Coleman 400UTV-3 Owner's Manual
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Coleman 400UTV-3 Owner's Manual

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POWERSPORTS
POWERSPORTS
POWERSPORTS
400UTV-2
400UTV-2
400UTV-3
400UTV-3
No one under the
No one under the
age of 16 should
age of 16 should
operate this ATV
operate this ATV
OWNER'S MANUAL
(888)-405-8725 Coleman Powersports
364 S. Smith Rd. Tempe, AZ. 85281

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Do you have a question about the 400UTV-3 and is the answer not in the manual?

Questions and answers

Rickey A AULGUR
March 3, 2025

Engine stalling out

0
1 comments:
Mr. Anderson
March 3, 2025

The Coleman 400UTV-3 engine may be stalling due to several possible reasons:

1. Air Cleaner Blockage – A clogged air cleaner can restrict airflow, affecting engine performance. Cleaning the air cleaner core may help.
2. Muffler or Spark Arrestor Blockage – A blocked muffler or spark arrestor can cause power loss. Cleaning the spark arrestor may resolve the issue.
3. Air Leaks – Leaks in the air cleaner or admission line can impact fuel-air mixture, leading to stalling. Checking and sealing any leaks is recommended.
4. Low Octane Fuel – Using gasoline with a low octane rating may cause engine issues. Using the recommended fuel can prevent stalling.
5. Carburetor or Fuel Filter Blockage – A clogged carburetor or fuel filter can restrict fuel flow, leading to engine stalling. Cleaning or replacing these components can help.

Checking and addressing these issues can improve engine performance and prevent stalling.

This answer is automatically generated

0
Rickey A AULGUR
March 3, 2025

What oil to use in coleman 400

0
1 comments:
Mr. Anderson
March 3, 2025

The recommended engine oil for the Coleman 400UTV-3 should meet API service SG type or higher and JASO standard MA. It should not contain chemical additives, should not have a diesel specification of "CD" or higher quality than specified, and should not be labeled "ENERGY CONSERVING II" or higher.

This answer is automatically generated

0
david
April 21, 2025

need diagram showing how to replace shift Fork plate 2020 400 ut side by side

0
david
April 21, 2025

I need to know how to change the shift Fork plate 2020 400 ut side by side

0

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Summary of Contents for Coleman 400UTV-3

  • Page 1 OWNER’S MANUAL POWERSPORTS POWERSPORTS POWERSPORTS 400UTV-2 400UTV-2 400UTV-3 400UTV-3 No one under the No one under the age of 16 should age of 16 should operate this ATV operate this ATV (888)-405-8725 Coleman Powersports 364 S. Smith Rd. Tempe, AZ. 85281...
  • Page 2 Owner’s Manual...
  • Page 3 Owner,s Manual INTRODUCTION Congratulations on your purchase of the Coleman HS400UTV-2/HS400UTV-3. 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 UTV 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 INJURY Particularly important information is distinguished in this manual by the following OR DEATH. 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, bystander or a person inspecting or repairing the machine.

  • Page 5: Important Notice

    Owner,s Manual IMPORTANT NOTICE This UTV is designed and manufactured for OFF - ROAD use only. It is illegal and unsafe to operate this UTV on any public street, road or highway. This UTV 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 Powersports Limited On-Command Four-Wheel-Drive and Warranty Differential Gear Lock Switches 4-11 Throttle Pedal 4-15 Location of the Warning and Brake Pedal 4-16 Safety Labels Parking brake pedal 4-16 Drive Select Lever 4-17 Safety Information Fuel Tank Cap...
  • Page 7 Owner,s Manual Measuring Tire Pressure 5-13 Pre-Operation Checks Tire Wear Limit 5-14 Brakes Front and Rear Brakes Brake Pedal Operation Brake Fluid Level Starting a Cold Engine Brake Operation Starting a Warm Engine Fuel Jump Starting Engine Oil Warming Up Coolant Drive Select Lever Operation and Final Gear Oil...
  • Page 8 Owner,s Manual Braking ECU and EFI System inspection 8-11 Going Uphill Engine Oil and Oil Filter Cartridge 8-11 Going Downhill 7-11 To Check Engine Oil Level 8-11 Crossing Through Shallow Water To Change the Engine Oil (With or 7-12 Vehicle Immersion Without Oil Fliter Cartridge 7-14 Rear Axle Differential Lock...
  • Page 9 Owner,s Manual Cleaning the Air Filter Elements 8-26 Tail / Brake Light Bulb Cleaning the Spark Arrester 8-30 Replacement 8-51 Valve Clearance 8-32 Troubleshooting 8-52 Common Problems in Vehicle 8-53 Front Brake Pad Check 8-32 Rear Brake Pad Check 8-33 Cleaning and Storage Checking the Brake Fluid Level 8-34...
  • Page 10 Owner,s Manual...
  • Page 11 The Product is warranted to be free from manufacturing defects in material and workmanship for a period of 1 year from the date of purchase shown on the sales receipt. During this period of time Coleman Powersports will, at its option, either repair or replace any original Coleman Powersports part which is covered by this warranty and is proven to be defective in workmanship or material.
  • Page 12 How to get service under this warranty: To get warranty service, call Coleman Powersports at 888-405-8725 for the location of your local servicing retailer / dealer. Please do not return the product to the retailer where the product was purchased unless instructed to do so by Coleman Powersports.
  • Page 13 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 14: Location Of The Warning And Safety Labels

    Location of the Warning and Safety Labels...
  • Page 15 Location of the Warning and Safety Labels Read and understand all of the labels on your vehicle. They contain important information for safe and proper operation of your vehicle. Never remove any labels from your vehicle. If a label becomes difficult to read or comes off, a replacement label is available by contacting the dealer.
  • Page 16 Location of the Warning and Safety Labels...
  • Page 17 Location of the Warning and Safety Labels...
  • Page 18 Location of the Warning and Safety Labels...

  • Page 19: Safety Information

    Safety Information SAFETY INFORMATION This off-highway utility vehicle handles differently from other vehicles including cars and UTVs. SEVERE INJURY OR DEATH can result if you do not follow these instructions: Read this manual and all labels carefully and follow the operating procedures described. ●...
  • Page 20 Safety Information Never attempt jumps or other stunts. ● Always inspect your vehicle each time you use it to be sure it is in safe operating condition, Always ● follow the inspection and maintenance procedures and schedules described in this manual. Always keep hands, arms, feet, and legs inside the vehicle at all times during operation.
  • Page 21 Safety Information Never operate on hills that are slippery or ones where you will not be able to see far enough ahead of ● you. Never go over the top of a hill at speed if you cannot see what is on other side. Always follow proper procedures for going uphill.
  • Page 22 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 23 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 vehicle in an area with adequate ventilation.

