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Bennche Bighorn 400 Owner's Manual

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Summary of Contents for Bennche Bighorn 400

  • Page 2 Owner's Manual...
  • Page 3 Owner's Manual INTRODUCTION Congratulations on your purchase of the Bennche Bighorn 400. 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 On-Command Four-Wheel-Drive and Location of the Warning and Differential Gear Lock Switches 4-10 Safety Labels Throttle Pedal 4-14 Brake Pedal 4-15 Safety Information Parking brake pedal 4-15 Drive Select Lever 4-16 Description and Vehicle Fuel Tank Cap 4-17 Identification Seats 4-18...
  • Page 7 Owner's Manual Brake Fluid Leakage Starting a Cold Engine Brake Operation Starting a Warm Engine Fuel Jump Starting Gasohol Warming Up Engine Oil Drive Select Lever Operation and Coolant Reverse Final Gear Oil Vehicle Break-in Period Differential Gear Oil Engine Break-In Throttle Pedal Parking Throttle Freeplay...
  • Page 8 Owner's Manual Going Uphill To Check Engine Oil Level 8-11 Going Downhill 7-11 To Change the Engine Oil (With or Crossing Through Shallow Water Without Oil Filter Cartridge 7-12 Vehicle Immersion 7-14 Replacement ) 8-13 Front Axle Differential Lock Final Gear Oil 7-15 8-15 Riding Over Rough Terrain...
  • Page 9 Owner's Manual Cleaning the Spark Arrester Troubleshooting 8-29 8-48 Valve Clearance 8-31 Solution To Common Problems In Front Brake Pad Check Vehicle 8-31 8-50 Rear Brake Pad Check 8-32 Cleaning and Storage Checking the Brake Fluid Level 8-32 Cleaning Brake Fluid Replacement 8-33 Storage Checking the Brake Pedal...

  • Page 10: Location Of The Warning And Safety Labels

    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 11 Location of the Warning and Safety Labels...
  • Page 12 Location of the Warning and Safety Labels...
  • Page 13 Location of the Warning and Safety Labels...
  • Page 14 Location of the Warning and Safety Labels...

  • Page 15: 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 16 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 17 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 18 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 19 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 20: 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 21 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 22: 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 23: 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 24: 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 25 Control Functions Forward Indicator 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 26: Speedometer Unit

    Control Functions Low Battery charge indicator Position light indicator Indicates a low charge on the battery. If light The light being on means that the position is illuminated, re-charge battery. If recharging light in the front headlight has been turned the battery does not fix the issue, have a service center inspect the battery and UTV.

  • Page 27: Odometer And Trip Meter Modes

    Control Functions 5. Tachometer buttons, one located on the left side and one 6. Odometer/Trip meter A / Trip meter B/Clock/Hour button on the right side. Quickly pressing the 7. Metric/mile button 8. Speedometer button on the left side toggles the display from the odometer, to the tripometer, and Speedometer unit functions: then to the hours meter;...

  • Page 28: Clock Time Adjustment

    Control Functions consumption. 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.

  • Page 29: Fault Code Indicator

    Control Functions gear lock button is set to out position, which should unlock the differential and press in means the differential is not operational and the yellow and the gray buttons to the 2WD is locked. When riding an UTV on muddy and unlocked position.
  • Page 30 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 31: Switches

    Control Functions Switches Set the switch to “OFF” to turn off all lights. 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. If this should happen, remove the battery and recharge it.

  • Page 32: On-Command Four-Wheel-Drive And Differential Gear Lock Switches

    Control Functions 4-10  Two-wheel drive (”2WD”): Power is sup- On-Command Four-Wheel–Drive and Differential Gear Lock Switches plied to the rear wheels only.  Four-wheel drive (“4WD”): Power is supplied to the rear and front wheels.  Four–wheel drive with the differential gear locked (“4WD-LOCK”): Power is supplied to the rear and front wheels when the differential gear is locked.
  • Page 33 4-11 Control Functions On-Command Four-Wheel-Drive Switch WARNING “2WD/4WD” POTENTIAL HAZARD 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 UNLOCK in some circumstances.
  • Page 34 Control Functions 4-12 To change from 4WD to 2WD Stop the vehicle, and then set the switch to “2WD”。The 4WD indicator will go out in the multi-function display. On-Command Differential Gear Lock Switch “2WD/LOCK” To lock the differential gear in 4WD, stop the vehicle, make sure the On-Command four-wheel-drive switch is set to “4WD”, On-Command differential lock switch “4WD/LOCK”...
  • Page 35 4-13 Control Functions NOTE: WARNING  When the switch is set to “LOCK”, the POTENTIAL HAZARD differential gear lock indicator and Riding too fast while the vehicle is in indicator lights will flash until the 4WD-LOCK. differential gear is locked. WHAT CAN HAPPEN ...

