Farr 400UTV Owner's Manual - page 30

Manual is about: Racing car

Summary of 400UTV

  • Page 1

    Farr 400utv owner's manual.

  • Page 3: Introduction

    Introduction congratulations on your purchase of the 400utv-ec. It represents the result of many years of experience in the production of fine sporting, utvs, and pacesetting racing machines. With the purchase of this utv, you can now appreciate the high degree of craftsmanship and reliability. This...

  • Page 4: Note:

    Important manual information failure to follow the warnings contained in this manual can result in serious injury or death. Particularly important information is distinguished in this manual by the following notations: the safety alert symbol means attention! Your safety is involved! Failure to foll...

  • Page 5: Important Notice

    Important notice curve speed must be smaller than 30km/h. This utv has been passed the ec certificate, it can run on any public street, road, and highway. Please check your local riding laws and regulations before operating this utv. When the temperature is below -20℃ (-4°f), please park the utv in ...

  • Page 6

    Contents 1 location of the warning 2 and specification labels……1-1 2 . Safety information………………2-1 3 . Description and vehicle identification………………………3-1 identification number records…………3-3 vehicle identification number and model label………………………………3-3 verification sign of ec……………………3-4 4 . Control u...

  • Page 7

    Trailer hitch bracket……………………4-25 auxiliary dc jack………………………4-25 5 pre-operation checks…………5-1 brakes……………………………………5-2 front and rear brakes brake pedal…5-2 brake fluid level………………………5-3 brake operation…………………………5-3 fuel………………………………………5-4 gasohol…………………………………5-5 engine oil………………………………5-6 coolant…………...

  • Page 8

    Going downhill…………………………7-10 crossing through shallow water……7-11 vehicle immersion……………………7-13 rear axle differential lock …………7-14 riding over rough terrain……………7-15 riding in brush or wooded areas……………………………………7-16 encountering obstacles on the trail………………………………………7-17 8 . Periodic maintenance an...

  • Page 9

    Brake light switch adjustment………8-30 cable inspection and lubrication……8-31 brake pedal and accelerator pedal lubrication………………………8-32 rear knuckle upper and lower pivot lubrication………………………8-32 steering shaft lubrication……………8-33 wheel removal………………………8-34 wheel installation………………………8-34 battery………...

  • Page 10

    1-1 location of the warning and specification labels.

  • Page 11

    1-2 read and understand all of the labels on your vehicle. They contain important information for safe and proper operation of your vehicle. Never remove any labels from your vehicle. If a label becomes difficult to read or comes off, a replacement label is available from your dealer. ①.

  • Page 12

    1-3 ② ③ ④ ⑤.

  • Page 13

    1-4 ⑥ ⑦ ⑧.

  • Page 14

    1-5 ⑨ ⑩.

  • Page 15

    2-1 this utility vehicle handles differently from other vehicles including cars and utvs. 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. ● this vehicle is designed to carry the driv...

  • Page 16

    2-2 always follow the inspection and maintenance procedures and schedules described in this manual. ● always keep both hands, arms, feet, and legs inside the vehicle at all times during operation. Keep your feet on the floorboard. Never hold onto the enclosure. Otherwise, your hands could be injured...

  • Page 17

    2-3 ● always follow proper procedures for going uphill. If you lose control and cannot continue up a hill, back down the hill with the engine in reverse gear. Use engine braking to help you go slowly. If necessary, use the brakes gradually to help you go slowly. ● always check terrain before going d...

  • Page 18

    2-4 warning potential hazard improper handling of gasoline. What can happen gasoline can catch fire and you could be burned. How to avoid the hazard always turn off the engine when refueling. Do not refuel right after the engine has been running and is still very hot. Do not spill gasoline on the en...

  • Page 19

    2-5 warning potential hazard starting or running the engine in a closed area. What can happen exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. How to avoid the hazard always operate your vehicle in an area with adequate ventilation..

  • Page 20

    3-1 description and vehicle identification 1. Headlights 2. Front shock absorber assembly 3. Brake fluid reservoir 4. Rear mirror 5. Ignition switch assembled 6. Driver seat 7. Battery 8. Fuses 9. Left body protection plate 10. Driver seat belt 11. Air filter element 12. Cargo bed 13. Tail/brake lig...

  • Page 21

    3-2 26. Parking brake lever 27. Steering wheel 28. Ignition switch 29. Multi-function display gauge 30. Auxiliary dc jack 31. Drive select lever 32. Accelerator pedal 33. Brake pedal 34. Release parking handle note: the vehicle you have purchased may differ slightly from those in the figures of this...

  • Page 22

    3-3 identification number records record the vehicle identification number and model label information in spaces provided for assistance when ordering spare parts from a dealer or for reference in case the vehicle is stolen. 1. Vehicle identification number: 2. Model label information ○ ● vehicle id...

  • Page 23

    3-4 verification sign of ec record the information on this label in the space provided. This information will be needed to order spare parts from your dealer. 1. Verification sign of ec.

  • Page 24: Control Functions

    4-1 control functions ignition switch 1. Ignition switch functions of the respective switch positions are as follows: on: all electrical circuits are supplied with power, and the headlights and taillights come on when the light switch is on. Off: all electrical circuits are switched off. The key can...