  • Page 24: Description And Vehicle Identification

    Description and Vehicle Identification Headlights Spark arrester Front shock absorber assembly Rear shock absorber assembly Brake fluid reservoir CVT-belt case Driver seat Fuel tank cap Battery Passenger seat belt Fuses Right body protection plate Left body protection plate Spark plug Driver seat belt Oil filter cartridge Air filter element...
  • Page 25 Description and Vehicle Identification Parking brake lever Steering wheel Ignition switch Light switch On-Command four-wheel-drive and differential lock switches Multi-function display gauge Auxiliary DC jack Drive select lever Accelerator pedal Brake pedal Release parking handle NOTE: The vehicle you have purchased may differ slightly from those in the figures of this manual.

  • Page 26: Identification Number Records

    Description and Vehicle Identification Identification Number Records Vehicle Identification Number Record the Vehicle Identification Number and The Vehicle Identification Number is stamped model label information in spaces provided for into the frame. assistance when ordering spare parts from a service center or for reference in case the vehicle is stolen.

  • Page 27: Control Functions

    Control Functions CONTROL FUNCTIONS Functions of the respective switch positions are as follows: Ignition Switch All electrical circuits are supplied with power. Headlights and taillights come on when the light switch is turned to the “on” position. OFF: All electrical circuits are switched off. The key can be removed in this position.

  • Page 28: Indicator And Warning Lights

    Control Functions Indicator and Warning Lights CAUTION: Do not operate the electric starter ● continuously for more than 5 seconds at a time. Wait at least 5 seconds between each start attempt to prevent damage to the starter Do not turn the key to the “START” ●...
  • Page 29 Control Functions Forward indicator light Light “F” specified level, this light comes on to warn This indicator light comes on when the drive that the coolant temperature is too hot. If select lever is in the “F” position. the light comes on during operation, stop the engine as soon as it is safe to do so and Mechanical Parking Brake Indicator Light allow the engine to cool down for about 15...
  • Page 30 Control Functions system, so the driver can acknowledge fault Position light indicator The light being on means that the position of the EPS in time to take some measures to light fixed in the front headlight has been keep himself/herself safe. turned on.

  • Page 31: Speedometer Unit

    Control Functions Low Battery charge indicator If the fault indicator light for the EPS  Indicates a low charge on the battery. If light system is lit, the EPS system has found is illuminated, re-charge battery. If recharging some fault during the ECU self-checking the battery does not fix the issue, have a process.

  • Page 32: Odometer And Trip Meter Modes

    Control Functions 5. Tachometer On the display panel there are two large 6. Odometer/Trip meter A / Trip meter B/Clock/Hour button buttons, one located on the left side and one 7. Metric/mile button 8. Speedometer on the right side. Quickly pressing the button on the left side toggles the display from the odometer, to the trip meter, and the Speedometer unit functions:...
  • Page 33 Control Functions To change the display from miles per hour to Four-wheel drive indicator “ ” kilometers per hour press the right side There are two 4WD indicators on the display button on the display. This will also change panel. The left 4WD indicator has a blinking displayed mileage from...

  • Page 34: Fault Code Indicator

    Control Functions means the differential is not operational and should unlock the differential and press in is locked. When riding an UTV on muddy and the yellow and the gray buttons to the 2WD slippery roads or when climbing a steep hill, unlocked position.
  • Page 35 Control Functions If there are more than one fault code, they will be shown in rolling sequence. When fault codes are present, in order to see the time press the clock button, the time will be shown. Then after five seconds, the fault code returns again.

  • Page 36: Switches

    Control Functions 4-10 Set the switch to “ ”to turn on the high beam and the taillights. Set the switch to “OFF” to turn off all lights. Switches CAUTION: Do not use the headlights with the engine turned off for an extended period. The battery may discharge to the point that the starter motor will not operate properly.

  • Page 37: Differential Gear Lock Switches

    4-11 Control Functions differential gear lock switch “4WD”/ “LOCK”. Select the appropriate drive according to terrain and the conditions. On-Command Four-Wheel–Drive and  Two-wheel drive (”2WD”): Power is sup- Differential Gear Lock Switches plied to the rear wheels only.  Four-wheel drive (“4WD”): Power is supplied to the rear and front wheels.
  • Page 38 Control Functions 4-12 Always stop the vehicle before changing from 2WD to 4WD or from 2WD to 2WD–Differential UNLOCK. WARNING On-Command Four-Wheel-Drive Switch POTENTIAL HAZARD “2WD/4WD” Changing from 2WD to 4WD or from 2WD to 2WD-Differential UNLOCK, or vice-versa while the vehicle is moving. WHAT CAN HAPPEN The vehicle handles differently in 4WD than in 2WD and in 2WD- Differential...
  • Page 39 4-13 Control Functions To change from 2WD to 4WD Stop the vehicle, be sure the select lever is set to position ，and then set the switch to “4WD”. When the vehicle is in 4WD, the 4WD indicator will come on in the multi-function display.
  • Page 40 Control Functions 4-14 differential gear lock indicator light will come vehicle is in 4WD-LOCK, and allow extra on along with the differential gear lock time and distance for maneuvers. indicator in the multifunction meter unit display. To release the differential gear lock, NOTE: stop the vehicle and set the switch to “4WD”.

  • Page 41: Throttle Pedal

    4-15 Control Functions Before starting the engine, check the throttle Throttle Pedal pedal to be sure it is operating smoothly. Press the throttle pedal down to increase Make sure the throttle pedal fully returns to engine speed. Spring pressure returns the the idle position as soon as it is released.

  • Page 42: Brake Pedal

    Control Functions 4-16 Brake Pedal WARNING Press the brake pedal to slow or stop the POTENTIAL HAZARD vehicle. Malfunction of the throttle or pedal. WHAT CAN HAPPEN The accelerator pedal could be hard to operate, making it difficult to speed up or slow down when you need to.

  • Page 43: Drive Select Lever

    4-17 Control Functions vehicle from moving while parked. To set the parking brake, depress the parking brake pedal completely. To release the parking brake, Pull down the parking brake release handle and depress the parking pedal simultaneously; Release the handle and lift foot off the parking brake gradually.

  • Page 44: Fuel Tank Cap

    Control Functions 4-18 1. Drive select lever 1. Fuel tank cap Fuel Tank Cap Remove the fuel tank cap by turning it counter clockwise.

  • Page 45: Starter

    4-19 Control Functions Seats Starter (choke) “ ” Starting a cold engine requires a richer To remove the seat bench, pull front of seat air-fuel mixture. A separate choke cable upward, then slide seat forward. supplies this mixture. Move in direction to open choke Move in direction to turn close choke...

  • Page 46: Seat Belts

    Control Functions 4-20 Seat belts This vehicle is equipped with three-point seat WARNING belts for both the operator and passenger. POTENTIAL HAZARD Always wear seat belts while riding in the A loose seat. vehicle. WHAT CAN HAPPEN The operator could lose control or the operator and/or passenger could fall if the seat is loose during operation.
  • Page 47 4-21 Control Functions Proper use of the seat belts involves the following steps: 1. Hold the latch plate as you pull the belt across your lap and chest. Make sure the belt is not twisted and is not caught on any portion of the vehicle, your clothing, or any equipment you are carrying.
  • Page 48 Control Functions 4-22 5. To release the buckle, firmly press the release button. WARNING POTENTIAL HAZARD Not wearing the seat belt or wearing the seat belt improperly. WHAT CAN HAPPEN There is an increased risk of being killed or seriously injured in an accident. HOW TO AVOID THE HAZARD Always wear your seat belt when riding in 1.

