Catvic 350ATV Instruction Manual

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I M P O RTA N T MANUAL INFORMATION

FAILURE TO F O L L O W THE W ARNINGS CONTAINED IN THIS MANUAL CAN

RESULT IN SERIOUS INJURY OR DEATH.

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

NOTE:

The Safety Alert Symbol means ATTENTION! BECOME A L E RT!

YOUR SAFETY IS INVO LVED!

Failure to follow warning instructions could result in aevere

injury or death to the machine operator, a bystander or a person

inspecting or repairing the machine.

A CAUTION indicates special precautions that must be taken to

avoid damage to the machine

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

Table of Contents

Summary of Contents for Catvic 350ATV

Page 1 I M P O RTA N T MANUAL INFORMATION FAILURE TO F O L L O W THE W ARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME A L E RT! YOUR SAFETY IS INVO LVED! Failure to follow warning instructions could result in aevere...
Page 2 H a n d l e b a r s w i t c h e s ........1 7 T h r o t t l e l e v e r .
Page 3 D i ff e r e n t i a l g e a r o i l r e p l a c e m e n t ....11 0 B a t t e r y m a i n t e n a n c e .
Page 4 L O C ATION OF THE W ARNING A N D S P E C I F I C ATION LABELS 1111 1-111111...
Page 6: Safety Information
SAFETY INFORMATION AN AT V IS NOT A TO Y AND CAN BE HAZARDOUS TO OPERATE. An AT V h a n d l e s d i ff e r e n t l y from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, e v e n during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take p r o p e r p r e c a u t i o n s .
Page 7 Always follow proper procedures for climbing hills as described in this manual. Check the ter- rain carefully 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 h i l l a t h i g h s p e e d .
Page 8 When transport i n g t h e AT V in another vehicle, be sure it is kept upright and that the fuel cock is in the “OFF” posi- POTENTIAL HAZARD tion. Otherwise, fuel may leak out of the Improper handling of gasoline. carbure t o r o r f u e l t a n k .
Page 9: Identificat I O N
DESCRIPTION AND MACHIN IDENTIFICATION 1 2 . F r o n t s h o c k a b s o r b e r a s s e m b l y 1 . R e a r s h o c k a b s o r b e r a s s e m b l y s p r i n g p r e l o a d a d j u s t i n g r i n g s p r i n g p r e l o a d a d j u s t i n g r i n g 1 3 .
Page 10: Control Function
CONTROL FUNCTIONS Indicates a potential hazard that could re s u l t i n s e r i o u s i n j u ry o r d e a t h . Main switch Functions of the respective switch positions a r e a s f o l l o w s : The engine can be started only at this position 1.
Page 11 Oil temperature w a r n i n g l i g h t “ ” Speed demenstration When the oil temperature reaches a specified Speed demenstration is moving speed of the ATV. level, this light comes on to warn that the en- Total course demenstration gine oil temperature is too hot.
Page 12: Handlebar Switches
Handlebar switches c o r r e s p o n d i n g l y , a n d i n d i c a t o r l i g h t ” ” o n t h e m e t e r p l a t e a l s o w i l l l i g h t o r b e o u t c o r r e s p o n d i n g l y .
Page 13 POTENTIAL HAZARD Changing from 2WD to 4WD or from 4WD to 2WD while the AT V is moving. W H AT CAN HAPPEN The AT V handles diff e rently in 2WD than in 4WD in some circumstances. Changing from 2WD to 4WD or from t h e AT V to unexpectedly handle diff e r ently.
Page 14: Throttle Lever
Speed limiter The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed POTENTIAL HAZARD to the maximum. Turning in the adjusting screw Improper adjustment of the speed limit- limits the maximum engine power available and e r and thro t t l e .
Page 15 Parking brake ing the engine. This could of control or a Use the parking brake when you have to start c o l l i s i o n . the engine or park the machine, especially on The brake could overh e a t i f y o u r i d e t h e AT V a s l o p e .
