and reducing exhaust emission you should inspect those service items for routine maintenance I Inspect and clean lubricate on adusi or rep ace if see A et C ean ae Rep ace T TER PE EUR Lubrication System Oil filter AR TR RRR TR TR RRR RRR RRR Adjust Differential gear oil Eo PRE ERE R E ARA R R RE er Clean ina gear oi OR 4 R EEE E PR RR EER E ERE pace Fuel strainer________ c CE c e Cc Tighten Carburetor E E E A A ER E E E RE RE LA LU Fuel pipe JE ME A ER RE EEN EA O RS POS DTO a Airsupply Aircleaner Tec lc el Tel e Te ce repacementarefond En gt rec ESE E A A Pe CRETE A AA EE A A AAA A e y Transmissio Cam chain BH vided that exhaust nsystem
21. ge the differential gear oil 5 Add the recommended differential gear oil to the brim of the 1 Place the ATV on a level surface filler hose as shown Note The differential gear oil level must be checked on a cold engine 2 Place an oil pan under the differential gear case to collect the used oil 3 Remove the differential gear oil filler bolt and the differential gear oil drain bolt to drain the oil from the differential gear case Filler bolt 6 Install the filler bolt and then tighten it to the specified torque Tightening torque differential gear oil filler bolt 1 5kg m 7 Check the differential gear case for oil leakage If oil is leaking check for the cause E Recommended Oil Specification and Grade Oil specification SAE 85W 140 Full capacity 300 c c Replacing volume 250 c c Drain bolt 43 E Final gear oil 4 Install the drain bolt and then tighten it to the specified torque The final gear oil changed as follows at the intervals specified in Tightening torque final gear oil drain bolt the periodic maintenance 1 5kg m 5 Add the recommended final gear oil to the brim of the filler Change the final gear oil hose as shown 1 Place the ATV on a level surface Note The final gear oil level must be checked on a cold engine 2 Place an oil pan under the final gear case to collect the used oil 3 Remove the final gear oil filler bolt and the final gear oil drain bolt to drain t
22. he conditions e usa proper riding techniques to avoid vehicle ovarturns on his and rough terrain and in turns e avoid pared surfaces pavement may senously afeti handling and control READ THE OWNERS MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS 1 72110 A03 030 ATV must be stopped before shifting transmission lever Always apply foot brake or hand brake to shift from NEUTRAL N Keep RPM under 2250 rpm to prove shifting smooth Do not shift gear while riding 3 Improper tire pressure or overloading can cause loss of control Loss of control can result in severe injury or death Cold tire pressure Front 5 1 psi 35 kpa Rear 5 1 psi 35 nee O Maximum weight capacity 3301bs 150kg 72110 403 020 4 POTENTIAL HAZARD Hol exhaust system WHAT CAN HAPPEN Ory grass or brush or other combustible material accumulated around the engine 3768 Could catch fire Someone touching tha ax Faust System during or ater operation could be burnad F2110 A01 050 5 MAXIMUM FRONT LOAD 35 Ib 16 kg NEVER sit here 6 MAXIMUM REAR LOAD 65 lb 30 kg NEVER sit here 7 Riding Precautions BR400 4WD ATV is a special multipurpose four wheel Notes A You should familiarize yourself with basic motorbike with entertainment features In this section we will operations of this ATV before you try more difficult operational techniques To ensure t
23. he oil from the final gear case Filler bolt 6 Install the filler bolt and then tighten it to the specified torque Tightening torque final gear oil filler bolt 1 5kg m 7 Check the final gear case for oil leakage If oil is leaking check for the cause Drain bolt E Recommended Oil Specification and Grade Oil specification SAE 85W 140 Full capacity 300 c c Replacing volume 250 c c 44 E Fuel Check and Refueling Refuel Unleaded 95 as early as possible How to use the fuel cap 1 2 First stop the engine Turning the cap clockwise you can open the cap while turning counterclockwise you can tighten the cap When starting the engine turn the ignition switch from the OFF to ON position Notes Smoking is strictly prohibited when refueling the ATV Stop the engine before refueling No need to add any additive in fuel when refilling Addition of any additive may cause engine failure Do not top up fuel to the opening Otherwise fuel may spill as it may expand by heat or sunlight and lead to the risk of hazard 45 1 Key hole 2 Key Front and Rear Brake Fluid Level Check and B rake fluid refilling Refilling 1 Position the handlebars in the middle Remove two fixing Brake fluid level check screws on the cover of the brake fluid reservoir and then take 1 Position the handlebars in the middle Check front and rear out the cover brake fluid lev