  • Page 49: Glove Compartment

    4-23 Control Functions Glove Compartment CAUTION: To prevent damage to the glove compartment do not place metal products, like tools or sharp edged products directly in the glove compartment. If they must be stored, wrap them in appropriate cushion material. .

  • Page 50: Cargo Bed

    Control Functions 4-24 Cargo Bed Opening and Closing the Tailgate 1. Cargo bed 2. Tailgate 1. Tailgate 2. Latch (×2) To open Unhook latches, and lower the tailgate. To close Place tailgate in original up position, then hook latches.
  • Page 51 4-25 Control Functions Lifting and Lowering the Cargo Bed WARNING POTENTIAL HAZARD Pinch points. WHAT CAN HAPPEN You or someone else could be pinched between the cargo bed and the frame when the bed is being lowered. HOW TO AVOID THE HAZARD 1.
  • Page 52 Control Functions 4-26 WARNING WARNING POTENTIAL HAZARD POTENTIAL HAZARD Overloading the cargo bed. Carrying a passenger in the cargo bed. WHAT CAN HAPPEN WHAT CAN HAPPEN Could cause changes in vehicle handling The passenger could fall, be thrown out, which could lead to an accident. or be struck by objects in the cargo bed.

  • Page 53: Front And Rear Shock Adjustment

    4-27 Control Functions Front and Rear Shock Adjustment(Option 1) The spring preload can be adjusted to suit the operating conditions. You can reduce preload for a softer ride, or increase preload if the vehicle is bottoming out on rough terrain. CAUTION: Frequent or severe bottoming out can cause increased wear or damage to the vehicle.
  • Page 54 Control Functions 4-28 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 55 4-29 Control Functions Front and Rear Shock Adjustment(Option 2) WARNING ·Do not dispose of a damaged or worn out shock absorber assembly yourself. These shock absorber assemblies Take the shock absorber assembly to a contain highly pressurized nitrogen gas, HSUN dealer for any service. read understand following...
  • Page 56 Control Functions 4-30 Spring preload A special wrench can be obtained at a · 1. Loosen the locknut. HSUN dealer to make this adjustment. The spring preload setting is determined 2. Turn the spring preload adjusting nut in · by measuring distance A, shown in the direction ⓐ...
  • Page 57 4-31 Control Functions damping, and in direction F to decrease the Spring travel setting(Front) rebound damping force and thereby soften Minimum(soft): 375mm(14.76 in) the damping. Maximum(hard): 490mm(19.29 in) Spring travel setting(Rear) Minimum(soft): 402mm(15.83 in) Maximum(hard): 490mm(19.29 in) 3. Tighten the locknut. NOTE: Always tighten the locknut against the adjusting nut, and then tighten it to the...
  • Page 58 Control Functions 4-32 Compression damping force Turn compression damping force WARNING adjusting screw (use 2.5mm allen wrench) in ·Suspension components become hot direction ⓐ to increase the compression during operation. Never touch damping force and thereby harden the compression damping force adjusting damping, and in direction ⓑ...

  • Page 59: Trailer Hitch Bracket

    4-33 Control Functions Auxiliary DC Jack Trailer Hitch Bracket The auxiliary DC jack is located at the right This vehicle is equipped with a 1 1/4 inch side of the front panel. receiver bracket for a standard trailer hitch. The auxiliary DC jack can be used for Trailer towing equipment can be obtained at suitable work lights, radios, etc.
  • Page 60 Control Functions 4-34 1. Set the light switch to “OFF”. 2. Start the engine. (See pages 6-1-6-3.) Maximum rated capacity for the auxiliary 3. Open the auxiliary DC jack cap, and then DC jack: insert the accessory power plug into the DC 12V, 120W (10 A) jack.

  • Page 61: Pre-Operation Checks

    Pre Operation Checks Before using this vehicle, check the following items: ITEM ROUTINE PAGE Check operation, free play, fluid level and fluid leakage ● Brakes 5-2 - 5-3，8-33 - 8-36 Fill with DOT 4 brake fluid if necessary ● Check for proper operation, condition and free play Parking brake 6-9 - 6-10 ●...

  • Page 62: Brakes

    Pre Operation Checks Brakes WARNING Always check the brake pedal travel and the POTENTIAL HAZARD brake fluid reservoir level before each use of Failure to inspect the vehicle before the vehicle. When applied, the brake pedal operating. Failure to properly maintain the should feel firm.
  • Page 63 Pre Operation Checks 8-36.) fluid reservoir. Apply the brakes firmly for one Check operation of the brake pedal. Brake minute. If there is any leakage, have the vehicle pedal should move smoothly and should feel inspected by a service center. firm when the brakes are applied.

  • Page 64: Fuel

    Pre Operation Checks Fuel WARNING Make sure there is sufficient gasoline in the POTENTIAL HAZARD tank. Driving with improperly operating brakes. WHAT CAN HAPPEN Recommended fuel: You could lose braking ability, which could Unleaded gasoline only lead to an accident. Fuel tank capacity: HOW TO AVOID THE HAZARD 6.86 gal (26 L )
  • Page 65 Pre Operation Checks Your engine has been designed to use regular unleaded gasoline with a pump octane number WARNING ([R+M] /2) of 91 or higher, or research octane POTENTIAL HAZARD number of 91 or higher. If knocking or pinging Improper care when refueling. occurs, use a different brand of gasoline or WHAT CAN HAPPEN premium unleaded fuel.

  • Page 66: Engine Oil

    Pre Operation Checks Engine Oil Coolant Make sure the engine oil is at the specified level. Check the coolant level in the coolant reservoir when the engine is cold. (The coolant level will Add oil as necessary. (See pages 8-11—8-15.) vary with engine temperature.) The coolant level is satisfactory if it is between the minimum CAUTION:...

  • Page 67: Final Gear Oil

    Pre Operation Checks Final Gear Oil Coolant reservoir capacity Make sure the final gear oil is at the specified (up to the maximum level mark): level. Add oil as necessary. (See pages 8-18 - 0.627L(0.555lmp qt, 0.663US qt) 8-19 for details.) Recommended oil: WARNING SAE 80 API GL-4 Hypoid gear oil...

  • Page 68: Throttle Pedal

    Pre Operation Checks Recommended oil: WARNING SAE 80 API GL-5 Hypoid gear oil Failure to check or maintain proper operation of the throttle system can result in an accident Throttle Pedal leading to serious injuries or death. Check to see that the Throttle pedal operates Never start or operate this vehicle if it has a correctly.

  • Page 69: Throttle Freeplay

    Pre Operation Checks Throttle Freeplay Throttle Freeplay Adjustment If the throttle pedal has excessive play due to 1. Remove seat. cable stretch or mis-adjustment, it will cause a 2. Loosen the throttle cable column nut. Adjust the throttle cable so the throttle pedal delay in throttle response, especially at low freeplay is 1/16 to 1/8 inches (1.5-3mm).

