Coleman POWERSPORTS HS360ATV Owner's Manual
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Coleman POWERSPORTS HS360ATV Owner's Manual

Coleman 400atv
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POWERSPORTS
POWERSPORTS
POWERSPORTS
HS360ATV
HS400ATV
No one under the
age of 16 should
operate this ATV
OWNER'S MANUAL
(888)-405-8725 Coleman Powersports
364 S. Smith Rd. Tempe, AZ. 85281
REV032514

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Summary of Contents for Coleman POWERSPORTS HS360ATV

  • Page 1 OWNER’S MANUAL POWERSPORTS POWERSPORTS POWERSPORTS HS360ATV HS400ATV No one under the age of 16 should operate this ATV (888)-405-8725 Coleman Powersports 364 S. Smith Rd. Tempe, AZ. 85281 REV032514...
  • Page 2 Owner’s Manual...
  • Page 3 Owner’s Manual INTRODUCTION 400ATV Congratulations on your purchase of the Coleman . This Owner’s / Operator’s manual will provide you information regarding safe operation, operational instructions, maintenance and care. Fully understanding this manual and following all of the instructions herein will provide the knowledge needed to have safe and enjoyable ATV operation.

  • Page 4: Important Manual Information

    Owner’s Manual IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS Particularly important information is distinguished in this manual by the INJURY OR DEATH. following notations: The Safety Alert Symbol means ATTENTION! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander or a person inspecting or repairing the machine.

  • Page 5: Important Notice

    Owner’s Manual IMPORTANT NOTICE Curve speed must be smaller than 30km/h (18.64 mph). This ATV is designed and manufactured for OFF - ROAD use only. It is illegal and unsafe to operate this ATV on any public street, road or highway. This ATV complies with all applicable OFF - ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture.

  • Page 6: Table Of Contents

    Owner’s Manual Coleman Limited Warranty Recoil Starter 4-12 Fuel Tank Cap 4-12 Location of the Warning and Seat 4-12 Specification Labels Storage Compartment 4-13 Front Carrier 4-14 Safety Information Rear Carrier 4-14 Front and Rear Shock Absorber Description and Vehicle...
  • Page 7 Owner’s Manual How to Measure Tire Pressure 5-10 Exhaust System 7-11 Tire Wear Limit 5-11 Be Careful Where You Ride 7-12 Turning Your ATV 7-18 Operation Climbing Uphill 7-20 Starting a Cold Engine Riding Downhill 7-25 Starting a Warming Engine Crossing a Slope 7-27 Warming Up...
  • Page 8 Owner’s Manual Front Brake Lever Free Play 8-34 Engine Oil and Oil Filter Adjusting the Rear Brake Lever 8-35 Cartridge 8-10 Adjusting the Brake Pedal 8-36 Final Gear Oil 8-15 Adjusting the Rear Brake Light Differential Gear Oil 8-17 Switch 8-36 Cooling System 8-19...
  • Page 9 Owner’s Manual Cleaning Storage Specifications 10-1 11-1 Fault code of Electronic Injection System USA EPA Emissions Limited Warranty 12-1...
  • Page 10 During this period of time, Coleman Powersports, will, at its option, either repair or replace any original Coleman part which is covered by this warranty and is proven to be defective in workmanship or material.
  • Page 11 Length of Implied Warranties Any implied warranties are limited to the duration set forth in this warranty. Coleman Powersports does not make any claim as to the merchantability or fitness for a particular purpose which would extend longer than the duration of this written warranty.

  • Page 12: Location Of The Warning And Specification Labels

    Location of the Warning and Safety Labels LOCATION OF THE WARNING AND SPECIFICATION LABELS...
  • Page 13 Location of the Warning and Safety Labels Read and understand all of the labels on your machine. They contain important ① 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 ②...
  • Page 14 Location of the Warning and Safety Labels ④ ⑤ ⑥...
  • Page 15 Location of the Warning and Safety Labels ⑦ ⑧...
  • Page 16 Location of the Warning and Safety Labels ⑨ ⑩ ⑪ ⑫...

  • Page 17: Safety Information

    Safety Information SAFETY INFORMATION AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper precautions.
  • Page 18 Safety Information 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, long-sleeved shirt or jacket, and long pants. Never consume alcohol or drugs before or while operating this ATV. ...
  • Page 19 Safety Information Always follow proper procedures for turning as described in this manual. Practice turning  at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed. Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on ...
  • Page 20 Safety Information steep hill if possible. Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid  stalling, use proper gear range and maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight uphill.
  • Page 21 Safety Information Always be sure there are no obstacles or people behind you when you operate in  reverse. When it is safe to proceed in reverse, go slowly.  Always use the size and type tires specified in this manual. ...
  • Page 22 Safety Information 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 ATV in an area with adequate ventilation.
  • Page 23 Safety Information 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.
  • Page 24 Description and Vehicle Identification 1. Rear shock absorber assembly spring pre load 12.Front shock absorber assembly spring adjusting ring preload adjusting ring 2. Spark arrester 13. V-belt cooling duct check hose 3. Storage box and tool kit 14. Oil filter cartridge 4.

  • Page 25: Identification Number Records

    Description and Vehicle Identification Identification number records Vehicle identification number Record the key identification number, vehicle The vehicle identification number is stamped identification number model label into the frame. information in the spaces provided for assistance when ordering spare parts from a dealer or for reference in case the vehicle is stolen.

  • Page 26: Control Functions

    Control Functions CONTROL FUNCTIONS The engine can be started only at this Main switch position and the headlights and taillight come Functions of the respective switch positions on when the light switch is on. are as follows: OFF: All electrical circuits are switched off. The key can be removed in this position.

  • Page 27: Indicator And Warning Lights

    Control Functions Indicator and Warning Lights Neutral Indicator Light “N” This indicator light comes on when the drive select lever is in the “N” position. Reverse Indicator Light “R” This indicator light comes on when the drive select lever is in the “R” reverse position. On-Command Four-Wheel-Drive Indicator The On-Command four-wheel-drive indicator “...
  • Page 28 Control Functions Coolant Temperature Warning indicator Trip meter “ ” Trip meter only records while the key is in the When the coolant temperature reaches a “ON” position. Once the key is turned off, specified level, this light comes on to warn the trip meter will re-set.
  • Page 29 Control Functions High beam indicator Speedometer The light being on means headlight is at high Indicates the moving speed of the ATV. beam mode Odometer Keeps track of total kilometers/miles driven on ATV. Metric system indicator light Distance and speed is measured in km/h, Miles system indicator light Distance and speed is measured in mph.