  • Page 25: Combination Switch

    4-2 least 5 seconds between each operation of the electric starter to let it cool. ● do not turn the key to the “start” position with the engine running, or damage to the electric starter can result. ● see starting instructions prior to starting the engine. (see pages 6-1 — 6-3 for details.) combina...

  • Page 26

    4-3 beam. ● set the switch to “off”, to turn off all the lights. ● set the switch to “ ” to turn on the little lights in the headlights and the taillights. 1 caution: do not use the headlights more than fifteen minutes if the engine is turned off. Otherwise the battery may discharge to the point tha...

  • Page 27

    4-4 indicator and warning lights 1. On-command four-wheel-drive indicator “ ”/ “ ” 2. Parking brake indicator light “p” 3. Reverse indicator light “r” 4. Neutral indicator light “n” 5. High- range indicator light “f” 6. Position light indicator 7. On-command differential lock indicator “diff. Lock” ...

  • Page 28

    4-5 neutral indicator l ight “n” this indicator light comes on when the drive select lever is in the “n” position. Reverse indicator l ight “r” this indicator light comes on when the drive select lever is in the “r” reverse position. Parking brake indicator l ight “p” this indicator light comes on w...

  • Page 29

    4-6 allow the engine to cool down for about 15 minutes. 1 caution:  the engine may overheat if the vehicle is overloaded. If this happens, reduce the load to specification.  after restarting, make sure that the light is out. Continuous use while the light is on may cause damage to the engine. High...

  • Page 30

    4-7 battery power shorted indicator shows the battery is overused. Please take out the battery, re-charge and check the discharged reason. Multi-function display gauge 1. “trip/odo” button 2. Clock/hour meter 3.Tachometer 4.Left turn indicator 5.Right turn indicator 6.Speedometer 7.Metric/mile butto...

  • Page 31

    4-8 “trip/odo” button, and then push the “trip/odo” button for at least three seconds. The trip meters can be used to estimate the distance that can be traveled with a full tank of fuel. This information will enable you to plan future fuel stops. Note: holding in the “trip/odo” button and then turni...

  • Page 32

    4-9 1. Fuel meter 2. Fuel level warning indicator 1. Rear license bracket 2. Rear license light on-command four-wheel –drive and differential gear lock switches 1. On-command four-wheel –drive switch “2wd”/ “4 wd” 2. Differential gear lock switc h “lock”/ “2wd” this vehicle is equipped with an on-co...

  • Page 33

    4-10 plied to the rear wheels only.  four- wheel drive (“4wd”): power is supplied to the rear and front wheels.  four –wheel drive with the differential gear locked (“4wd-lock”): power is supplied to the rear and front wheels when the differential gear is locked (“diff. Lock”). Unlike the 4wd mode...

  • Page 34

    4-11 on-command four-wheel-drive switch “2wd/4wd” 1. On-command four –wheel-drive switch “2wd/4wd” 2. Select lever to change from 2wd to 4wd stop the vehicle, be sure the select lever is set to position ,and then set the switch to “4wd”. When the vehicle is in 4wd, the 4wd indicator “ ” will come on...

  • Page 35

    4-12 set the switch to “lock”. When the differential gear is locked, the differential gear lock indicator light (“diff. Lock”) will come on along with the differential gear lock indicator “ ” in the multifunction meter unit display. To release the differential gear lock, stop the vehicle and set the...

  • Page 36

    4-13 accelerator pedal press the accelerator pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check that the accelerator pedal returns normally before staring the engine. 1. Accelerator pedal before starting the engine, check the accel...

  • Page 37

    4-14 brake pedal press the brake pedal to slow or stop the vehicle. 1. Brake pedal parking brake pedal the parking brake pedal is located at the left side of the driver’s seat. It will help hold the vehicle from moving while parked. To set the parking brake, treadle the parking pedal completely . To...

  • Page 38

    4-15 1. Parking brake pedal 2. Parking brake pedal release lever drive select lever the drive select lever is used to shift the vehicle into low, high, neutral and reverse positions. (refer to pages 6-4—6-5 for the drive select lever operation.) 1. Drive select lever.

  • Page 39

    4-16 fuel tank cap remove the fuel tank cap by turning it counter clockwise. 1. Fuel tank cap starter (choke) “ ” starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies this mixture. Move in direction to turn on the starter (choke) move in direction to turn of...

  • Page 40

    4-17 1. Driver / passenger seat to install a seat, insert the projection on the rear of the seat into the seat holders and push down on the seat at the front. Warning potential hazard a loose seat. What can happen the operator could lose control or the operator or passenger could fall if the seat is...

  • Page 41

    4-18 seat belts this vehicle is equipped with three-point seat belts for both the operator and passen- ger. Always wear the seat belt while riding in the vehicle. 1. Seat belt (×2) 2. Latch plate (×2) 3. Buckle (×2) to wear the seat belt properly, do the following: 1. Hold the latch plate as you pul...

  • Page 42

    4-19 shoulder and across your chest. The shoulder belt should fit against your chest. If it is loose, pull the belt out all the way and then let it retract. 5. To release the buckle, firmly press the release button. 1. Buckle 2. Release button warning potential hazard not wearing the seat belt. Wear...

