Coleman 400UTV-3, 400UTV-2 Owner's Manual

POWERSPORTS

OWNER’S MANUAL

(888)-405-8725 Coleman Powersports
364 S. Smith Rd. Tempe, AZ. 85281

400UTV-2

400UTV-3

No one under the

age of 16 should

operate this ATV

Owner’s Manual

Owner,s Manual

INTRODUCTION

Congratulations on your purchase of the Coleman HS400UTV-2/HS400UTV-3. This Owner’s /

Operator’s manual will provide you information regarding safe operation, operational instructions,

maintenance and care. Fully understanding this manual and following all of the instructions herein will

provide the knowledge needed to have safe and enjoyable UTV operation.

If you have any questions regarding the operation or maintenance of your UTV, please contact

Coleman Powersports 888-405-8725.

IMPORTANT SAFETY MESSAGES

● READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR UTV. MAKE SURE

YOU UNDERSTAND ALL INSTRUCTIONS.

● PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE UTV.

● NEVER OPERATE THE UTV WITHOUT PROPER TRAINING OR INSTRUCTION.

● THIS UTV, AND ANY OTHER UTV OVER 90cc, SHOULD NOT BE RIDDEN BY ANYONE UNDER 16 YEARS

OF AGE.

Owner’s Manual

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, bystander or a person inspecting or repairing the

machine.

A CAUTION indicates special precautions that must be taken to avoid damage

to the machine.

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

NOTE:

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.

Please check your local riding laws and regulations before operating this UTV.

When the temperature is below -4°F (-20°C), park the UTV in a place where the temperature is higher
than -4°F (-20°C). Start the UTV after the UTV has warmed up. Please see page 6-3 on the warming up
process.

Follow the proper parking procedures when the temperature is higher than 100°F (38°C): turn off the
engine; make sure the radiator fan is on for 3 minutes before turning off the power switch.

Starting the UTV for the first time will take longer because the fuel will need reach the fuel injectors. To
start the UTV the first time, hold the ignition key on at 5-second intervals. Allow the starter to rest 15
seconds between each start attempt.