  • Page 36: Throttle Pedal

    Control Functions 4-14 pedal to be sure it is operating smoothly. Throttle Pedal Make sure the throttle pedal fully returns to Press the throttle pedal down to increase the idle position as soon as it is released. engine speed. Spring pressure returns the pedal to the rest position when released.

  • Page 37: Brake Pedal

    4-15 Control Functions WARNING Press the brake pedal to slow or stop the vehicle. POTENTIAL HAZARD 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 38: Drive Select Lever

    Control Functions 4-16 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 39: Fuel Tank Cap

    4-17 Control Functions 1. Drive select lever 1. Fuel tank cap Fuel Tank Cap Remove the fuel tank cap by turning it counter clockwise.

  • Page 40: Seats

    Control Functions 4-18 Seats To remove the seat bench, pull front of seat WARNING upward, then slide seat forward. POTENTIAL HAZARD A loose seat. WHAT CAN HAPPEN The operator could lose control or the operator and/or passenger could fall if the seat is loose during operation.

  • Page 41: Seat Belts

    4-19 Control Functions Proper use of the seat belts involves the Seat belts following steps: This vehicle is equipped with three-point seat 1. Hold the latch plate as you pull the belt belts for both the operator and passenger. across your lap and chest. Make sure the Always wear seat belts while riding in the belt is not twisted and is not caught on vehicle.
  • Page 42 Control Functions 4-20 1. Buckle 2. Release button 1. Buckle 2. Latch plate 4. Position the shoulder belt over your shoulder and across your chest. The shoulder belt should fit against your chest. If seat belt is loose, pull the belt out all the way then let it retract.

  • Page 43: Glove Compartment

    4-21 Control Functions Glove Compartment WARNING CAUTION: POTENTIAL HAZARD To prevent damage to the glove Not wearing the seat belt or wearing the compartment do not place metal products, seat belt improperly. like tools or sharply edged products directly WHAT CAN HAPPEN in the glove compartment.

  • Page 44: Cargo Bed

    Control Functions 4-22 Cargo Bed . Open. 1. Cargo bed 2. Tailgate...

  • Page 45: Opening And Closing The Tailgate

    4-23 Control Functions Opening and Closing the Tailgate Lifting and Lowering the Cargo Bed 1. Tailgate 2. Latch (×2) 1. Cargo bed release lever To lift To open Push down cargo bed release lever on left or Unhook latches, and lower the tailgate. right side of the vehicle;...
  • Page 46 Control Functions 4-24 WARNING WARNING POTENTIAL HAZARD POTENTIAL HAZARD Pinch points. Overloading the cargo bed. WHAT CAN HAPPEN WHAT CAN HAPPEN You or someone else could be pinched Could cause changes in vehicle handling between the cargo bed and the frame which could lead to an accident.

  • Page 47: Front And Rear Shock Adjustment

    4-25 Control Functions Front and Rear Shock Adjustment(Option 1) The spring preload can be adjusted to suit WARNING the operating conditions. POTENTIAL HAZARD You can reduce preload for a softer ride, or Carrying a passenger in the cargo bed. increase preload if the vehicle is bottoming WHAT CAN HAPPEN out on rough terrain.
  • Page 48 Control Functions 4-26 Standard position: B A-Minimum(soft) E-Maximum(hard) 1. Spring preload adjusting ring 2. Position indicator NOTE: A special wrench can be obtained at a 1. Special wrench service center to make this adjustment.
  • Page 49 4-27 Control Functions Front and Rear Shock Adjustment(Option 2) WARNING WARNING POTENTIAL HAZARD These shock absorber assemblies Improper shock absorber adjustment. contain highly pressurized nitrogen gas, WHAT CAN HAPPEN read understand following Uneven adjustment can cause poor information before handling the shock handling and loss of stability, which absorber assemblies.
  • Page 50 ⓐ to increase the spring Take the shock absorber assembly to a preload thereby harden BENNCHE dealer for any service. suspension, and in direction ⓑ to decrease the spring preload and thereby The spring preload, rebound damping and soften the suspension.
  • Page 51 4-29 Control Functions · A special wrench can be obtained at a BENNCHE dealer to make this adjustment. Spring travel setting(Front) · The spring preload setting is determined Minimum(soft): 375mm(14.76 in) by measuring distance A, shown in the Maximum(hard): 490mm(19.29 in) illustration.
  • Page 52 Control Functions 4-30 damping force and thereby harden the Compression damping force damping, and in direction F to decrease the Turn compression damping force rebound damping force and thereby soften adjusting screw (use 2.5 allen wrench) in direction ⓐ to increase the compression the damping.