  • Page 43

    4-20 glove compartment 1 caution: to protect from damage, do not put metal products, like tools or sharply edged products directly in the glove compartment. If they must be stored, wrap them in appropriate cushion material. A . Open. Cargo bed 1. Cargo bed 2. Tailgate opening and closing the tailgat...

  • Page 44

    4-21 to open unhook the latches, and then lower the tailgate. To close place the tailgate in the original position, and then hook the latches. Lifting and lowering the cargo bed 1. Cargo bed release lever to lift push down the cargo bed release lever on the left or right side of the vehicle, and the...

  • Page 45

    4-22 keep hands and fingers away from the pinch points between the bed and the frame. Warning potential hazard overloading the cargo bed what can happen could cause changes in vehicle handling which could lead to an accident. How to avoid the hazard never exceed the stated maximum load limit for thi...

  • Page 46

    4-23 warning potential hazard carrying a passenger in the cargo bed. What can happen the passenger could fall, be thrown out, or be struck by objects in the cargo bed. How to avoid the hazard never carry a passenger in the cargo bed. This cargo bed is designed to carry cargo only. Front and rear sho...

  • Page 47

    4-24 1. Spring preload adjusting ring 2. Position indicator note: a special wrench can be obtained at a dealer to make this adjustment. Standard position: b a-minimum(soft) e-maximum(hard) 1. Special wrench.

  • Page 48

    4-25 warning potential hazard improper shock absorber adjustment. What can happen uneven adjustment can cause poor handling and loss of stability, which could lead to an accident. How to avoid the hazard always adjust the shock absorbers on the left and right side to the same setting. Trailer hitch ...

  • Page 49

    4-26 the auxiliary dc jack can be used for suitable work lights, radios, etc. The auxiliary dc jack should only be used when the engine is running. 1. Auxiliary dc jack cap 1. Set the light switch to “off”. 2. Start the engine. (see pages 6-1-6-3.) 3. Open the auxiliary dc jack cap, and then insert ...

  • Page 50

    4-27 may overload the circuit and cause the fuse to blow.  if accessories are used without the engine running or with the headlights turned on, the battery will lose its charge and engine starting may become difficult.  do not use an automotive cigarette lighter or other accessories with a plug th...

  • Page 51: Pre-Operation Checks

    5-1 pre-operation checks before using this vehicle, check the following points: item routine page brakes ● check operation, free play, fluid level and fluid leakage. ● fill with dot 4 brake fluid if necessary. 5-2—5-3,8-26—8-30 parking brake ● check for proper operation, condition and free play. 6-6...

  • Page 52

    5-2 warning potential hazard failure to inspect the vehicle before operating. Failure to properly maintain the vehicle. What can happen increases the possibility of an accident or equipment damage. How to avoid the hazard always inspect your vehicle each time you use it to make sure the vehicle is i...

  • Page 53

    5-3 check the operation of the brake pedal. It should move smoothly and there should be a firm feeling when the brakes are applied. If not, have the vehicle inspected by a dealer. Brake fluid level check the brake fluid level. Add fluid if necessary. (see pages 8-28) recommended brake fluid: dot 4 b...

  • Page 54

    5-4 warning potential hazard driving with improperly operating brakes. What can happen you could lose braking ability, which could lead to an accident. How to avoid the hazard always check the brakes at the start of every ride. Do not operate the vehicle if you find any problem with the brakes. If a...

  • Page 55

    5-5 your engine has been designed to use regular unleaded gasoline with a pump octane number ([r+m] /2) of 86 or higher, or research octane number of 93 or higher. If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel. Unleaded fuel will give you longer spark plug...

  • Page 56

    5-6 engine oil make sure the engine oil is at the specified level. Add oil as necessary. (see pages 8-7 —8-10.) 1 caution:  in order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “cd” o...

  • Page 57

    5-7 warning potential hazard removing the radiator cap when the engine and radiator are still hot. What can happen you could be burned by hot fluid and steam blown out under pressure. How to avoid the hazard wait for the engine to cool before removing the radiator cap. Always use a thick rag over th...

  • Page 58

    5-8 throttle pedal check to see that the throttle pedal operates correctly. It must operate smoothly and fully spring back to the idle position when released. Have a dealer repair as necessary for proper operation. Warning failure to check or maintain proper operation of the throttle system can resu...

  • Page 59

    5-9 throttle free play if the throttle pedal has excessive play due to cable stretch or mis-adjustment, it will cause a delay in throttle response, especially at low engine speed. The throttle may also not open fully. If the throttle pedal has no free play, the throttle may be hard to control, and t...

  • Page 60

    5-10 steering wheel inspection check the steering wheel for specified free play and smooth operation。 1. Position the vehicle on level ground. 2. Lightly turn the steering wheel left and right. 3. There should be 0.8″-1.0″ (20-25 mm) of free play. If there is excessive free play or strange noises, o...

  • Page 61

    5-11 tires warning potential hazard operating this vehicle with improper tires, or with improper or uneven tire pressure. What can happen use of improper tires on this vehicle, or operation of this vehicle with improper or uneven tire pressure, may cause loss of control, increasing your risk of acci...

  • Page 62

    5-12 under severe riding conditions. The following are minimums: front 126kpa (1.26kgf/cm 2 , 18psi) rear 126kpa (1.26kgf/cm 2 , 18psi) 4. Use no more than the following pressures when seating the tire beads. Front 250kpa (2.5kgf/cm 2 , 36psi) rear 250kpa (2.5kgf/cm 2 , 36psi) higher pressures may c...