Page 16 Fuel tank cap Remove the fuel tank cap by turning it coun- t e r c l o c k w i s e . POTENTIAL HAZARD Starting the engine without shifting into the neutral position. W H AT CAN HAPPEN The AT V could start to move unexpect- edly, which could cause an accident.
Page 17 S t a r t e r ( c h o k e ) “ ” Starting a cold engine requires a richer air- f u e l mixture. A s e p a r a t e s t a r t e r c i r c u i t s u p p l i e s t h i s m i x t u r e .
Page 18 Storage box NOTE: There is a check hose at the bottom of the Maximum load limit: 2 kg (4.4 lb) storage box. If any water collects in this hose, remove the hose, empty it, and then install it. To pro t e c t f rom damage, do not put metal products, like tools or sharply edged prod- ucts directly in the storage box.
Page 19 Rear shock absorber adjustment The spring preload can be adjusted to suit the r i d e r’ s w e i g h t a n d r i d i n g c o n d i t i o n s . A d j u s t t h e s p r i n g p r e l o a d a s f o l l o w s : To increase the spring preload, turn the ad- j u s t i n g r i n g i n d i r e c t i o n a .
Page 20 PRE-OPERATION CHECKS Before using this machine, check the following points: I T E M R O U T I N E 111111 PA G E 34-35 C h e c k o p e r a t i o n , f r e e p l a y , f l u i d l e v e l a n d f l u i d l e a k a g e . Front brake F i l l w i t h D O T 4 b r a k e f l u i d i f n e c e s s a r y .
Page 21 Brake fluid leakage (front brake) Check to see if any brake fluid is leaking out of t h e h o s e , j o i n t o r b r a k e f l u i d r e s e r v o i r o f t h e f r o n t POTENTIAL HAZARD b r a k e .
Page 22 Gasohol There are two types of gasohol; gasohol containing ethanol and that containing methanol. Gasohol POTENTIAL HAZARD containing ethanol can be used if ethanol content Improper c a re when re f u e l i n g . does not exceed 10%. Gasohol containing W H AT CAN HAPPEN methanol is not recommended by AT V because Fuel can spill, which can cause a fire and...
Page 23 D i ff e re n t i a l g e a r o i l Fittings and fasteners Make sure the diff e r e n t i a l g e a r o i l i s a t t h e Always check the tightness of chassis fittings and s p e c i f i e d l e v e l .
Page 24 How to measure t i re p ressure U s e t h e l o w - p r e s s u r e t i r e g a u g e . NOTE: T h e l o w - p r e s s u r e t i r e g a u g e i s i n c l u d e d a s standard equipment.
Page 25 Starting a cold engine O P E R ATION POTENTIAL HAZARD Indicates a potential hazard that could re s u l t i n Freezing control cables in cold weather . serious injury or death. W H AT CAN HAPPEN You could be unable to contro l t h e AT V, which could lead to an accident or colli- POTENTIAL HAZARD...
Page 26 NOTE: s t a r t s w i t c h , I f t h e e n g i n e f a i l s t o s t a r t , r e l e a s e t h e See the “Engine break-in”...
Page 27 S h i f t i n g : reverse 1. Bring the machine to a complete stop and r e t u r n t h e t h r o t t l e l e v e r t o t h e c l o s e d p o s i t i o n . 2 .
Page 28 Engine break-in E a c h f u l l t h r o t t l e a c c e l e r a t i o n s e q u e n c e should be T h e r e i s n e v e r a m o r e i m p o r t a n t p e r i o d i n t h e l i f e f o l l o w e d w i t h a s u b s t a n t i a l r e s t p e r i o d f o r t h e of your machine than the period between zero...
Page 29 Parking on a slope 1 . B r i n g t h e m a c h i n e t o a s t o p b y a p p l y i n g t h e b r a k e s .
Page 30 Loading weight. You Do not exceed the maximum tongue Carg o o r a t r a i l e r c a n c h a n g e t h e s t a b i l i t y a n d can measure tongue weight with a bathroom h a n d l i n g o f a n AT V.
Page 31 Indicates a potential hazard that could re s u l t i n s e r i o u s i n j u ry o r d e a t h .
Page 33 RIDE WITH CARE A N D G O O D H O W TO AVOID THE HAZARD J U D G E M E N T Beginning and inexperienced operators should complete the certified training course Get training if you are inexperienced. o ff e re d b y AT V.