  • Page 70: Steering Wheel Inspection

    Pre Operation Checks 5-10 Steering Wheel Inspection and release when the release button is pushed Check the steering wheel for specified freeplay firmly. Wash off any dirt or mud which could and smooth operation。 affect operation. Have a service center repair as 1.

  • Page 71: Tires

    5-11 Pre Operation Checks WARNING POTENTIAL HAZARD Operating this vehicle with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this vehicle, or operation of this vehicle with improper or uneven tire pressure, may cause loss of control, increasing your risk of accident.
  • Page 72 Pre Operation Checks 5-12 3. Tire pressure below the minimum specified could cause the tire to dislodge from the rim under severe riding conditions. The following are minimums: Front 9psi (63kpa 0.64kgf/cm Rear 9psi (63kpa 0.64kgf/cm 4. Use no more than the following Pressures when seating the tire beads.

  • Page 73: Specifications

    5-13 Pre Operation Checks How to measure tire pressure Use the tire pressure gauge. NOTE: The tire pressure gauge is included as standard equipment. Make two measurements of the tire pressure and use the second reading. Dust or dirt in the gauge could cause the first reading to be incorrect.

  • Page 74: Tire Wear Limit

    Pre Operation Checks 5-14 Tire Wear Limit When the tire groove decreases to 0.12 in (3 mm) due to wear, replace the tire a. Tire wear limit...

  • Page 75: Operation

    Operation Starting a cold engine WARNING WARNING POTENTIAL HAZARD POTENTIAL HAZARD Operating vehicle without being familiar Freezing control cables in cold weather. with all controls. WHAT CAN HAPPEN WHAT CAN HAPPEN You could be unable to control the Loss of control, which could cause an vehicle, which could lead to an accident accident or injury.
  • Page 76 Operation NOTE: When the drive select lever is in the Position③: Cold engine start ambient ● neutral position, the neutral indicator temperature above 86°F (30℃) light should come on. If the neutral indicator light does not come on, ask a service center to inspect the electric circuit.

  • Page 77: Starting A Warm Engine

    Operation Starting a warm engine NOTE: If the engine fails to start, release the key, To start a warm engine, refer to the“Starting and then try starting again. Wait a few a cold engine” section. The choke should not seconds before the next attempt. Each be used.
  • Page 78 Operation NOTE: Do not connect the negative lead of the jumper cable to the negative terminal of the battery in the vehicle. Be especially careful not to: ● touch the positive lead of the jumper cable to the negative lead. ●...

  • Page 79: Warming Up

    Operation 9. Close the hood. accelerator pedal. Warming up To get maximum engine life, always warm up Apply the brakes, and then shift by the engine before starting off. Never moving the drive select lever along the accelerate hard with a cold engine! To see shift guide.
  • Page 80 Operation 3. Release the brakes and press the accelerator pedal gradually. Shifting: Neutral to Reverse 1. Stop the vehicle. Keep your foot off the accelerator pedal. 2. Depress the brake pedal. 3. Shift from neutral to reverse or vice versa by moving the drive select lever along the shift guide.
  • Page 81 Operation Vehicle Break-in Period 4. Check behind for people or obstacles, and then release the brake pedal. The break-in period for your new UTV 5. Press the accelerator pedal gradually vehicle is the first 25 hours of operation, or and continue to watch to the rear while the time it takes to use the first three tanks backing.
  • Page 82 Operation Use of any engine oil not recommended maximum) full throttle operation under load ● in this manual will cause severe damage does not harm the engine. to the engine。 Each full throttle acceleration sequence should be followed with a substantial rest Engine Break-In period for the engine by cruising at lower rpm’s so the engine can rid itself of the...

  • Page 83: Parking

    Operation throttle at any time. period. After Break-In: The vehicle can now be operated normally. Parking When parking, stop the engine and shift the Brake System Break-in drive select lever into the neutral position. Apply only moderate braking force for the Apply the parking brake to help prevent the first 50 stops.

  • Page 84: Parking On A Slope

    Operation 6-10 Parking on a slope WARNING POTENTIAL HAZARD Parking on a hill or other incline. WHAT CAN HAPPEN The vehicle could roll out of control, increasing the chance of an accident. HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines. If 1.
  • Page 85 6-11 Operation Accessories can shift position or come off while you Accessories can affect the handing and are operating could affect your ability to control of your vehicle. Keep the following in control the vehicle. mind when considering an accessory or Do not mount an accessory where it ●...
  • Page 86 Operation 6-12 judgment when carrying cargo or towing a Do not exceed the maximum tongue ● trailer. Keep the following points in mind: weight. You can measure tongue weight Never exceed the weight limits shown. with a bathroom scale. Put the tongue of ●...
  • Page 87 6-13 Operation with controls or your ability to see where you are going. WARNING Drive slower than you would without a POTENTIAL HAZARD ● load. The more weight you carry, the Overloading this vehicle or carrying or slower you should go. Although towing cargo improperly.

  • Page 88: Your Vehicle

    Your Vehicle DRIVING YOUR VEHICLE WARNING GETTING TO KNOW YOUR VEHICLE POTENTIAL HAZARD This off-highway utility vehicle will handle Not wearing the seat belt. and maneuver differently form an ordinary Wearing the seat belt improperly. passenger car or other vehicle. WHAT CAN HAPPEN Before you begin to use your vehicle, be sure There is increased risk of being killed or...
  • Page 89 Your Vehicle The total weight of operator, passenger, WARNING accessories, cargo, trailer tongue weight, and the vehicle itself must not exceed POTENTIAL HAZARD 1880lbs (853Kg). Carrying a passenger in the cargo bed. WHAT CAN HAPPEN The passenger could fall or be struck by objects in the cargo bed.
  • Page 90 Your Vehicle The driver and passenger must always wear WARNING a seat belt, an approved motorcycle helmet, eye protection and protective clothing, POTENTIAL HAZARD Overloading this vehicle or carrying or including over-the-ankle boots, gloves, a towing cargo improperly. long-sleeved shirt or jacket, and long pants. WHAT CAN HAPPEN Keep hands and feet inside the vehicle at all Could cause changes in vehicle handling...
  • Page 91 Your Vehicle WARNING HOW TO AVOID THE HAZARD POTENTIAL HAZARD Always wear an approved motorcycle Operating this vehicle without wearing an helmet that fits properly. You should also approved motorcycle helmet, eye wear: protection, and protective clothing. Eye Protection WHAT CAN HAPPEN (Goggles or Face Shield) Operating without...

  • Page 92: Learning To Operate Your Vehicle

    Your Vehicle LEARNING TO OPERATE YOUR VEHICLE neutral, and follow the instructions on page You should become familiar with the 6-1 to start the engine. Once it has warmed performance characteristics of the vehicle in up and you have turned the choke off, you a large, flat area that is free of obstacles and are ready to begin driving your vehicle.