  • Page 63

    5-13 how to measure tire pressure use the tire pressure gauge. Note: the tire pressure gauge is included as standard equipment. Make two measurements of the tire pressure and use the second reading. Dust or dirt in the gauge could cause the first reading to be incorrect. Set pressure with tires cold...

  • Page 64

    5-14 tire wear limit when the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. A. Tire wear limit tires for public use if you need to drive the utv on public road, please switch to the tires with public road use tread, which can explore its performance. Always use the public ro...

  • Page 65: Operation

    6-1 operation warning potential hazard operating vehicle without being familiar with all controls. What can happen loss of control, which could cause an accident or injury. How to avoid the hazard read the owner ’s manual carefully. If there is a control or function you do not understand, ask your d...

  • Page 66

    6-2 note: ● when the drive select lever is in the neutral position, the neutral indicator light should come on. If the neutral indicator light does not come on, ask a dealer to inspect the electric circuit. ● the engine can be started in any gear if the brake is applied. However, it is recommended t...

  • Page 67

    6-3 note: if the engine fails to start, release the key, and then try starting again. Wait a few seconds before the next attempt. Each cranking should be as short as possible to preserve battery energy. Do not crank the engine more than 5 seconds on each attempt. 5. If the engine is started with the...

  • Page 68

    6-4 1. Jumper cable positive lead 2. Jumper cable negative lead 5. Connect the negative lead of the jumper cable to the negative terminal of the charged battery and the other end of the negative lead to an unpainted metal surface of the vehicle. Note: do not connect the negative lead of the jumper c...

  • Page 69

    6-5 warming up to get maximum engine life, always warm up the engine before starting off. Never accelerate hard with a cold engine! To see whether or not the engine is warm, check if it responds to the throttle normally with the starter (choke) turned off. Drive select lever operation and reverse dr...

  • Page 70

    6-6 shifting: neutral to reverse 1. Stop the vehicle. Keep your foot off the accelerator pedal. 2. Apply the brake pedal. 3. Shift from neutral to reverse or vice versa by moving the drive select lever along the shift guide. 1. Drive select lever note: ● when in reverse, the reverse indicator light ...

  • Page 71

    6-7 warning potential hazard improperly operating in reverse. What can happen you could hit an obstacle or person behind you, resulting in serious injury. How to avoid the hazard when you shift into reverse, make sure there are no obstacles or people behind you. When it is safe to proceed, go slowly...

  • Page 72

    6-8 life of your vehicle than the period between zero and 25hours. For this reason, we ask that you carefully read the following material. Because the engine is brand new, you must not put an excessive load on it for the first several hours of running. During the first 25 hours, the various parts in...

  • Page 73

    6-9 braking when the brake system is new could damage brake pads and rotors. Cvt break-in (clutches/belt) a proper break-in of the clutches and drive belt will ensure a longer life and better performance. Break in the clutches and belt by operating at slower speeds during the break-in period as reco...

  • Page 74

    6-10 parking on a slope warning potential hazard parking on a hill or other incline. What can happen the vehicle could roll out of control, increasing the chance of an accident. How to avoid the hazard avoid parking on hills or other inclines. If you must park on an incline, apply the parking brake,...

  • Page 75

    6-11 accessories and loading accessories accessories can affect the handing and control of your vehicle. Keep the following in mind when considering an accessory or operating a vehicle which has accessories. ● choose only accessories designed for your vehicle. Your dealer has a variety of genuine ac...

  • Page 76

    6-12 loading cargo or a trailer can change the stability and handling of a vehicle. You must use common sense and good judgment when carrying cargo or towing a trailer. Keep the following points in mind: ● never exceed the weight limits shown. An overloaded vehicle can be unstable. Maximum loading l...

  • Page 77

    6-13 an accident. ● make sure the load does not interfere with controls or your ability to see where you are going. ● drive more slowly than would without a load. The more weight you carry, the slower you should go. Although conditions vary, it is good practice not to exceed low range whenever you a...

  • Page 78: Driving Your Vehicle

    7-1 driving your vehicle getting to know your vehicle this off-highway utility vehicle will handle and maneuver differently form an ordinary passenger car or other vehicle. Before you begin to use your vehicle, be sure you have read this owner ’s manual completely and understand all of the controls....

  • Page 79

    7-2 warning potential hazard carrying a passenger in the cargo bed. What can happen the passenger could fall or be struck by objects in the cargo bed. How to avoid the hazard never carry a passenger in the cargo bed. The cargo bed is designed to carry cargo only. The total weight of operator, passen...

  • Page 80

    7-3 warning potential hazard overloading this vehicle or carrying or towing cargo improperly. What can happen could cause changes in vehicle handling which could lead to an accident. How to avoid the hazard never exceed the stated load capacity for this vehicle. Cargo should be properly distributed ...

  • Page 81

    7-4 warning potential hazard operating this vehicle without wearing an approved motorcycle helmet, eye protection, and protective clothing. What can happen operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. Operating w...

