IMPORTANT NOTICE
This machine is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this machine
on any public street, road or highway.
This machine complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect
at the time of manufacture.
Please check your local riding laws and regulations before operating this ATV.
USER'S MANUAL
Summary of RD400
Page 1
Important notice this machine is designed and manufactured for off-road use only. It is illegal and unsafe to operate this machine on any public street, road or highway. This machine complies with all applicable off-road noise level and spark arrester laws and regulations in effect at the time of ma...
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Congratulations on your purchase of the rd400. This manual will provide you with a good basic under it also includes basic maintenance and inspection procedures. If you have any questions regarding the operation or maintenance of your atv, please consult a dealer. Read this manual together with tips...
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Your safety is involved! Failure to follow warning instructions could result in injury or failure to follow the warnings contained in this manual can result in particularly important information is distinguished in this manual by the following notations: a caution indicates special precautions that ...
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Contents safety information control functions 4. Main switch indicator and warning lights 5. Peration checks pre-o handlebar switches throttle lever speed limiter front brake lever brake and rear brake leve lever parking brake drive select lever recoil starter fuel tank cap fuel cock front and rear ...
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6.Operation starting a cold engine starting a warm engine warming up drive select lever operation and reverse driving engine break-in parking parking on a slope accessories and loading getting to know your atv ride with care and good judgment be careful where you ride turning your atv climbing uphil...
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Rear brake shoe inspection brake fluid level check brake fluid replacement front brake lever free play rear brake pedal and lever adjustment adjusting the rear brake light switch cable inspection and lubrication lubricating the brake levers and brake pedal wheel installation battery 10.Specification...
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Location of the warning and specification labels 1 user's manual.
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Read and understand all of the labels on your machine. They contain important information for safe and proper operation of your atv. Never remove any labels from your atv. If a label becomes difficult to read or comes off, a replacement label is available from your dealer. 2 user's manual 2 improper...
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User's manual 3 never ride with passengers. Riding with passenges can cause a loss of control, resulting in severe injury or death ! Warning improper atv use can result in severe injury or death, never always: locate and read owner,s manual. Follow all instructions and warnings. Operate: • without p...
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4 user's manual operating this atv if you are under the age of 16increases your chance of severe injury or death. Never operate this atv if lyou are under age 16. ! Warning ⑨ drive select lever • read owner’s manual carefully before operating. • atv must be stopped before shifting select lever. • sh...
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An atv handles differently ther vehicles including motorcycles and cars. Acollision or rollover can occur quickly, even maneuvers such as turning and riding on hills or over obstacles, if you fail to take from o during routine proper precautions. Severe injury or death can result if you do not follo...
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Never operate an atv without wearing an approved motorcycle helmet that fits properly. You should also wear eye protection (goggles or face shield), gloves, boots, a long-sleeved shirt or a jacket, and long pants. Never consume alcohol or drugs before or while operating this atv. Never operate at sp...
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Always follow proper procedures for climbing hills as described in this manual. Check the ter before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly. Never go over the top of a hill at high speed. Rain ...
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Always be careful when skidding or sliding. Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control. Never ope...
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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 immediately after the engine has been running and is still very hot. Do not spill gasoline on the engine o...
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Potential hazard what can happen how to avoid the hazard starting or running the engine in a closed area. Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. Always operate your atv in an area with adequate ventilation. 10 user's manual.
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1 rear shock absorber assembly spring pre load adjusting ring 2 spark arrester 3 storage box and tool kit 4 spa k plug 5 front shock absorber a sembly spring pre load adjusting ring 6 brake pedal 7 v-belt case 8 uel cock 9 ai rfilter case fuses tail/ brake ligh t r s f note: the machine you have pur...
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12 vehicle identification number the vehicle identification number is stamped into the frame. Vehicle identification number (front left side) the vehicle identification number is used to identify your machine. Note: ① user's manual.
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Control functions indicates a potential hazard that could result in serious injury or death. Main switch functions of the respective switch positions are as follows: main switch ① 13 user's manual on: off: the engine can be started only at this position and the headlights and taillight come on whent...
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14 indicator and warning lights neutral indicator light “n” reverse indicator light “r” four-wheel drive indicator light “ ” oil temperature warning light ① ② ③ ③ neutral indicator light “n” reverse indicator light “r” this indicator light comes on when the drive select lever is in the “n” position....
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Four-wheel-drive indicator light this indicator light comes on when the 2wd/ 4wd switch is in the 4wd position. Note: due to the synchronizing mechanism in the differential gear case, the light may not come on until the atv starts moving. Oil temperature warning light ? 15 the engine may overheat if...
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Oil temperature warning light checking method 16 turn the main switch to "on"and the engine stop switch to oil temperature warning light does not come on. Push shart switch with the transmission in neutral. Oil temperature warning light comes on momentarily. Oil temperature warning light does not co...