  • Page 53: Trailer Hitch Bracket

    4-31 Control Functions Trailer Hitch Bracket This vehicle is equipped with a 1 1/4 inch WARNING receiver bracket for a standard trailer hitch. ·Suspension components become hot Trailer towing equipment can be obtained at during operation. Never touch a service center. (See pages 6-10－6-12 for compression damping force adjusting precaution information.) screw,...

  • Page 54: Auxiliary Dc Jack

    Control Functions 4-32 Auxiliary DC Jack 1. Set the light switch to “OFF”. 2. Start the engine. (See pages 6-1-6-2.) The auxiliary DC jack is located at the right 3. Open the auxiliary DC jack cap, and then side of the front panel. insert the accessory power plug into the The auxiliary DC jack can be used for jack.
  • Page 55 4-33 Control Functions Maximum rated capacity for the auxiliary DC jack: DC 12V, 120W (10 A) CAUTION:  Do not use accessories requiring more than the above maximum capacity. This may overload the circuit and cause the fuse to blow. ...

  • Page 56: 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 - 5-3，8-32 - 8-33 Fill with DOT 4 brake fluid if necessary ● Check for proper operation, condition and free play Parking brake ●...

  • Page 57: Brakes

    Pre Operation Checks WARNING Brakes 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 58: Brake Fluid Level

    Pre Operation Checks 8-326.) 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 59: Fuel

    Pre Operation Checks WARNING Fuel 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 7.4 gal (28L )

  • Page 60: Gasohol

    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 61: 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 Add oil as necessary. (See pages 8-11—8-15.) when the engine is cold. (The coolant level will vary with engine temperature.) The coolant level is satisfactory if it is between the minimum CAUTION:...

  • Page 62: 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 63: Throttle Pedal

    Pre Operation Checks WARNING Recommended oil: 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 64: Throttle Freeplay

    Pre Operation Checks Throttle Freeplay Throttle Freeplay Adjustment If the throttle pedal has excessive play due to 1. Remove seat. 2. Loosen the throttle cable column nut. cable stretch or mis-adjustment, it will cause a 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 65: Steering Wheel Inspection

    5-10 Pre Operation Checks and release when the release button is pushed Steering Wheel Inspection 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 66 Pre Operation Checks 5-11 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 67 5-12 Pre Operation Checks 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 68: How To Measure Tire Pressure

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

  • Page 69: Tire Wear Limit

    5-14 Pre Operation Checks 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 70: 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 71: Starting A Warm Engine

    Operation seconds before the next attempt. Each NOTE: cranking should be as short as possible to When the drive select lever is in the ● preserve battery energy. Do not crank the neutral position, the neutral indicator engine more than 5 seconds on each light should come on.
  • Page 72 Operation 4. Connect the negative lead of the jumper 1. Open the seat. (See pages 4-18). cable to the negative terminal of the 2. Remove the battery compartment cover. charged battery and the other end of the 3. Using a charged 12V battery, connect negative lead to an unpainted metal the positive lead of the jumper cable to surface of the vehicle.

  • Page 73: Warming Up

    Operation the vehicle and charged battery, and Otherwise, the transmission may be then disconnect the positive lead of the damaged. jumper cable from the charged battery and the battery in the vehicle. Shifting: Neutral to Forward 7. Install the battery compartment cover. 1.
  • Page 74 Operation NOTE: Depress the brake pedal before shifting ● to “reverse”position. The brake pedal is attached to a cable ● that is connected to a position pin in the gearshift assembly. Only when the brake pedal is depressed will the gearshift lever be able to move from neutral to reverse.