Owner,s Manual

Coleman Powersports Limited
Warranty

Location of the Warning and
Safety Labels

1-1

Safety Information

2-1

Description and Vehicle
Identification

3-1

Identification Number Records

3-3

Vehicle Identification Number

3-3

Control Functions

4-1

Ignition Switch

4-1

Indicator and Warning Lights

4-2

Use of EPS system

4-4

Speedometer Unit

4-5

Odometer and Trip Meter Modes

4-6

Fault code indicator

4-8

Switches

4-10

On-Command Four-Wheel-Drive and
Differential Gear Lock Switches

4-11

Throttle Pedal

4-15

Brake Pedal

4-16

Parking brake pedal

4-16

Drive Select Lever

4-17

Fuel Tank Cap

4-18

Starter

4-18

Seats

4-19

Seat Belts

4-20

Glove Compartment

4-23

Cargo Bed

4-24

Opening and Closing the Tailgate

4-24

Lifting and Lowering the Cargo
Bed

4-25

Front and Rear Shock Adjustment

4-27

Trailer Hitch Bracket

4-29

Auxiliary DC Jack

2

3 1 4

Owner,s Manual

Pre-Operation Checks

5-1

Brakes

5-2

Front and Rear Brakes Brake Pedal

5-2

Brake Fluid Level

5-3

Brake Operation

5-3

Fuel

5-4

Engine Oil

5-6

Coolant

5-6

Final Gear Oil

5-7

Differential Gear Oil

5-7

Throttle Pedal

5-8

Throttle Freeplay

5-9

Throttle Freeplay Inspection

5-9

Throttle Freeplay Adjustment

5-9

Steering Wheel Inspection

5-10

Seat Belts

5-10

Fittings and Fasteners

5-10

Lights

5-10

Switches

5-10

Tires

5-11

Measuring Tire Pressure

5-13

Tire Wear Limit

5-14

Operation

6-1

Starting a Cold Engine

6-1

Starting a Warm Engine

6-3

Jump Starting

6-3

Warming Up

6-5

Drive Select Lever Operation and
Reverse

6-5

Parking

6-9

Parking on a Slope

6-10

Accessories and Loading

6-11

Your Vehicle

7-1

Getting To Know Your Vehicle

7-1

Learning To Operate Your Vehicle

7-5

Turning Your Vehicle

7-6

Operating Improperly in Reverse

7-7

5

6

7

Owner,s Manual

Braking

7-8

Going Uphill

7-8

Going Downhill

7-11

Crossing Through Shallow Water

7-12

Vehicle Immersion

7-14

Rear Axle Differential Lock

7-15

Riding Over Rough Terrain

7-16

Riding in Brush or Wooded Areas

7-17

Encountering Obstacles on the
Trail

7-18

Periodic Maintenance and
Adjustment

8-1

Periodic Maintenance Chart for
the Emission Control System

8-3

General Maintenance and
Lubrication Chart

8-4

Hood

8-6

To Open

8-6

To Close

8-7

EFI System

8-8

ECU and EFI System inspection

8-11

Engine Oil and Oil Filter Cartridge

8-11

To Check Engine Oil Level

8-11

To Change the Engine Oil (With or
Without Oil Fliter Cartridge
Replacement

8-12

Checking the Final Gear Oil Level

8-15

Changing the Final Gear Oil

8-16

Differential Gear Oil

8-18

Checking the Differential Gear Oil

8-18

Changing the Differential Gear Oil

8-19

Oil cooler

8-20

Coolant

8-21

Checking the Coolant Level

8-21

Changing the Coolant

8-22

Axle Boots

8-23

Spark Plug Inspection

8-24

Removal

8-24

Inspection

8-25

Installation

8-25

8

Owner,s Manual

Cleaning the Air Filter Elements

8-26

Cleaning the Spark Arrester

8-30

Valve Clearance

8-32

Front Brake Pad Check

8-32

Rear Brake Pad Check

8-33

Checking the Brake Fluid Level

8-34

Brake Fluid Replacement

8-35

Checking the Brake Pedal

8-35

Brake Light Switch Adjustment

8-37

Cable Inspection and Lubrication

8-38

Brake Pedal and Accelerator
Pedal Lubrication

8-38

Rear Knuckle Upper and Lower
Pivot Lubrication

8-39

Steering Shaft Lubrication

8-40

Wheel Installation

8-41

Battery

8-43

Battery Maintenance

8-45

Fuse Replacement

8-46

Replacing Headlight Bulb

8-48

Tail / Brake Light Bulb
Replacement

8-51

Troubleshooting

8-52

Common Problems in Vehicle

8-53

Cleaning and Storage

9-1

Cleaning

9-1

Storage

9-3

Specifications

10-1

Faultcode of Electronic
Injection System

11-

1

USA EPA Emissions Limited
Warranty

12-1

9

10

11

12

Owner,s Manual

Coleman Powersports Limited Warranty

Coleman Powersports LIMITED WARRANTY

This Warranty is NOT the Emissions Control Warranty. Please note this is a general Limited Warranty for this
product. It IS NOT an Emissions Control Warranty. Please see the Emissions Control Warranty in this manual.

The Warranty:
Coleman Powersports Inc offers the following warranty to the initial purchaser of this new Coleman Powersports
product. The initial purchaser is defined as the first person to purchase a new Coleman Powersports product from
an Authorized Retailer of Coleman Powersports products.

The limited warranty period for this product is 1 year from the date of purchase shown on the original sales receipt.

What is a Defect?
The Product is warranted to be free from manufacturing defects in material and workmanship for a period of 1 year
from the date of purchase shown on the sales receipt. During this period of time Coleman Powersports will, at its
option, either repair or replace any original Coleman Powersports part which is covered by this warranty and is
proven to be defective in workmanship or material.

To qualify for this warranty the part:

1. Must have been purchase from Coleman Powersports or from an authorized Coleman Powersports Retailer.

2. This warranty does not apply to any vehicle which is used in competition or used in a manner not consistent
with the normal and proper intended use for the vehicle. This vehicle is not intended for rental or commercial use.

Coleman PowersportsLimited Warranty

Who Can Perform Repairs Under this Warranty?
Repairs under this warranty should be performed by an authorized Coleman Powersports retailer or comparable
servicing dealer.

How to get service under this warranty:
To get warranty service, call Coleman Powersports at 888-405-8725 for the location of your local servicing retailer /
dealer. Please do not return the product to the retailer where the product was purchased unless instructed to do
so by Coleman Powersports. The retailer of this product does not make any warranty of its own and has no
authority to implement this warranty on behalf of Coleman Powersports without the approval of Coleman
Powersports. A COPY OF YOUR SALES RECEIPT IS REQUIRED FOR WARRANTY SERVICE.

What this Warranty Does Not Cover:
This warranty does not cover the following

1. Damage due to lack or improper maintenance as described in this manual.

2. Damage which is caused by normal use and not caused by a defect in materials or workmanship.

3. Use of the product which is not consistent with the intended use as described in the operating instructions.

4. Any expendable maintenance item which need replacement or service as part of normal maintenance, unless
such items have defects in material or workmanship which cause failure or premature wear.

5. Any product which has been altered or modified in a manner not consistent with the original design of the
product or in a manner not approved by Coleman Powersports.

6. Tires

7. Damage or failures due to abuse, neglect, or misuse of the product.

Coleman Powersports Limited Warranty

Limitations of this Warranty:
This warranty does not cover and Coleman Powersports disclaims any responsibility for:

1. Loss of time or loss of use of the product.

2. Transportation costs to and from the authorized center.

3. Other loss or damage to other equipment or personal items.

Length of Implied Warranties:
Any implied warranties are limited to the duration set forth in this warranty. Coleman Powersports does not make
any claim as to the merchantability or fitness for a particular purpose which would extend longer than the duration
of this written warranty.

Check your State Laws as some State Laws do not allow limitations as to the duration of an implied warranty.
Some States may also not allow limitation or exclusions based on incidental or consequential damages.

Location of the Warning and Safety Labels 1-1

1-2 Location of the Warning and Safety Labels

4

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.
1

2

3

Location of the Warning and Safety Labels 1-3

5

6

7

8

9

10

1-4 Location of the Warning and Safety Labels

11

12

13

14

15

Location of the Warning and Safety Labels 1-5

16

18

17

19

2-1 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.

● This vehicle is designed to carry the driver and one passenger. NEVER CARRY PASSENGERS IN

THE CARGO BED.

● Always be sure the driver and passenger are wearing seat belts.

● Never give a ride to a passenger who is too small to reach and hold the handgrip fixed before the

seat.

● Always avoid operating the vehicle on any paved surfaces, including sidewalks, driveways, parking

lots, and streets.

● Never operate this vehicle on any public street, road, or highway, even dirt or gravel streets.

● Never operate this vehicle without wearing an approved motorcycle helmet that fits properly. You

should also wear eye protection (goggles or a face shield), gloves, over-the-ankle boots, long-sleeved
shirt or jacket, and long pants.

● Never consume alcohol or drugs before or while operating this vehicle.

● Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is proper

for the terrain, visibility, operating conditions, and your experience.

SAFETY INFORMATION

Safety Information 2-2

● 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. Keep your

feet on the floorboard. Never hold onto the enclosure. Your hand could be injured if it is caught
between the enclosure and an obstacle outside the vehicle.

● Always keep both hands on the steering wheel when driving.

● Never wrap your thumbs and fingers around the steering wheel. This is particularly important when

driving in rough terrain. The front wheels will move right and left as they respond to the terrain, and
this movement will be felt in the steering wheel. A sudden jolt could wrench the steering wheel around,
and your thumbs or fingers could be injured if they are in the way of the steering wheel spokes.

● Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to

changing terrain conditions when driving the vehicle.

● Never operate on excessively rough, slippery, or loose terrain until you have learned and practiced

the skills necessary to control the vehicle on such terrain. Always be especially cautious on these
kinds of terrain.

● Never turn at excessive speed. Practice turning at slow speeds before attempting to turn at faster

speeds. Do not attempt turns on steep inclines.

● Never operate the vehicle on hills that are too steep for it or for your abilities. Go straight up and down

hills where possible. Maximum slope angle: 15°.

2-3 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. 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. Go as slowly as possible. Never go down a hill at high

speed.

● Always check for obstacles before operating in a new area.

● Never operate the vehicle in fast flowing water or water deeper than the floorboards on this model.

Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If
necessary, apply the brake several times to let friction dry out the linings.

● Always be sure there are no obstacles or people behind you when you operate in reverse. When it is

safe to proceed in reverse, go slowly.

● Do not brake abruptly when carrying loads in the cargo bed.

● Always use the size and type of tires specified in this manual.

● Always make sure the tires have the proper tire pressure as described in this manual.

● Never exceed the stated load capacity. Cargo should be as far forward in the bed as possible, and

distributed evenly from side to side. Be sure cargo is secured so that it cannot move around during
operation. Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer.
Allow greater distance for braking.

Safety Information 2-4

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. Do not spill gasoline on the engine or exhaust pipe（or muffler）when
refueling. Never refuel while smoking, or while in the vicinity of sparks, open flames, or other
sources of ignition such as the pilot light of water heaters and clothes dryers. When transporting
the vehicle in another vehicle, be sure it is kept in an upright position. Otherwise, fuel may leak
out of the engine or fuel tank.
WHAT CAN HAPPEN
Gasoline is poisonous and can cause injuries.
HOW TO AVOID THE HAZARD
If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in
your eyes, see your doctor immediately. If gasoline spills on your skin, wash with soap and
water. If gasoline spills on your clothing, change your clothes.

2-5 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.

Description and Vehicle Identification 3-1

1. Headlights

2. Front shock absorber assembly

3. Brake fluid reservoir

4. Driver seat

5. Battery

6. Fuses

7. Left body protection plate

8. Driver seat belt

9. Air filter element

10. Cargo bed

11. Tail/brake lights

12. Spark arrester

13. Rear shock absorber assembly

14. CVT-belt case

15. Fuel tank cap

16. Passenger seat belt

17. Right body protection plate

18. Spark plug

19. Oil filter cartridge

20. Radiator cap

21. Coolant reservoir

3-2 Description and Vehicle Identification

22. Parking brake lever

23. Steering wheel

24. Ignition switch

25. Light switch

26. On-Command four-wheel-drive and differential lock switches

27. Multi-function display gauge

28. Auxiliary DC jack

29. Drive select lever

30. Accelerator pedal

31. Brake pedal

32. Release parking handle

NOTE:
The vehicle you have purchased may differ slightly from

those in the figures of this manual.

Description and Vehicle Identification 3-3

Identification Number Records

Record the Vehicle Identification Number and

model label information in spaces provided for

assistance when ordering spare parts from a

service center or for reference in case the

vehicle is stolen.

1. VEHICLE IDENTIFICATION NUMBER:

2. MODEL LABEL INFORMATION

Vehicle Identification Number

The Vehicle Identification Number is stamped

into the frame.

1. Vehicle identification number

NOTE:

The vehicle identification number is used to

identify your vehicle.

4-1 Control Functions

CONTROL FUNCTIONS

Ignition Switch

1. Ignition Switch

Functions of the respective switch positions

are as follows:

ON:

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.

START:

The electric starter is engaged by turning and

holding the key in this position. Release the

key when the engine starts.

Control Functions 4-2

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”

position while engine is running, or

damage to the electric starter could

result.

● See starting instructions prior to starting

the engine. (See pages 6-1 - 6-3 for

details.)

Indicator and Warning Lights

1. Four-wheel locked showing light

2. Fault indicator light of EPS system

3. Differential gear lock indicator

4. Coolant temperature warning light“ ”

5. Emergency indicator

6. Mechanical parking brake indicator light “ ”

7. Forward indicator light “F”

8. Neutral indicator light “N”

9. Reverse indicator light “R”

10. Engine indicator light “P”

11. Oil Overheat Indicator

12. Low Battery charge indicator

4-3 Control Functions

Forward indicator light Light “F”

This indicator light comes on when the drive

select lever is in the “F” position.

Mechanical Parking Brake Indicator Light

“ ”

This indicator light comes on when the

mechanical parking brake is applied.

Neutral Indicator Light “N”

This indicator light comes on when the drive

select lever is in the “N” position.

Reverse Indicator Light “R”

This indicator light comes on when the drive

select lever is in the “R” reverse position.

Coolant Temperature Warning Light “ ”

When the coolant temperature reaches a

specified level, this light comes on to warn

that the coolant temperature is too hot. If

the light comes on during operation, stop the

engine as soon as it is safe to do so and

allow the engine to cool down for about 15

minutes.

CAUTION:

 The engine may overheat if the vehicle is

overloaded. If this happens, reduce the

load to specification.

 After restarting, make sure that the light

is out. Continuous use while the light is
on may cause damage to the engine.

High beam indicator

The light being on means headlight is at high

beam mode.

Control Functions 4-4

Position light indicator

The light being on means that the position

light fixed in the front headlight has been

turned on.

Emergency indicator“ ”

The light being on means emergency lamp is

on.

Fault indicator light and fault codes

The Fault meter is an important part of the

UTV. The meter works together with EPS

system and monitors the working condition of

EPS system.

Fault is displayed by the fault indicator light

and the fault code indicator of the EPS

system, so the driver can acknowledge fault

of the EPS in time to take some measures to

keep himself/herself safe.