24. he rider s and others safety anyone describe important notes and techniques in order for you to safely ride this ATV Please read this manual thoroughly and 3 F ia AP teni who drinks takes drugs or medicine is not spend some time practicing on your new Pay attention permitted to ride this ATV on your safety and that of others The rider s ability to control this ATV will be reduced by the effects of medicine or alcohol If you do not have any experience riding an ATV you can only ride it with instruction by a licensed or qualified instructor First of all you have to ride it slowly to feel and adjust yourself to the ATV even if you are an experienced rider Do not attempt to utilize the maximum limits of this ATV E Attire To ensure safety the rider shall wear a safety helmet goggles gloves boots and protective clothing when riding this ATV Protective A clothing E fR LEE Goggles Gloves BOOTS E Check Before Riding Conduct a pre riding check in accordance with Check before riding in user s manual on Page 32 before riding to ensure safety and the service life of this ATV Your ability of controlling this ATV will be affected by insufficient tire pressure or a tire that is out of specification Contact your service center for inspection to reduce the risk of an accident NW Particular Attention on Parts That May Cause NW Load Weight Limit Burn Maximum allow
25. ination with the front or the rear brake handle lever being pulled tight or the brake pedal being depressed a E 28 When Starting The Engine Press the startup rocker switch and the engine can be started If cio starts too cool let the engine warm up for 2 3 If the ATV has been stored for a long time or when the fuel tank minutes Do not rev the engine to high speed while it is idling This can is empty it is very likely that you can not start the engine even if ensure the engine life the fuel tank has been topped up Now you should drain fuel in Notes the carburetor by loosening the draining screw using a Once the engine starts to run immediately release the startup rocker screwdriver and then restart the engine Swen X Smoking is strictly prohibited when draining fuel Do not press the startup rocker switch while the engine is running or it will lead to an adverse effect to the engine Do not press the startup switch for over four seconds when the electric motor is used to start the engine When The Engine is Difficult to Start If the engine does not start within 3 4 seconds after pressing the startup switch you may need to push the choke lever to the left which can help engine start up Note Note After the engine warms up for 2 3 minutes you must push the After draining fuel in the carburetor remember to tighten the draining screw Otherwise this can cause hazard due choke
26. ing and lubricating the cables The operation and the condition of all cables should be checked before each ride and the cables and cable ends should be lubricated if necessary If a cable is damage or dose not move smoothly please take it to a dealer or service center check or replace it Lubricating the drive shaft universal joint The drive shaft universal joint must be lubricated at the intervals specified in the periodic maintenance and lubrication chart Lubricating the steering shaft The steering shafts must be lubricated at the intervals specified in the periodic maintenance and lubrication chart Lubricating the upper and lower arm pivots The upper and lower arm pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart Lubricating the knuckle pivots The knuckle pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart Lubricate the pivoting points using a grease gun Rear axle Lubricating the knuckle shafts The knuckle shafts must be lubricated at the intervals specified in the periodic maintenance and lubrication chart E Lubricating Each Part of the ATV E Axle boots Visually check that all parts that need lubrication are sufficiently The axle boots must be checked for damage at the intervals lubricated specified in the periodic maintenance and lubrication chart Check the axle boots for tears or dama
