Farr 400UTV Owner's Manual
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Farr 400UTV Owner's Manual

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FARR 400UTV OWNER'S MANUAL

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Summary of Contents for Farr 400UTV

  • Page 1 FARR 400UTV OWNER'S MANUAL...
  • Page 3 INTRODUCTION Congratulations on your purchase of the 400UTV-EC. It represents the result of many years of experience in the production of fine sporting, UTVs, and pacesetting racing machines. With the purchase of this UTV, you can now appreciate the high degree of craftsmanship and reliability.
  • Page 4 IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander or a person inspecting or repairing the machine.
  • Page 5 IMPORTANT NOTICE Curve speed must be smaller than 30km/h. This UTV has been passed the EC certificate, it can run on any public street, road, and highway. Please check your local riding laws and regulations before operating this UTV. When the temperature is below -20℃ (-4°F), please park the UTV in the place where the temperature is higher than -20℃...

  • Page 6: Table Of Contents

    CONTENTS Indicator and Warning Lights……………4-4 LOCATION OF THE WARNING AND SPECIFICATION LABELS……1-1 Multi-Function Display Gauge…………4-7 Odometer and Trip Meter Modes………4-7 2. SAFETY INFORMATION………………2-1 Clock Mode………………………………4-8 Fuel gauge………………………………4-8 3. DESCRIPTION AND VEHICLE On-Command Four-Wheel–Drive IDENTIFICATION………………………3-1 And Differential Gear Lock Switches…4-9 Identification Number Records…………3-3 Accelerator Pedal………………………4-13 Vehicle identification number and Brake Pedal……………………………4-14...
  • Page 7 Trailer Hitch Bracket……………………4-25 Tires……………………………………5-11 Auxiliary DC Jack………………………4-25 How To Measure Tire Pressure………5-13 Tire Wear Limit…………………………5-14 PRE-OPERATION CHECKS…………5-1 Tires for Public use……………………5-14 Brakes……………………………………5-2 Front and Rear Brakes Brake Pedal…5-2 6． OPERATION………………………………6-1 Brake Fluid Level………………………5-3 Starting a cold engine……………………6-1 Brake Operation…………………………5-3 Starting a warm engine…………………6-3 Fuel………………………………………5-4 Jump-starting……………………………6-3 Warming Up………………………………6-5...
  • Page 8 Going Downhill…………………………7-10 Final Gear Oil Crossing Through Shallow Water……7-11 Checking the Final Gear Oil Level……8-11 Vehicle Immersion……………………7-13 Changing the Final Gear Oil…………8-12 Rear Axle Differential Lock …………7-14 Differential Gear Oil……………………8-13 Riding Over Rough Terrain……………7-15 Checking the Differential Gear Oil Level…8-13 Changing the Differential Gear Oil …8-14 Riding In Brush Or Wooded Areas……………………………………7-16...
  • Page 9 Brake Light Switch Adjustment………8-30 Cable Inspection And Lubrication……8-31 Brake Pedal And Accelerator Pedal Lubrication………………………8-32 Rear Knuckle Upper And Lower Pivot Lubrication………………………8-32 Steering Shaft Lubrication……………8-33 Wheel Removal………………………8-34 Wheel Installation………………………8-34 Battery…………………………………8-35 Battery Maintenance…………………8-37 Fuse Replacement……………………8-37 Replacing A Headlight Bulb……………8-40 Tail/Brake Light Bulb Replacement……………………………8-42 Check and solution to Common Problems in Vehicle……………………8-44...

  • Page 10: Location Of The Warning And Specification Labels

    LOCATION OF THE WARNING AND SPECIFICATION LABELS...
  • Page 11 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 from your dealer.
  • Page 12 ② ④ ③ ⑤...
  • Page 13 ⑥ ⑧ ⑦...
  • Page 14 ⑨ ⑩...

  • Page 15: Safety Information

    SAFETY INFORMATION This utility vehicle handles differently from other vehicles including cars and UTVs. can result if you do not follow these instructions: SEVERE INJURY OR DEATH Read this manual and all labels carefully and follow the operating procedures described. ●...
  • Page 16 Always follow the inspection and maintenance procedures and schedules described in this manual. Always keep both hands, arms, feet, and legs inside the vehicle at all times during operation. ● Keep your feet on the floorboard. Never hold onto the enclosure. Otherwise, your hands could be injured if it is caught between the enclosure and an obstacle outside the vehicle.
  • Page 17 Always follow proper procedures for going uphill. If you lose control and cannot continue up a hill, ● back down the hill with the engine in reverse gear. Use engine braking to help you go slowly. If necessary, use the brakes gradually to help you go slowly. Always check terrain before going down hills.
  • Page 18 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 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 Turning-light, Rear Front shock absorber assembly Spark arrester Brake fluid reservoir Rear shock absorber assembly Rear mirror CVT-belt case Ignition Switch Assembled Fuel tank cap Driver seat Passenger seat belt Battery Right body protection plate Fuses Spark plug Left body protection plate...
  • Page 21 Parking brake lever Steering wheel Ignition switch 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

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

  • Page 23: Verification Sign Of Ec

    Verification sign of EC Record the information on this label in the space provided. This information will be needed to order spare parts from your dealer. 1. Verification sign of EC...