Page 34 T h i s AT V i s d e s i g n e d t o c a r ry operator and cargo only - passengers pro h i b i t e d . POTENTIAL HAZARD Carrying a passenger o n t h i s AT V. W H AT CAN HAPPEN Gre a t l y reduces your ability to balance and contro l t h i s AT V.
Page 35 Do not operate after consuming alcohol or drugs. Operator’ s performance capability is reduced by POTENTIAL HAZARD t h e i n f l u e n c e o f a l c o h o l o r d r u g s . Operating this AT V a f t e r consuming alco- hol or drugs.
Page 36 Speed limiter F o r r i d e r s l e s s e x p e r i e n c e d w i t h t h i s m o d e l , t h i s Indicates a potential hazard that could re s u l t m o d e l i s e q u i p p e d w i t h a s p e e d l i m i t e r i n t h e in serious injury or death.
Page 37 During operation Always keep your feet on the footboards during operation. Otherwise your feet may contact the POTENTIAL HAZARD r e a r w h e e l s . Removing hands from handlebars or f e e t f rom footboards during operation. W H AT CAN HAPPEN Removing even one hand or f o o t c a n reduce your ability to contro l t h e AT V o r could...
Page 38 Modifications POTENTIAL HAZARD Operating this AT V with improper m o d i f i - c a t i o n s . W H AT CAN HAPPEN Improper i n s t a l l a t i o n o f a c c e s s o r i e s o r modification of this vehicle may cause changes in handling which in some situ- ations could lead to an accident.
Page 39 Know the terrain where you ride. Ride cautiously i n u n f a m i l i a r a r e a s . S t a y a l e r t f o r h o l e s , ro c k s , o r ro o t s i n t h e t e r r a i n , a n d o t he r hidden hazards which may cause the AT V t o u p s e t .
Page 40 When riding in an area where you might not W H AT CAN HAPPEN easily be seen, such as desert terrain, mount a You could be in a collision. You could c a u t i o n f l a g o n t h e AT V. DO NOT u s e t h e f l a g be injure d .
Page 41 TURNING YOUR AT V H O W TO AV OID THE HAZARD To achieve maximum traction while riding off - Always follow proper p rocedures for road, the two rear wheels are mounted solidly turning as described in this Owner’ s o n o n e a x l e a n d t u r n t o g e t h e r a t t h e s a m e s p e e d .
Page 42 CLIMBING UPHILL H O W TO AV OID THE HAZARD Use proper riding techniques to avoid vehicle Never operate the AT V on hills too steep overturns on hills. Be sure that you can maneuv- f o r t h e AT V o r f o r your a b i l i t i e s . P r a c t i c e e r y o u r AT V w e l l o n f l a t g r o u n d b e f o r e a t t e m p t - on smaller hills before attempting large i n g a n y i n c l i n e a n d t h e n p r a c t i c e r i d i n g f i r s t o n...
Page 43 I f y o u a r e c l i m b i n g a h i l l a n d y o u f i n d t h a t y o u have not properly judged your ability to make it t o t h e t o p , y o u s h o u l d t u r n t h e AT V around while POTENTIAL HAZARD you still have forward motion (provided you...
Page 44: Parking Brake
I f y o u r AT V h a s s t a l l e d o r s t o p p e d a n d y o u b e l i e v e y o u c a n c o n t i n u e u p t h e h i l l , r e s t a r t c a r e f u l l y t o make sure you do not lift the front wheels which POTENTIAL HAZARD...
Page 45 RIDING DOWNHILL When this AT V is in 4WD, all wheels (front and r e a r ) a r e i n t e r c o n n e c t e d b y t h e d r i v e t r a i n . This When riding your AT V d o w n h i l l , s h i f t y o u r w e i g h t means that applying either the front brake or the a s f a r t o t h e r e a r a n d u p h i l l s i d e o f t h e AT V a s...
Page 46 CROSSING A SLOPE Traversing a sloping surface on your AT V r e quires you to properly position your weight to POTENTIAL HAZARD maintain proper balance. Be sure that you have Improperly cro s s i n g h i l l s o r turning on l e a r n e d t h e b a s i c r i d i n g s k i l l s o n f l a t g r o u n d b e - h i l l s .