  • Page 30: Handlebar Switches

    Control Functions Handlebar switches beam and the taillight. Set the switch to “OFF” to turn off all the lights. CAUTION: Do not use the headlights with the engine turned off for more than thirty minutes. The battery may discharge to the point that the starter motor will not operate properly.

  • Page 31: Engine Stop Switch

    Control Functions On-Command four-wheel drive CAUTION: Switch “2WD/4WD” See starting instructions prior to starting the engine. (See pages 6-1—6-2 for details.) Engine stop switch “ / ” Make sure that the engine stop switch is set to “ ” before starting the engine. The engine stop switch controls ignition and can be used at all times to stop the engine, especially in an emergency.
  • Page 32 Control Functions To change from 2WD to 4WD stop the vehicle，and then set the switch to “4WD”. When the vehicle is in 4WD, the 4WD indicator light will come on in the WARNING multi-function display. POTENTIAL HAZARD To change from 4WD to 2WD Changing from 2WD to 4WD or from stop the vehicle, and then set the switch to “2WD”。the 4WD indicator “...

  • Page 33: Throttle Lever

    Control Functions Throttle lever Before starting the engine, check the throttle Once the engine is running, movement of the to be sure it is operating smoothly. Make sure throttle lever will increase the engine speed. it returns to the idle position as soon as the Regulate the speed of the machine by lever is released.

  • Page 34: Speed Limiter

    Control Functions Speed limiter The speed limiter keeps the throttle from fully WARNING opening, even when the throttle lever is pushed to the maximum. Turning in the POTENTIAL HAZARD adjusting screw limits the maximum engine Improper adjustment of the speed limiter and power available decreases...

  • Page 35: Front Brake Lever

    4-10 Control Functions to apply the rear brake. Front brake lever The front brake lever is located on the right handlebar. Pull it toward the handlebar to apply the front brake. 1. Brake pedal 1. Brake lever1 Brake pedal and rear brake lever The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left handlebar.

  • Page 36: Drive Select Lever

    Control Functions 4-11 Drive select lever Recoil starter Firmly grasp the handle and pull slightly until The drive select lever is used to shift your engagement can be felt. Then pull forcefully, machine into the forward, neutral and being careful not to pull the rope all the way reverse.

  • Page 37: Fuel Tank Cap

    4-12 Control Functions Fuel tank cap WARNING Remove the fuel tank cap by turning it POTENTIAL HAZARD counterclockwise. Starting the engine without shifting into the neutral position. WHAT CAN HAPPEN The ATV could start to move unexpectedly, which could cause an accident. HOW TO AVOID THE HAZARD Shift the drive select lever into the neutral position and apply the parking brake before...
  • Page 38 Control Functions 4-13 SEAT NOTE: Make sure that the seat is securely filed. To remove the seat, pull the seat lock lever upward and pull up the seat at the rear. 1.Projection（×2） 2.Seat holder（×2） 1.Seat 2.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.

  • Page 39: Storage Compartment

    4-14 Control Functions Storage compartment Storage compartment The storage compartment is located under Front carrier the seat. Front carrier Maximum load limit: When storing the owner’s manual or other 20kg (44lb) documents in the storage compartment, be sure to wrap them in a plastic bag so that they will not get wet.

  • Page 40: Rear Carrier

    Control Functions 4-15 Rear carrier Rear carrier Maximum load limit: 35kg (77lb) 1. Rear carrier...

  • Page 41: Adjustment

    4-16 Control Functions Front and rear shock absorber adjustment The spring preload can be adjusted to suit rider’s weight and riding conditions. NOTE: When adjusting the rear shock absorbers, the rear wheels need to be removed. (See pages 8-39 — 8-40 removal installation procedures.) 1.
  • Page 42 Control Functions 4-17 Standard position: B WARNING A- Minimum (soft) POTENTIAL HAZARD E- Maximum (hard) 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.

  • Page 43: Pre Operation Checks

    Pre Operation Checks Before using this machine, check the following points: ITEM ROUTINE PAGE Check operation, free play, fluid level and fluid leakage. 5-2—5-3, ● Brakes Fill with DOT 4 brake fluid if necessary. 8-34 ● Check for proper operation, condition and free play. Parking brake ●...

  • Page 44: Front And Rear Brakes

    Pre Operation Checks Front and rear brakes WARNING Brake levers and brake pedal Check that there is no free play in the front POTENTIAL HAZARD brake lever. If there is free play, have a Failure to inspect the ATV before operating. dealer adjust it.

  • Page 45: Brake Fluid Level

    Pre Operation Checks Brake fluid level out to make sure they are working properly. If Check the brake fluid level. Add fluid if the brakes do not provide proper braking performance, inspect the brake pads for necessary. (See pages 8-32—8-33.) wear.(See page 8-32—8-33) Recommended brake fluid: DOT 4 WARNING...

  • Page 46: Fuel

    Pre Operation Checks Fuel Your engine has been designed to use Make sure there is sufficient gasoline in the regular unleaded gasoline with a pump tank. octane number ([R+M]/2) of 86 or higher, or research octane number of 91 or higher. If knocking or pinging occurs, use a different Recommended fuel: brand of gasoline or premium unleaded fuel.
  • Page 47 Pre Operation Checks abnormally and exhaust to be deteriorated. WARNING POTENTIAL HAZARD Improper care when refueling. WHAT CAN HAPPEN Fuel can spill, which can cause a fire and severe injury. Fuel expands when it heats up. If the fuel tank is overfilled, fuel could spill out due to heat from the engine or the sun.

  • Page 48: Engine Oil

    Pre Operation Checks Engine Oil Recommended engine oil type and Make sure the engine oil is at the specified quantity: level. Add oil as necessary. See page 10-2 CAUTION: Final gear oil  In order to prevent clutch slippage (since Make sure the final gear oil is at the specified the engine oil also lubricates the clutch), level.