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Handlebar switches ① light switch “ / /off” ② “ / engine stop switch ” ③ ” start switch “ light switch / /off “ ” set the switch to “ ” to turn on the low beam and the taillight. Set the switch to “ ” to turn on the high beam and the taillight. Set the switch to ff to turn off all the lights. O engi...
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18 start switch “ ” the starter motor cranks the engine when this switch is pushed. See starting instructions prior to starting the engine. (see page 43 for details). On-command four-wheel drive switch “2wd /4wd” to change from two-wheel drive (2wd) to four-wheel drive (4wd), stop theatvand set the ...
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Potential hazard changing from 2wd to 4wd or from 4wd to 2wd while the atv is moving. What can happen theatv handles differently in 2wd than in 4wd in some circumstances. Changing from 2wd to 4wd or from the atv to unexpectedly handle diffe ntly. This could distract the operator and increase the ris...
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20 throttle lever once the engine is running, movement of the throttle lever will increase the engine speed. Regulate the speed of the machine by varying the throttle position. Because the throttle is spring-loaded, the machine will decelerate, and the engine will return to an idle any time the hand...
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Speed limiter the speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting screw limits the maximum engine power available and decreases the maximum speed of the atv. ① ② locknut adjusting screw a 12 mm (0.47 in) potential h...
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22 front brake lever the front brake lever is located on the right handlebar. Pull it toward the handlebar to apply the front brake. Brake pedal and rear brake lever. The brake pedal is located on the right side of theatv and the rear brake lever is located on the left handlebar. Push down on the pe...
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Parking brake use the parking brake when you have to start the engine or park the machine, especially on a slope. Apply the rear brake lever and push down the lock plate to apply the parking brake. Squeeze the rear brake lever to release the parking brake. ① lock plate potential hazard improper use ...
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24 drive select lever the drive select lever is used to shift your machine into the forward, neutral and reverse positions. (refer to page 46 for the drive select lever operation.) ① drive select lever recoil starter firmly grasp the handle and pull slightly until engagement can be felt. Then pull f...
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Fuel tank cap remove the fuel tank cap by turning it counter clockwise. 1 fuel tank cap potential hazard starting the engine without shifting into the neutral position. What can happen the atv could start to move unexpect edly, which could cause an accident. How to avoid the hazard shift the drive s...
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26 fuel cock the fuel cock supplies fuel from the fuel tank to the carburetor. The fuel cock has three positions. This indicates reserve. If you run out of fuel the carburetor. Normal riding is done with the lever in this position. With the lever in this position, fuel flows to flow. Alway s tur n t...
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Starter (choke) “ ” starting a cold engine requires a richer air-fuel mixture. Aseparate starter circuit supplies this mixture. Move in direction a to turn on the starter(choke). Move in direction to turn off the starter(choke). A refer to tarting a cold engine for proper operation. (see page 43). ①...
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28 seat to remove the seat, pull the seat lock lever upward and pull up the seat at the rear. ① ② seat seat lock lever to install the seat, insert the projections on the front of the seat into the seat holders and push down on the seat at the rear. Make sure that the seat is securely fitted. Note: ①...
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Storage box maximum load limit: 2 kg (4.4 lb). To protect from damage, do not put metal products, like tools or sharply edged products directly in the storage box. If they must be stored, wrap them in appropriate cushion material. ① storage box note: there is a check hose at the bottom of the storag...
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30 front carrier rear carrier maximum load limit: 40 kg (88 lb). Maximum load limit: 80 kg (176 lb). Front shock absorber adjustment. The spring preload can be adjusted to suit the rider ’s weight and riding conditions. Adjust the spring preload as follows. To increase the spring preload, turn the a...
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Rear shock absorber adjustment the spring preload can be adjusted to suit the rider weight and riding conditions. Adjust the spring preload as follows: to increase the spring preload, turn the ad justing ring in direction a . To decrease the spring preload, turn the ad justing ring in direction b . ...
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32 note: a special wrench can be obtained at a dealer to make this adjustment. Standard position: 2 1 - minimum (soft). 5 - maximum (hard). ① special wrench. Indicates a potential hazard that could result in serious injury or death. User's manual.
Page 39
Pre-operation checks before using this machine, check the following points: user's manual item routine front brake check operation, free play, fluid level and fluid leakage. Fill with dot 4 brake fluid if necessary. Rear brake check fuel level. Fuel fill with fuel if necessary. Check oil level. Engi...
Page 40
Potential hazard what can happen how to avoid the hazard failure to inspect the atv before operating. Failure to properly maintain the atv. Increases the possibility of an accident or equipment damage. Always inspect your atv each time you use it to make sure the atv is in safe operating condition. ...
Page 41
Brake fluid leakage (all brake) check to see if any brake fluid is leaking out of the hose, joint or brake fluid reservoir of the front brake. Apply the brake firmly for one minute. If the lever moves slowly inward, there may be a leak in the brake system. If there is any leakage, the brake system s...