  • Page 82

    7-5 learning to operate your vehicle you should become familiar with the performance characteristics of the vehicle in a large, flat area that is free of obstacles and other vehicles. Practice control of the accelerator pedal, brakes, steering, and drive select lever. Drive first at slow speed and b...

  • Page 83

    7-6 1 caution: do not shift from low to high or vice versa without coming to a complete stop and waiting for the engine to return to normal idle speed. Damage to the engine or drive train may occur. Turning your vehicle the vehicle is easier to steer in two-wheel drive (2wd) than four-wheel drive (4...

  • Page 84

    7-7 operating improperly in reverse improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures 。 follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Apply the throttl...

  • Page 85

    7-8 braking braking ability is affected by the type of terrain. In most cases, gradually application of the brakes is more effective than abrupt braking, particularly on loose surfaces like gravel. Always allow for greater braking distance on rough, loose, or slippery surfaces. Going uphill do not a...

  • Page 86

    7-9 warning potential hazard operating on excessively steep hills. What can happen the vehicle can over turn more easily on extremely steep hills than on level surfaces or small hills. How to avoid the hazard never operate your vehicle on hills too steep for it or your abilities. Never operate vehic...

  • Page 87

    7-10 drive select lever in reverse so you can use the engine brake if necessary to slow your descent. Release the brake and begin to coast down the hill. Use engine braking as much as possible, gently applying the brakes when necessary. Going downhill check the terrain carefully before going down a ...

  • Page 88

    7-11 before starting down hill, make sure the vehicle is in low-range 4wd. On most slopes, this will let you use engine braking to help you go downhill slowly. Go as slowly as possible. If you start going too fast, gently apply the brakes. Avoid sudden application of the brakes, which could cause th...

  • Page 89

    7-12 warning potential hazard operating this vehicle through deep or fast-flowing water. What can happen loss of control, which could result in an accident including overturn, which could increase the risk of drowning. How to avoid the hazard never operate this vehicle in fast flowing water or in wa...

  • Page 90

    7-13 vehicle immersion caution: if your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it’s impossible to take your vehicle to a dealer before starting it, follow the steps outlined b...

  • Page 91

    7-14 1.air filter case check hose 1.cvt gear box inspection hole front axle differential lock when driving on rugged or muddy roads, locking the differential case in the front axle gearbox will give you the best traction. In this case, the two front wheels will be driven at the same rate. It may not...

  • Page 92

    7-15 riding over rough terrain operating over rough terrain should be done with caution. Look for obstacles that could cause damage to the vehicle or could lead to a rollover accident. Avoid jumping the vehicle as injury, loss of control, and damage to the vehicle could occur. Warning potential haza...

  • Page 93

    7-16 riding in brush or wooded areas when operating in areas with brush or trees, watch carefully on both sides and above the vehicle for obstacles such as branches that the vehicle might hit, causing an accident, or for brush that might enter the vehicle as you pass and strike the driver or passeng...

  • Page 94

    7-17 encountering obstacles on the trail if you cannot go around an obstacle such as a fallen tree trunk or a ditch, stop the vehicle where it is safe to do so. Set the parking brake and get out to inspect the area thoroughly. Look from both your approach side and the exit side. If you believe you c...

  • Page 95

    8-1 periodic maintenance and adjustment periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible. Safety is an obligation of the vehicle owner. The most important points of vehicle inspection, adjustment and lubrication are explained ...

  • Page 96

    8-2 warning potential hazard servicing an engine while it is running. What can happen moving parts can catch clothing or par- ts of the body, causing injury. Electrical components can cause sho- cks or can start fires. How to avoid the hazard turn off the engine when performing maintenance unless ot...

  • Page 97

    8-3 periodic maintenance chart for the emission control system note: ● for vehicles not equipped with an odometer or hour meter, follow the month maintenance intervals. ● for vehicles equipped with an odometer or an hour meter, follow the km(mi) or hours maintenance intervals. However, keep in mind ...

  • Page 98

    8-4 general maintenance and lubrication chart item routine whichever comes first initial every month 1 3 6 6 12 km (mi) 320 (200) 1,200 (750) 2,400 (1,500) 2,400 (1,500) 4,800 (3,000) hours 20 75 150 150 300 rear brake* ● check operation/brake pad wear/fluid leakage/see note page 8-6. ● correct if n...

  • Page 99

    8-5 item routine whichever comes first initial every month 1 3 6 6 12 km (mi) 320 (200) 1,200 (750) 2,400 (1,500) 2,400 (1,500) 4,800 (3,000) hours 20 75 150 150 300 engine mount* ● check for cracks or damage. ● check bolt tightness. ○ ○ ○ steering system* ● check operation and for looseness. Replac...

  • Page 100

    8-6 hood to open unhook the hood latches, and then slowly tilt the hood up until it stops. 1. Latch(×2) 1. Hood to close lower the hood slowly to its original position, and then hook the hood latches. Secure projections ① on the underside of the hood into slots ② on the back of the instrument panel....

  • Page 101

    8-7 1. Projection (×2) 2. Slot (×2) 1 caution:  make sure that all cables and wires are in place when closing the hood.  do not drive the vehicle with the hood open, unlatched, or removed. Engine oil and oil filter cartridge the engine oil level should be checked before each operation. In addition...