  • Page 24: Control Unctions

    and the headlights and taillights come on CONTROL FUNCTIONS when the light switch is on. OFF: Ignition Switch All electrical circuits are switched off. The key can be removed in this position. START: The electric starter is engaged by turning and holding the key in this position.

  • Page 25: Combination Switch

    Combination switch least 5 seconds between each operation Light switch “ ” of the electric starter to let it cool. / OFF/ Do not turn the key to the “START” ● position with the engine running, or damage to the electric starter can result. See starting instructions prior to starting ●...

  • Page 26: Turning Light Switch

    beam. Emergency light button ● Set the switch to “OFF”， to turn off all the Press this button. The four turning lights will lights. spark continuously. At the same time, the ● Set the switch to “ ” to turn on the buzzer will sound.

  • Page 27: Indicator And Warning Lights

    Indicator and Warning Lights On-Command Differential Gear Lock Indicator Light “DIFF. LOCK” This indicator light and the On-Command differential gear lock indicator in the display come on when the On-command differential gear lock switch is set to the “ ” position. LOCK NOTE: When the switch is set to “LOCK”, the...
  • Page 28 Neutral Indicator Light “N” On-Command Four-Wheel-Drive Indicator “ ”/ “ ” This indicator light comes on when the drive select lever is in the “N” position. The On-Command four-wheel-drive indicator “ ” comes on when the On-Command four- wheel-drive switch is set to the “4WD” Reverse Indicator Light “R”...
  • Page 29 Coolant temperature warning indicator “ ” allow the engine to cool down for about 15 minutes. When the coolant temperature reaches to a specified level, this light comes on to warn that the coolant temperature is too hot. If the CAUTION: light comes on during operation, stop the ...

  • Page 30: Multi-Function Display Gauge

    The multi-function meter unit is equipped Battery Power Shorted Indicator with the following: Shows the battery is overused. Please take  Speedometer (which shows the riding out the battery, re-charge and check the speed) discharged reason.  Odometer (which shows the total distance traveled) Multi-Function Display Gauge ...

  • Page 31: Clock Mode

    “TRIP/ODO” button, and then push the To Set the Clock “TRIP/ODO” button for at least three seconds. 1. Set into the clock mode. The trip meters can be used to estimate the 2. Press the watch button for 3-5 seconds. 3.

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

    On-Command Four-Wheel–Drive and Differential Gear Lock Switches 1. Fuel meter 2. Fuel level warning indicator 1. On-Command four-wheel –drive switch “2WD”/ “4 WD” 2. Differential gear lock switch “LOCK”/ “2WD” This vehicle is equipped with an On-Command four–wheel-drive switch “2WD”/ “4WD”and a differential gear lock switch “4WD”/ “LOCK”.
  • Page 33  plied to the rear wheels only. WARNING  Four-wheel drive (“4WD”): Power is POTENTIAL HAZARD Changing from 2WD to 4WD or from supplied to the rear and front wheels. 2WD to 2WD-Differential UNLOCK, or  Four–wheel drive with the differential vice-versa while the vehicle is moving.
  • Page 34 stop the vehicle, and then set the switch to On-Command Four-Wheel-Drive Switch “2WD”。the 4WD indicator “ ” will go out in “2WD/4WD” the multi-function display. On-Command Differential Gear Lock Switch “4WD/LOCK” 1. On-Command four –wheel-drive switch “2WD/4WD” 2. Select lever To change from 2WD to 4WD stop the vehicle, be sure the select lever is set to position ，and then set the switch to...
  • Page 35 set the switch to “LOCK”. When the Always ride at a slow speed when the differential gear is locked, the differential vehicle is in 4WD-LOCK, and allow gear lock indicator light (“DIFF. LOCK”) will extra time and distance for maneuvers. come on along with the differential gear lock indicator “...

  • Page 36: Accelerator Pedal

     Accelerator Pedal WARNING Press the accelerator pedal down to increase POTENTIAL HAZARD Malfunction of the throttle or pedal. engine speed. Spring pressure returns the WHAT CAN HAPPEN pedal to the rest position when released. The accelerator pedal could be hard to Always check that the accelerator pedal operate, making it difficult to speed up returns normally before staring the engine.

  • Page 37: Brake Pedal

    pedal completely . Brake Pedal To release the parking brake, Pull down the Press the brake pedal to slow or stop the handle and treadle the parking pedal vehicle. simultaneously; Release the handle but keep treadling the pedal for a whilw, then release the parking pedal completely ，...

  • Page 38: Drive Select Lever

    1. Drive select lever 1. Parking brake pedal 2. Parking brake pedal release lever Drive Select Lever The drive select lever is used to shift the vehicle into low, high, neutral and reverse positions. (Refer to pages 6-4—6-5 for the drive select lever operation.) 4-15...

  • Page 39: Fuel Tank Cap

    Refer to “Starting a cold engine” for proper Fuel Tank Cap operation. (See pages 6-1—6-3. ) Remove the fuel tank cap by turning it counter clockwise. A. Starter (choke) “N” 1. Fully open 1. Fuel tank cap 2. Half open 3.
  • Page 40  WARNING POTENTIAL HAZARD A loose seat. WHAT CAN HAPPEN The operator could lose control or the operator or passenger could fall if the seat is loose during operation. HOW TO AVOID THE HAZARD Make sure the seat is securely latched. 1.