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36 fuel make sure there is sufficient gasoline in the tank. Recommended fuel: unleaded gasoline only fuel tank capacity: total: 13.5 l (2.97 imp gal, 3.57 us gal) reserve: 3.3 l (0.73 imp gal, 0.87 us gal) use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal en...
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Gasohol there are two types of gasohol; gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if ethanol content does not exceed 10%. Gasohol containing methanol is not recommended by atv because it may cause fuel system damage or vehicle performance problem...
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38 engine oil make sure the engine oil is at the specified level. Add oil as necessary. (see pages 102--107). In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “cd” or oils of a hig...
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Differential gear oil make sure the differential gear oil is at the specified level. Add oil as necessary. (see pages 110--111 for details). Recommended oil:sae 80 api gl-4 hypoid gear oil. Throttle lever check to see that the throttle lever operates correctly. It must open smoothly and spring back ...
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40 potential hazard what can happen how to avoid the hazard operating this atv with improper tires, or with improper or uneven tire pressure. Use of improper tires on this atv, or operationof this atv with improper or uneven tire pressure, may cause loss of control, increasing your risk of accident....
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How to measure tire pressure use the low-pressure tire gauge. Note: the low-pressure tire 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 c...
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42 tire wear limit when the tire groove decreases to 3 mm (0.12 in)due to wear, replace the tire. A tire wear limit. User's manual.
Page 49
Operation indicates a potential hazard that could result in serious injury or death. Potential hazard operating atv 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 manual carefully. If there is...
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44 note: ° ° ° ° ° when the drive select lever is in the neutral position, the neutral indicator light should come on. If it does not come on, ask a atv dealer to inspect the electric circuit. The engine can be started in any gear if the brake pedal is applied. However, it is recommended to shift in...
Page 51
If the engine fails to start, release the start switch, then push the start switch again. Pause 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 10 seconds on each attempt. If the battery is discharged, ...
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46 drive select lever operation and reverse driving. Before shifting, stop the machine and return the throttle lever to its closed position. Otherwise, the transmission may be damaged. Shifting: forward 1. Bring the machine to a complete stop and return the throttle lever to the closedposition. 2. S...
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Shifting: reverse 1. Bring the machine to a complete stop and return the throttle lever to the closed position. 2. Apply the brake pedal. 3. Shift the gear from neutral to reverse and vice versa by moving the drive select lever along the shift guide. 4. Check behind for people or obstacles, then rel...
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48 potential hazard what can happen how to avoid the hazard improper operation in reverse. You could hit an obstacle or person behind you, resulting in serious injury. When you shift into reverse, make sure there are no obstacles or people behind you. When it is safe to proceed, go slowly. User's ma...
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Engine break-in there is never a more important period in the life of your machine than the period between zero and 20 hours. 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 ...
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50 10-20 hours: after break-in: avoid prolonged operation above 3/4 throttle. Rev the machine freely but do not use full throttle at any time. Avoid prolonged full throttle operation.Vary speeds occasionally. Parking when parking, stop the engine and shift into neutral. Turn the fuel cock to “off” a...
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1. Bring the machine to a stop by applying the brakes. 2. Stop the engine. 3. With the rear brake lever and pedal applied, apply the parking brake, and then lowly release the brake pedal. Potential hazard parking on a hill or other incline. What can happen theatv could roll out of control, increas t...
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52 accessories can affect the handling and control of your atv. Keep the following in mind when considering an accessory or operating an atv which has accessories. Choose only accessories designed for your atv. Your atv dealer has a variety of genuine atv accessories. Other accessories may also be a...
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Loading cargo or a trailer can change the stability and handling of an atv. 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 over loaded atv can be unstable. Maximum loading limit vehicle l...
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54 ride more slowly than you would without a load. The more weight you carry, the slower you should go. Allow more braking distance. A heavier vehicle takes longer to stop. Avoid making sharp turns unless at very slow speeds. Avoid hills and rough terrain. Choose terrain carefully. Added weight affe...
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Indicates a potential hazard that could result in serious injury or death. 55 user's manual.
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56 user's manual.
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57 user's manual.
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58 indicates a potential hazard that could result in serious injury or death. Getting to know your atv this atv is for recreation and utility use. This section, r i d i n g y o u r at v, p r o v i d e s g e n e r a l at vr i d i n g i n st r u c ti o n s for recreational riding. The skills and t ec ...
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Ride with care and good judgement get training if you are inexperienced. Beginners should get training from a certifiedinstructor. Become familiar with thisatv at slow speeds first, even if you are an experienced operator. Do not attempt to operate at maximum perfor mance until you are totally famil...
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60 not recommended for children under 16 years of age. Failure to follow the age recommendations for this atv. Use by children of atvs that are not recommended for their age can lead to severe injury or death of the child. A child under 16 should never operate an atv with engine size greater than 90...