  • Page 49: Differential Gear Oil

    Pre Operation Checks Differential gear oil to bring the level up to maximum level mark. Make sure the differential gear oil is at the Change the coolant every two years. (See specified level. Add oil as necessary. (See pages 8-20—8-23 for details.) pages 8-17—...

  • Page 50: Fittings And Fasteners

    Pre Operation Checks Have a dealer repair as necessary for proper WARNING operation. POTENTIAL HAZARD Fittings and fasteners Removing the radiator cap when the engine Always check the tightness of chassis fittings and radiator are still hot. and fasteners before a ride. Take the WHAT CAN HAPPEN machine to a dealer or refer to the Service You could be burned by hot fluid and steam...

  • Page 51: Tires

    Pre Operation Checks Tires WARNING Check and adjust tire pressures when the tires are cold. POTENTIAL HAZARD Tire pressures must be equal on both sides. Operating this ATV with improper tires, or with 3. Tire pressure below the minimum specified improper or uneven tire pressure.

  • Page 52: How To Measure Tire Pressure

    Pre Operation Checks 5-10 How to measure tire pressure Use the low-pressure tire gauge. Recommended Minimum Maximum pressure NOTE: 10psi (70kpa 9 psi (63kpa, 11psi,(77kpa, Front (0.70kgf/ cm 0.64kgf/ cm 0.77kgf/ cm The low-pressure tire gauge is included as standard equipment.

  • Page 53: Tire Wear Limit

    5-11 Pre Operation Checks Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. a. Tire wear limit...

  • Page 54: Operation

    Operation Starting a cold engine WARNING WARNING POTENTIAL HAZARD POTENTIAL HAZARD Operating ATV without being familiar with all Freezing control cables in cold weather. WHAT CAN HAPPEN controls. WHAT CAN HAPPEN You could be unable to control the ATV, which Loss of control, which could cause an accident could lead to an accident or collision.
  • Page 55 Operation and warming up position. 5. Press the “Start” button, then the engine will Position 3: Cold engine start ambient turn over and should start. above 25°C(80°F) and warm engine NOTE: start position. ● When the drive select lever is in the neutral position, the neutral indicator light should AMBIENT TEMP./STARTER(CHOKE) POSITION come on.

  • Page 56: Warming Up

    Operation  If the engine fails to start, release the start CAUTION: switch, then push it again. Pause a few See the “Engine break-in” section prior to seconds before the next attempt. Each operating engine for the first time. cranking should be as short as possible to preserve battery energy.

  • Page 57: Drive Select Lever Operation And Reverse Driving

    Operation Drive select lever operation and reverse driving CAUTION: Before shifting, you must stop the ATV and return the throttle lever to the closed position, otherwise the transmission may be damaged. 1. Drive select lever Shifting: Neutral to Forward NOTE: 1.
  • Page 58 Operation from reverse without applying the rear brake. should be on. If the light does not come on, ask a dealer to inspect the electrical circuit. Due to the synchronizing mechanism in the 1. Bring the ATV to a complete stop and return engine, the light may not come on until the ATV the throttle lever to the closed position.
  • Page 59 Operation a proper break-in period. Careful treatment of a WARNING new engine and drive components will result in more efficient performance and longer life for POTENTIAL HAZARD these components. Perform the following Improperly operating in reverse. procedures carefully. WHAT CAN HAPPEN You could hit an obstacle or person behind you, CAUTION: resulting in serious injury.

  • Page 60: Engine Break-In

    Operation Engine Break-In engine by cruising at lower r/min so the engine can rid itself of the temporary build up of heat. There is never a more important period in the If any abnormality is noticed during this period, life of your vehicle than the period between zero consult a dealer.

  • Page 61: Accessories And Loading

    Operation Brake System Break-in considering an accessory or operating an ATV Apply only moderate braking force for the first which has accessories. 50 stops. Aggressive or overly forceful braking Choose only accessories designed for your ATV. when the brake system is new could damage brake pads and rotors.
  • Page 62 Operation accessories. The ATV may handle differently Pulling load (total weight of trailer and than it does without accessories. cargo): 550kgf (1,212lbf) Tongue weight (vertical weight on trailer Loading hitch point):30kgf (66lbf) Cargo or a trailer can change the stability and handling of an ATV.
  • Page 63 6-10 Operation Tie down cargo securely to the carriers. Make handling of the ATV. sure cargo in the trailer cannot move around. A WARNING shifting load can cause an accident. POTENTIAL HAZARD Make sure the load does not interfere with Overloading this ATV or carrying or towing cargo controls or your ability to see where you are improperly.

  • Page 64: Driving Your Vehicle

    Your Vehicle DRIVING YOUR VEHICLE begin to ride, be sure you have read this This ATV is mainly for utility use, but may Owner’s Manual completely and understand also be used for recreation. This section, the operation of the controls. Pay particular driving your ATV, provides general ATV riding attention to the safety information on pages instructions for recreational riding.
  • Page 65 Your Vehicle the machine’s handling and performance NO child under 16 years of age should operate this ATV characteristics. WARNING WARNING POTENTIAL HAZARD POTENTIAL HAZARD Operating this ATV without proper instruction. Failure to follow the age recommendations for WHAT CAN HAPPEN this ATV.
  • Page 66 Your Vehicle This ATV is designed to carry operator and cargo only - passengers prohibited. WARNING 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 harm and/or...

  • Page 67: Apparel

    Your Vehicle Apparel WARNING POTENTIAL HAZARD Operating this ATV 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.
  • Page 68 Your Vehicle Do not operate after consuming alcohol or drugs. HOW TO AVOID THE HAZARD Operator’s performance capability is reduced Always wear an approved motorcycle helmet by the influence of alcohol or drugs. that fits properly. You should also wear: eye protection (goggles or face shield) gloves...

  • Page 69: Judgment

    Your Vehicle proper care of the ATV. WARNING WARNING POTENTIAL HAZARD POTENTIAL HAZARD Operating this ATV after consuming alcohol or Failure to inspect the ATV before operating. drugs. Failure to properly maintain the ATV. WHAT CAN HAPPEN WHAT CAN HAPPEN Could seriously affect your judgment.
  • Page 70 Your Vehicle WARNING WARNING POTENTIAL HAZARD POTENTIAL HAZARD Operating this ATV at speeds too fast for your Operating this ATV with improper tires, or with skills or the conditions. improper or uneven tire pressure. WHAT CAN HAPPEN WHAT CAN HAPPEN Increases your chances of losing control of Use of improper tires on this ATV, or operation the ATV, which can result in an accident.