  • Page 41: Seat Belts

    belt is not twisted and is not caught on Seat belts any portion of the vehicle, your clothing, This vehicle is equipped with three-point seat or any equipment you are carrying. belts for both the operator and passen- 2. Push the latch plate into the buckle until it ger.
  • Page 42  shoulder and across your chest. The WARNING shoulder belt should fit against your POTENTIAL HAZARD chest. If it is loose, pull the belt out all the Not wearing the seat belt. way and then let it retract. Wearing the seat belt improperly. 5.

  • Page 43: Glove Compartment

    Glove Compartment Cargo Bed CAUTION: To protect from damage, do not put metal products, like tools sharply edged products directly in the glove compartment. If they must stored, wrap them appropriate cushion material. 1. Cargo bed 2. Tailgate Opening and Closing the Tailgate .

  • Page 44: Lifting And Lowering The Cargo Bed

    To lift To open Push down the cargo bed release lever on Unhook the latches, and then lower the the left or right side of the vehicle, and then tailgate. slowly lift up the cargo bed until it stops. To lower To close Lower the cargo bed slowly to its original Place the tailgate in the original position, and...
  • Page 45  Keep hands and fingers away from the WARNING pinch points between the bed and the POTENTIAL HAZARD frame. Overloading the cargo bed WHAT CAN HAPPEN Could cause changes vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated maximum load limit for this cargo bed.

  • Page 46: Front And Rear Shock Adjustment

     Front and Rear Shock Adjustment WARNING The spring preload can be adjusted to suit POTENTIAL HAZARD the operating conditions. Carrying a passenger in the cargo bed. You can reduce preload for a softer ride, or WHAT CAN HAPPEN increase preload if frequent bottoming The passenger could fall, be thrown occurs.
  • Page 47 1. Special wrench 1. Spring preload adjusting ring 2. Position indicator NOTE: A special wrench can be obtained at a dealer to make this adjustment. Standard position: B A-Minimum(soft) E-Maximum(hard) 4-24...

  • Page 48: Trailer Hitch Bracket

     Trailer Hitch Bracket WARNING This vehicle is equipped with a 5 cm (2 in) POTENTIAL HAZARD receiver bracket for a standard trailer hitch. Improper shock absorber adjustment. Trailer towing equipment can be obtained at WHAT CAN HAPPEN a dealer. (See pages 6-11 － 6-13 for Uneven adjustment can cause poor precaution information.) handling and loss of stability, which...
  • Page 49 The auxiliary DC jack can be used for used, cover it with the cap. suitable work lights, radios, etc. The auxiliary DC jack should only be used when the engine is running. 1. Auxiliary DC jack Maximum rated capacity for the auxiliary Auxiliary DC jack cap DC jack: 1.
  • Page 50 may overload the circuit and cause the fuse to blow.  If accessories are used without the engine running or with the headlights turned on, the battery will lose its charge and engine starting may become difficult.  Do not use an automotive cigarette lighter or other accessories with a plug that gets hot because the jack can be damaged.

  • Page 51: Pre-Operation Checks

    PRE-OPERATION CHECKS Before using this vehicle, check the following points: ITEM ROUTINE PAGE Check operation, free play, fluid level and fluid leakage. ● Brakes 5-2—5-3，8-26—8-30 Fill with DOT 4 brake fluid if necessary. ● Check for proper operation, condition and free play. ●...

  • Page 52: Brakes

    Brakes WARNING Always check brake pedal travel and the brake POTENTIAL HAZARD fluid reservoir level before each use of the Failure to inspect the vehicle before vehicle. When applied, the brake pedal should operating. Failure to properly maintain feel firm. Any sponginess would indicate a the vehicle.

  • Page 53: Brake Fluid Level

    Check the operation of the brake pedal. Brake Operation should move smoothly and there should be a Test the brakes at slow speed after starting out firm feeling when the brakes are applied. If not, to make sure they are working properly. If the have the vehicle inspected by a dealer.

  • Page 54: Fuel

    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 Unleaded gasoline only could lead to an accident. Fuel tank capacity: HOW TO AVOID THE HAZARD 13.5L ( 2.97lmp gal, 3.57US gal ) Always check the brakes at the start of...

  • Page 55: Gasohol

    Your engine has been designed to use regular WARNING unleaded gasoline with a pump octane number POTENTIAL HAZARD ([R+M] /2) of 86 or higher, or research octane Improper care when refueling. number of 93 or higher. If knocking or pinging WHAT CAN HAPPEN occurs, use a different brand of gasoline or Fuel can spill, which can cause a fire and...

  • Page 56: Engine Oil

    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 8-7 —8-10.) 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: and maximum level marks on the coolant...

  • Page 57: Final Gear Oil

    Final Gear Oil WARNING Make sure the final gear oil is at the specified POTENTIAL HAZARD level. Add oil as necessary. (See pages 8-14 Removing the radiator cap when the —8-15 for details.) engine and radiator are still hot. Recommended oil: WHAT CAN HAPPEN SAE 80 API GL-4 Hypoid gear oil You could be burned by hot fluid and...