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This atv is designed to carry operator and cargo only passengers prohibited. Potential hazard carrying a passenger on this atv. What can happen greatly reduces your ability to balance and control this atv. Could cause an accident, resulting in harm to you and/or your passenger. How to avoid the haza...
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62 apparel potential hazard what can happen op e r a ti n g th i s at v wi th o u t we ar i n g a n a p p r o v e d motorcycle helmet, eye protection and protective clothing. Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of anac...
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Do not operate after consuming alcohol ordrugs. Operator performance capability is reduced by the influence of alcohol or drugs. Potential hazard operating this atv after consuming alco ol or drugs. H what can happen could seriously affect your judgment. Could cause you to react more slowly. Could a...
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64 pre-operation checks always p erf or m the p re -o per atio n ch eck s l isted o n page 33 before riding for safety and proper care of the atv. Potential hazard what can happen how to avoid the hazard failure to inspect the atv before operating. Failure to properly maintain the atv. Increases the...
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Indicates a potential hazard that could result in serious injury or death. Do not operate at speeds too fast for your skills or the conditions. Potential hazard operating thisatv at speeds too fast for your skills or the conditions. What can happen increases your chances of losing control of theatv ...
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66 loading and accessories use extra caution when riding the atv with additional loads, such as accessories or cargo. Theatv’s handling may be adversely affected. Reduce your speed when adding additional loads. Maximum loading limit vehicle loading limit: 210 kg (463 lb). Total weight of cargo, ride...
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During operation always keep your feet on the footboards during operation. Otherwise your feet may contact the rear wheels. Potential hazard removing hands from handlebars or feet from footboards during operation. What can happen removing even one hand or foot can reduce your ability to control thea...
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68 avoid wheelies and jumping. You may lose control of the atv or overturn. Attempting wheelies, jumps, and other stunts. Increases the chance of an accident, including an overturn. Never attempt stunts, such as wheelies or jumps. Don’t try to show off. Potential hazard what can happen how to avoid ...
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Modifications potential hazard operating this atv with improper modifications. What can happen improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident. How to avoid the hazard never modify this atv through ...
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Exhaust system the exhaust system on the atv is very hot during and following operation. To prevent burns, avoid touching the ex hau st syste m. Par k t he atv in a plac e wh ere pedestrians or children are not likely to touch it. 70 do not touch the hot exhaust system. Do not park the atv in a plac...
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Potential hazard operating this atv on paved surfaces. What can happen atvs are designed for off-road use only. Paved surfaces may seriously affect handling and control of the atv, and may cause the vehicle to go out of control. How to avoid the hazard always avoid paved surfaces, including sidewalk...
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72 do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles. Potential hazard what can happen how to avoid the hazard operating this atv on public streets, roads or highways. You can collide with another vehicle. Never operate this atv o...
Page 79
Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hiddenhazards which may cause the atv to upset. Potential hazard failure to use extra care when operating this atv on unfamiliar terrain. What can happen you can come...
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74 potential hazard what can happen how to avoid the hazard failure to use extra care when operatingon excessively rough, slippery or loose terrain. Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. Do not operate on excessively rough, slipper...
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When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the atv. Do not use the flag pole bracket as a trailer hitch. Potential hazard operating in areas where you might not be seen by other off-road vehicles. What can happen you could be in a colli...
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76 with the engine idling, return the starter (choke)to the closed position, shift the drive select lever into th e fo rwar d p ositi on , a nd t hen rel ease the p ar kin g brake. Apply the throttle slowly and smoothly. The centrifugal clutch will engage and you will start to accelerate. If the thr...
Page 83
Turning your atv to achieve maximum traction while riding off road, the two rear wheels are mounted solidly on one axle and turn together at the same speed. Therefore, unless the wheel on the in side of the turn is allowed to slip or lose some traction, the atv will resist turning. A special turning...
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78 this procedure should be practiced at slow speed many times in a large off-road area with no obstacles. If an incorrect technique is used, your atv may continue to go straight. If the atv doesn’t turn, come to a stop and then practice the procedure again. If the riding surface is slippery or loos...
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79 climbing uphill use proper riding techniques to avoid vehicle overturns on hills. Be sure that you can maneuver your atv well on flat ground before attempt ing any incline and then practice riding first on gentle slopes. Try more difficult climbs only after you have developed your skill. In all c...
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80 potential hazard what can happen how to avoid the hazard climbing hills improperly. Could cause loss of control or cause the atv to overturn. Always follow proper procedures for climbing hills as described in this owner ’s manual. Always check the terrain carefully before you start up any hill. N...
Page 87
Potential hazard improperly crossing hills or turning onhills. What can happen could cause loss of control or cause the atv to overturn. How to avoid the hazard never attempt to turn theatv around on any hill until you have mastered the turning technique as described in the owner manual on level gro...
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82 when crossing the side of a hill: always follow proper procedures as described in the owner’s manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the atv. User's manual.
Page 89
If your atv has stalled or stopped and you believe you can continue up the hill, restart carefully to make sure you do not lift the front wheels which could cause you to lose control. If you are unable to continue up the hill, dismount the atv on the uphill side. Physically turn the atv around and t...