  • Page 71: Loading And Accessories

    Your Vehicle Speed limiter Loading and accessories For riders less experienced with this model, Use extra caution when riding the ATV with this model is equipped with a speed limiter in additional loads, such as accessories or the throttle lever housing. The speed limiter cargo.

  • Page 72: During Operation

    Your Vehicle During operation WARNING Always keep your feet on the footboards during operation. Otherwise your feet may POTENTIAL HAZARD contact the rear wheels. Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident.
  • Page 73 7-10 Your Vehicle Avoid wheelies and jumping. You may lose WARNING control of the ATV or overturn. WARNING POTENTIAL HAZARD POTENTIAL HAZARD Removing hands from handlebars or feet from footboards during operation. Attempting wheelies, jumps, and other stunts. WHAT CAN HAPPEN WHAT CAN HAPPEN Removing even one hand or foot can re-duce Increases...

  • Page 74: Modifications

    Your Vehicle 7-11 Modifications Exhaust system WARNING The exhaust system on the ATV is very hot during and following operation. To prevent POTENTIAL HAZARD burns, avoid touching the exhaust system. Operating this with improper modifications. Park the ATV in a place where pedestrians or WHAT CAN HAPPEN children are not likely to touch it.

  • Page 75: Be Careful Where You Ride

    7-12 Your Vehicle BE CAREFUL WHERE YOU RIDE HOW TO AVOID THE HAZARD This ATV is designed for off-road use only. Do not operate, idle, or park the ATV in dry Riding on paved surfaces can cause loss of grass or other dry ground cover. control.
  • Page 76 Your Vehicle 7-13 WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even dirt or gravel one. In many states it is illegal to operate ATVs on public streets, roads and highways.
  • Page 77 7-14 Your Vehicle Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV to upset. WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain.
  • Page 78 Your Vehicle 7-15 WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and...
  • Page 79 7-16 Your Vehicle When riding in an area where you might not WARNING easily be seen, such as desert terrain, mount a caution flag on the ATV. DO NOT use the POTENTIAL HAZARD flag pole bracket as a trailer hitch. Operating in areas where you might not be seen by other off-road vehicles.
  • Page 80 Your Vehicle 7-17 Do not ride in areas posted “no trespassing”. Always avoid riding on paved surfaces: the Do not ride on private property without ATV is designed for off-road use only, and getting permission. handling maneuvers are more difficult to perform on pavement.

  • Page 81: Turning Your Atv

    7-18 Your Vehicle accelerate. If the throttle is applied too special turning technique must be used to abruptly, the front wheels may lift off the allow the ATV to make turns quickly and ground resulting in a loss of directional easily.
  • Page 82 Your Vehicle 7-19 begin to turn the handlebars in the desired This procedure should be practiced at slow direction. As you do so, put your weight on speed many times in a large off-road area the footboard to the outside of the turn with no obstacles.

  • Page 83: Climbing Uphill

    7-20 Your Vehicle while negotiating a turn, lean more to the control. inside. It may also be necessary to gradually WARNING let off on the throttle and steer to the outside of the turn to avoid tipping over. Remember: POTENTIAL HAZARD Avoid higher speeds until you are thoroughly Operating on excessively steep hills.
  • Page 84 Your Vehicle 7-21 standing on the footboards and leaning forward over the handlebars. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill. WARNING POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn.
  • Page 85 7-22 Your Vehicle If you are climbing a hill and you find that you have not properly judged your ability to make on level ground. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if it to the top, you should turn the ATV around possible.
  • Page 86 Your Vehicle 7-23 If your ATV has stalled or stopped and you either the front or rear brake because the believe you can continue up the hill, restart wheels on the uphill side could come off the carefully to make sure you do not lift the front ground.
  • Page 87 7-24 Your Vehicle WARNING 4WD: Apply both front and rear brakes POTENTIAL HAZARD gradually. When fully stopped, lock the Stalling, rolling backwards or improperly parking brake. dismounting while climbing a hill. Dismount on uphill side or to a side if WHAT CAN HAPPEN pointed straight uphill.

  • Page 88: Riding Downhill

    Your Vehicle 7-25 RIDING DOWNHILL train. This means that applying either the When riding your ATV downhill, shift your front brake or the rear brake will brake all weight as far to the rear and uphill side of the wheels. When descending hills, using either ATV as possible.
  • Page 89 7-26 Your Vehicle WARNING cause the vehicle to lean sharply to one side. POTENTIAL HAZARD Go straight down the hill where possible. Going down a hill improperly. WHAT CAN HAPPEN 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.

  • Page 90: Crossing A Slope

    Your Vehicle 7-27 CROSSING A SLOPE balance, gradually steer again in the Traversing a sloping surface on your ATV direction you wish to travel. WARNING requires you to properly position your weight to maintain proper balance. Be sure that you POTENTIAL HAZARD have learned the basic riding skills on flat Improperly crossing hills or turning on hills.

  • Page 91: Crossing Through Shallow Water

    7-28 Your Vehicle CROSSING THROUGH SHALLOW WATER Always follow proper procedures as described The ATV can be used to cross slow moving, in the Owner’s Manual. shallow water of up to a maximum of 35 cm Avoid hills with excessively slippery or loose (14 inches) in depth.
  • Page 92 Your Vehicle 7-29 WARNING POTENTIAL HAZARD Operating this ATV through deep or fast flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident. HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing water or in water deeper than specified in your Owner’s Test your brakes after leaving the water.
  • Page 93 7-30 Your Vehicle the ATV in fresh water if it has been operated in salt water or muddy conditions. CAUTION: Air filter case check hose 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 check hose and the drive select lever box check hose.
  • Page 94 Your Vehicle 7-31 1. V-belt cooling duct check hose (Left side) 1. Storage box check hose 1. V-belt case drain plug 1. Drive select lever box check hose...