  • Page 93: Turning Your Vehicle

    Your Vehicle CAUTION: Position your hands on the steering wheel so Do not shift from low to high or vice versa that your thumbs and fingers do not wrap without coming to a complete stop and around the wheel. This is particularly waiting for the engine to return to normal idle important when driving in rough terrain.

  • Page 94: Operating Improperly In Reverse

    Your Vehicle Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Apply the throttle lightly. Never open the throttle suddenly. 3. Back up slowly. 4. Apply the brakes lightly for stopping. Operating Improperly in Reverse 5.

  • Page 95: Braking

    Your Vehicle BRAKING Braking ability is affected by the type of terrain. In most cases, gradually application of the brakes is more effective than abrupt braking, particularly on loose surfaces like gravel. Always allow for greater braking distance on rough, loose, or slippery surfaces.
  • Page 96 Your Vehicle some hills are too steep for you to climb. Choose carefully which hills you attempt to Maximum slope angle: 15° climb. Avoid hills with slippery surfaces or ones where you will not be able to see far enough ahead of you.
  • Page 97 7-10 Your Vehicle Before climbing the hill, first be sure you are WARNING operating in low range 4WD or, if necessary, POTENTIAL HAZARD with 4WD Diff. Lock. To climb a hill, you need Operating on excessively steep hills. traction, momentum, and steady throttle. WHAT CAN HAPPEN Travel fast enough to keep your momentum The vehicle can over turn more easily on...

  • Page 98: Going Downhill

    Your Vehicle 7-11 behind you and plan your descent. Shift the drive select lever in reverse so you can use WARNING the engine brake if necessary to slow your POTENTIAL HAZARD descent. Release the brake and begin to Going down a hill improperly. coast down the hill.

  • Page 99: Crossing Through Shallow Water

    7-12 Your Vehicle Before starting downhill, make sure the CROSSING THROUGH SHALLOW WATER vehicle is in low-range 4WD. On most slopes, If you must cross shallow, slow moving water this will let you use engine braking to help up to the depth of the vehicle’s floorboards, you go downhill slowly.
  • Page 100 Your Vehicle 7-13 CAUTION： WARNING After riding your vehicle in water, be sure to POTENTIAL HAZARD Operating this vehicle through deep or drain the trapped water by removing the fast-flowing water. check hose at the bottom of the air filter case, WHAT CAN HAPPEN the CVT-belt cooling duct check hose, the Loss of control, which could result in an...

  • Page 101: Vehicle Immersion

    7-14 Your Vehicle Vehicle Immersion 5. Dry the spark plugs and reinstall them, or CAUTION: install new plugs. 6. Attempt to start the engine. If necessary, If your vehicle becomes immersed, major repeat the drying procedure. engine damage can result if the machine is 7.
  • Page 102 Your Vehicle 7-15 CAUTION: Make sure all components that are washed and assembled are coated lightly with grease. 1．CVT Gear Box inspection hole Front Axle Differential Lock When driving on rugged or muddy roads, locking the differential case in the front axle gearbox will give you the best traction.

  • Page 103: Riding Over Rough Terrain

    7-16 Your Vehicle destroyed the soil structure. Even if you lock WARNING the differential, the front wheels may POTENTIAL HAZARD continue to slip and will not drive the vehicle Failure to use extra care when operating ahead. this vehicle on unfamiliar terrain. WHAT CAN HAPPEN Riding Over Rough Terrain You can come upon hidden rocks,...

  • Page 104: Riding In Brush Or Wooded Areas

    Your Vehicle 7-17 Riding in Brush or Wooded Areas When operating in areas with brush or trees, watch carefully on both sides and above the vehicle for obstacles such as branches that the vehicle might hit, causing an accident, or for brush that might enter the vehicle as you pass and strike the driver or passenger.

  • Page 105: Encountering Obstacles On The Trail

    7-18 Your Vehicle Encountering Obstacles on the Trail WARNING If you cannot go around an obstacle such as a fallen tree trunk or a ditch, stop the vehicle POTENTIAL HAZARD where it is safe to do so. Set the parking Improperly operating over obstacles.

  • Page 106: Periodic Maintenance And Adjustment

    Periodic Maintenance and Adjustment Periodic inspection, adjustment and NOTE: lubrication will keep your vehicle in the safest If you do not have a torque wrench available and most efficient condition possible. Safety during a service operation requiring one, take is an obligation of the vehicle owner. The your vehicle to a service center to check the most important points of vehicle inspection, torque settings and adjust them as...
  • Page 107 Periodic Maintenance and Adjustment WARNING WARNING POTENTIAL HAZARD POTENTIAL HAZARD Operating this vehicle with improper Servicing an engine while it is running. modifications. WHAT CAN HAPPEN WHAT CAN HAPPEN Moving parts can catch clothing or parts Improper installation of accessories or of the body, causing injury.

  • Page 108: Periodic Maintenance Chart For The Emission Control System

    Periodic Maintenance and Adjustment Periodic Maintenance Chart for the Emission Control System ● For vehicles not equipped with an odometer or hour meter, follow the month maintenance intervals. ● For vehicles equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. However, keep in mind that if the vehicle is not used for a long period, the month maintenance intervals should be followed.

  • Page 109: General Maintenance And Lubrication Chart

    Periodic Maintenance and Adjustment General Maintenance and Lubrication Chart INITIAL EVERY Month Whichever ITEM ROUTINE Miles 1,200 2,400 2,400 4,800 Comes first (Km) (200) (750) (1,500) (1,500) (3,000) hours (1,500) ● Check operation/brake pad wear/fluid leakage/see Rear Brake* NOTE page 5-2-5-3. ○...
  • Page 110 Periodic Maintenance and Adjustment INITIAL EVERY Month Whichever ITEM ROUTINE Miles 1,200 2,400 2,400 4,800 Comes first (Km) (1,500) (3,000) (200) (750) (1,500) hours (1,500) ● Check for cracks or damage. Engine Mount* ○ ○ ○ ● Check bolt tightness. ●...

  • Page 111: Hood

    Periodic Maintenance and Adjustment Hood To Open Unhook the hood latches, and then slowly tilt the hood up until it stops. 1. Hood 1. Latch (×2)

  • Page 112: To Close

    Periodic Maintenance and Adjustment To Close CAUTION: Lower the hood slowly to its original position,  Make sure that all cables and wires are in and then hook the hood latches. place when closing the hood. Secure projections on the underside of the ...

  • Page 113: Efi System

    Periodic Maintenance and Adjustment EFI system EFI engine was completely different from the engine which uses carburetor, it consist of ECU, EFI-cables, sensors, actuators and other advanced components. As the following pictures: 1. ECU 1. Oxygen sensor 2. Oxygen sensor threaded sleeve 3.
  • Page 114 Periodic Maintenance and Adjustment 1. High voltage wire 2.Ignition signal plug 3. Ignition coil 2. Water temperature sensor 1. Fuel injector 2. Bent pipe, inlet pipe 3. Intake air temperature sensor/ pressure sensor 4. Ducting dampers 1. Air damper degree sensor 2.
  • Page 115 8-10 Periodic Maintenance and Adjustment Air damper different negative pressure and opening of For the purpose of adjustment of air intake air damper. Adjust the engine fuel injection volume. volume can adjust the output power and output torque. Idle speed stepper motor Water temperature sensor To stabilize the idle speed For testing cooling water temperature,...