  • Page 75: Vehicle Break-In Period

    Operation NOTE: When in reverse, the reverse indicator ● WARNING light should be on. If the light does not POTENTIAL HAZARD come on, ask a service center to inspect Improperly operating in reverse. the reverse indicator light electrical WHAT CAN HAPPEN circuit.

  • Page 76: Engine Break-In

    Operation There is never a more important period in the is as important as a proper break-in period. life of your vehicle than the period between Careful treatment of a new engine and drive zero and 25 hours. components will result in more efficient For this reason, we ask that you carefully performance and longer life for these read the following material.

  • Page 77: Parking

    Operation rpm’s so the engine can rid itself of the Brake System Break-in temporary build up of heat. If any Apply only moderate braking force for the abnormality is noticed during this period, first 50 stops. Aggressive or overly forceful consult a service center.

  • Page 78: Parking On A Slope

    Operation drive select lever into the neutral position. Parking on a slope Apply the parking brake to help prevent the WARNING vehicle from rolling. 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.

  • Page 79: Accessories

    6-10 Operation Accessories Accessories can affect the handing and control of your vehicle. Keep the following in mind when considering an accessory or operating a vehicle that has accessories. Choose only accessories designed for ● your vehicle. Your service center has a variety of genuine accessories.

  • Page 80: Loading

    Operation 6-11 can shift position or come off while you judgment when carrying cargo or towing a are operating could affect your ability to trailer. Keep the following points in mind: control the vehicle. Never exceed the weight limits shown. ●...
  • Page 81 6-12 Operation Do not exceed the maximum tongue with controls or your ability to see where ● weight. You can measure tongue weight you are going. with a bathroom scale. Put the tongue of Drive slower than you would without a ●...
  • Page 82 Operation 6-13 WARNING POTENTIAL HAZARD Overloading this vehicle or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this vehicle.
  • Page 83 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 84 Your Vehicle The total weight of operator, passenger, WARNING accessories, cargo, trailer tongue weight, and the vehicle itself must not exceed POTENTIAL HAZARD 2180lbs (989Kg). Carrying a passenger in the cargo bed. WHAT CAN HAPPEN The passenger could fall or be struck by objects in the cargo bed.
  • Page 85 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 86 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 87: 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 88: 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 89: 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 90: 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 91 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 92 Your Vehicle 7-10 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 93: Going Downhill

    7-11 Your Vehicle 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 94: Crossing Through Shallow Water

    Your Vehicle 7-12 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 95 7-13 Your Vehicle 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 96: Vehicle Immersion

    Your Vehicle 7-14 5. Dry the spark plugs and reinstall them, or Vehicle Immersion install new plugs. CAUTION: 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 97: Front Axle Differential Lock

    7-15 Your Vehicle 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 98: Riding Over Rough Terrain

    Your Vehicle 7-16 traction, because the skid process has WARNING destroyed the soil structure. Even if you lock POTENTIAL HAZARD the differential, the front wheels may Failure to use extra care when operating continue to slip and will not drive the vehicle this vehicle on unfamiliar terrain.

  • Page 99: Riding In Brush Or Wooded Areas

    7-17 Your Vehicle 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 100: Encountering Obstacles On The Trail

    Your Vehicle 7-18 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 101 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 102 Periodic Maintenance and Adjustment WARNING WARNING POTENTIAL HAZARD POTENTIAL HAZARD Servicing an engine while it is running. Operating this vehicle with improper WHAT CAN HAPPEN modifications. Moving parts can catch clothing or parts WHAT CAN HAPPEN of the body, causing injury. Improper installation of accessories or Electrical components can cause shocks modification of this vehicle may cause...

  • Page 103: 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 104: Periodic Maintenance And Adjustment

    Periodic Maintenance and Adjustment General Maintenance and Lubrication Chart INITIAL EVERY Month Whichever ITEM ROUTINE Miles 2,400 4,800 1,200 2,400 Comes first (Km) (1,500) (3,000) (200) (750) (1,500) hours ● Check operation/brake pad wear/fluid leakage/see Rear Brake* NOTE page 5-2-5-3 ○...
  • Page 105 Periodic Maintenance and Adjustment INITIAL EVERY Month Whichever ITEM ROUTINE Miles 2,400 4,800 1,200 2,400 Comes first (Km) (1,500) (3,000) (200) (750) (1,500) hours ● Check for cracks or damage. Engine Mount* ○ ○ ○ ● Check bolt tightness. ● Check operation and for looseness. Replace if Steering System* damaged.