Page 90
84 if you begin rolling backwards: keep weight uphill. 2wd: never apply the rear brake while rolling backwards. Apply the front brake. When fully stopped, apply the rear brake as well, and then lock the parking brake. 4wd: apply both front and rear brakes gradually. When fully stopped, lock the park...
Page 91
Riding downhill when riding your atv downhill, shift your weight as far to the rear and uphill side of the atv as possible. Move back on the seat and sit with your arms straight. Engine compression will do most of the braking for you. For maximum engine compression braking effect, change to 4wd befo...
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86 potential hazard what can happen how to avoid the hazard going down a hill improperly. Could cause loss of control or cause the atv to overturn. Always follow proper procedures for going down hills as described in this owner ’s manual. Note: a special technique is required when braking as you go ...
Page 93
Crossing a slope traversing a sloping surface on your atv re uires you to properly position your weight to maintain proper balance. Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface. Avoid slopes with slippery surfaces or rough terrain ...
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88 user's manual.
Page 95
Crossing through shallow water the atv can be used to cross slow moving,sha water of up to a maximum of 35 cm (14 inches) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset theatv....
Page 96
90 test your brakes after leaving the water. Do not continue to ride your atv without verifying that you have regained proper braking ability. After riding your atv in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case, the v-belt cooling duct c...
Page 97
① drive select lever box check hose. ① v-belt case drain plug. 91 ① v-belt cooling duct check hose (left front side of atv). Storage box check hose. ① user's manual.
Page 98
92 riding over rough terrain riding over rough terrain should be done with caution. Look out for obstacles which could cause damage to the atv or could lead to an upset or accident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the atv as loss of control and ...
Page 99
Sliding and skidding care should be used when riding on loose or slippery surfaces since the atv may slide. If unexpected and uncorrected, sliding could lead to anaccident. To reduce the tendency for the front wheels to slide in loose or slippery conditions, positioning your weight over the front wh...
Page 100
94 with practice, over a period of time, skill at controlled sliding can be developed. The terrain should be chosen carefully before attempting such maneuvers, since both stability and control are reduced. Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces su...
Page 101
This section is designed to be a reference guide only. Be sure to read each section on riding techniques completely. If your atv does no turn when you want it to: bring the atv to a stop and practice the turning maneuvers again. Be sure you are putting your weight on the footboard to the outside of ...
Page 102
96 if your atv is traversing a sloping surface: be sure to ride with your weight positioned towards the uphill side of theatv to maintain proper balance. If the atv starts to tip, steer down the hill ( if there are no obstacles in your way) to regain balance. If you discover that the atv is going to...
Page 103
97 periodic maintenance and adjustment potential hazard what can happen how to avoid the hazard periodic inspection, adjustment and lubrication will keep your machine in the safest and most efficient condition possible. Safety is an obligation of the machine owner. The most important points of machi...
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98 ① ② ③ owner ’s manual. Owner ’s tool kit. Low-pressure tire gauge. If you do not have a torque wrench available during a service operation requiring one, take your machine to a atv dealer to check the torque settings and adjust them as necessary. Note: potential hazard what can happen how to avoi...
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99 periodic maintenance/lubrication for atvs not equipped with an odometer or an hour meter, follow the maintenance intervals. For atvs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. However, keep in mind that if the atv isn’t used for a long period of...
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100 2 0 7 5 1 50 150 3 00 3 6 6 1 2 3 20 (200) 1,200 1,200 2,400 4,800 (750) (1,500) (1,500) (3,000) 1 replace.(warm engine before draining). Engine oil axle boots* engine oil filter cartridge replace. Engine oil strainer* clean. Final gear oil differential gear oil check for oil leakage. Replace ev...
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101 2 0 7 5 1 50 150 3 00 3 6 6 1 2 3 20 (200) 1,200 1,200 2,400 4,800 (750) (1,500) (1,500) (3,000) 1 item month routine whichever comes first every inital k m (m i) hours correct if necessary. Check all chassis fittings and fasteners. Fittings and fasteners* adjust headinght beams. Check operation...
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102 panel removal and installation the panel illustrated needs to be removed to perform some of the maintenance described in this chapter. Refer to this section each time the panel has to be removed or installed. Panel a ① panel a to remove remove the bolt, and then take the panel off. To install pl...
Page 109
103 engine oil and oil filter cartridge to check the engine oil level the engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter cartridge replaced at the intervals specified in the periodic maintenance and lubrication chart. 1. Place the atv on ...
Page 110
104 5. Insert the dipstick in the oil filler hole (without screwing it in), and then remove it again to check the oil level. The engine oil should be between the minimum and maximum level marks. Note: maximum level mark minimum level mark ① ② 7. Insert the dipstick into the oil filler hole, and then...