  • Page 102

    8-8 note: the engine oil should be between the minimum and maximum level marks. 1. Maximum level mark 2. Minimum level mark 3. Dipstick 4. Engine 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 it to the correct level. 7....

  • Page 103

    8-9 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. Oil filter cartridge 2. Oil filter bolt note: an oil filter wrench is available at a nearby dealer. 5. Apply a light coat of engine oil to the o-ring of the ne...

  • Page 104

    8-10 tightening torque: oil filter cartridge: 17nm (1.7m·kgf, 12 ft·lbs) 1. Oil filler cartridge 2. Torque bolt 7. Install the engine oil drain bolt, and then tighten it to the specified torque. Tightening torque: engine oil drain bolt: 24nm (2.4m·kgf, 17 ft·lbs) 8. Add the specified amount of recom...

  • Page 105

    8-11 the crankcase. 9. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause. 10. Turn the engine off, wait at least ten minutes, and then check the oil level and correct it if necessar...

  • Page 106

    8-12 1 caution: be sure no foreign material enters the final gear case. 4. Install the oil filler bolt, and then tighten it to the specified torque. Tightening torque: final gear oil filler bolt: 23 nm (2.3 m·kgf, 16.3 ft·lbs) changing the final gear oil 1. Place the vehicle on a level surface. 2. P...

  • Page 107

    8-13 recommended oil: sae 80 api gl-4hypoid gear oil oil quantity: 0.4 l (0.35 lmp qt, 0.42 us qt) 1 caution: be sure no foreign material enters the final gear case. 6. Install the oil filler bolt, and then tighten it to the specified torque. Tightening torque: final gear oil filler bolt: 23 nm (2.3...

  • Page 108

    8-14 1 caution: 1. Be sure no foreign material enters the differential gear case. 2. Please clean the sensor every 500km (310miles). 2. Install the differential gear oil filler bolt, and then tighten it to the specified torque. Tightening torque: differential gear oil filler bolt: 23nm (2.3 m·kgf, 1...

  • Page 109

    8-15 5. Fill the differential gear case with the recommended oil. Recommended oil: sae 80 api gl-5 hypoid gear oil oil quantity: 0.28l (0.25 lmp qt, 0.3 us qt) 1 caution: be sure no foreign material enters the differential gear case. 6. Install the differential gear oil filler bolt, and then tighten...

  • Page 110

    8-16 1. Coolant reservoir cap 2. Maximum level mark 3. Minimum level mark 4. If the coolant is at or below the minimum level mark, remove the reservoir cap, add coolant to the maximum level mark, install the reservoir cap, and then close the hood. Coolant reservoir capacity (up to the maximum level ...

  • Page 111

    8-17 note: ● adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant, have a dealer check the antifreeze content of the coolant as soon as possible. ● the radiator fan is automatically switched on or off according to the coolant temperature i...

  • Page 112

    8-18 spark plug inspection removal 1. Remove hood (see pages 8-6) 2. Remove the spark plug cap. 3. Use the spark plug wrench in the tool kit to remove the spark plug as shown. 1. Spark plug cap 1. Spark plug wrench inspection the spark plug is an important engine component and is easy to inspect. Th...

  • Page 113

    8-19 instead, take the vehicle to a dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. If electrode erosion becomes excessive, or if carbon and other deposits are excessive, you should replace the spar...

  • Page 114

    8-20 tightening torque: spark plug: 17.5 nm(1.75 m·kgf, 12.4 ft·lbs) note: if a torque wrench is not available when you are installing the spark plug, a good estimate of the correct torque is 1/4 to 1/2 turn past finger tight. Have the spark plug tightened to the specified torque as soon as possible...

  • Page 115

    8-21 and the screws fixing the air cleaner, and then remove the air cleaner. 1. Holder (×3) 2. Air filter case cover 4. Remove the air filter element. 5. Remove the sponge material from its frame. 1. Air filter element 1. Air filter frame 2. Sponge material 3. Element retaining plate.

  • Page 116

    8-22 6. Wash the sponge material gently but thoroughly in solvent. Warning potential hazard using low flash point solvents or gasoline to clean the sponge material. What can happen low flash point solvents or gasoline can catch fire or explode. How to avoid the hazard use parts cleaning solvent to c...

  • Page 117

    8-23 1. Crankcase breather hose 13. Install the engine cover. 14. Install the seats. Note: the air filter element should be cleaned every 20-40 hours. It should be cleaned and lubricated more often if the vehicle is operated in extremely dusty areas. Each time air filter element maintenance is perfo...

  • Page 118

    8-24 cleaning the spark arrester be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Remove the bolts. 1、bolt(×3) 2. Remove the tailpipe by pulling it out of the muffler. 3.tap the tailpipe lightly, and then use a wire brush to remove any carbon deposits from the spa...

  • Page 119

    8-25 warning potential hazard improper cleaning of the spark arrester. Hot exhaust system. What can happen could injure the eyes. Could cause burns. Could cause carbon monoxide poisoning, possibly leading to death. Could start a fire. How to avoid the hazard when cleaning the spark arrester: always ...

  • Page 120

    8-26 front brake pad check each brake pad is provided with wear indicator grooves, which allow you to check the brake pad wear without having to disassemble the brake system. To check the brake pad wear, check the wear indicator grooves. If a brake pad has worn to the point that the wear indicator g...