When fault occurs in the EPS system, the

indicator light will be lit up on consol. At the

same time, the fault code will display on the

consol.

 When turning on the main switch

(Ignition key) of the UTV, the EPS

system will automatically enter into its

working state.

 Check the consol. If the fault indicator

light of the EPS system is not lit, the

EPS system is ready for regular use.

4-5 Control Functions

 If the fault indicator light for the EPS

system is lit, the EPS system has found

some fault during the ECU self-checking

process. Consult with your dealer for

repair.

Oil Overheat Indicator

The light will turn on when the UTV is

overheating

NOTE:

If the engine is overheating, stop the UTV

immediately. Do not start the engine again

until the UTV has been inspected and

repaired by a service center.

Low Battery charge indicator

Indicates a low charge on the battery. If light
is illuminated, re-charge battery. If recharging
the battery does not fix the issue, have a
service center inspect the battery and UTV.

Speedometer Unit

1. Left turn indicator light

2. “TRIP/ODO” button

3. Clock/Hour meter

4. Right turn indicator light

Control Functions 4-6

5. Tachometer

6. Odometer/Trip meter A / Trip meter B/Clock/Hour button

7. Metric/mile button

8. Speedometer

Speedometer unit functions:

 a speedometer (which shows the speed)
 an odometer (which shows the total

distance covered)

 a trip meter (which can be cleared and

then show any new distances traveled)

 an RPM indicator (which shows the

revolutions per minute of the engine)

 a clock
 an EFI fault code indicator (which shows

the fault code for problems with the EFI )

Odometer and trip meter modes

On the display panel there are two large

buttons, one located on the left side and one

on the right side. Quickly pressing the

button on the left side toggles the display

from the odometer, to the trip meter, and the

to the hours meter; then it starts the cycle

over.

The odometer displays the total distance

traveled by the UTV. The trip meter records

distances for a specific trip and can record

distances from 0 through 999.9 miles.

To reset a trip meter, hold down the right

button for an extended period of time until the

trip meter resets. The trip meter can be used

to estimate the distance that can be traveled

with a full tank of fuel. This information will

enable you to judge the fuel consumption.

4-7 Control Functions

To change the display from miles per hour to

kilometers per hour press the right side

button on the display. This will also change

the displayed mileage from miles to

kilometers.

Clock time adjustment

Press the left button and hold for three

seconds and the clock goes into the hour

‘set’ mode.

1. Press the right button to set the hour.

2. Press the left button again and the clock

goes into the minute ‘set’ mode.

3. Press the right button to set the minutes.

4. Press the left button again and the clock

will exit the ‘set’ mode.

Four-wheel drive indicator “ ”

There are two 4WD indicators on the display

panel. The left 4WD indicator has a blinking

circle on the front axle when the grey and

yellow 4WD selector buttons are pressed in

indicating the “4WD” function has been

activated. This position also indicates that

the 4WD is NOT locked. This allows the

wheels on the left and right sides to rotate at

different speeds to accommodate turning.

Differential gear lock indicator

The right 4WD symbol will show an ‘X’ over

the center of the front axle when the lever is

moved to the right and the yellow differential

gear lock button is set to “out” position, which

Control Functions 4-8

means the differential is not operational and

is locked. When riding an UTV on muddy and

slippery roads or when climbing a steep hill,

make sure the 4WD lock indicator is on.

When riding on a flat road at a comparatively

high speed, adjust the settings to

“2WD/UNLOCK” where there are no

symbols in either of the 4WD indicators.

Riding the UTV while the differential is

functioning and is NOT locked, may improve

the stability and safety of the UTV during

operation.

CAUTION:

When the selector is set to 4WD, the right

4WD symbol front axle will have an ‘X’ in the

middle . When riding on good surfaces you

should unlock the differential and press in

the yellow and the gray buttons to the 2WD

unlocked position. There should be no

symbols showing in either the left or right

4WD indicators.

CAUTION:

If the display indicators flash or the

speedometer does not show the speed while

the UTV is in motion, Ask a dealer to check

the speed sensor and circuits.

Fault code indicator

When the EFI encounters faults, the ECU will

send the fault code to the instrument display,

and it will flash on the clock.

4-9 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. Only after the fault is

fixed, will the time show automatically.

The description for the fault codes are shown

in Chapter 11 of this manual.

Fuel level indicator

The fuel level display will indicate the fuel

volume. When the fuel is getting low the fuel

pump symbol will flash.

1. Fuel level indicator 2. Fuel level warning indicator

Control Functions 4-10

Switches

1. Light switch “OFF/ / ”

Light Switch “OFF/ / ”

Set the switch to “ ”to turn on the low beam

and the taillights.

Set the switch to “ ”to turn on the high

beam and the taillights.

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.

4-11 Control Functions

On-Command Four-Wheel–Drive and

Differential Gear Lock Switches

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”.

Select the appropriate drive according to

terrain and the conditions.

 Two-wheel drive (”2WD”): Power is sup-

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.

Unlike the 4WD mode, all wheels turn at

the same speed regardless of traction.

Control Functions 4-12

WARNING

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.
Changing from 2WD to 4WD or from 2WD
to 2WD–Differential UNLOCK, or
vice-versa while moving may cause the
vehicle to unexpectedly handle
differently. This could distract the
operator and increase the risk of losing
control and an accident.
HOW TO AVOID THE HAZARD

Always stop the vehicle before changing
from 2WD to 4WD or from 2WD to
2WD–Differential UNLOCK.

On-Command Four-Wheel-Drive Switch

“2WD/4WD”

1. On-Command four –wheel-drive switch “2WD/4WD”

2. Select lever

4-13 Control Functions

To change from 2WD to 4WD

Stop the vehicle, be sure the select lever is
set to position ，and then set the switch to
“4WD”. When the vehicle is in 4WD, the 4WD
indicator will come on in the multi-function
display.

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”,

move the select lever to position , and then

set the switch to “LOCK”.