  • Page 58: Throttle Pedal

    Throttle Pedal WARNING Check to see that the Throttle pedal operates Failure to check or maintain proper correctly. It must operate smoothly and fully operation of the throttle system can result in spring back to the idle position when released. an accident and lead to serious injury or Have a dealer repair as necessary for proper death if the throttle pedal sticks during...

  • Page 59: Throttle Free Play

    Throttle Free play Throttle Free play Adjustment If the throttle pedal has excessive play due to 1. Remove both seats. Remove the middle cable stretch or mis-adjustment, it will cause a cover of the engine, ( see PAGE 8-6 ) 2.

  • Page 60: Steering Wheel Inspection

    firmly. Wash off any dirt or mud which could Steering Wheel Inspection Check the steering wheel for specified free play affect operation. Have a dealer repair as and smooth operation。 necessary for proper operation. 1. Position the vehicle on level ground. Fittings and Fasteners 2.

  • Page 61: Tires

    Tires 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. HOW TO AVOID THE HAZARD 1.
  • Page 62 under severe riding conditions. The following are minimums: Front 126kpa (1.26kgf/cm , 18psi) Rear 126kpa (1.26kgf/cm , 18psi) 4. Use no more than the following Pressures when seating the tire beads. Front 250kpa (2.5kgf/cm , 36psi) Rear 250kpa (2.5kgf/cm , 36psi) Higher pressures may cause the tire to burst.

  • Page 63: How To Measure Tire Pressure

    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 64: Tire Wear Limit

    Tire Wear Limit Tires for Public use When the tire groove decreases to 3 mm (0.12 If you need to drive the UTV on public road, in) due to wear, replace the tire. please switch to the tires with public road use tread, which can explore its performance.

  • Page 65: 6． Operation

    Starting a cold engine OPERATION WARNING WARNING POTENTIAL HAZARD POTENTIAL HAZARD Freezing control cables cold Operating vehicle without being weather. familiar 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 or injury.
  • Page 66 Position ③ : Cold engine start ambient NOTE: When the drive select lever is in the temperature above 25℃(77°F) ● neutral position, the neutral indicator warm engine start light should come on. If the neutral position. indicator light does not come on, ask a dealer to inspect the electric circuit.

  • Page 67: Starting A Warm Engine

    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 starter (choke) seconds before the next attempt. Each should not be used.
  • Page 68 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. ● reverse the polarity of the jumper cables when connecting to the batteries-battery explosion and/or serious damage to the 1.

  • Page 69: Warming Up

    Warming up 2. Apply the brakes, then shift by moving To get maximum engine life, always warm up the drive select lever along the shift the engine before starting off. Never guide. accelerate hard with a cold engine! To see NOTE: whether or not the engine is warm, check if it Make sure that the drive select lever is...
  • Page 70 Shifting: Neutral to Reverse reverse indicator light electrical circuit. 1. Stop the vehicle. Keep your foot off the Due to the synchronizing mechanism in ● accelerator pedal. the engine, the light may not come on 2. Apply the brake pedal. until the vehicle starts moving.
  • Page 71 Careful treatment of a new engine and drive WARNING components will result in more efficient POTENTIAL HAZARD performance and longer life for these Improperly operating in reverse. components. Perform following WHAT CAN HAPPEN procedures carefully. You could hit an obstacle or person behind you, resulting in serious injury.
  • Page 72 life of your vehicle than the period between abnormality is noticed during this period, zero and 25hours. consult a dealer. For this reason, we ask that you carefully 0-10 Hours: read the following material. Because the Avoid continuous operation above half engine is brand new, you must not put an throttle.

  • Page 73: Parking

    braking when the brake system is new could damage brake pads and rotors. CVT Break-in (Clutches/Belt) A proper break-in of the clutches and drive belt will ensure a longer life and better performance. Break in the clutches and belt by operating at slower speeds during the break-in period as recommended.

  • Page 74: Parking On A Slope

    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 1. Bring the vehicle to a stop by applying Avoid parking on hills or other inclines.

  • Page 75: Accessories And Loading

    Accessories and loading are operating could affect your ability to control the vehicle. Accessories Accessories can affect the handing and Do not mount an accessory where it ● control of your vehicle. Keep the following in could interfere with your ability to control mind when considering an accessory or the vehicle.
  • Page 76 Loading Choose a trailer hitch drawbar designed ● Cargo or a trailer can change the stability for use with a 5 cm (2in) receiver.(See and handling of a vehicle. page 4-25 for more information) You must use common sense and good Do not exceed the maximum tongue ●...
  • Page 77 an accident. WARNING Make sure the load does not interfere ● POTENTIAL HAZARD with controls or your ability to see where Overloading this vehicle or carrying or you are going. towing cargo improperly. Drive more slowly than would without a ●...