  • Page 106: 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 107: 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 108: 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 threaded sleeve 2. Exhaust Pipe 3.
  • Page 109 Periodic Maintenance and Adjustment 1. Fuel injector 2. Intake Pipe 1. Water temperature sensor 3. Intake Pipe Joint 4. Intake temperature sensor/pressure sensor 5. Throttle...
  • Page 110 Periodic Maintenance and Adjustment 8-10 conditions, the 2 parameters- opening of air 1. Throttle 2. Idle speed stepper motor damper and pressure of air intake determine 3. Intake temperature sensor/pressure sensor the engine’s working condition, ECU will 4. Air damper degree sensor adjust the fuel injection volume according to different negative pressure and opening of Air damper...

  • Page 111: Efi System Inspection

    8-11 Periodic Maintenance and Adjustment controller，according to the information from sensors, has been calculated to ensure accurate control in different conditions from the nozzle of the fuel injection volume. To achieve fuel-efficient emissions performance of the EFI engine. EFI System inspection If the EFI system has failure, the meter will display the appropriate failure code, you can also use the special "EFI system failure...
  • Page 112 Periodic Maintenance and Adjustment 8-12 3. Check the engine oil level on a cold engine. NOTE: If the engine was started before checking the oil level, be sure to warm up the engine sufficiently, and then wait at least ten minutes until the oil settles for an accurate reading.

  • Page 113: To Change The Engine Oil (With Or Without Oil Filter Cartridge Replacement)

    8-13 Periodic Maintenance and Adjustment To Change the Engine Oil (With or NOTE: Without Oil Filter Cartridge Replacement) Skip steps 4-6 if the oil filter cartridge is not 1. Remove the seat. being replaced. 2. Place an oil pan under the engine to 4.
  • Page 114 Periodic Maintenance and Adjustment 8-14 5. Apply a light coat of engine oil to the Tightening torque: O-ring of the new oil filter cartridge. Oil filter cartridge: NOTE: 12 ft·lbs (17Nm 1.7m·kgf) Make sure the O-ring is seated properly. 1. Oil filler cartridge 2.

  • Page 115: Final Gear Oil

    8-15 Periodic Maintenance and Adjustment 8. Add the specified amount of  Make sure that no foreign material enters the crankcase. recommended engine oil, and then install the engine oil filler cap and tighten it. 9. Start the engine, and then let it idle for Recommended engine oil: several minutes while checking it for oil See page 10-2.

  • Page 116: Changing The Final Gear Oil

    Periodic Maintenance and Adjustment 8-16 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 117 8-17 Periodic Maintenance and Adjustment Recommended oil: SAE 80 API GL-4Hypoid gear oil Oil quantity: 0.42 qt (0.4 L) CAUTION: Be sure no foreign material enters the final gear case. 1. Final gear oil drain bolt 4. Install the drain bolt, and then tighten it to 6.

  • Page 118: Differential Gear Oil

    Periodic Maintenance and Adjustment 8-18 Differential Gear Oil CAUTION: Checking the Differential Gear Oil Level 1. Place the vehicle on a level surface. 1. Be sure no foreign material enters the 2. Remove the differential gear oil filler bolt differential gear case. and check the oil level.
  • Page 119 8-19 Periodic Maintenance and Adjustment and differential gear oil drain bolt to drain 5. Fill the differential gear case with the the oil. recommended oil. Recommended oil: SAE 80 API GL-5 Hypoid gear oil Oil quantity: 0.3 qt (0.28L) CAUTION: Be sure no foreign material enters the differential gear case.

  • Page 120: Oil Cooler

    Periodic Maintenance and Adjustment 8-20 because the flying stone can easily break the Oil cooler oil cooler and cause oil leak. CAUTION: If the oil cooler is blocked, it will make the oil temperature overheated and damage the engine. Coolant The coolant level should be checked before each ride.