27. l drive 36 Warning Potential hazard Riding to fast while the ATV is in four wheel drive differential gear lock What can happen All wheels turn at the same speed when the differential gear is locked so it takes more effort to turn The ATV The effort needed to turn increases with the riding speed You may lose control and have an accident if you cannot make a sharp enough turn for the speed you are traveling How to avoid the hazard Always ride at a slow speed when the ATV is in differential gear lock and allow extra time and distance for maneuvers E Prolonged Engine Life Depends Upon Correct Riding NW When Applying Brakes Simultaneously Apply Both Keep the ATV speed no more than 40 km h during the first Front and Rear Brake Handle Levers month when new ATV starts to operate Engine running in After returning the accelerator lever back to its OFF period position firmly hold the brake handle levers and step on foot brake Ideally when applying brakes start to slowly pull the brake handle levers and then pull them firmly to the end Notes Care should be taken if applying only one brake handle lever on one side it is easy to cause the ATV to skid and be unstable Do not attempt to apply emergency brakes during riding it is easy to cause the ATV to skid and is very dangerous for the rider 3 Do Not Apply Emergency Brake and Have a Quick Turn NW Riding with Particular Attention in
28. lever back to its original position Otherwise the engine to fuel leakage speed will be affected 5 Normal Usage When riding The rear brake handle lever is kept at the braking position and then put the shift stick to the H or R position Note When the engine is idling do not push the accelerator to rev the engine The rider shall put both of his feet on floor panel and keep his body upright with two hands holding the handlebars Do not make haste relax carefully heed surrounding conditions and ride safely Note Before riding the rear brake handle levers should be kept at braking positions 31 Placing the parking lever back to its original position OFF is in the brake releasing unlocking status J a d fi P ALAA ha CT aya a a OFHUNLOCK Note After releasing the parking brake on the rear wheels do not push or press the accelerator lever to avoid jerking ahead and causing the risk of hazard 32 Release the rear brake handle lever and slowly push the accelerator lever the ATV will start to run smoothly Note Do not push the accelerator with force to avoid dash out of the ATV NW Normal Riding Make sure that the surroundings are safe before setting out on the The speed of the ATV is controlled via the accelerator lever trip See Riding Precautions Pushing the accelerator lever the speed increases The accelerator l
29. lly represents a problem in the system Recommended anti freeze Te she Anti freeze Prescribed concentration 30 50 in cold zone Concentration and anti freeze temperature 120 25 150 30 240 40 350 50 91 Notes Use soft water to mix with anti freeze Note that low grade coolant will shorten the radiator service life Under normal conditions coolant should be replaced once a year or every 10000km E Changing Coolant Notes Care should be taken when opening the radiator cap as coolant may be very hot with high pressure Steam may cause burn and hazards Wait until the radiator cools down Use a piece of cloth to cover the cap and slowly open it Cover Right Storage Box In case that coolant drips on the painted surface immediately rinse it with clean water lt How to drain coolant gt 1 First open the cover 2 Push downward the radiator cap and turn counterclockwise to open the cap 3 Remove the draining bolt and let coolant drain out Tilting the ATV rightward may facilitate coolant to drain faster 4 Take out the Aux Liquid Bottle and pour out coolant 92 E Filling Coolant Position the draining bolt and Aux Liquid Bottle in place First fill up the radiator and then the Aux Liquid Bottle until the coolant level reaches the upper limit Ensure that the radiator cap and Aux Liquid Bottle cap are firmly closed Start the