  • Page 116: Engine Oil And Oil Filter Cartridge

    Periodic Maintenance and Adjustment 8-11 achieve fuel-efficient emissions Engine Oil and Oil Filter Cartridge The engine oil level should be checked performance of the EFI engine. before each operation. In addition, the oil must be changed and the oil filter cartridge EFI System inspection replaced at the intervals specified in the If the EFI system has failure, the meter will...

  • Page 117: Replacement

    8-12 Periodic Maintenance and Adjustment NOTE: and then tighten the oil filler cap. The engine oil should be between the 8. Install the console. minimum and maximum level marks. To Change the Engine Oil (With or Without Oil Filter Cartridge Replacement) 1.
  • Page 118 Periodic Maintenance and Adjustment 8-13 1. Engine oil drain bolt 1. Oil filter cartridge 2. Oil filter bolt NOTE: NOTE: Skip steps 4-6 if the oil filter cartridge is not An oil filter wrench is available at a nearby being replaced. service center.
  • Page 119 8-14 Periodic Maintenance and Adjustment 1. Oil filler cartridge 2. Torque bolt O-ring 7. Install the engine oil drain bolt, and then 6. Install the new oil filter cartridge with an tighten it to the specified torque. oil filter wrench, and then tighten it to the Tightening torque: specified torque with a torque wrench.

  • Page 120: Checking The Final Gear Oil Level

    Periodic Maintenance and Adjustment 8-15 9. Start the engine, and then let it idle for Recommended engine oil: several minutes while checking it for oil See page 10-2. leakage. If oil is leaking, immediately turn Oil quantity: the engine off and check for the cause. Without oil filter cartridge replacement: 10.

  • Page 121: Changing The Final Gear Oil

    8-16 Periodic Maintenance and Adjustment CAUTION: Be sure no foreign material enters the final gear case. 4. Install the oil filler bolt, and then tighten it to the specified torque. Tightening torque: 1. Speed meter sensor 2. Final gear oil Final gear oil filler bolt: 3.
  • Page 122 Periodic Maintenance and Adjustment 8-17 the brim of the filler hole. Recommended oil: SAE 80 API GL-4Hypoid gear oil Oil quantity: 0.42 qt (0.4 L) CAUTION: 1. Final gear oil drain bolt Be sure no foreign material enters the final 4.

  • Page 123: Differential Gear Oil

    8-18 Periodic Maintenance and Adjustment Tightening torque: Final gear oil filler bolt: 16.3 ft·lbs (23 Nm, 2.3 m·kgf) 7. Check for oil leakage. If oil leakage is found, check for the cause. Differential Gear Oil Checking the Differential Gear Oil Level 1.

  • Page 124: Changing The Differential Gear Oil

    Periodic Maintenance and Adjustment 8-19 2. Install the differential gear oil filler bolt, and then tighten it to the specified torque. Tightening torque: Differential gear oil filler bolt: 16.3 ft·lbs (23Nm, 2.3 m·kgf) Changing the Differential Gear Oil 1. Place the vehicle on a level surface. 2.

  • Page 125: Oil Cooler

    8-20 Periodic Maintenance and Adjustment and then tighten it to the specified torque. Tightening torque: Tightening torque: Differential gear oil drain bolt: Differential gear oil filler bolt: 16.3 ft·lbs (23Nm, 2.3m·kgf) 16.3 ft·lbs (23Nm, 2.3m·kgf) 7. Check for oil leakage. If oil leakage is found, check for the cause.

  • Page 126: Coolant

    Periodic Maintenance and Adjustment 8-21 Coolant Before each use of the UTV, check and The coolant level should be checked before remove the sand, leaves and other foreign each ride. objects from the gap between the protection net and oil cooler. Then wash the sand from Checking the Coolant Level the air flowing gap in the oil cooler, ensure 1.

  • Page 127: Changing The Coolant

    8-22 Periodic Maintenance and Adjustment Coolant reservoir capacity (up to the maximum level mark): 0.663 qt (0.627L) CAUTION: Mix anti freeze with distilled water only. However, if distilled water is not available, soft water can be used for refilling. Changing the Coolant Coolant reservoir cap The coolant must be changed by a service Maximum level mark...

  • Page 128: Axle Boots

    Periodic Maintenance and Adjustment 8-23 Axle Boots Total amount: Check the protective boots for holes or tears. 1.40 qt (1.32L) If any damage is found, have them replaced Coolant reservoir capacity by a service center. (up to the maximum level mark): 0.65 qt (0.627 L) NOTE: Adding water instead of coolant lowers...

  • Page 129: Spark Plug Inspection

    8-24 Periodic Maintenance and Adjustment Spark plug cap 1. Rear axle boot (×2 each side) Spark Plug Inspection Removal Remove hood (See pages 8-6) 2. Remove the spark plug cap. 3. Use the spark plug wrench in the tool kit to remove the spark plug as shown.

  • Page 130: Inspection

    Periodic Maintenance and Adjustment 8-25 Inspection The spark plug is an important engine Specified spark plug: component and is easy to inspect. The DR8EA (NGK) condition of the spark plug can indicate the condition of the engine. Installation The ideal color of the porcelain insulator 1.
  • Page 131 8-26 Periodic Maintenance and Adjustment NOTE: If a torque wrench is not available when you Spark plug gap: are installing the spark plug, a good estimate 0.023-0.027 in (0.6-0.7mm) of the correct torque is 1/4 to 1/2 turn past finger tight. Have the spark plug tightened to 2.
  • Page 132 Periodic Maintenance and Adjustment 8-27 then remove the air cleaner. 1. Holder (×3) 2. Air filter case cover Air filter check hose 1. Remove the seats. (See pages 4-19 - 4-20 for seat removal and installation 4. Remove the air filter element. procedure.) 5.
  • Page 133 8-28 Periodic Maintenance and Adjustment 3. Element retaining plate 6. Wash the sponge material gently but thoroughly in solvent. WARNING POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the sponge material. 1. Air filter element WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode.
  • Page 134 Periodic Maintenance and Adjustment 8-29 CAUTION: Do not twist the sponge material when squeezing it. 8. Inspect the sponge material and replace it if damaged. 9. Thoroughly apply foam air filter oil or other quality liquid foam air filter oil (not spray type) to the sponge material.

  • Page 135: Cleaning The Spark Arrester

    8-30 Periodic Maintenance and Adjustment air filter element maintenance is performed, Cleaning the Spark Arrester check the air inlet to the air filter case for Be sure the exhaust pipe and muffler are obstructions. Check the air filter element cool before cleaning the spark arrester. rubber joint to the throttle valve and manifold 1.
  • Page 136 Periodic Maintenance and Adjustment 8-31 tailpipe and inside of the tailpipe housing. Tightening torque: Tailpipe bolt: 8.5 ft·lbs (12 Nm, 1.2 m·kgf) WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester. Hot exhaust system. WHAT CAN HAPPEN 1. Tailpipe 2. Spark arrester Could injure the eyes.