  • Page 95: Riding Over Rough Terrain

    7-32 Your Vehicle RIDING OVER ROUGH TERRAIN obstacles. Riding over rough terrain should be done with caution. Look out for obstacles which Never attempt to ride over large obstacles, could cause damage to the ATV or could lead such as large rocks or fallen trees. to an upset or accident.
  • Page 96 Your Vehicle 7-33 If the rear wheels of your ATV start to slide sideways, control can usually be regained (if With practice, over a period of time, skill at there is room to do so) by steering in the controlled sliding can be developed. The direction of the slide.
  • Page 97 7-34 Your Vehicle CONCLUSION: be avoided on extremely slippery surfaces such as ice, since all control may be lost. 1. If your ATV doesn’t turn when you want it WARNING ● Bring the ATV to a stop and practice the POTENTIAL HAZARD turning maneuvers again.
  • Page 98 Your Vehicle 7-35 ● Applying the brakes or accelerating is not ● If the ATV starts to tip, steer down the hill recommended until you have corrected the (if there are no obstacles in your way) to slide. regain balance. 4．If your ATV can’t make it up a hill you are ●...

  • Page 99: Periodic Maintenance And Adjustment

    Periodic Maintenance and Adjustment Owner’s manual and tool kit Periodic Maintenance And Adjustment You are recommended to put this owner’s Periodic inspection, adjustment manual in the vinyl bag and always carry it in lubrication will keep your machine in the the storage box.
  • Page 100 Periodic Maintenance and Adjustment completing your preventive WARNING maintenance and minor repairs. The tools provided in the Owner’s tool kit are sufficient POTENTIAL HAZARD for this purpose, except that a torque wrench Operating this with improper is also necessary to properly tighten nuts and modifications.

  • Page 101: Periodic Maintenance Chart For The Emission Control System

    Periodic Maintenance and Adjustment Periodic maintenance chart for the emission control system ● For ATV, which is not equipped with an odometer or an hour meter, follow the month maintenance intervals. ● For ATV, which is equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed.

  • Page 102: General Maintenance And Lubrication Chart

    Periodic Maintenance and Adjustment General maintenance and lubrication chart INITIAL EVERY Month Whichever ITEM ROUTINE Comes first 1,200 2,400 2,400 4,800 (Mi) (200) (750) (1,500) (1,500) (3,000) Hours Drive chain Check and adjust slack/alignment/clean/lube. ● ○ ○ ○ ○ ○ Check operation/fluid leakage/See NOTE.
  • Page 103 Periodic Maintenance and Adjustment INITIAL EVERY Month Whichever ITEM ROUTINE Comes first 1,200 2,400 2,400 4,800 (Mi) (200) (750) (1,500) (1,500) (3,000) Hours Fittings Check all chassis fittings and fasteners. ● ○ ○ ○ ○ ○ fastener Correct if necessary. ●...

  • Page 104: Panel Removal And Installation

    Periodic Maintenance and Adjustment Panel removal and installation Place the panel in the original position and The panel illustrated needs to be removed to install the bolt. perform some of the maintenance described in this chapter. CAUTION: Refer to this section each time the panel has to be removed or installed.

  • Page 105: Efi System

    Periodic Maintenance and Adjustment EFI system An EFI engine is completely different from an engine which uses a carburetor, it consist of an ECU, EFI cables, sensors, actuators and other advanced components. 1. ECU 1. Oxygen sensor assy 2. Oxygen sensor threaded sleeve 3.
  • Page 106 Periodic Maintenance and Adjustment 1. Idle speed stepper motor 2. Air damper degree sensor 3. Air damper Air damper For the purpose of adjustment of air intake volume. 1. Air damper 2. Intake temperature sensor/ pressure sensor 3. Seat, fuel injector 4.
  • Page 107 Periodic Maintenance and Adjustment Idle speed stepper motor Water temperature sensor To stabilize the idle speed For testing cooling water temperature, Fuel injector according to the temperature difference, Inject the fuel into the cylinder ECU will automatically revise fuel injection volume, to ensure the smooth operation of Intake temperature sensor the engine at all times.

  • Page 108: Efi System Inspection

    Periodic Maintenance and Adjustment 8-10 EFI System inspection Engine oil and oil filter cartridge If the EFI system has failure, the meter will The engine oil level should be checked display the appropriate failure code. before each ride. In addition, the oil must be can also use a special "EFI system failure changed and the oil filter cartridge replaced diagnostic apparatus"...
  • Page 109 8-11 Periodic Maintenance and Adjustment 1. Maximum level mark 2. Minimum level mark 1. Engine oil filler cap 6. If the engine oil is at or below the minimum 5. Insert the dipstick in the oil filler hole level mark, sufficient (without screwing it in), and then remove it recommended type to raise it to the correct...
  • Page 110 Periodic Maintenance and Adjustment 8-12 NOTE: To change the engine oil (with or without oil filter cartridge replacement) Skip steps 4--6 if the oil filter cartridge is not 1. Start the engine, warm it up for several being replaced. minutes, and then turn off. 2.
  • Page 111 8-13 Periodic Maintenance and Adjustment Make sure the O-ring is seated properly. 1. Oil filter wrench 1. O-ring 6. Install the new oil filter cartridge with an oil NOTE: filter wrench, and then tighten it to the An oil filter wrench is available at a nearby specified torque with a torque wrench.
  • Page 112 Periodic Maintenance and Adjustment 8-14 8. Add the specified amount of recommended engine oil, and then install the engine oil filler cap and tighten it. CAUTION: In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives.

  • Page 113: Final Gear Oil

    8-15 Periodic Maintenance and Adjustment oil level and correct it if necessary. Final gear oil 2. Place the ATV on a level surface. The final gear case must be checked for oil 3. Place a container under the final gear case leakage before each ride.
  • Page 114 Periodic Maintenance and Adjustment 8-16 6. Fill the final gear case with the specified amount of the recommended oil. Recommended oil: SAE 80 API GL-4 Hypoid gear oil Oil quantity: 0.4 L (0.42 qt) CAUTION: Be sure no foreign material enters the final gear case.

  • Page 115: Differential Gear Oil

    8-17 Periodic Maintenance and Adjustment 9. Install the final gear case cover bolts, and then tighten them to the specified torque. CAUTION: Differential gear oil Be sure no foreign material enters the Checking the differential gear oil 1. Place the ATV on a level surface. differential gear case.
  • Page 116 Periodic Maintenance and Adjustment 8-18 the oil. 5. Fill the differential gear case with the recommended oil. Recommended oil: SAE 80 API GL-4 Hypoid gear oil Oil quantity: 0.28 L (0.3 qt) CAUTION: Be sure no foreign material enters the differential gear case.