Page 111
105 to change the engine oil (with or without oil filter cartridge replacement). 1. Start the engine, warm it up for several minutes, and then turn it off. 2. Place an oil pan under the engine to collect the used oil, and then remove the engine oil filler cap. 3. Remove the engine oil drain bolt to ...
Page 112
106 an oil filter wrench is available at a nearby atvdealer. 5. Apply a light coat of engine oil to the o-ring of the new oil filter cartridge. Make sure the o-ring is seated properly. Note: note: ① o-ring ① oil filter wrench user's manual.
Page 113
107 6. Install the new oil filter cartridge with an oil filter wrench, and then tighten it to the specified torque with a torque wrench. Torque wrench ① 7. Install the engine oil drain bolt, and then tighten it to the specified torque. Tightening torque: engine oil drain bolt: 23 n·m (2.3 m·kgf, 16 ...
Page 114
108 in order to prevent clutch slipppage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “cd” or oils of a higher quality than specified. In addition, do not use oils labeled “energy conserving ii” or higher. Make s...
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109 3. If the oil is below the brim of the filler hole, · · add sufficient oil of the recommended type to raise it to the correct level. Be sure no foreign material enters the final gear case. 4. Install the oil filler bolt, and then tighten it tothe specified torque. Tightening torque: final gear o...
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110 4. Remove the oil filler bolt and the drain bolt to drain the oil. Final gear oil drain bolt 5. Install the drain bolt, and then tighten it to the specified torque. Tightening torque: final gear oil drain bolt: 23 nm (2.3 m·kgf, 16 ft·lbf) 6. Add the recommended final gear oil to the brim of the...
Page 117
111 differential gear oil replacement 1. Place the machine on a level surface. 2. Place a container under the differential gear case to catch the oil. 3. Remove the oil filler bolt and oil drain bolt to drain the oil. Differential gear oil filler bolt ① differential gear oil drain bolt 4. Install th...
Page 118
112 5. Fill the differential gear case with the specified amount of the recommended oil. Do not exceed the specified differential gear oil quantity when filling. Overfilling will cause the oil to seep out of the breather hose during and after riding. The differential gear oil level cannot bechecked....
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113 axle boots. Check the protective boots for holes or tears.If any damage is found, have them replaced by a atv dealer. Axle boot ( 2 each side) ① spark plug inspection removal. 1. Remove the spark plug cap. Spark plug cap ① user's manual.
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114 2. Use the spark plug wrench in the owner’s tool kit to remove the spark plug as shown. Spark plug wrench the spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate the condition of the engine. The ideal color on the white insulator aroun...
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115 2. Clean the surface of the spark plug gasket tightening torque: spark plug: 17.5 nm (1.75 m·kgf, 12.5 ft lbf) and its mating surface, and then wipe off any grime from the spark plug threads. 3. Install the spark plug and tighten it to the specified torque. · note: if a torque wrench is not avai...
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116 air filter element cleaning. There is a check hose at the bottom of the air filter case. If dust or water collects in this hose, empty the hose and clean the air filter element and air filter case. 1. Remove the seat. (see page 28 for seat 2. Remove the air filter case cover by unhook note: remo...
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117 4. Wash the element gently but thoroughly in solvent. 5. Wash the element gently but thoroughly in solvent. ① ② ③ air filter element frame air filter element lock plate potential hazard what can happen how to avoid the hazard using low flash point solvents or gasoline to clean the air filter ele...
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118 8. Apply atv foam air filter oil or other quality foam air filter oil to the air filter element. The air filter element should be wet but not dripping. 9. Pull the air filter element over its frame, and then install the lock plate. 10. Install the air filter element assembly. 11. Install the air...
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119 v-belt cooling duct check hose if dust or water collects in the v-belt cooling duct check hose, remove the hose and clean it. V-belt cooling duct check hose (left front side of atv) ① v-belt case drain plug after riding in water deep enough to allow it to enter the v-belt case, remove this plug ...
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120 spark arrester cleaning. Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Remove the bolts. 2. Remove the tailpipe by pulling it out of the muffler. 3. Tap the tailpipe lightly, and then use a wire brush to remove any carbon deposits from the spark arrester po...
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121 potential hazard what can happen how to avoid the hazard improper cleaning of the spark arrester.Hot exhaust system. Could injure the eyes. Could cause burns. Could cause carbon monoxide poisoning,possibly leading to death. Could start a fire. When cleaning the spark arrester: always let the exh...
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122 idle speed adjustment note: a diagnostic tachometer must be used for this procedure. 1. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min. The engine is warm when it quickly responds to the throttle. 2. Co...
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123 the select lever safety system cable streches with use , resulting in improper function. To prevent this, the cable must be adjusted regularly. This adjustment, however, should be left to a atv dealer. Select lever safety system cable adjustment throttle lever adjustment. Adjust the engine idlin...
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124 a throttle lever free play front brake pad check note: check the brake pads for damage and wear. If a brake pad thickness is less than 1 mm (0.04 in), have a atv dealer replace the pads as a set. The wheels need to be removed to check the brake pads. (see pages 134--135 for removal and installat...