30. n and grade 39 Final gear oil Change the final gear oil ooccoo 40 Recommended oil specification and grade 40 Fuel Check and Refueling 41 Front and Rear Brake Fluid Level Check and Refilling 42 Headlight Check Headlight Beaming Distance Adjustment 44 TPS ENECK Sen a 45 Front and Rear Shock Absorber Check occooccccccocccccccocccoccnns 46 Front and Rear Shock Absorber Adjustment 46 Changing Coolant eese a E 48 Filling Coolant 49 How to Replace the Air Cleaner 50 Spark Plug CHECK senses 51 Checking the wheel bearings cooccooccccnoconcncnconoconocanonanononos 52 Lubricating Each Part of the ATV Axle boots 53 Simple Maintenance nn 54 Regular Maintenance Table ooccoccccncoccccnconcococancnnoncnnnnos 55 Battery Electrolyte Check 56 FRE DIGGING ines PUSO ericsson 57 Consumer information vs c202osvoieessaboieesebreioustoteberabavebocduacelecdiowen s 58 When Falure DOC Susini E E E E 59 SDCSCHICANONSE sepa cds id lalo ida 61 Important Message Negligence of the following signs and warnings may cause serious damage and even death Warning sticker location 3 improper use of ATVs can resullin SEVERE INJURY or DEATH NEVER operate e Without proper training or instruction at speade too fast tor your akila or t
31. nd onlookers E Making Turns When you approach a turn first slow down and smoothly turn the handlebars to the direction you are going Also move your gravity to the outer floor panel and tilt your upper body to the inner side of the turn which enables your control at the turn to be smoother and safer E Going Uphill Note When going uphill move your gravity as forward as possible Also sit in the front part of the seat and bend your upper body forward Keep a steady speed in the uphill process and keep the ATV balanced If the slope is too high to proceed and the ATV is moving backward apply the front brake to slow down and carefully control the ATV to slip down If it is beyond control the rider should immediately get off from the left side to avoid the risk of being crushed by the ATV once it turns over Do not apply only the rear brake to avoid the ATV flipping over Do not abruptly apply the accelerator E Going Downhill E Riding Through Water Note Place your gravity as backward as possible and straighten Watch the speed of water current and its depth if riding through both of your arms Keep the ATV in balance and apply the water is necessary If water flows very fast or is deep the rear brake to slow down your speed performance of the ATV will be affected which may cause unsafety to the rider Unless otherwise necessary do not press the accelerator lever Do not apply only the front brake to avoid th
32. ning when fuel under 1 level speed meter cisco range 0 19 km h 0 424 MPH Ciao uni km imie Tachometer Oisploy range 0 78000 rom lisolay unit 10 rom OL ronge 0990009 km mile Automatically reset after 2929 02 km mie Osoa unit Tkm mie Trip A B meter Olsploy range 0 999 9 km reset automatically after 866 6 km mils Booo uni 0 tkm imile 25 Prosa Mr Had aa hm Wma oe e DO eana Drive mode display He 0240 Rear Wheel Drive F4 04D Be ifferential Lock Adjust button U Press Adjust button to switch display belween ODO Tio A Trip E MAX Adjust button X 3 seconds ln he mon ODO screen keep pressing Adjust buffon for 3 seconds 10 sich aislar unit between Kile in the Tip A screen keep pressing Adjust button for 3 seconds fo reset frip record On the Tip B screen keep pressing Adjust button for 3 seconds to reset trip B record Oui the MAX screen keep pressing Adjust Button for 3 seconds fo reset MAX record Tire circumference and sensor position setting You must setting again after change fire Gin man screen press down the Select amp Adjust X 3 seconds lo enfer he fire crcurmierence and senso Om senting A Please measure the tire circumference Mhetire you will install the sensor on and make sure fhe number of mognet sensor point You Could instan fhe magnet info ie dise screw or he sprocket screw Press Adjust butt
33. on 3 times fo enter sensor point seling screen Bo example The ecreumierance has been chonge fram 1480 mm fo 7650mm Pleose select button to odiust the number OU would like fo sel or exompre The fre circumference is 1850rmim Obres Adjust button fo move fo the digital You would like lo set The sensor point setting screen are flashing OM NOTE deci pare ites Ing range Current lire is setting Ov 1680mm elreumite rence with 1 sensor point J Barsi Adjust button to bock fo main screen O or example The sensor poini hos been change from 1 point to paint PS You could define he lhe main screen volve os ihe storing point and ihe ferminal poini fo reme mecsure Ne whee Ciroumerence with o measuring i OPress Select button fo select the dighal you wouid ike fo set 26 4 Starting the Engine Electrically 1 Before starting the engine first check oil and fuel levels Turn the ignition switch to the ON position 1 Key hole 2 Key Note When the ignition switch is turned on check that the neutral indicator light comes on The gear should be in neutral when the engine is started 27 2 Pull tight the front or the rear brake handle lever or step on the brake pedal Note When starting the engine the ignition circuit for the electric startup can only be energized with actuation of the startup switch in comb