  • Page 121

    8-27 1. Brake pad wear indicator groove checking the brake fluid level insufficient 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 the minimum level mark and replenish if necessary. A low brake flu...

  • Page 122

    8-28 deteriorate, causing leakage and poor braking performance recommended brake fluid: dot 4  refill with the same type of brake fluid. Mixing fluids may result a harmful chemical reaction and lead to poor braking performance.  be careful that water does not enter the brake fluid reservoir when r...

  • Page 123

    8-29 1. Brake pedal warning potential hazard operating with improperly serviced or adjusted brakes. What can happen you could lose braking ability, which could lead to an accident. How to avoid the hazard after servicing:  make sure the brakes operate smo- othly and that the brake pedal posi- tion ...

  • Page 124

    8-30 brake light switch adjustment the brake light switch, which is activated by the brake pedal, is properly adjusted when the brake light comes on just before braking takes effect. If necessary, adjust the brake light switch as follows. 1. Open the hood. (see pages 8-7 —8-8 for hood opening and cl...

  • Page 125

    8-31 cable inspection and lubrication warning potential hazard damaged control cables. What can happen corrosion can result when the outer covering of control cables becomes damaged. Cables can also become frayed or kinked. Operation of controls could be restricted, which could cause an accident or ...

  • Page 126

    8-32 brake pedal and accelerator pedal lubrication lubricate the pivoting parts. Recommended lubricant: lithium-based grease (all-purpose grease) rear knuckle upper and lower pivot lubrication lubricate the knuckle upper and lower pivots with a grease gun. Recommended lubricant: lithium-based grease.

  • Page 127

    8-33 steering shaft lubrication lubricate the pivot points. Recommended lubricant: lithium-based grease (all-purpose grease) upper universal joint ,steering transmitssion shaft lower universal joint ,steering transmitssion shaft front balance rod.

  • Page 128

    8-34 rear balance rod wheel removal loosen the wheel nuts. Elevate the vehicle and place a suitable stand under the frame. Remove the nuts from the wheel. Remove the wheel. 1. Nut (×4) wheel installation 1. Install the wheel and the nuts. Note: ● the arrow mark on the tire must point toward the rota...

  • Page 129

    8-35 1. Arrow mark 1. Tapered nut 2. Lower the vehicle so that the wheel is on the ground. 3. Tighten the wheel nuts to the specified torque. Battery this vehicle is equipped with a sealed-type battery. Therefore it is not necessary to check the electrolyte or add distilled water in the battery. If ...

  • Page 130

    8-36 warning potential hazard failure to handle batteries or battery electrolyte carefully. What can happen you could be poisoned. You could be severely burned by the sulfuric acid in battery electrolyte. Batteries produce explosive gases. How to avoid the hazard avoid contact with skin, eyes or clo...

  • Page 131

    8-37 battery maintenance 1. When the vehicle is not used for a month or longer, remove the battery and store it in a cool, dark place. Completely recharge the battery before reinstallation. 2. Always make sure the connections are correct when putting the battery back in the vehicle. 1. Negative batt...

  • Page 132

    8-38 1. Battery compartment cover 2. Screw m6×8 2. Turn the key to “off” and turn off the electrical circuit in question. 1 caution: to prevent accidental short-circuiting, turn off the ignition switch when checking or replacing a fuse. Warning otential hazard using an improper fuse what can happen ...

  • Page 133

    8-39 1. Main fuse 2. Spare main fuse 3. Headlight fuse 4. Ignition fuse 5. Auxiliary dc jack fuse 6. 2wd/4wd fuse 7. Signaling system fuse 8. Meter fuse 9. Backup fuse (for odometer and clock) specified fuse: main fuse: headlight fuse: ignition fuse: auxiliary dc jack fuse: signaling system fuse: ca...

  • Page 134

    8-40 replacing a headlight bulb if a headlight bulb burns out, replace it as follows. 1. Lift the hood up. (see pages 8-7-8-8 for hood opening and closing procedures.) 2. Remove the cover at the rear of the headlight by pulling it off. 1. Cover at the rear of the headlight 3. Remove the headlight bu...

  • Page 135

    8-41 1. Headlight bulb holder 1. Do not touch the glass part of the bulb. Warning potential hazard a headlight bulb is hot when it is on and immediately after it is turned off. What can happen you can be burned, or a fire could start if the bulb touches something flammable. How to avoid the hazard w...

  • Page 136

    8-42 7. Install the bulb holder by pushing it in and turning it clockwise. 8. Install the bulb holder cover and the cover at the rear of the headlight. 1 caution: make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly. 9. Close the hood. 10. Adjust the ...

  • Page 137

    8-43 1. Tail/brake light bulb holder 6. Install the panel by installing the quick fasteners and bolts, and then tighten the bolts to the specified torque. Tightening torque: panel bolt: 6.5n·m (0.65 m·kgf,4.7 ft·lbs).

  • Page 138

    8-44 check and solution to common problems in vehicle here you can see some tables on the common problems which may come up when you are driving a utv, which will help to solve these problems. To repair a utv requires technical skills, if you cannot fix it up yourself, please contact your dealer. Ta...