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125 rear brake shoe inspection a wear indicator is provided on the rear brake.This indicator allows checking of brake shoe wear without disassembling the brake. Apply the rear brake and check the position of the indicator. If the indicator reaches the wear limit line, ask a atv dealer to replace sho...
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126 ① observe these precautions: when checking the brake fluid level, make sure the top of the brake fluid reservoir is level. Use only the designated quality brake fluid, otherwise, the rubber seals may deteriorate,causing leakage and poor brake performance. User's manual recommended brake fluid: d...
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127 brake fluid replacement complete fluid replacement should be done only by trained service personnel. Have a dealer replace the following components during periodic maintenance or when they are damaged or leaking. Replace the oil seals every two years. Replace the brake hoses every four years. Fr...
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128 potential hazard what can happen how to avoid the hazard operating with improperly serviced or adjusted brakes. You could lose braking ability, which could lead to an accident. After servicing: make sure the brakes operate smoothly and that the free play is correct. Make sure the brakes do not d...
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129 brake lever free play adjustment 1. Loosen the locknut and fully turn in the adjusting bolt at the brake lever. Locknut adjusting bolt ① ② user's manual.
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130 2. Turn in the adjusting nut on brake cable toprovide a gap of 0-1 mm (0-0.04 in) between the brake camshaft lever and the pin. Adjusting nut (brake lever cable) a gap ① 3. Turn the adjusting bolt at the brake lever until the free play at the brake lever pivot is 3-5mm (0.12-0.20 in). Locknut ad...
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131 potential hazard what can happen how to avoid the hazard operating with improperly serviced or adjusted brakes. You could lose braking ability, which could lead to an accident. After servicing: make sure the brakes operate smoothly and that the free play is correct. Make sure the brakes do not d...
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132 ① ② rear brake light switch adjusting nut cable inspection and lubrication potential hazard what can happen how to avoid the hazard damaged control cables. Corrosion can result when the outer covering of control cables becomes damaged. Cables can also become frayed or kinked. Operation of contro...
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133 lubricating the brake levers and brake pedal lubricate the pivoting parts. To access the brake pedal pivot, remove panel a.(see page 102 for panel removal and installation procedures). Recommended lubricant: lithium-soap-based grease (all-purpose grease) note: user's manual.
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134 wheel removal. 1. Loosen the wheel nuts. 2. Elevate the atv and place a suitable stand under the frame. 3. Remove the nuts from the wheel. 4. Remove the wheel. Nut ( 4) ① user's manual.
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135 wheel installation. 1. Install the wheel and the nuts. Tapered nuts are used for both the front and rear wheel. Install the nut with its tapered side towards the wheel. The arrow mark on the tire must point toward the rotating direction of the wheel. Tapered nut note: ① 2. Lower the atv so that ...
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136 battery potential hazard what can happen how to avoid the hazard this machine is equipped with a sealed-type battery. Therefore it is not necessary to check the electrolyte or add distilled water in the battery. If the battery seems to have discharged, consult a atv dealer. Do not try to remove ...
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137 battery maintenance 1. When the machine is not used for a month or longer, remove the battery and store it in a cool, dark place. Completely recharge the battery before reinstallation. A special battery charger (constant voltage/ampere or constant voltage) is required for recharging a sealed-typ...
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138 ① ② ③ main fuse spare main fuse fuse box specified fuses: main fuse: 30a headlight fuse: 15 a ignition fuse: 15 a four-wheel drive fuse: 3 a signaling system fuse: 10 a ① ② ③ ④ ⑤ headlight fuse ignition fuse four-wheel drive fuse signaling system fuse spare fuse ( 3) user's manual.
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139 potential hazard what can happen how to avoid the hazard using an improper fuse. An improper fuse can cause damage to the electrical system which could lead to a fire. Always use a fuse of the specified rating. Never use a material in place of the proper fuse. To prevent accidental short-circuit...
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140 2. Remove the headlight bulb holder by turning it counte rclockwise. 3. Remove the defective bulb by unhooking the headlight bulb holder tabs. ① headlight bulb holder ① headlight bulb holder tab ( 2) user's manual.
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141 potential hazard what can happen how to avoid the hazard a headlight bulb is hot when it is on and immediately after it is turned off. You can be burned, or a fire could start if the bulb touches something flammable. Wait for the bulb to cool before touching or removing it. 4. Insert a new headl...
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142 5. Install the headlight bulb holder by turning it clockwise. 6. Install the headlight bulb holder cover at the rear of the headlight. Headlight beam adjustment it is advisable to have a atv dealer make this adjustment. To raise the beam, turn the adjusting screw in direction a . To lower the be...
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143 tail/brake light bulb replacement if the tail/brake light bulb burns out, have a atv dealer replace it. Troubleshooting although atv machines receive a rigid inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems...