1. On-Command differential lock switch “4WD/LOCK”

2. Select lever

When the differential gear is locked, the

Control Functions 4-14

differential gear lock indicator light will come
on along with the differential gear lock
indicator in the multifunction meter unit
display. To release the differential gear lock,
stop the vehicle and set the switch to “4WD”.

WARNING

POTENTIAL HAZARD
Riding too fast while the vehicle is in

4WD-LOCK.
WHAT CAN HAPPEN
All wheels turn at the same speed when

the differential is locked, so it takes more
effort to turn the vehicle. The amount of
effort required is greater the faster you
go. You may lose control and have an
accident if you cannot make a sharp
enough turn for the speed you are
traveling.

HOW TO AVOID THE HAZARD
Always operate at a slow speed when the

vehicle is in 4WD-LOCK, and allow extra
time and distance for maneuvers.

NOTE:

 When the switch is set to “LOCK”, the

differential gear lock indicator and

indicator lights will flash until the

differential gear is locked.

 When the differential gear lock indicator

and indicator lights are flashing, turning

the steering wheel back and forth will

help the differential gear lock to engage.

 Riding before the differential gear lock is

properly engaged (e.g., when the

indicator and indicator light are flashing)

will cause the engine speed to be limited

until engagement is complete.

4-15 Control Functions

Throttle Pedal

Press the throttle pedal down to increase

engine speed. Spring pressure returns the

pedal to the rest position when released.

Always check that the throttle pedal returns

normally before staring the engine.

1. Throttle pedal

Before starting the engine, check the throttle
pedal to be sure it is operating smoothly.
Make sure the throttle pedal fully returns to
the idle position as soon as it is released.

Control Functions 4-16

WARNING

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. This could
cause an accident.
HOW TO AVOID THE HAZARD
Check the operation of the accelerator
pedal before you start the engine. If the
accelerator pedal does not work
smoothly, check for the cause. Correct
the problem before operating the vehicle.
Consult a service center if you cannot
find or solve the problem yourself.

Brake Pedal

Press the brake pedal to slow or stop the

vehicle.

1. Brake pedal

Parking brake pedal

The parking brake pedal is located at the left
side of the driver’s seat. It will help hold the

4-17 Control Functions

vehicle from moving while parked.
To set the parking brake, depress the parking
brake pedal completely.
To release the parking brake, Pull down the
parking brake release handle and depress
the parking pedal simultaneously; Release
the handle and lift foot off the parking brake
gradually. Spring pressure helps return the
pedal to the released position. Be sure to
fully release the parking brake before starting
out. Failure to do so may result in poor
performance and premature wearing of the
rear brake and V-belt.

1. Parking brake pedal

2. Parking brake pedal release lever

Drive Select Lever

The drive select lever is used to shift the
vehicle into forward, neutral and reverse
positions. (Refer to pages 6-5 for drive select
lever operation.)

Control Functions 4-18

1. Drive select lever

Fuel Tank Cap

Remove the fuel tank cap by turning it

counter clockwise.

1. Fuel tank cap

4-19 Control Functions

Starter (choke) “ ”

Starting a cold engine requires a richer
air-fuel mixture. A separate choke cable
supplies this mixture.

Move in direction to open choke

Move in direction to turn close choke
Refer to “Starting a cold engine” for proper
operation. (See pages 6-1 - 6-3.)

A. Choke knob 1. Fully open

2. Half open 3. Closed

Seats

To remove the seat bench, pull front of seat

upward, then slide seat forward.

1. Driver / Passenger seat

To install seat bench, insert tabs on rear of
seat into the seat holders located on the UTV
frame. Push down the front of the seat until it
snaps in place.

Control Functions 4-20

WARNING

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.
HOW TO AVOID THE HAZARD
Make sure the seat is securely latched.

Seat belts

This vehicle is equipped with three-point seat

belts for both the operator and passenger.

Always wear seat belts while riding in the

vehicle.

1. Seat belt (×2) 2. Latch plate (×2)

3. Buckle (×2)

4-21 Control Functions

Proper use of the seat belts involves the
following steps:

1. Hold the latch plate as you pull the belt
across your lap and chest. Make sure the
belt is not twisted and is not caught on
any portion of the vehicle, your clothing,
or any equipment you are carrying.

2. Push the latch plate into the buckle until it
clicks. Pull up on the latch plate to make
sure it is secure.

3. Place the lap portion of the belt low on
your hips. Push down on the buckle end
of the belt as you pull up on the shoulder
part so the belt is snug across your hips.

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.

Control Functions 4-22

5. To release the buckle, firmly press the
release button.

1. Buckle 2. Release button

WARNING

POTENTIAL HAZARD

Not wearing the seat belt or wearing the

seat belt improperly.

WHAT CAN HAPPEN

There is an increased risk of being killed

or seriously injured in an accident.

HOW TO AVOID THE HAZARD

Always wear your seat belt when riding in

the vehicle.

Be sure the seat belt is close fitting

across your hips and chest and is latched

securely.

4-23 Control Functions

Glove Compartment

CAUTION:

To prevent damage to the glove

compartment do not place metal products,

like tools or sharp edged products directly in

the glove compartment. If they must be

stored, wrap them in appropriate cushion

material.

a. Open.

Control Functions 4-24

Cargo Bed

1. Cargo bed 2. Tailgate

Opening and Closing the Tailgate

1. Tailgate 2. Latch (×2)

To open

Unhook latches, and lower the tailgate.

To close

Place tailgate in original up position, then

hook latches.

4-25 Control Functions

Lifting and Lowering the Cargo Bed

1. Cargo bed release lever

To lift

Push down cargo bed release lever on left or
right side of the vehicle; slowly lift up cargo
bed until it stops.

To lower

Lower cargo bed slowly to its original position
and be sure it locks into place.

Maximum load limit: 350lb (158kg)

WARNING

POTENTIAL HAZARD

Pinch points.