  • Page 139

    8-45 table 2 : check and solution of common problems in brake system . S/n problems solutions 1 brake system is locked up. 1.check if the handle of parking brake return to its position. 2.check if the brake discs are deformed. 3.check if the calipers' hydraulic cylinders get stuck, or the fixing par...

  • Page 140

    8-46 s/n problems solutions 4 vehicle go deflected when braked at high speed. 1.check if left & right brake force' deviation of front brake is with specified limit. 2.check if the brake force of front brake go down, which cause the rear wheels are locked up before the front wheels when braked. 3.che...

  • Page 141

    8-47 s/n problems solutions 3 rear differential won't work. 2. Check if the differential lock control magneto plug in rear bridge reduction gear box are broken. 3. Check if the wire is broken. 4 meter display abnormal- ly. 1. Check if the sensor is broken. 2. Check if the meter is broken. 3. Check i...

  • Page 142

    8-48 s/n problems solutions 2 front wheels shake seri- ously in running. 2. Check the main ball pins to find out if they are broken. 3. Check the lock screws of front wheels and axles to find out if they are loose or broken. 4. Check the inner splines of front wheel hubs and outer splines of front w...

  • Page 143

    8-49 s/n problems solutions 5 shock absorbers beco- me soft and not comfort- table in running. 1. Check if overloaded. 2. Check if the springs are two soft after after long time running. 3. Check if the shock absorbers lose their damping force in their travel. 6 front bridge makes noise in running. ...

  • Page 144

    8-50 table5: check and solution of common problems in engine system s/n problems solutions 1 idle speed can not be adjusted 1. Check the throttle cable for seizure 2. Check the adjustment knob of carburetor for damage or wear 3.Check the needle of carburetor to see if it can be placed to the bottom ...

  • Page 145

    8-51 s/n problems solutions 6 coolant boils 1.Check the cooling fin of radiator for blocked by soil or dirt 2.Check the speed sensor of radiator for damage and check fan for failure 3.Check if antifreeze can meet the requirement stated in the owner manual. 4.Check the coolant loop for mixed with air...

  • Page 146

    8-52 note: if it is difficult to get the recommended coolant, tap water can be temporarily used, provided that it is changed to the recommended coolant as soon as possible. Warning potential hazard removing the radiator cap when the engine and radiator are still hot. What can happen you could be bur...

  • Page 147: Cleaning And Storage

    9-1 cleaning and storage a. Cleaning frequent, thorough cleaning of your vehicle will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the vehicle: a. Block off the end of the exhaust pipe to prevent water entr...

  • Page 148

    9-2 6. Clean the seats with a vinyl upholstery cleaner to keep the cover pliable and glossy. 7. Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid combination cleaner-waxes. Many contain abrasives which may scratch the paint or protective finish. When finished, start...

  • Page 149

    9-3 b. Storage long term storage (60 days or more) of your vehicle will require some preventive procedures to guard against deterioration. After thoroughly cleaning the vehicle, prepare for storage as follows: 1. Fill the fuel tank with fresh fuel and add the specified amount of fuel stabilizer and ...

  • Page 150

    9-4 7. If storing in a humid or salty atmosphere, coat all exposed metal surfaces with a light film of oil. Do not apply oil to any rubber parts or the seat covers. 8. Remove the battery and charge it. Store it in a dry place and recharge it once a month. Do not store the battery in an excessively w...

  • Page 151

    10-1 specifications model 400utv-ec dimensions: overall length overall width overall height seat height wheelbase ground clearance minimum turning radius 2680mm (105.5 in) 1320mm (52.0 in) 1870mm (73.6 in) 840mm (33.1 in) 1830mm (72.0 in) 300mm (11.8 in) 3500mm (137.8 in) basic weight: with oil and ...

  • Page 152

    10-2 model 400utv-ec engine oil: type recommended engine oil classification quantity: without oil filter cartridge replacement with oil filter cartridge replacement api service sg type or higher, jaso standard ma 1 caution: in order to prevent clutch slippage (since the engine oil also lubricates th...

  • Page 153

    10-3 model 400utv-ec final gear case oil: type quantity: sae80 api gl-4 hypoid gear oil 0.4l (0.35 lmp qt, 0.42 us qt) differential gear case oil: type quantity: sae80 api gl-5 hypoid gear oil 0.28l (0.25 lmp qt, 0.3us qt) radiator capacity (including all routes): 1.5l (1.32 lmp qt, 1.59 us qt) air ...

  • Page 154

    10-4 model 400utv-ec transmission: primary reduction system secondary reduction system cvt reduction ratio transmission type operation reverse gear forward gear v-belt shaft drive 0.625~2.714 v-belt automatic right hand operation chassis: frame type caster angle trail steel tube frame 4.0° 21.0mm (0...

  • Page 155

    10-5 model 400utv-ec brakes: system type front rear operation front and rear unified dual disc brake dual disc brake foot operation suspension: front suspension rear suspension double wishbone double wishbone shock absorber: front shock absorber rear shock absorber coil spring/oil damper coil spring...

  • Page 156

    10-6 model 400utv-ec bulb voltage, wattage × quantity: headlight tail/brake light front/rear turning light license light 12v35.0w/35.0w × 2 12v5.0w/21.0w × 2 12v10.0w/10.0w × 2 12v3.0w indicator lights: neutral indicator light reverse indicator light coolant temperature warning light parking brake i...