  • Page 78: Driving 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 have...
  • Page 79 The total weight of operator, passenger, WARNING accessories, cargo, trailer tongue weight, POTENTIAL HAZARD and the vehicle itself must not exceed 914Kg Carrying a passenger in the cargo bed. (See “Loading” on page 6-11.) (1848 lb). WHAT CAN HAPPEN Carrying a passenger and cargo can affect The passenger could fall or be struck vehicle handling.
  • Page 80 The driver and passenger must always wear WARNING a seat belt and an approved motorcycle POTENTIAL HAZARD Overloading this vehicle or carrying or helmet. Also wear eye protection and towing cargo improperly. protective clothing, including over-the-ankle WHAT CAN HAPPEN boots, gloves, a long-sleeved shirt or jacket, Could cause changes...
  • Page 81 HOW TO AVOID THE HAZARD WARNING POTENTIAL HAZARD Always wear an approved motorcycle Operating this vehicle without wearing helmet that fits properly. You should an approved motorcycle helmet, eye also wear: protection, and protective clothing. Eye Protection WHAT CAN HAPPEN (Goggles or Face Shield) Operating without Gloves...

  • Page 82: Learning To Operate Your Vehicle

    LEARNING TO OPERATE YOUR VEHICLE Perform the Pre-Operation Checks on pages should become familiar with 5-1－5-15. Set the parking brake, shift to performance characteristics of the vehicle in neutral, and follow the instructions on page a large, flat area that is free of obstacles and 6-1 to start the engine.

  • Page 83: Turning Your Vehicle

    Position your hands on the steering wheel so 1CAUTION: that your thumbs and fingers do not wrap Do not shift from low to high or vice versa around the wheel. This is particularly without coming to a complete stop and important when driving in rough terrain.

  • Page 84: Operating Improperly In Reverse

    Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures 。 Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2.

  • Page 85: Braking

    Maximum slope angle: 15° 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 86 WARNING Before climbing the hill, first be sure you are POTENTIAL HAZARD operating in low range 4WD or, if necessary, Operating on excessively steep hills. with 4WD Diff. Lock. To climb a hill, you WHAT CAN HAPPEN need traction, momentum, and steady The vehicle can over turn more easily throttle.

  • Page 87: Going Downhill

    WARNING drive select lever in reverse so you can use the engine brake if necessary to slow your POTENTIAL HAZARD Going down a hill improperly. descent. Release the brake and begin to WHAT CAN HAPPEN coast down the hill. Use engine braking as Could cause loss of control or cause much as possible, gently applying the brakes the vehicle to overturn.

  • Page 88: Crossing Through Shallow Water

    Before starting down hill, make sure the CROSSING THROUGH SHALLOW WATER vehicle is in low-range 4WD. On most If you must cross shallow, slow moving water slopes, this will let you use engine braking to up to the depth of the vehicle’s floorboards, help you go downhill slowly.
  • Page 89 1CAUTION： WARNING POTENTIAL HAZARD After riding your vehicle in water, be sure to 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 drive select lever box check hose and the...

  • Page 90: Vehicle Immersion

    install new plugs. Vehicle Immersion 6. Attempt to start the engine. If necessary, CAUTION： repeat the drying procedure. If your vehicle becomes immersed, major 7. Take the vehicle to your dealer for engine damage can result if the machine is service as soon as possible, whether you not thoroughly inspected.
  • Page 91 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. In this case, the two front wheels will be driven at the same rate. It may not be useful to lock the differential case after you’ve lost traction, because the skid process has destroyed the soil structure.

  • Page 92: Riding Over Rough Terrain

    Riding Over Rough Terrain WARNING Operating over rough terrain should be done POTENTIAL HAZARD with caution. Look for obstacles that could Failure extra care when cause damage to the vehicle or could lead to operating this vehicle on unfamiliar a rollover accident. Avoid jumping the terrain.

  • Page 93: Riding In Brush Or Wooded Areas

    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 94: Encountering Obstacles On The Trail

    Encountering Obstacles On The Trail WARNING If you cannot go around an obstacle such as POTENTIAL HAZARD a fallen tree trunk or a ditch, stop the vehicle Improperly operating over obstacles. where it is safe to do so. Set the parking WHAT CAN HAPPEN brake and get out to inspect the area Could cause loss of control or a...

  • Page 95: Periodic Maintenance And Adjustment

    PERIODIC MAINTENANCE AND NOTE: ADJUSTMENT If you do not have a torque wrench available during a service operation requiring one, take Periodic inspection, adjustment and lubrication your vehicle to dealer to check the torque will keep your vehicle in the safest and most settings and adjust them as necessary.
  • Page 96 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 par- WHAT CAN HAPPEN ts of the body, causing injury. Improper installation of accessories or Electrical components can cause sho- modification of this vehicle may cause cks or can start fires.

  • Page 97: Periodic Maintenance Chart For The Emission Control System

    Periodic Maintenance Chart for the Emission Control System NOTE: ● 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 isn’t used for a long period of time, the month maintenance intervals should be followed.

  • Page 98: General Maintenance And Lubrication Chart

    General Maintenance and Lubrication Chart INITIAL EVERY Month Whichever ITEM ROUTINE 1,200 2,400 2,400 4,800 Comes first (mi) (200) (750) (1,500) (1,500) (3,000) hours ● Check operation/brake pad wear/fluid leakage/see ○ ○ ○ ○ ○ Rear Brake* NOTE page 8-6. ●...
  • Page 99 INITIAL EVERY Month Whichever ITEM ROUTINE 1,200 2,400 2,400 4,800 Comes first (mi) (200) (750) (1,500) (1,500) (3,000) hours ● Check for cracks or damage. ○ ○ ○ Engine Mount* ● Check bolt tightness. ● Check operation and for looseness. Replace if ○...