Page 47 CROSSING T H R O U G H S H A L L O W W AT E R The AT V can be used to cross slow moving,shall- ow water of up to a maximum of 35 cm (14 i n c h e s ) i n d e p t h .
Page 48 1 . V- b e l t c o o l i n g d u c t c h e c k h o s e ( l e f t f r o n t s i d e o f ATV) 1.
Page 49 SLIDING AND SKIDDING I f t h e r e a r w h e e l s o f y o u r AT V s t a r t t o s l i d e s i d e - w a y s , c o n t r o l c a n u s u a l l y b e r e g a i n e d ( i f t h e r e i s Care should be used when riding on loose or slip- r o o m t o d o s o ) b y s t e e r i n g i n t h e d i r e c t i o n o f t h e...
Page 50 W H AT TO DO IF . . . I f y o u r AT V s t a r t s t o s l i d e s i d e w a y s : S t e e r i n t h e d i r e c t i o n o f t h e s l i d e i f y o u h a v e This section is designed to be a reference guide the room.
Page 52 POTENTIAL HAZARD Operating this AT V with improper modi- f i c a t i o n s . W H AT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situ- ations could lead to an accident.
Page 53 EVERY INITA L month whichever 2,400 1,200 4,800 1,200 ITEM ROUTINE comes first (mi) (750) (1,500) (1,500) (3,000) (200) hours Engine oil Replace.(Warm engine before draining.) Engine oil filter cartridge Replace. Engine oil strainer* Clean. Final gear oil Check for oil leakage. Differential gear oil Replace every 12 months.
Page 54 Panel removal and installation Panel A The panel illustrated needs to be removed to To remove perform some of the maintenance described in R e m o v e t h e b o l t , a n d t h e n t a k e t h e p a n e l o f f . t h i s c h a p t e r .
Page 55 5 . I n s e r t t h e d i p s t i c k i n t h e o i l f i l l e r h o l e ( w i t h - 7 .
Page 56 1 . O i l f i l t e r w r e n c h 1 . O - r i n g NOTE: A n o i l f i l t e r w r e n c h i s a v a i l a b l e a t a n e a r b y AT V d e a l e r .
Page 57 F i n a l g e a r o i l Final gear oil measurement In order to prevent clutch slipppage (since 1 . P l a c e t h e m a c h i n e o n a l e v e l s u r f a c e . the engine oil also lubricates the clutch), 2 .
Page 58: Recommended Oil
4 . R e m o v e t h e o i l f i l l e r b o l t a n d t h e d r a i n b o l t t o Recommended oil: d r a i n t h e o i l .
Page 59 5 . F i l l t h e d i f f e r e n t i a l g e a r c a s e w i t h t h e s p e c i f i e d amount of the recommended oil.
Page 60 2. Use the spark plug wrench in the owner’ s I n s t e a d , t a k e t h e AT V t o a AT V d e a l e r. You should tool kit to remove the spark plug as shown.
Page 61 Air filter element cleaning NOTE: There is a check hose at the bottom of the air f i l t e r c a s e . I f d u s t o r w a t e r c o l l e c t s i n t h i s h o s e , empty the hose and clean the air filter element a n d a i r f i l t e r c a s e .
Page 62 8 . A p p l y a t v f o a m a i r f i l t e r o i l o r o t h e r q u a l i t y NOTE: The air filter element should be cleaned every f o a m a i r f i l t e r o i l t o t h e a i r f i l t e r e l e m e n t .
Page 63 Spark arrester cleaning Be sure the exhaust pipe and muffler are cool b e f o r e c l e a n i n g t h e s p a r k a r r e s t e r . 1 .
Page 64 Idle speed adjustment NOTE: A diagnostic tachometer must be used for this procedure. 1 . S t a r t t h e e n g i n e a n d w a r m i t u p f o r a f e w minutes at approximately 1,000 to 2,000 r/min.
Page 65 Front brake pad check Check the brake pads for damage and wear. If a brake pad thickness is less than 1 mm (0.04 in), h a v e a AT V d e a l e r r e p l a c e t h e p a d s a s a s e t . a .
Page 66 Observe these precautions: Brake fluid may deteriorate painted surface s o r s u r e When checking the brake fluid level, make p l a s t i c p a r t s . Always clean up spilled fluid t h e t o p o f t h e b r a k e f l u i d r e s e r v o i r i s l e v e l .