  • Page 121: Changing The Coolant

    8-21 Periodic Maintenance and Adjustment temperature. level mark, remove the reservoir cap, add coolant to the maximum level mark, NOTE: install the reservoir cap, and then close The coolant should be between the minimum the hood. and maximum level marks. Coolant reservoir capacity (up to the maximum level mark): 0.663 qt (0.627L)

  • Page 122: Axle Boots

    Periodic Maintenance and Adjustment 8-22 on or off according to the coolant Recommended antifreeze: temperature in the radiator. High quality ethylene glycol antifreeze containing corrosion inhibitors for Axle Boots aluminum engines. Antifreeze and water mixing ratio: 1:1 Check the protective boots for holes or tears. If any damage is found, have them replaced Total amount: by a service center.

  • Page 123: Spark Plug Inspection

    8-23 Periodic Maintenance and Adjustment Spark plug cap 1. Rear axle boot (×2 each side) Spark Plug Inspection Removal Remove seat (See pages 4-18 for remove seat ) 2. Remove the spark plug cap. 3. Use the spark plug wrench in the tool kit to remove the spark plug as shown.

  • Page 124: Inspection

    Periodic Maintenance and Adjustment 8-24 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 125 8-25 Periodic Maintenance and Adjustment of the correct torque is 1/4 to 1/2 turn past finger tight. Have the spark plug tightened to Spark plug gap: the specified torque as soon as possible. 0.023-0.027 in (0.6-0.7mm) 4. Install the spark plug cap. 2.
  • Page 126 Periodic Maintenance and Adjustment 8-26 1. Holder (×3) 2. Air filter case cover Air filter check hose 1. Remove the seats. (See pages 4-18 for 4. Remove the air filter element. seat removal) 5. Remove the sponge material from its 2.
  • Page 127 8-27 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 128 Periodic Maintenance and Adjustment 8-28 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 129: Cleaning The Spark Arrester

    8-29 Periodic Maintenance and Adjustment operated in extremely dusty areas. Each time Cleaning the Spark Arrester air filter element maintenance is performed, Be sure the exhaust pipe and muffler are check the air inlet to the air filter case for cool before cleaning the spark arrester.
  • Page 130 Periodic Maintenance and Adjustment 8-30 tailpipe and inside of the tailpipe housing. 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 Could injure the eyes. Could cause burns. Could cause carbon monoxide 1.

  • Page 131: Valve Clearance

    8-31 Periodic Maintenance and Adjustment Valve Clearance The correct valve clearance changes with use, resulting in improper fuel-air supply or engine noise. To prevent this, the valve clearance must be adjusted regularly. This adjustment however, should be left to a professional service technician.

  • Page 132: Rear Brake Pad Check

    Periodic Maintenance and Adjustment 8-32 Rear brake pad check Checking the Brake Fluid Level Each brake pad is provided with wear Insufficient brake fluid may let air enter the indicator grooves, which allow you to check brake system, possibly causing the brakes to the brake pad wear without having to become ineffective.

  • Page 133: Brake Fluid Replacement

    8-33 Periodic Maintenance and Adjustment Recommended brake fluid: DOT 4  Refill with the same type of brake fluid. Mixing fluids may result a harmful chemical reaction and lead to poor braking performance.  Be careful that water does not enter the brake fluid reservoir when refilling.

  • Page 134: Checking The Brake Pedal

    Periodic Maintenance and Adjustment 8-34 when they are damaged or leaking.  Replace the oil seals every two years.  Replace the brake hoses every four years. Checking the Brake Pedal Have a service center check the brakes at the intervals specified in the periodic maintenance and lubrication chart.

  • Page 135: Brake Light Switch Adjustment

    8-35 Periodic Maintenance and Adjustment Brake Light Switch Adjustment The brake light switch, which is activated by WARNING the brake pedal, is properly adjusted when POTENTIAL HAZARD the brake light comes on just before braking Operating with improperly serviced or takes effect.

  • Page 136: Cable Inspection And Lubrication

    Periodic Maintenance and Adjustment 8-36 Cable Inspection and Lubrication WARNING POTENTIAL HAZARD Damaged control cables. WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged. Cables can also become frayed or kinked. Operation of controls could be restricted, which could cause an accident 1.

  • Page 137: Brake Pedal And Accelerator Pedal Lubrication

    8-37 Periodic Maintenance and Adjustment Rear Knuckle Upper and Lower Pivot Lubrication Recommended lubricant: Lubricate the knuckle upper and lower pivots Engine oil：see page 10-2 with a grease gun. Brake Pedal and Accelerator Pedal Lubrication Lubricate the pivoting parts. Recommended lubricant: Lithium-based grease (all-purpose grease) Recommended lubricant:...