  • Page 117: Cooling System

    8-19 Periodic Maintenance and Adjustment Cooling system 1. Place the ATV on a level surface. 2. Check the coolant level in the coolant reservoir when the engine is cold, as the coolant level will vary with engine temperature. NOTE: The coolant should be between the minimum and maximum level marks.

  • Page 118: Changing The Coolant

    Periodic Maintenance and Adjustment 8-20 Changing the coolant CAUTION: WARNING Hard water or salt water is harmful to the POTENTIAL HAZARD Removing the radiator cap when the engine engine. You may use soft water if you cannot and radiator are still hot. get distilled water.
  • Page 119 8-21 Periodic Maintenance and Adjustment 1. Trough .3. Remove the radiator cap. 1. Coolant drain bolt 1. Radiator cap 4. Remove the coolant reservoir cap. 5. Disconnect the hose on the coolant reservoir side, and then drain the coolant from the coolant reservoir.
  • Page 120 Periodic Maintenance and Adjustment 8-22 10 Nm (1.0m·kgf, 7.2ft·lbf) 8. Install the coolant reservoir hose. 9. Pour the recommended coolant into the reservoir to the maximum level mark, and then install the reservoir cap. 10. Pour the recommended coolant into the radiator until it is full, and then install the radiator cap.

  • Page 121: Axle Boots

    8-23 Periodic Maintenance and Adjustment by a dealer. CAUTION: Hard water or salt water is harmful to the engine. You may use soft water if you cannot get distilled water. 11. Start the engine and let it idle for several minutes.
  • Page 122 Periodic Maintenance and Adjustment 8-24 1. Spark plug wrench 1. Spark plug cap 2. Use the spark plug wrench in the owner’s Inspection tool kit to remove the spark plug as shown. 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.
  • Page 123 8-25 Periodic Maintenance and Adjustment attempt to diagnose such problems yourself. grime from the threads. Instead, take the ATV to a dealer. You should 3. Install the spark plug and tighten it to the periodically re-move and inspect the spark specified torque.

  • Page 124: Air Filter Elements Cleaning

    Periodic Maintenance and Adjustment 8-26 are installing a spark plug, a good estimate of the correct torque is 1/4 to 1/2 turn past 1. Remove the seat. (See page 4-15 for seat finger tight. Have the spark plug tightened to removal and installation procedures.) the specified torque as soon as possible.
  • Page 125 8-27 Periodic Maintenance and Adjustment 5. Wash the air filter element gently but thoroughly in solvent. WARNING POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the air filter element. WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode.

  • Page 126: Spark Arrester Cleaning

    Periodic Maintenance and Adjustment 8-28 check the air inlet to the air filter case for 7. Inspect the air filter element and replace it obstructions. if damaged. Check the air filter element rubber joint to the 8. Apply roam air filter oil or other quality throttle and manifold fittings for an airtight foam air filter oil to the air filter element.
  • Page 127 8-29 Periodic Maintenance and Adjustment Be sure the exhaust pipe and muffler are 1. Bolt (×3) 2. Tailpipe 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 portion of the tailpipe and inside of the tailpipe housing.

  • Page 128: V-Belt Cooling Duct Check Hose

    Periodic Maintenance and Adjustment 8-30 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 1.

  • Page 129: Valve Clearance Adjustment

    8-31 Periodic Maintenance and Adjustment parts. Select lever safety system cable adjustment The select lever safety system cable stretches with use, resulting in improper function. To prevent this, the cable must be adjusted regularly. This adjustment, however, should be left to a dealer. Throttle lever adjustment 1.V-belt case drain plug NOTE:...

  • Page 130: Front Brake Pad Check

    Periodic Maintenance and Adjustment 8-32 a. Brake pad thickness 1. Locknut 2. Adjusting bolt NOTE: a. Throttle lever free play The wheels need to be removed to check the Front brake pad check brake pads. (See pages 8-39 — 8-40 for removal and installation procedures.) Check the brake pads for damage and wear.

  • Page 131: Checking The Brake Fluid Level

    8-33 Periodic Maintenance and Adjustment have a dealer replace the pads. system leakage. If the brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage. 1. Brake pad a. Brake pad thickness Checking the brake fluid level 1.

  • Page 132: Front Brake Lever Free Play

    Periodic Maintenance and Adjustment 8-34 causing leakage poor brake complete fluid replacement. performance. Have dealer replace following components during periodic maintenance or Recommended brake fluid: DOT 4 when they are damaged or leaking. Replace the oil seals every two years. Replace the brake hoses every four years.

  • Page 133: Adjusting The Rear Brake Lever

    8-35 Periodic Maintenance and Adjustment 1. Loosen the locknut. Front brake lever free play 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 smoothly ...

  • Page 134: Adjusting The Brake Pedal

    Periodic Maintenance and Adjustment 8-36 If correct free play cannot be obtained, ask a dealer to make that adjustment. NOTE: When adjusting the urgent brake lever free play: Be sure not to step on the brake pedal.  Make sure the brake pedal does not ...

  • Page 135: Switch

    8-37 Periodic Maintenance and Adjustment rear brake light switch in place. To make the system. Replacement of brake components requires brake light come on earlier, turn the adjusting professional knowledge. A dealer should nut in direction a. To make the brake light perform these procedures.

  • Page 136: Brake Pedal

    Periodic Maintenance and Adjustment 8-38 brake pedal WARNING Lubricate the pivoting parts. POTENTIAL HAZARD Damaged control cables. NOTE: WHAT CAN HAPPEN Corrosion can result when the outer covering To access the brake pedal pivot, remove of control cables becomes damaged. Cables panel A.

  • Page 137: Wheel Removal

    8-39 Periodic Maintenance and Adjustment 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. 1. Nut (×4) Wheel installation 1. Install the wheel and the nuts. NOTE: Wheel removal...

  • Page 138: Battery

    Periodic Maintenance and Adjustment 8-40 The arrow mark on the tire must point toward the rotating direction of the wheel. Tapered nuts are used for both the front and rear wheels. Install the nut with its tapered side towards the wheel. 1.