34. propriate engine power is reached tighten the retaining nut again Note The play of the accelerator lever should be 1 to 4 mm which can avoid jerking ahead when the engine is started 1 Retaining nut 2 Adjusting screw 21 NW Manual Choke Rocker Switch M Shift Stick To make the ATV to stop move forward or reverse use When the engine starts too cool the engine can be the shift stick to shift gears With pulling and releasing the rear brake handle lever easier to start up with the choke switch being pushed leftward L Low range H High range H L N Neutral R Reverse After the engine warms up for 2 3 minutes push the rocker switch back to its original position push Note The shift stick should be placed at the N position when the engine starts up or stops to avoid the risk of hazard After the engine starts up and when operating the shift stick you should also pull the rear brake handle lever or the engine will stop This serves as a Safe interrupting system 22 NW Parking Lever Rear Brake M Flagpole Holder How to use it This allows you to position the desired flags in the holder Turn the rear brake lever to the left side tightly NP BAY How to release it CIPull parking lever to the right side it will return automaticto its position the rear brake will be relieved at the same time Note When starting the engine or parking the ATV apply the parking lev
35. r to lock the rear wheels keep drained fuel After the fuel is drained tighten the draining screw Draining screw a LE i P z a F z 4 ON LOCK Note If the play of the rear brake handle lever is incorrect it will not lock the rear wheels which will lead to the risk of hazard 40 6 Check Before Riding E Pre riding Check NW Oil Check and Refilling Make it a habit to check the ATV before riding Oil level check F fet dt t malfuncti d 1 Start the engine and let it warm up for 2 3 minutes eee ie ibaa Ania OS Then turn off the ignition switch for 2 3 minutes accident from happening it is necessary to have a Visually check the oil window pre riding check 2 If the oil level is at the lower limit refill oil until the level a reaches the upper limit Even for a relatively simple and easy trip a pre riding check is also required If an abnormality is found ride your ATV to the nearest workshop or service center for inspection and repair E Recommended Oil Specification and Grade Oil specification SAE 15W40 API SL or above Engine oil grade SL or above certified by API American Petroleum Institute Oil capacity Full capacity 2 5 liter Replacing volume 1 8 liter Notes Note If the ATV is parked on a tilted surface or the engine just stops the oil level will not be accurate When the engine stops it is still very hot If you check the oil level or replace oil
36. right after care should be taken to avoid being burn To prevent using low grade oil it is recommended you go to a workshop of the dealer from whom you purchased your ATV or the service center for oil change 41 E Changing Oil 1 Place the ATV on a level surface Oil filling cap 2 Start the engine and let it warm up for 2 3 minutes and then turn off the ignition switch and remove the oil filling cap 3 Remove the oil pan drain plug at the bottom of the engine Turning clockwise the plug to tighten it and turn counterclockwise to loosen it Use a container to keep the ET s ab drained oil Note Engine oil tank and gear box are integrated In order to drain the oil thoroughly remove the engine oil tank drain plug 1 and gear box oil drain plug 2 4 After oil is drained up tighten the oil pan drain plug Then fill in correct oil with appropriate volume 5 Visually check that the oil level is between the upper and lower limits Then tighten the oil filling cap 6 The tightening torque for the oil pan drain plug is 2 5 kg m Note To reduce the risk of getting burn do not change oil when the engine is still very hot 42 E Differential gear oil 4 Install the drain bolt and then tighten it to the specified torque The differential gear oil changed as follows at the intervals Tightening torque differential gear oil drain bolt specified in the periodic maintenance 1 5kg m E Chan
Download Pdf Manuals
Related Search