WHAT CAN HAPPEN

You or someone else could be pinched

between the cargo bed and the frame

when the bed is being lowered.

HOW TO AVOID THE HAZARD

Before closing the bed, be sure others are

standing away from the vehicle. Keep

hands and fingers away from pinch points

between the bed and frame.

Control Functions 4-26

WARNING

POTENTIAL HAZARD

Overloading the cargo bed.

WHAT CAN HAPPEN

Could cause changes in vehicle handling

which could lead to an accident.

HOW TO AVOID THE HAZARD

Never exceed the stated maximum load

limit for this cargo bed.

Cargo should be properly distributed and

securely attached.

Reduce speed when carrying cargo.

Allow greater distance for braking.

WARNING

POTENTIAL HAZARD

Carrying a passenger in the cargo bed.

WHAT CAN HAPPEN

The passenger could fall, be thrown out,

or be struck by objects in the cargo bed.

HOW TO AVOID THE HAZARD

Never carry a passenger in the cargo bed.

This cargo bed is designed to carry cargo

only.

4-27 Control Functions

Front and Rear Shock Adjustment(Option 1)

The spring preload can be adjusted to suit

the operating conditions.

You can reduce preload for a softer ride, or

increase preload if the vehicle is bottoming

out on rough terrain.

CAUTION:

Frequent or severe bottoming out can cause

increased wear or damage to the vehicle.

Adjust the spring preload as follows.

To increase the spring preload, turn the

adjusting ring in direction .
To decrease the spring preload, turn the

adjusting ring in direction .

1. Spring preload adjusting ring

2. Position indicator

NOTE:

A special wrench can be obtained at a

service center to make this adjustment.

Control Functions 4-28

Standard position: B

A-Minimum(soft)

E-Maximum(hard)

1. Special wrench

WARNING

POTENTIAL HAZARD

Improper shock absorber adjustment.

WHAT CAN HAPPEN

Uneven adjustment can cause poor

handling and loss of stability, which

could lead to an accident.

HOW TO AVOID THE HAZARD

Always adjust the shock absorbers on

the left and right side to the same setting.

4-29 Control Functions

Front and Rear Shock Adjustment(Option 2)

WARNING

These shock absorber assemblies

contain highly pressurized nitrogen gas,

read and understand the following

information before handling the shock

absorber assemblies.

·Do not tamper with or attempt to open

the cylinder assemblies.

· Do not subject the shock absorber

assemblies to an open flame or other

high heat source. This may cause the unit

to explode due to excessive gas

pressure.

·Do not deform or damage the cylinders

in any way. Cylinder damage will result in

poor damping performance.

·Do not dispose of a damaged or worn

out shock absorber assembly yourself.

Take the shock absorber assembly to a

HSUN dealer for any service.

The spring preload, rebound damping and

compression damping forces of the front

and rear shock absorber assemblies can be

adjusted to suit the operating conditions.

NOTE:

Never turn an adjusting mechanism beyond

the minimum and maximum settings.

Control Functions 4-30

Spring preload

1. Loosen the locknut.

2. Turn the spring preload adjusting nut in

direction ⓐ to increase the spring

preload and thereby harden the
suspension, and in direction ⓑ to

decrease the spring preload and thereby

soften the suspension.

·A special wrench can be obtained at a

HSUN dealer to make this adjustment.

·The spring preload setting is determined

by measuring distance A, shown in the

illustration. The shorter distance A is, the

lower the spring preload; the longer distance

A is, the higher the spring preload. With each

complete turn of the adjusting nut.

1. Locknut 2. Spring preload adjusting nut

3. Special wrench

1. Distance A

4-31 Control Functions

Spring travel setting(Front)

Minimum(soft): 375mm(14.76 in)

Maximum(hard): 490mm(19.29 in)

Spring travel setting(Rear)

Minimum(soft): 402mm(15.83 in)

Maximum(hard): 490mm(19.29 in)

3. Tighten the locknut.

NOTE:

Always tighten the locknut against the

adjusting nut, and then tighten it to the

specified torque.

Rebound damping force

Turn the rebound damping force adjusting

screw in direction S to increase the rebound

damping force and thereby harden the

damping, and in direction F to decrease the

rebound damping force and thereby soften

the damping.

1.Rebound damping force adjusting screw

Control Functions 4-32

Compression damping force

Turn the compression damping force

adjusting screw (use 2.5mm allen wrench) in
direction ⓐ to increase the compression

damping force and thereby harden the
damping, and in direction ⓑ to decrease the

compression damping force and thereby

soften the damping.

1. Compression damping force adjusting screw

WARNING

·Suspension components become hot

during operation. Never touch the

compression damping force adjusting

screw, the rebound damping force

adjusting screw or the oil reservoir with

your bare hand or skin until suspension

components have cooled.

·Always adjust the shock absorber

assemblies on the left and right side to

the same setting. Uneven adjustment can

cause poor handling and loss of stability,

which could lead to an accident.

4-33 Control Functions

Trailer Hitch Bracket

This vehicle is equipped with a 1 1/4 inch

receiver bracket for a standard trailer hitch.

Trailer towing equipment can be obtained at
a service center. (See pages 6-11－6-13 for

precaution information.)

1. Trailer hitch bracket

Auxiliary DC Jack

The auxiliary DC jack is located at the right
side of the front panel.
The auxiliary DC jack can be used for
suitable work lights, radios, etc.
The auxiliary DC jack should only be used
when the engine is running.

1. Auxiliary DC jack cap

Control Functions 4-34

1. Set the light switch to “OFF”.

2. Start the engine. (See pages 6-1-6-3.)

3. Open the auxiliary DC jack cap, and then

insert the accessory power plug into the
jack.

4. When the auxiliary DC jack is not being

used, cover it with the cap.

2. Auxiliary DC jack

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.

 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 accessory with a plug that
gets hot. A hot plug can damage the
auxiliary jack.