Page 67 Rear brake pedal and lever adjustment Brake pedal free play adjustment POTENTIAL HAZARD 1 . F u l l y l o o s e n t h e a d j u s t i n g n u t o n t h e b r a k e Operating with improperly serviced or l e v e r c a b l e a t t h e r e a r w h e e l .
Page 68 2 . T u r n i n t h e a d j u s t i n g n u t o n b r a k e c a b l e t o 3 . T u r n t h e a d j u s t i n g b o l t a t t h e b r a k e l e v e r u n t i l t h e f r e e p l a y a t t h e b r a k e l e v e r p i v o t i s 3 p r o v i d e a g a p o f 0 1 m m ( 0...
Page 69 Cable inspection and lubrication POTENTIAL HAZARD Damaged control cables. W H AT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged. Cables can also become frayed or kinked. Operation of controls 1 . R e a r b r a k e l i g h t s w i t c h 2 .
Page 70 Wheel removal 1. Loosen the wheel nuts. 2. Elevate the AT V and place a suitable s t a n d u n d e r t h e f r a m e . 3. Remove the nuts from the wheel. 4.
Page 71 Battery H O W TO AVOID THE HAZARD This machine is equipped with a sealed-type Avoid contact with skin, eyes or c l o t h - battery. Therefore it is not necessary to check i n g . Always shield eyes when working t h e e l e c t r o l y t e o r a d d d i s t i l l e d w a t e r i n t h e b a t - near batteries.
Page 72 1. Headlight fuse 1 . M a i n f u s e 2 . S p a r e m a i n f u s e 2 . I g n i t i o n f u s e 3.
Page 73 2. Remove the headlight bulb holder by turning it counterclockwise. 1 . H e a d l i g h t b u l b h o l d e r t a b ( ¡Á 1. Headlight bulb holder 3.
Page 74 5 . I n s t a l l t h e h e a d l i g h t b u l b h o l d e r b y t u r n i n g i t Headlight beam adjustment c l o c k w i s e .
Page 75 POTENTIAL HAZARD Checking the fuel system while smok- ing or near an open flame. W H AT CAN HAPPEN Fuel can ignite or explode, causing se- vere injury or property damage. H O W TO AVOID THE HAZARD Do not smoke when checking the fuel system.
Page 76 CLEANING AND STO R A G E Excessive water pressure may cause water A. CLEANING seepage and deterioration of wheel bearings, Frequent, thorough cleaning of your machine brakes, transmission seals and electrical de- w i l l n o t o n l y e n h a n c e i t s a p p e a r a n c e b u t w i l l vices.
Page 77 B. STORAGE 2. Remove the spark plug, pour about one table- Long term storage (60 days or more) of your spoon of SAE 10W30 or 20W40 motor oil in machine will require some preventive proce t h e s p a r k p l u g h o l e a n d r e i n s t a l l t h e s p a r k p l u g . dures to guard against deterioration.
Page 78: Specifications
SPECIFICATIONS Model 350AT V 400AT V Di mensions: 1,984mm (78.1in) 1,984mm (78.1in) Overall length 1,085mm (42.7in) 1,085mm (42.7in) Overall width 1,120mm (44.1in) 1,120mm (44.1in) Overall height Seat height 827mm (32.6in) 827mm (32.6in) Wheel base 1,233mm (48.5in) 1,233mm (48.5in) Ground clearance 245mm (9.65in) 245mm (9.65in) 3,000mm (118.1in)
Page 79 Model 350ATV/400AT V F i n a l g e a r c a s e o i l : Type SAE80 API GL-4 Hypoid gear oil Quantity: 0 . 2 3 L ( 0 . 2 0 I m p q t , 0 . 2 4 U S q t )
Page 80 Model 350ATV/400AT V Suspension: Front su spensi on Double wishbone Re ar suspension Swi ngar m (monocross) Shock absorber: C o i l s p r i n g / o i l d a m p e r Front shock absorber...
Page 81: Noise Regulation
NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: F e d e r a l l a w p r o h i b i t s t h e f o l l o w i n g a c t s o r t h e c a u s i n g t h e r e o f : ( 1 ) T h e r e m o v a l o r r e n d e r i n g i n o p e r a t i v e by any person other than for purposes of maintenance, repair, or replacement of any device or element o f d e s i g n i n c o r p o r a t e d i n t o a n y n e w v e h i c l e f o r t h e p u r p o s e o f n o i s e c o n t r o l p r i o r t o i t s s a l e o r d e l i v e r y t o t h e u l t i m a t e p u r c h a s e r o r w h i l e i t i s i n u s e o r ( 2 ) t h e u s e o f t h e v e h i c l e a f t e r s u c h d e v i c e o r e l e m e n t...

This manual is also suitable for:

400atv