  • Page 138: Steering Shaft Lubrication

    Periodic Maintenance and Adjustment 8-38 Steering Shaft Lubrication Lower universal joint, steering transmission shaft Lubricate the pivot points. Recommended lubricant: Lithium-based grease (all-purpose grease) Upper universal joint, steering transmission shaft...

  • Page 139: Wheel Installation

    8-39 Periodic Maintenance and Adjustment 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 140: Battery

    Periodic Maintenance and Adjustment 8-40 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) Battery Arrow mark This vehicle is equipped with a sealed-type battery.
  • Page 141 8-41 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 142: Battery Maintenance

    Periodic Maintenance and Adjustment 8-42 Battery Maintenance CAUTION: 1. When the vehicle is not used for a month A special battery charger (constant or longer, remove the battery and store it voltage/ampere or constant voltage) is in a cool, dark place. Completely required for recharging a sealed-type battery.
  • Page 143 8-43 Periodic Maintenance and Adjustment 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 144 Periodic Maintenance and Adjustment 8-44 Specified Fuse: Main Fuse: 30.0A Headlight Fuse: 15.0A ECU Fuse: 15.0A Auxiliary DC Jack Fuse: 10.0A Signaling System Fuse: 10.0A 2WD/4WD Fuse 10.0A Backup Fuse: 5.0A/10.0A/15.0A Speedometer/ECU 5.0A 1. Relay assembly 2. Backup fuse -normal open Fuse: 3.

  • Page 145: Replacing Headlight Bulb

    8-45 Periodic Maintenance and Adjustment Replacing Headlight Bulb If a headlight bulb burns out, replace it as follows. 1. Lift the hood up. (See pages 8-6 - 8-7 for hood opening and closing procedures.) 2. Remove the cover at the rear of the headlight by pulling it off.
  • Page 146 Periodic Maintenance and Adjustment 8-46 WARNING POTENTIAL HAZARD A headlight bulb is hot when it is on and immediately after it is turned off. WHAT CAN HAPPEN You can be burned, or a fire could start if the bulb touches something flammable. HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it.

  • Page 147: Tail/Brake Light Bulb Replacement

    8-47 Periodic Maintenance and Adjustment turning it clockwise. 2. Install the bulb holder cover and the cover at the rear of the headlight. CAUTION: Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly. 3.

  • Page 148: Troubleshooting

    Periodic Maintenance and Adjustment 8-48 Troubleshooting Although vehicles receive a rigid inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems can cause poor starting and loss of power. The troubleshooting chart describes a quick, easy procedure for making checks.
  • Page 149 8-49 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 150: Solution To Common Problems In Vehicle