5-1 Pre Operation Checks

Before using this vehicle, check the following items:

ITEM

ROUTINE

PAGE

Brakes

● Check operation, free play, fluid level and fluid leakage

● Fill with DOT 4 brake fluid if necessary

5-2 - 5-3，8-33 - 8-36

Parking brake

● Check for proper operation, condition and free play

6-9 - 6-10

Fuel

● Check fuel level

● Fill with fuel if necessary

5-4 - 5-5

Engine/Gear box oil

● Check oil level

● Fill with oil if necessary

5-6 - 5-7

Coolant reservoir

● Check coolant level

● Fill with coolant if necessary

5-6，8-20- 8-21

Final gear oil /
Differential gear oil

● Check for leakage

5-7

Accelerator pedal

● Check for proper accelerator pedal operation

5-8 - 5-10

Seat belts

● Check for proper operation and belt wear

5-10

Steering

● Check for proper operation

5-10

Fittings and fasteners

● Check all fittings and fasteners

5-10

Lights and switches

● Check for proper operation

5-10

Wheels and tires

● Check tire pressure, wear and damage

5-2 - 5-14，8-39 - 8-42

Axle boots

● Check for damage

8-23

Instrument

● Check for correct operation

4-2 - 4-8

Light/Indicator

● Check for light / indicator operation

4-2 - 4-8

Pre Operation Checks 5-2

WARNING

POTENTIAL HAZARD

Failure to inspect the vehicle before

operating. Failure to properly maintain the

vehicle.

WHAT CAN HAPPEN

Increases the possibility of an accident or

equipment damage.

HOW TO AVOID THE HAZARD

Always inspect your vehicle each time you

use it to make sure the vehicle is in safe

operating condition. Always follow the

inspection and maintenance procedures

and schedules described in the Owner’s

Manual.

Brakes

Always check the brake pedal travel and the

brake fluid reservoir level before each use of

the vehicle. When applied, the brake pedal

should feel firm. Any sponginess will indicate a

possible fluid leak or low brake fluid level, which

must be corrected before riding.

If you discover any irregularities in brake

system operation, including excessive pedal

travel, contact your service center for proper

diagnosis and repairs.

Front and Rear Brakes / Brake Pedal

Check for correct brake pedal free play. If the

brake pedal free play is incorrect, have a
service center adjust it. (See pages 8-33－

5-3 Pre Operation Checks

8-36.)

Check operation of the brake pedal. Brake

pedal should move smoothly and should feel

firm when the brakes are applied. If there is a

problem, have the brakes inspected by a

service center.

Brake Fluid Level

Check the brake fluid level.

Add fluid if necessary. (See pages 8-33-8-34)

Recommended brake fluid: DOT 4

Brake Fluid Leakage

Check to make sure there is no brake fluid

leaking out of brake hoses, joints or the brake

fluid reservoir. Apply the brakes firmly for one

minute. If there is any leakage, have the vehicle

inspected by a service center.

Brake Operation

Test the brakes at a slow speed when starting

out to make sure they are working properly. If

brakes do not provide proper braking

performance, inspect the brake system. (See
pages 8-33—8-36.)

Pre Operation Checks 5-4

WARNING

POTENTIAL HAZARD

Driving with improperly operating brakes.

WHAT CAN HAPPEN

You could lose braking ability, which could

lead to an accident.

HOW TO AVOID THE HAZARD

Always check the brakes at the start of

every ride. Do not operate the vehicle if you

find any problems with the brakes. If a

problem cannot be corrected by the

adjustment procedures provided in this

manual, have the vehicle inspected by a

service center.

Fuel

Make sure there is sufficient gasoline in the

tank.

Recommended fuel:

Unleaded gasoline only

Fuel tank capacity:

6.86 gal (26 L )

CAUTION:

Use only unleaded gasoline. The use of leaded

gasoline will cause severe damage to internal

engine parts, such as the valves and piston

rings, as well as to the exhaust system.

5-5 Pre Operation Checks

Your engine has been designed to use regular

unleaded gasoline with a pump octane number

([R+M] /2) of 91 or higher, or research octane

number of 91 or higher. If knocking or pinging

occurs, use a different brand of gasoline or

premium unleaded fuel. Unleaded fuel will give

you longer spark plug life and reduced

maintenance cost.

Gasohol

There are two types of gasohol: gasohol

containing ethanol and that containing methanol.

Gasohol containing ethanol can be used if

ethanol content does not exceed 10%. Gasohol

containing methanol is not recommended

because it may cause fuel system damage or

vehicle performance problems.

WARNING

POTENTIAL HAZARD

Improper care when refueling.

WHAT CAN HAPPEN

Fuel can spill, which can cause a fire and

severe injury.

Fuel expands when it heats up. If the fuel

tank is overfilled, fuel could spill out due to

heat from the engine or the sun.

HOW TO AVOID THE HAZARD

Do not overfill the fuel tank. Be careful not

to spill fuel, especially on the engine or

exhaust pipe. Wipe up any spilled fuel

immediately. Be sure the fuel tank cap is

closed securely.

Pre Operation Checks 5-6

Engine Oil

Make sure the engine oil is at the specified level.
Add oil as necessary. (See pages 8-11—8-15.)

CAUTION:

 In order to prevent clutch slippage (since

the engine oil also lubricates the clutch), do
not mix any chemical additives. Do not use
oils with a diesel specification of “CD” or oils
of a higher quality than specified. In addition,
do not use oils labeled “ENERGY
CONSERVING II” or higher.

 Make sure that no foreign material enters

the crankcase.

Recommended engine oil type and
quantity:

See page 10-2

Coolant

Check the coolant level in the coolant reservoir
when the engine is cold. (The coolant level will
vary with engine temperature.) The coolant
level is satisfactory if it is between the minimum
and maximum level marks on the coolant
reservoir. If the coolant level is at or below the
minimum level mark, add additional coolant to
bring the level up to maximum level mark. If
coolant is not available, add distilled water.
Change the coolant every two years. (See
pages 8-20 - 8-22) for details.