  • Page 139: Battery Maintenance

    8-41 Periodic Maintenance and Adjustment This machine is equipped with a sealed-type Always shield eyes when working near batteries. Keep out of reach of children. battery. Therefore it is not necessary to Antidote: check the electrolyte or add distilled water in EXTERNAL: Flush with water.

  • Page 140: Fuse Replacement

    Periodic Maintenance and Adjustment 8-42 CAUTION: special battery charger (constant voltage/ampere or constant voltage) is required for recharging a sealed-type battery. Using a conventional battery charger may shorten the battery life. 2. Always make sure the connections are correct when putting the battery back in the 1.

  • Page 141: Replacing A Headlight Bulb

    8-43 Periodic Maintenance and Adjustment If a headlight bulb burns out, replace it as Specified fuses: Main fuse: 30 A follows. Signaling system fuse 1. Remove the bulb holder cover at the rear Four-wheel drive fuse: of the headlight by pulling it off. Headlight fuse: Ignition fuse: WARNING...
  • Page 142 Periodic Maintenance and Adjustment 8-44 Headlight bulb holder tab (×2) 1. Headlight bulb holder 3. Remove the defective bulb by unhooking WARNING the headlight bulb holder tabs. 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.

  • Page 143: Headlight Beam Adjustment

    8-45 Periodic Maintenance and Adjustment 4. Insert a new headlight bulb into the bulb holder by pushing it in. CAUTION: Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass; the luminosity of the bulb and the bulb life will be adversely affected.

  • Page 144: Replacement

    Periodic Maintenance and Adjustment 8-46 CAUTION: 1. Headlight beam adjusting screw It is advisable to have a dealer make this adjustment. Tail/brake light bulb replacement If the tail/brake light bulb burns out, have a ATV dealer replace it. 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 ATV, which will help to solve these problems.
  • Page 145 8-47 Periodic Maintenance and Adjustment WARNING POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame. WHAT CAN HAPPEN Fuel can ignite or explode, causing severe injury or property damage. HOW TO AVOID THE HAZARD Do not smoke when checking the fuel system.
  • Page 146 Periodic Maintenance and Adjustment 8-48 oil leakage. 3.Change for new bottom protection plate. Table 2 Checks and Solutions to Common Problems in the Brake System . ： Problems Solutions 1.Check if the brake discs are deformed. Brake system is locked 2.Check if caliper hydraulic cylinders are stuck, or the fixing parts of calipers are deformed.
  • Page 147 8-49 Periodic Maintenance and Adjustment 5. Check if there is air in the brake lines. Remove air in lines if necessary 6. Check brake fluid level in master cylinder. The brake fluid level should be between the full and low line. Problems Solutions 1.Check if the brake discs are deformed.
  • Page 148 Periodic Maintenance and Adjustment 8-50 3.Check if spring force's deviation of shock absorbers in front left & right suspension are within specified limit. 4.Check if the damper rubber sleeves connecting front suspension rock and frame are damaged. Table 3: Check and Solution of Common Problems in Electrical System Problems Solutions 1.Check if the headlight switch functions well.
  • Page 149 8-51 Periodic Maintenance and Adjustment 3.Check if the wire is broken. 1.Check if the sensor is broken. 2.Check if the meter is broken. Meter displays abnormally. 3.Check if the surface of the speed sensor is contaminated with dust or other debris. Problems Solutions 1.Check if switch is broken.
  • Page 150 Periodic Maintenance and Adjustment 8-52 Table 4: Check and Solution of Common Problems in Running System Problems Solutions 1.Check the fix screws connecting the steering wheel to the steering stem. Make sure they are not loose or broken 2.Check the ball joints on the ends of the tie rods to find out Steering wheel is loose if they are loose or broken.
  • Page 151 8-53 Periodic Maintenance and Adjustment frame to find out if they are worn or missing. Problems Solutions 1. Check axle bearings in wheels for damage. 2.Check the swing arm bearing and connection. Make sure the bearing and connections are not loose or broken 3.Check the inner splines of rear wheel hubs and outer Rear wheels shake splines of rear wheel axles to find out if they are worn or...
  • Page 152 Periodic Maintenance and Adjustment 8-54 Problems Solutions 1.Check if overloaded. Shock absorbers become soft and 2.Check if springs are worn from extended use. uncomfortable while running. 3.Check shock absorber dampening force for failure 1.Check if the splines on the drive shafts are worn or broken. Reduction Gear box or 2.Check if the splines on the left &...
  • Page 153 8-55 Periodic Maintenance and Adjustment Table5: Check and Solution of Common Problems in Engine System Problems Solutions 1.Check battery for specified voltage. Idle speed is not stable 2.Check rectifier output for specified voltage. 1.Check to make sure both cylinders are working. Power performance 2.Check gasoline nozzle for blockage.
  • Page 154 Periodic Maintenance and Adjustment 8-56 Problems Solutions Engine is difficult to start 2.If the temperature is under -18℃,place the vehicle in at low temperature warmer place for start-up. 1.Check the radiator cooling fins for blockage. 2.Check speed sensor on radiator for damage and Check for fan failure.
  • Page 155 8-57 Periodic Maintenance and Adjustment Problems Solutions 6. Check if the air cleaner is blocked. Engine will not start 7. Check if the oil circuit is smooth. 8. Check if the exhaust system is blocked. 1.Check ECU for damage. 2.Check EFI cable for damage. Only one cylinder is working.
  • Page 156 Periodic Maintenance and Adjustment 8-58 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.