  • Page 100: Hood

    Hood To Open Unhook the hood latches, and then slowly tilt the hood up until it stops. 1. Hood To Close Lower the hood slowly to its original position, and then hook the hood latches. 1. Latch(×2) Secure projections ① on the underside of the hood into slots ②...

  • Page 101: Engine Oil And Oil Filter Cartridge

    periodic maintenance and lubrication chart. To Check Engine Oil Level 1. Place the vehicle on a level surface. 2. Remove the console. (See page 8-9 for console removal and installation proce- dures.) 3. Check the engine oil level on a cold engine.

  • Page 102: To Change The Engine Oil (With Or Without Oil Filter Cartridge Replacement)

    NOTE: To Change the Engine Oil (With or The engine oil should be between the Without Oil Filter Cartridge Replacement) minimum and maximum level marks. 1. Remove the console. (See page 8-9 for console removal installation procedures.) 2. Place an oil pan under the engine to collect the used oil, and then remove the engine oil filler cap.
  • Page 103 NOTE: Skip steps 4-6 if the oil filter cartridge is not 5. Apply a light coat of engine oil to the being replaced. O-ring of the new oil filter cartridge. 4. Remove the oil filter cartridge with an oil NOTE: filter wrench.
  • Page 104 filler cap and tighten it. Tightening torque: Oil filter cartridge: 17Nm (1.7m·kgf, 12 ft·lbs) Recommended engine oil: See page 10-2. Oil quantity: Without oil filter cartridge replacement: 2.2L (1.94 lmp qt, 2.33 US qt) With oil filter cartridge replacement: 2.3 L (2.02 lmp qt, 2.43 US qt) 1CAUTION: 1.

  • Page 105: Final Gear Oil

    the crankcase. 9. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause. 10. Turn the engine off, wait at least ten 1.

  • Page 106: Changing The Final Gear Oil

    1CAUTION: Be sure no foreign material enters the final gear case. 4. Install the oil filler bolt, and then tighten it to the specified torque. 1. Final gear oil drain bolt Tightening torque: 4. Install the drain bolt, and then tighten it to Final gear oil filler bolt: the specified torque.

  • Page 107: Differential Gear Oil

    Differential Gear Oil Recommended oil: SAE 80 API GL-4Hypoid gear oil Checking the Differential Gear Oil Level Oil quantity: 1. Place the vehicle on a level surface. 0.4 L (0.35 lmp qt, 0.42 US qt) 2. Remove the differential gear oil filler bolt and check the oil level.

  • Page 108: Changing The Differential Gear Oil

    1CAUTION: 1. Be sure no foreign material enters the differential gear case. 2. Please clean the sensor every 500km (310miles). 2. Install the differential gear oil filler bolt, and then tighten it to the specified torque. 1. Differential gear oil drain bolt Tightening torque: Differential gear oil filler bolt: 4.

  • Page 109: Coolant

    Coolant 5. Fill the differential gear case with the recommended oil. The coolant level should be checked before each ride. Recommended oil: SAE 80 API GL-5 Hypoid gear oil Checking the Coolant Level Oil quantity: 1. Place the vehicle on a level surface. 0.28L (0.25 lmp qt, 0.3 US qt) 2.

  • Page 110: Changing The Coolant

    1CAUTION: Mix anti freeze with distilled water only. However, if distilled water is not available, soft water may be used for refilling. Changing the Coolant The coolant must be changed by a dealer at the intervals specified in the periodic Coolant reservoir cap maintenance and lubrication chart.

  • Page 111: Axle Boots

    NOTE: Adding water instead of coolant lowers ● the antifreeze content of the coolant. If water is used instead of coolant, have a dealer check the antifreeze content of the coolant as soon as possible. The radiator fan is automatically switched ●...

  • Page 112: Spark Plug Inspection

    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. 1. Spark plug wrench Inspection The spark plug is an important engine component and is easy to inspect.

  • Page 113: Installation

    Instead, take the vehicle to a dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. If electrode erosion becomes excessive, or if carbon and other deposits are excessive, you should replace the spark plug with the specified plug.

  • Page 114: Cleaning The Engine Air Filter Elements

    hose, empty the hose and clean the air filter Tightening torque: element and air filter case. Spark plug: 17.5 Nm(1.75 m·kgf, 12.4 ft·lbs) NOTE: If a torque wrench is not available when you are installing the spark plug, a good estimate of the correct torque is 1/4 to 1/2 turn past finger tight.
  • Page 115 and the screws fixing the air cleaner, and then remove the air cleaner. 1. Air filter element 1. Holder (×3) 2. Air filter case cover 4. Remove the air filter element. 5. Remove the sponge material from its frame. 1. Air filter frame 2.
  • Page 116 8. Inspect the sponge material and replace 6. Wash the sponge material gently but it if damaged. thoroughly in solvent. 9. Thoroughly apply foam air filter oil or WARNING other quality liquid foam air filter oil (not POTENTIAL HAZARD spray type) to the sponge material. Using low flash point solvents or gasoline to clean the sponge material.
  • Page 117 element rubber joint to the carburetor and manifold fittings securely to avoid the possibility of unfiltered air entering the engine. 1CAUTION: Never operate the engine with the air filter 1. Crankcase breather hose element removed. This will allow unfiltered 13. Install the engine cover. air to enter, causing rapid engine wear and 14.