  • Page 137: Valve Clearance

    8-32 Periodic Maintenance and Adjustment disappeared, have a service center replace Do not start the engine when cleaning the exhaust system. the brake pads as a set. Valve Clearance The correct valve clearance changes with use, resulting in improper fuel-air supply or engine noise.

  • Page 138: Rear Brake Pad Check

    Periodic Maintenance and Adjustment 8-33 Rear brake pad check Each brake pad is provided with wear indicator grooves, which allow you to check the brake pad wear without having to disassemble the brake system. To check the brake pad wear, check the wear indicator grooves.
  • Page 139 8-34 Periodic Maintenance and Adjustment Checking the Brake Fluid Level Insufficient brake fluid may let air enter the brake system, possibly causing the brakes to become ineffective. Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary.

  • Page 140: Checking The Brake Pedal

    Periodic Maintenance and Adjustment 8-35 when they are damaged or leaking. Recommended brake fluid: DOT 4  Replace the oil seals every two years.  Refill with the same type of brake fluid.  Replace the brake hoses every four Mixing fluids may result a harmful years.
  • Page 141 8-36 Periodic Maintenance and Adjustment 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 Brake pedal and that the brake pedal position is correct.

  • Page 142: Brake Light Switch Adjustment

    Periodic Maintenance and Adjustment 8-37 Brake Light Switch Adjustment The brake light switch, which is activated by the brake pedal, is properly adjusted when the brake light comes on just before braking takes effect. If necessary, adjust the brake light switch as follows. 1.

  • Page 143: Brake Pedal And Accelerator Pedal Lubrication

    8-38 Periodic Maintenance and Adjustment Cable Inspection and Lubrication Lubricate the inner cables and the cable ends. If the cables do not operate smoothly, WARNING ask a service center to replace them. POTENTIAL HAZARD Damaged control cables. Recommended lubricant: WHAT CAN HAPPEN Engine oil：see page 10-2 Corrosion can result when the outer covering of control cables becomes...
  • Page 144 Periodic Maintenance and Adjustment 8-39 Recommended lubricant: Rear Knuckle Upper and Lower Pivot Lithium-based grease Lubrication Lubricate the knuckle upper and lower pivots with a grease gun.

  • Page 145: Steering Shaft Lubrication

    8-40 Periodic Maintenance and Adjustment Steering Shaft Lubrication Lubricate the pivot points. Lower universal joint, steering transmission shaft Recommended lubricant: Lithium-based grease (all-purpose grease) Upper universal joint, steering transmission shaft...
  • Page 146 Periodic Maintenance and Adjustment 8-41 Front balance rod 1. Nut (×4) Rear balance rod Wheel Installation 1. Install the wheel and the nuts. NOTE: The arrow mark on the tire must point ● toward the rotating direction of the wheel. Tapered nuts are used for both the front ●...
  • Page 147 8-42 Periodic Maintenance and Adjustment 1. Tapered nut Arrow mark 2. Lower the vehicle so that the wheel is on the ground. 3. Tighten the wheel nuts to the specified torque. Wheel nut torque: Front：49.7 ft·lbs (70Nm, 7.0 m·kgf) Rear：49.7 ft·lbs (70Nm, 7.0 m·kgf)

  • Page 148: Battery

    Periodic Maintenance and Adjustment 8-43 Battery CAUTION: This vehicle is equipped with a sealed-type battery. Therefore, it is not necessary to Do not try to remove the sealing caps of the battery cells. You may damage the battery. check the electrolyte or add distilled water in the battery.
  • Page 149 8-44 Periodic Maintenance and Adjustment WARNING POTENTIAL HAZARD Failure to handle batteries or battery electrolyte carefully. WHAT CAN HAPPEN You could be poisoned. You could be severely burned by the sulfuric acid in battery electrolyte. Batteries produce explosive gases. HOW TO AVOID THE HAZARD Avoid contact with skin, eyes or clothing.

  • Page 150: Battery Maintenance

    Periodic Maintenance and Adjustment 8-45 Battery Maintenance 1. When the vehicle is not used for a month or longer, remove the battery, charge it, and store it in a cool, dark place. Completely recharge the battery before reinstallation. 2. Always make sure the connections are correct when putting the battery back in 1.

  • Page 151: Fuse Replacement

    8-46 Periodic Maintenance and Adjustment Fuse Replacement The main fuse and the fuse box are located under the hood. (See pages 8-6 - 8-7 for hood opening and closing procedures.) If a fuse is blown, turn off the ignition switch and install a new fuse of the specified amperage.
  • Page 152 Periodic Maintenance and Adjustment 8-47 WARNING POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system, which could lead to a fire. HOW TO AVOID THE HAZARD Always use a fuse of the specified rating. Never use a material in place of the proper fuse.

  • Page 153: Replacing Headlight Bulb

    8-48 Periodic Maintenance and Adjustment Replacing Headlight Bulb Specified Fuse: If a headlight bulb burns out, replace it as Main Fuse: 30.0A follows. Headlight Fuse: 15.0A 1. Lift the hood up. (See pages 8-6 - 8-7 for Ignition Fuse: 10.0A hood opening and closing procedures.) 2.
  • Page 154 Periodic Maintenance and Adjustment 8-49 3. Remove the headlight bulb holder cover 6. Insert a new headlight bulb into the bulb by pulling it off. holder by pushing it in. 1. Headlight bulb holder cover 1. Headlight bulb holder 4. Remove the headlight bulb holder by pushing it in and turning it counter clockwise.
  • Page 155 8-50 Periodic Maintenance and Adjustment 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 156: Replacement

    Periodic Maintenance and Adjustment 8-51 the bulb) by turning it counter clockwise. 10. Adjust headlight beam if necessary. 3. Push the defective bulb in and turn it counter clockwise to remove it from the Tail/Brake Light Bulb Replacement bulb holder. 4.

  • Page 157: Troubleshooting

    8-52 Periodic Maintenance and Adjustment fasteners and bolts, and then tighten the properly service your vehicle. Imitation parts bolts to the specified torque. may look like original parts, but they are often inferior. Consequently, they have a shorter Tightening torque: service life and can lead to expensive Panel bolt: 6.5N·m (0.65 m·kgf，4.7 ft·lbs)