  • Page 157: Cleaning And Storage

    Cleaning and Storage CLEANING CAUTION: Frequent, thorough cleaning of your machine will not only enhance its appearance but also Excessive water pressure may cause water will improve its general performance and seepage and deterioration of wheel bearings, extend the useful life of many components. brakes, transmission seals and electrical 1.
  • Page 158 Cleaning and Storage chamois, clean towel or soft absorbent WARNING clothe. 6. Clean the seat with vinyl upholstery POTENTIAL HAZARD cleaner to keep the cover pliable and glossy. Operation with wet brakes after washing. 7. Automotive type wax may be applied to all WHAT CAN HAPPEN painted and chrome plated surfaces.
  • Page 159 Cleaning and Storage STORAGE 2. Remove the spark plug, pour about one tablespoon of SAE 10W40 or 20W40 motor Long-term storage (60 days or more) of your oil in the spark plug hole and reinstall the machine will require some preventive spark plug.
  • Page 160 Cleaning and Storage or more than 30 ℃ (86 °F). NOTE: Make any necessary repairs before storing the machine.
  • Page 161 10-1 Specification Model HS400ATV-2 Dimensions: Overall length 1,930mm (75.98in) Overall width 1,045mm (41.1in) Overall height 1,130mm (44.5in) Seat height 827mm (32.6in) Wheelbase 1,260mm (49.6in) Ground clearance 245mm (9.65in) Minimum turning radius 3,000mm (118.1in) Basic weight: With oil and full fuel tank 276 kg (607.9 lb) Engine: Engine type...

  • Page 162: Specifications

    Specifications 10-2 Model HS400ATV-2 Engine oil: Type API Service SE, SF, SG type or higher Recommended engine oil classification 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”...
  • Page 163 10-3 Specification Model HS400ATV-2 Final gear case oil: Type SAE80 API GL-4 Hypoid gear oil Quantity 0.23 L (0.2Imp qt, 0.24 US qt) Differential gear case oil: Type SAE80 API GL-4 Hypoid gear oil Quantity 0.35 L (0.31 Imp qt, 0.37 US qt) Radiator capacity (including all routes): 1.80 L (1.58 Imp qt, 1.90 US qt) Air filter:...
  • Page 164 Specifications 10-4 Model HS400ATV-2 Transmission: Primary reduction system V-belt Secondary reduction system Shaft drive Transmission type V-belt automatic Operation Left hand operation First gear 1.750 Primary ratio 0.690～2.297 Final ratio 3.142～10.459 Tire: Type Tubeless Size front 25 ×8-12 rear 25×10-12 Brake: Front brake Type...
  • Page 165 10-5 Specification Model HS400ATV-2 Suspension: Front suspension Double wishbone Rear suspension Swing arm (mono cross) Shock absorber: Front shock absorber Coil spring / oil damper Rear shock absorber Coil spring / oil damper Wheel travel: Front wheel travel 160 mm (6.30 in) 180 mm (7.09 in) Rear wheel travel...
  • Page 166 Specifications 10-6 Model HS400ATV-2 Electrical: Ignition system Generator system A.C. magneto Battery type YTX20L-BS or GSTX20L-BS Battery capacity 12 V, 21 Ah or 12V,18Ah Headlight type: Krypton bulb Bulb voltage, wattage ×quantity: 12 V, 30 W / 30 W×2 Head light Tail/brake light 12 V, 5 W / 21 W×1 Indicator light:...
  • Page 167 10-7 Specification Model HS400ATV-2 Fuses: Main fuse Headlight fuse Ignition fuse Auxiliary DC jack fuse Four-wheel-drive fuse Signaling system fuse Backup fuse...
  • Page 168 Fault Code of Electronic Injection System 11-1 Fault Code of Electronic Injection System DTC Description Related Calibration Number P0107 MAP Circuit Low Voltage or Open KsDGDM_MAP_ShortLow P0108 MAP Circuit High Voltage KsDGDM_MAP_ShortHigh P0112 IAT Circuit Low Voltage KsDGDM_IAT_ShortLow P0113 IAT Circuit High Voltage or Open KsDGDM_IAT_ShortHigh Coolant/Oil Temperature Sensor Circuit P0117...
  • Page 169 11-2 Fault Code of Electronic Injection System P0132 O2S 1 Circuit High Voltage KsDGDM_O2_1_ShortHigh P0031 O2S Heater Circuit High Voltage KsDGDM_O2_HeaterShortHigh P0032 O2S Heater Circuit Low Voltage KsDGDM_O2_HeaterShortLow P0201 Injector 1 Circuit Malfunction KsDGDM_INJ_CYL_A_Fault P0202 Injector 2 Circuit Malfunction KsDGDM_INJ_CYL_B_Fault P0230 FPR Coil Circuit Low Voltage or Open KsDGDM_FPP_CircuitShortLow...
  • Page 170 Fault Code of Electronic Injection System 11-3 P0563 System Voltage High KsDGDM_SysVoltHigh 1379 P0650 MIL Circuit Malfunction KsDGDM_MIL_Circuit 1616 P1693 Tachometer Circuit Low Voltage KsDGDM_TAC_Circuit_Low 1693 5779 P1694 Tachometer Circuit High Voltage KsDGDM_TAC_Circuit_High 1694 5780 P0137 O2S 2 Circuit Low Voltage KsDGDM_O2_2_ShortLow P0138 O2S 2 Circuit High Voltage...
  • Page 171 Hisun Motors Corp., U.S.A. 12-1 Emission Control System Warranty Statement YOUR WARRANTY RIGHTS AND OBLIGATIONS Hisun Motors Corp., U.S.A. (hereinafter “HISUN”) is pleased to explain the emission control system warranty on your Off-Road ATV or UTV vehicle. New off-road motor vehicles must be designed, built and equipped to meet California’s anti-smog standards.
  • Page 172 Hisun Motors Corp., U.S.A. 12-2 Emission Control System Warranty Statement As the vehicle owner, you should be aware that HISUN may deny your warranty coverage if your vehicle or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications. If you use your vehicle in any type of competitive event, this warranty is immediately and completely void.
  • Page 173 Hisun Motors Corp., U.S.A. 12-3 Emission Control System Warranty Statement (1) accident, (2) misuse, (3) repairs improperly performed or replacements improperly installed, unless performed by a HISUN authorized dealer, (4) use of improper replacement parts or accessories not conforming to specifications set forth by HISUN, which adversely affect performance and/or (5) Use in competitive racing or related events.
  • Page 174 Hisun Motors Corp., U.S.A. 12-4 Emission Control System Warranty Statement implied warranty lasts, so the above limitations may not apply to you. C. No dealer is authorized to modify this Limited Emission Control System Warranty issued by HISUN. IV. LEGAL RIGHTS. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
  • Page 175 POWERSPORTS (888)-405-8725 Coleman Powersports 364 S. Smith Rd. Tempe, AZ. 85281...

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