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144 potential hazard what can happen how to avoid the hazard checking the fuel system while smoking or near an open flame. Fuel can ignite or explode, causing severe injury or property damage. Do not smoke when checking the fuel system. Make sure there are no open flames or sparks in the area, inclu...
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145 1.Fuel turn the fuel cock lever to “off”. There is fuel. Remove the fuel hose from the fuel cock. Check the fuel flow. Nofuel. Fuel cock is clogged. Tuen the cock lever to “on”. Restart the engine. Check if there is fuel in the fueltank. Some fuel. Turn the fuel cock lever to “res”. Supply fuel....
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146 cleaning and storage a. Cleaning frequent, thorough cleaning of your machine will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the machine: a. Block off the end of the exhaust pipe to prevent water entr...
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147 6. Clean the seat 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 mar the paint or protective finish. When finished, start the ...
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148 b. Storage note: long term storage (60 days or more) of your machine will require some preventive proce dures to guard against deterioration. After thoroughly cleaning the machine, prepare for storage as follows: 1. Fill the fuel tank with fresh fuel and add the specified amount of atvfuel stabi...
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149 7. Remove the battery and charge it. Store it in a ° ° ° dry place and recharge it once a month. Do not store the battery in an excessively warm or cold place (less than 0 c(30 °f) or more than30 c (90 f)). Make any necessary repairs before storing the machine. Note: user's manual.
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150 specifications 76.8in 41.3in 42.9in 32.3in 48.2in 9.6 in 118.1in model rd400 di mensions: overall length overall width overall height seat height wheel base ground clearance minimum turing radius basic weight: with o il and full fuel tank 577.7 lbs oil cooling 4-stroke, sohc forward-inclined sin...
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151 wet, centrifugal automatic rd400 final gear case oil: type quantity: differen tial gear case oi l: type quantity: air filter : fuel: type fuel tank capacity fuel reser ve amount carburetor: type/quantity manufacturer spark plug: type/manufacturer spark plug gap clutch type: sae80 api gl-4 hypoid...
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152 transmission: primary reduction system secondary reduction system secondary reduction ratio transmission type operation forward gear reverse gear chassis: frame type caster angle trail tire: type size brake: front brake rear brake v-belt shaft dr ive 41/21 24/18 33/9 (9.545) v-belt automatic lef...
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153 rd400 model krypton bulb suspension: front suspension re ar suspension shock absorber: front shock absorber rear shock absorber wheel travel: front wheel travel rear wheel travel electrical: ignition system generator system battery type battery capacity head li ght type: double wishbone swingarm...
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154 rd400 model bulb voltage, wattage !A quantity: headlight tail/brake light neutral indicator light reverse indicator light oil temperature warning light four-wheel drive indicator light fuses: main fuse headlight fuse ignition fuse four-wheel drive fuse signaling system fuse 12 v, 30/30 w 2 12 v,...
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155 federal law prohibits the following acts or the causing thereof: (1) the removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to it...
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Maintenance records times date mileage items maintained dealer m d y m d y m d y m d y m d y m d y m d y m d y m d y m d y 1 2 3 4 5 6 7 8 9 10 500 1000 1500 3000 4500 6000 7500 9000 10500 12000 user's manual 156 oil oil/filter all nuts oil/filter oil/filter oil/filter oil/filter air filter oil/filt...
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Times date mileage(km) items maintained dealer m d y m d y m d y m d y m d y m d y m d y m d y m d y m d y 11 12 13 14 15 16 17 18 19 20 10000 oil / air cleaner spark plug / brake fluid user's manual 157 maintenance records.
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Warranty registration within 7 days dealer must register product warranty after a vehicle is sold. Qlink motor will keep record of all the registration forms for the warranty policy on all the units. No warranty claim will be processed unless the product warranty is registered with qlink motor. Vehi...
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Limited warranty selling a unit in the crate or without the proper set up will void all warranty coverage! All new qlink motor motorcycles and scooters are covered with 2 year limited warranty, and atvs are covered with 1 year limited warranty. Only qlink motor authorized dealers can submit warranty...
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Covered parts description covered period motor engine & transmission 2 years (unlimited miles) mechanical components carburetor 2 years (unlimited miles) electrical harness, cdi, inst. Cluster 2 years (unlimited miles) battery (when purchased with new unit) battery 30 days (unlimited miles) suspensi...
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Covered parts description covered period motor engine & transmission 1 year (unlimited miles) mechanical components carburetor 1 year (unlimited miles) electrical harness, cdi, inst. Cluster 1 year (unlimited miles) battery (when purchased with new unit) battery 30 days (unlimited miles) suspension ...
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Parts not covered under warranty: spark plugs throttle cable, idle cable brake line cable, clutch cable drive chains, drive belts air cleaner’s element & bracket rear brake shoes front / rear brake pads swing arm bushing light bulbs fuses rubber parts front / rear tires & tubes front / rear rims gea...