  • Page 158: Common Problems In Vehicle

    Periodic Maintenance and Adjustment 8-53 Solution to Common Problems in Vehicle Here you can see some tables on the common problems that may come up when you are driving a UTV, which will help to solve these problems. To repair a UTV requires technical skills, if you cannot fix it up yourself, please contact your service center.
  • Page 159 8-54 Periodic Maintenance and Adjustment Table 2：Solution of Common Problems in Brake System. Problems Solutions Check parking brake, make sure it is not set. Check if the brake discs are deformed. Brake system is locked up. Check if the calipers' hydraulic cylinders are stuck or the fixing parts of calipers are deformed.
  • Page 160 Periodic Maintenance and Adjustment 8-55 Check if brake discs are deformed. Front or rear brake system Check if the calipers' hydraulic cylinders are stuck or the fixing makes affricate noise. parts of calipers are deformed. Check both left and right front brakes, make sure there is no deviation when applying the brake Check to make sure the rear brakes do not lock up before the Vehicle pulls left or right...
  • Page 161 8-56 Periodic Maintenance and Adjustment Table 3: Solution of Common Problems in Electrical System Problems Solutions Check if the headlight switch functions well. Lights do not work. Check if the wires are broken. Check if the lamps or bulbs are broken. Check if the control switch on consol is working.
  • Page 162 Periodic Maintenance and Adjustment 8-57 Check if the speedometer sensor is working. Speedometer is not Check if the speedometer sensor is broken working Check if the surface of the speed sensor is contaminated with debris. Check if the switch is broken. Start switch (ignition Key) Check if wire is loose or broken.
  • Page 163 8-58 Periodic Maintenance and Adjustment Check the bearings in hubs. Make sure they are not missing or broken Check the main ball pins to find out if they are broken. Check the lug nuts and lock nuts of front wheels and axles to Front wheels shake during find out if they are loose or broken.
  • Page 164 Periodic Maintenance and Adjustment 8-59 if the rear wheel axles are bent. Check if tires are worn or deformed. Check if overloaded. Shock absorbers become Check if springs have excessive wear. spongy Check if shock absorbers have lost damping force. Check if the spline of intermediate driving shaft is broken.
  • Page 165 8-60 Periodic Maintenance and Adjustment Table5: Solution of Common Problems in Engine System Check throttle cable for seizure Idle speed cannot be Check the adjustment knob of carburetor for damage or wear adjusted. Check the needle of carburetor to see if it can be placed to the bottom Check if the high-voltage wire is in poor contact.
  • Page 166 Periodic Maintenance and Adjustment 8-61 low temperature goes down If the temperature is under -18 deg C (0 deg F), place the vehicle in a warmer place before attempting to start. Check cooling fins on radiator for debris, clean if necessary. Check temperature sensor of radiator for damage and Check fan for failure.
  • Page 167 8-62 Periodic Maintenance and Adjustment Check to see if engine is getting spark. Check and clean air filter Check fuel and oil level. Check if the exhaust system is blocked, including spark arrestor. 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.

  • Page 168: Cleaning And Storage

    Cleaning and Storage CAUTION: Cleaning Frequent, thorough cleaning of your vehicle Excessive water pressure may cause water will not only enhance its appearance but also seepage and deterioration of wheel bearings, will improve its general performance and brakes, transmission seals and electrical extend the useful life of many components.
  • Page 169 Cleaning and Storage chamois, clean towel or soft absorbent cloth. WARNING 6. Clean the seats with vinyl upholstery POTENTIAL HAZARD cleaner to keep the cover pliable and Operation with wet brakes after washing. glossy. WHAT CAN HAPPEN 7. Automotive type wax may be applied to Wet brakes may have reduced stopping all painted and chrome plated surfaces.

  • Page 170: Storage

    Cleaning and Storage Storage Specified amount: Long-term storage (60 days or more) of your 1 oz of stabilizer to each gallon of fuel (or vehicle will require some preventive 7.5 ml of stabilizer to each liter of fuel) procedures to guard against deterioration. After thoroughly cleaning the vehicle, NOTE: prepare for storage as follows:...
  • Page 171 Cleaning and Storage 6. Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering. 7. If storing in a humid or salty environment, coat all exposed metal surfaces with a light film of oil. Do not apply oil to any rubber parts or the seat covers.
  • Page 172 Specifications 10-1 Model HS400UTV-2/HS400UTV-3 Dimensions: Overall length 2680mm (105.5 in) Overall width 1320mm (52.0 in) for HS400UTV-2 Overall width 1550mm (61.0 in) for HS400UTV-3 Overall height 1870mm (73.6 in) Seat height 840mm (33.1 in) Wheelbase 1830mm (72.0 in) Ground clearance 300mm (11.8 in) Minimum turning radius 3500mm (137.8 in)
  • Page 173 10-2 Specifications Model HS400UTV-2/HS400UTV-3 Engine oil: Type API service SG type or higher, JASO standard MA 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 174 Specifications 10-3 Model HS400UTV-2/HS400UTV-3 Final gear case oil: Type SAE80 API GL-4 Hypoid gear oil Quantity: 0.4L (0.42 qt) Differential gear case oil: Type SAE80 API GL-5 Hypoid gear oil Quantity: 0.28L (0.3 qt) Radiator capacity (including all routes): 1.5 L (1.59 qt) Air filter: Wet element Fuel:...
  • Page 175 10-4 Specifications Model HS400UTV-2/HS400UTV-3 Clutch type: Wet, centrifugal automatic Transmission: Primary reduction system V-belt Secondary reduction system Shaft drive CVT reduction ratio 1.75 (35/20) Transmission type V-belt automatic Operation Right hand operation Chassis: Frame type Steel tube frame Caster angle 5.0°...
  • Page 176 Specifications 10-5 Model HS400UTV-2/HS400UTV-3 Brakes: Front brake Type Dual disc brake Ⅰ: Operation Right hand operation Rear brake Type Single disc brake Operation Left hand and right foot operation Front brake Type Dual disc brake Ⅱ: Operation Right hand operation Rear brake Type Dual disc brake...
  • Page 177 10-6 Specifications Model HS400UTV-2/HS400UTV-3 Electrical: Ignition system Generator system AC magneto U1L-11 or GSU1-9 Battery type 12V32.0Ah or 12V30.0Ah Battery capacity Bulb voltage, wattage × quantity: Headlight 12V35.0W/35.0W × 2 Tail/brake light 12V5.0W/21.0W × 2 Front/Rear turning light 12V10.0W/10.0W × 2 License light 12V3.0W Indicator lights:...
  • Page 178 Specifications 10-7 Model HS400UTV-2/HS400UTV-3 Main Fuse: 30.0A Headlight Fuse: 15.0A Ignition Fuse: 10.0A Auxiliary DC Jack Fuse: 10.0A Signaling System Fuse: 10.0A 2WD/4WD Fuse 3.0A...
  • Page 179 11-1 Fault Code of Electronic Injection System 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 180 Fault Code of Electronic Injection System 11-2 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 181 11-3 Fault Code of Electronic Injection System 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 182 Hisun Motors Corp., U.S.A. Emission Control System Warranty Statement 12-1 YOUR WARRANTY RIGHTS AND OBLIGATIONS Hisun Motors Corp., U.S.A. (hereinafter “HISUN”) is pleased to explain the emission control system warranty on your 2013 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 183 Hisun Motors Corp., U.S.A. Emission Control System Warranty Statement 12-2 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 184 Hisun Motors Corp., U.S.A. Emission Control System Warranty Statement 12-3 (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 185 Hisun Motors Corp., U.S.A. Emission Control System Warranty Statement 12-4 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 186 POWERSPORTS (888)-405-8725 Coleman Powersports 364 S. Smith Rd. Tempe, AZ. 85281...

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