  • Page 118: Cleaning The Spark Arrester

    Cleaning the Spark Arrester Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Remove the bolts. 1. Tailpipe 2. Spark arrester 4. Insert the tailpipe into the muffler and align the bolt holes. 5. Install the tailpipe by installing the bolts, 1、Bolt（×3）...

  • Page 119: Valve Clearance

    Valve Clearance WARNING POTENTIAL HAZARD The correct valve clearance changes with Improper cleaning of the spark arrester. use, resulting in improper fuel-air supply or Hot exhaust system. engine noise. To prevent this, the valve WHAT CAN HAPPEN Could injure the eyes. clearance must be adjusted regularly.

  • Page 120: Front Brake Pad Check

    Front Brake Pad Check NOTE: The wheels need to be removed to check the Each brake pad is provided with wear indicator grooves, which allow you to check brake pads. (See pages 8-4-18-42 for wheel the brake pad wear without having to removal and installation procedures.) disassemble the brake system.

  • Page 121: Checking The Brake Fluid Level

    The brake fluid reservoir is located under the hood. (See pages 8-7—8-8 for hood opening and closing procedure.) 1. Brake pad wear indicator groove Checking the Brake Fluid Level Insufficient brake fluid may let air enter the brake system, possibly causing the brakes to 1.

  • Page 122: Brake Fluid Replacement

    deteriorate, causing leakage and poor dealer replace the following components during periodic maintenance or when they braking performance are damaged or leaking. Recommended brake fluid: DOT 4  Replace the oil seals every two years.  Refill with the same type of brake fluid. ...
  • Page 123 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: Brake pedal  Make sure the brakes operate smo- othly and that the brake pedal posi- tion is correct.

  • Page 124: Brake Light Switch Adjustment

    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. Open the hood. (See pages 8-7—8-8 for hood opening and closing procedure.) 2.

  • Page 125: Cable Inspection And Lubrication

    Cable Inspection and Lubrication Lubricate the inner cables and the cable ends. If the cables do not operate smoothly, WARNING ask a dealer 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 damaged.

  • Page 126: Brake Pedal And Accelerator Pedal Lubrication

    Brake Pedal and Accelerator Pedal Rear Knuckle Upper and Lower Lubrication Pivot Lubrication Lubricate the pivoting parts. Lubricate the knuckle upper and lower pivots with a grease gun. Recommended lubricant: Lithium-based grease (all-purpose grease) Recommended lubricant: Lithium-based grease 8-32...

  • Page 127: Steering Shaft Lubrication

    Steering Shaft Lubrication Lower universal joint ,steering transmitssion Lubricate the pivot points. shaft Recommended lubricant: Lithium-based grease (all-purpose grease) Upper universal joint ,steering transmitssion shaft Front balance rod 8-33...

  • Page 128: Wheel Removal

    Rear balance rod 1. Nut (×4) Wheel Installation 1. Install the wheel and the nuts. Wheel Removal NOTE: Loosen the wheel nuts. The arrow mark on the tire must point ● Elevate the vehicle and place a suitable toward the rotating direction of the wheel. stand under the frame.

  • Page 129: Battery

    the ground. 3. Tighten the wheel nuts to the specified torque. Wheel nut torque: Front：70Nm（7.0 m·kgf, 49.7 ft·lbs） Rear：70Nm（7.0 m·kgf, 49.7 ft·lbs） Battery Arrow mark This vehicle is equipped with a sealed-type battery. Therefore it is not necessary to check the electrolyte or add distilled water in the battery.
  • Page 130 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. Always shield eyes when working near batteries.

  • Page 131: Battery Maintenance

    Battery Maintenance 1CAUTION: special battery charger (constant 1. When the vehicle is not used for a month voltage/ampere or constant voltage) is or longer, remove the battery and store it required for recharging a sealed-type battery. in a cool, dark place. Completely Using a conventional battery charger may recharge the battery before reinstallation.
  • Page 132 WARNING OTENTIAL 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 1.
  • Page 133 Specified Fuse: Main Fuse: 30.0A Headlight Fuse: 15.0A Ignition Fuse: 10.0A Auxiliary DC Jack Fuse: 10.0A Signaling System Fuse: 10.0A Carburetor Warmer Fuse: 10.0A 2WD/4WD Fuse 3.0A 1. Main fuse 2. Spare main fuse Backup Fuse: 10.0A 3. Headlight fuse 4.

  • Page 134: Replacing A Headlight Bulb

    Replacing a Headlight Bulb If a headlight bulb burns out, replace it as follows. 1. Lift the hood up. (See pages 8-7-8-8 for hood opening and closing procedures.) 2. Remove the cover at the rear of the headlight by pulling it off. 1.
  • Page 135 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 bulb touches something flammable. HOW TO AVOID THE HAZARD Wait for the bulb to cool before 1.