    Periodic Maintenance and Adjustment 8-50 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 151 8-51 Periodic Maintenance and Adjustment Problems Solutions 1. Replace Front Skid Plate with a new one. 2. Check if the gearbox or front differential / rear axles are Damaged Front Skip Plate damaged or leaking. 3. Check plastic cover for damaged and replace if needed. 1.
  • Page 152 Periodic Maintenance and Adjustment 8-52 Table 2：Solution of Common Problems in Brake System Problems Solutions 1. Check whether brake disc plates deformed or damaged. Locked braking system 2. Check whether hydraulic cylinder is locked or brake clamp assembly parts are deformed or damaged. 1.
  • Page 153 8-53 Periodic Maintenance and Adjustment Problems Solutions 1. Check if front brakes (left and right) are applying equal force to the right and left brake rotors. 2. Check if a lack of front brake power has caused the rear wheels to “lock up” locked before front wheels. 3.
  • Page 154 Periodic Maintenance and Adjustment 8-54 Table 3: Solution of Common Problems in Running System Problems Solutions 1. Check if the steering wheel nut is loose or damaged. 2. Check if the steering column clip and clip seat loose or Steering wheel is loose and shifts up and down damaged.
  • Page 155 8-55 Periodic Maintenance and Adjustment Problems Solutions 1. Check if the rear axle bearings are damaged. 2. Check if the sliding bearings connected to rear axle bearing housing and rocker arm are loose or damaged. 3. Check if the rear wheel and axle locknut are loose or Rear wheels sway...
  • Page 156 Periodic Maintenance and Adjustment 8-56 Problems Solutions 1. Check if the drive shaft spline is broken. 2. Check if the splines in left & right axles and front & rear drive shafts are broken. Front drive shaft makes 3. Check if the gears in rear drive shaft and reduction gear box noise during use.
  • Page 157 8-57 Periodic Maintenance and Adjustment Table 4: Solution of Common Problems in Electrical System Problems Solutions 1. Check if the headlight switch functions well. 2. Check if the wires are broken. Lights do not work. 3. Check if the lamps or bulbs are broken. 1.
  • Page 158 Periodic Maintenance and Adjustment 8-58 Problems Solutions 1. Check if the ECU is broken. 2. Check if the nozzle is clogged or the nozzle to the ECU connection is disconnected. 3. Check if the engine speed signal sensor is broken. 4.
  • Page 159 8-59 Periodic Maintenance and Adjustment Table5: Solution of Common Problems in Engine System Problems Solutions 1. Check and clean the core of air cleaner. Power or performance is falling. 2. Check muffler for partly blocked and clean spark arrestor. 1. Check air cleaner and admission line for leaks. 2.
  • Page 160 Periodic Maintenance and Adjustment 8-60 Problems Solutions 5. Check if the oil circuit is working properly. Engine cannot start. 6. Check if the exhaust system is blocked. 1. Check if the spark plug is loose. 2. Check if the cylinder head or cylinder body is loose. Cylinder and cylinder 3.
  • Page 161 8-61 Periodic Maintenance and Adjustment Problems Solutions 1. Check if the crankcase installed improperly. Crankcase and crankshaft 2. Check if the crankshaft is seized. 1. Check for improperly adjusted valve clearance. Valve gear 2. Check for improperly adjusted valve timing.
  • Page 162 Periodic Maintenance and Adjustment 8-62 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 163 Cleaning and Storage Cleaning CAUTION: 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 164 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 165: Cleaning And 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 166 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 atmosphere, coat all exposed metal surfaces with a light film of oil. Do not apply oil to any rubber parts or the seat covers.
  • Page 167 Bennche Bighorn 400 Dimensions: Overall length 2680mm (105.5 in) Overall width 1320mm (52.0 in) for Bighorn 400 Overall width 1550mm (61.0 in) for Bighorn 400 HD Overall height 1870mm (73.6 in) Seat height 840mm (33.1 in) Wheelbase 1830mm (72.0 in) Ground clearance 300mm (11.8 in)

  • Page 168: Specifications

    Specifications 10-2 Model Bennche Bighorn 400 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.
  • Page 169 10-3 Specifications Model Bennche Bighorn 400 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)
  • Page 170 Specifications 10-4 Model Bennche Bighorn 400 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 171 Double wishbone Shock absorber: Front shock absorber Coil spring/oil damper for Bighorn 400 Coil spring/oil or airbag damping for Bighorn 400 HD Rear shock absorber Coil spring/oil damper for Bighorn 400 Coil spring/oil or airbag damping for Bighorn 400 HD...
  • Page 172 Specifications 10-6 Model Bennche Bighorn 400 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 ×...
  • Page 173 10-7 Specifications Model Bennche Bighorn 400 Main Fuse: 30.0A Headlight Fuse: 15.0A ECU Fuse: 15.0A Auxiliary DC Jack Fuse: 10.0A Signaling System Fuse: 10.0A 2WD/4WD Fuse 10.0A...

  • Page 174: Fault Code Of Electronic Injection

    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 175 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 176 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 177 Where a warrantable condition exists, BENNCHE will repair your vehicle at no cost to you, including diagnosis, parts and labor. If an emission-related part on your vehicle is defective, the part will be repaired or replaced by BENNCHE. This is your EMISSION CONTROL SYSTEM WARRANTY.
  • Page 178 Emission Control System Warranty Statement 12-2 As the vehicle owner, you should be aware that BENNCHE 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 179 BENNCHE brand vehicle for any purpose. Some states do not allow the exclusion or limitation of any incidental or consequential damages, so the above limitations may not apply to you.
  • Page 180 VI. ADDITIONAL INFORMATION. Any replacement part that is equivalent in performance and durability may be used in the performance of any maintenance or repairs by the owner. However, BENNCHE is not liable for these parts. The owner is responsible for the performance of all required maintenance.

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