  • Page 136: Tail/Brake Light Bulb Replacement

    7. Install the bulb holder by pushing it in and turning it clockwise. 8. Install the bulb holder cover and the cover at the rear of the headlight. 1CAUTION: Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly.
  • Page 137 Tightening torque: Panel bolt: 6.5N·m (0.65 m·kgf，4.7 ft·lbs) Tail/brake light bulb holder 6. Install the panel by installing the quick fasteners and bolts, and then tighten the bolts to the specified torque. 8-43...

  • Page 138: Check And Solution To Common Problems In Vehicle

    Check and solution to Common Problems in Vehicle Here you can see some tables on the common problems which may come up when you are driving a 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 dealer.
  • Page 139 ： Table 2 Check and Solution of Common Problems in Brake System . Problems Solutions 1．Check if the handle of parking brake return to its position. Brake system is locked 2．Check if the brake discs are deformed. 3．Check if the calipers' hydraulic cylinders get stuck, or the fixing parts of calipers are deformed.
  • Page 140 Problems Solutions 1．Check if left & right brake force' deviation of front brake is with specified limit. 2．Check if the brake force of front brake go down, which Vehicle deflected cause the rear wheels are locked up before the front when braked at high wheels when braked.
  • Page 141 Problems Solutions 2. Check if the differential lock control magneto plug in rear rear differential won't bridge reduction gear box are broken. work. 3. Check if the wire is broken. 1. Check if the sensor is broken. Meter display abnormal- 2.
  • Page 142 Problems Solutions 2. Check the main ball pins to find out if they are broken. 3. Check the lock screws of front wheels and axles to find out if they are loose or broken. Front wheels shake seri- 4. Check the inner splines of front wheel hubs and outer ously in running.
  • Page 143 Problems Solutions 1. Check if overloaded. 2. Check if the springs are two soft after after long time Shock absorbers beco- running. me soft and not comfort- table in running. 3. Check if the shock absorbers lose their damping force in their travel.
  • Page 144 Table5: Check and Solution of Common Problems in Engine System Problems Solutions 1. Check the throttle cable for seizure 2. Check the adjustment knob of carburetor for damage or Idle speed can not be wear adjusted 3.Check the needle of carburetor to see if it can be placed to the bottom 1.
  • Page 145 Problems Solutions 1.Check the cooling fin of radiator for blocked by soil or dirt 2.Check the speed sensor of radiator for damage and Check fan for failure Coolant boils 3.Check if antifreeze can meet the requirement stated in the owner manual. 4.Check the coolant loop for mixed with air 1.Check the battery ,which with low electricity may cause the motor failure...
  • Page 146 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. Always use a thick rag over the cap.

  • Page 147: Cleaning And Storage

    1CAUTION: CLEANING AND STORAGE Excessive water pressure may cause water A. Cleaning seepage and deterioration of wheel bearings, Frequent, thorough cleaning of your vehicle brakes, transmission seals and electrical will not only enhance its appearance but will devices. Many expensive repair bills have improve its general performance and extend resulted from...
  • Page 148 6. Clean the seats with a vinyl upholstery WARNING cleaner to keep the cover pliable and POTENTIAL HAZARD glossy. Operation with brakes after 7. Automotive type wax may be applied to washing. all painted and chrome plated surfaces. WHAT CAN HAPPEN Avoid combination cleaner-waxes.

  • Page 149: Storage

    B. Storage Specified amount: 1 oz of stabilizer to each gallon of fuel (or Long term storage (60 days or more) of your 7.5 ml of stabilizer to each liter of fuel) vehicle will require some preventive procedures to guard against deterioration. NOTE: After thoroughly...
  • Page 150 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. 8. Remove the battery and charge it. Store it in a dry place and recharge it once a month.

  • Page 151: Specifications

    SPECIFICATIONS Model 400UTV-EC Dimensions: Overall length 2680mm (105.5 in) Overall width 1320mm (52.0 in) 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) Basic weight:...
  • Page 152 Model 400UTV-EC Engine oil: Type API service SG type or higher, JASO standard MA Recommended engine oil classification 1CAUTION: 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 153 Model 400UTV-EC Final gear case oil: Type SAE80 API GL-4 Hypoid gear oil Quantity: 0.4L (0.35 lmp qt, 0.42 US qt) Differential gear case oil: Type SAE80 API GL-5 Hypoid gear oil Quantity: 0.28L (0.25 lmp qt, 0.3US qt) Radiator capacity (including all routes): 1.5L (1.32 lmp qt, 1.59 US qt)
  • Page 154 Model 400UTV-EC Transmission: Primary reduction system V-belt Secondary reduction system Shaft drive CVT reduction ratio 0.625～2.714 Transmission type V-belt automatic Operation Right hand operation Reverse gear Forward gear Chassis: Frame type Steel tube frame Caster angle 4.0° Trail 21.0mm (0.83 in)
  • Page 155 Model 400UTV-EC Brakes: System Front and rear unified Type Front Dual disc brake Rear Dual disc brake Operation Foot operation Suspension: Front suspension Double wishbone Rear suspension Double wishbone Shock absorber: Front shock absorber Coil spring/oil damper Rear shock absorber...
  • Page 156 Model 400UTV-EC 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: Neutral indicator light Reverse indicator light Coolant temperature warning light Parking brake indicator light...

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