CAUTION:

Hard water or salt water is harmful to the engine.
You may use soft water if you cannot get
distilled water.

5-7 Pre Operation Checks

Coolant reservoir capacity
(up to the maximum level mark):

0.627L(0.555lmp qt, 0.663US qt)

WARNING

POTENTIAL HAZARD

Removing the radiator cap while the engine

and radiator are still hot.

WHAT CAN HAPPEN

You could be burned by hot fluid or 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. Allow any remaining pressure to

escape before completely removing the cap.

Final Gear Oil

Make sure the final gear oil is at the specified
level. Add oil as necessary. (See pages 8-18 ­8-19 for details.)

Recommended oil:
SAE 80 API GL-4 Hypoid gear oil

If desired, an SAE 80W90 hypoid gear oil may
be used for all conditions.

NOTE:

GL-5 or GL-6 rated hypoid gear oil may also be
used.

Differential Gear Oil

Make sure the differential gear oil is at the
specified level. Add oil as necessary. (See
pages 8-18- 8-20 for details.)

Pre Operation Checks 5-8

Recommended oil:
SAE 80 API GL-5 Hypoid gear oil

Throttle Pedal

Check to see that the Throttle pedal operates

correctly. The throttle pedal must operate

smoothly and fully spring back to idle position

when released. If the throttle pedal does not

operate properly, have the vehicle inspected by

a service center

WARNING

Failure to check or maintain proper operation

of the throttle system can result in an accident

leading to serious injuries or death.

Never start or operate this vehicle if it has a

sticking or improperly operating throttle pedal.

Immediately contact your service center for

service if throttle problems arise.

Always check the throttle pedal for free

movement before starting the engine.

Periodically check the throttle pedal during

operation.

5-9 Pre Operation Checks

Throttle Freeplay

If the throttle pedal has excessive play due to
cable stretch or mis-adjustment, it will cause a
delay in throttle response, especially at low
engine speed. The throttle may also not open
fully. If the throttle pedal has no freeplay, the
throttle may be hard to control, and the idle
speed may be erratic.
Check the throttle pedal freeplay, Adjust the
freeplay if necessary.

Throttle Freeplay Inspection

1. Set parking brake

2. Start the engine. Allow engine to warm up a
few minutes

3. Measure the distance the throttle pedal
moves before the engine begins to pick up
speed. Freeplay should 1/16 to 1/8 inches
(1.5-3mm).

Throttle Freeplay Adjustment

1. Remove seat.

2. Loosen the throttle cable column nut.
Adjust the throttle cable so the throttle pedal
freeplay is 1/16 to 1/8 inches (1.5-3mm).

1．Throttle Cable column nut

3. Tighten the Throttle Cable column nut.

4. Re-attach the seat

Pre Operation Checks 5-10

Steering Wheel Inspection

Check the steering wheel for specified freeplay
and smooth operation。

1. Position the vehicle on level ground.

2. Lightly turn the steering wheel left and right.

3. There should be 0.8″-1.0” (20-25 mm) of

freeplay.

If there is excessive freeplay, strange noises, or
steering feels rough or “catchy″, have the

steering system inspected by an authorized
service center。

Seat Belts

Make sure that both seat belts are not frayed or

damaged.

The seat belt must move smoothly when pulled

out and retract on its own when released. The

latch plate should click securely into the buckle

and release when the release button is pushed

firmly. Wash off any dirt or mud which could

affect operation. Have a service center repair as

necessary.

Fittings and Fasteners

Always check the tightness of the chassis

fittings and fasteners before each ride. Take the

vehicle to a service center or refer to the

Service Manual for correct torque specs.

Lights

Check the headlights and tail/brake lights to

make sure they are in good working condition.

Repair as necessary for proper operation.

Switches

Check the operation of all switches. Have a

service center repair as necessary.

5-11 Pre Operation Checks

WARNING

POTENTIAL HAZARD
Operating this vehicle with improper tires, or with improper or uneven tire pressure.
WHAT CAN HAPPEN
Use of improper tires on this vehicle, or operation of this vehicle with improper or uneven tire
pressure, may cause loss of control, increasing your risk of accident.
HOW TO AVOID THE HAZARD

1. The tires listed below have been approved by the Manufacturer for this model. Other tire
combinations are not recommended.

2. The tires should be set to the recommended tire pressure:

Front 10psi (70kpa ,0.7 kgf/cm2)

Rear 10psi (70kpa ,0.7 kgf/cm2 )

Check and adjust tire pressure when tires are cold. Front tires on both sides should be the

same tire pressure. Rear tires on both sides should be the same tire pressure.

Type

Size

Front

25×8-12

6PR

Rear

25×10-12

6PR

Pre Operation Checks 5-12

3. Tire pressure below the minimum specified could cause the tire to dislodge from the rim under

severe riding conditions. The following are minimums:

Front 9psi (63kpa 0.64kgf/cm2 )

Rear 9psi (63kpa 0.64kgf/cm2 )

4. Use no more than the following

Pressures when seating the tire beads.

Front 36psi (250kpa, 2.5kgf/cm2)

Rear 36psi (250kpa, 2.5kgf/cm2)

Higher pressures may cause the tire to burst. Inflate tires slowly and carefully. Fast inflation

could cause the tire to burst.

5-13 Pre Operation Checks

How to measure tire pressure

Use the tire pressure gauge.

NOTE:

The tire pressure gauge is included as standard

equipment. Make two measurements of the tire

pressure and use the second reading. Dust or

dirt in the gauge could cause the first reading to

be incorrect. Set pressure with tires cold. Set

tire pressures to the following specifications:

Recommended

pressure

Minimum

Maximum

Front

10psi

(0.70kgf/ cm2,

70kpa)

9psi

(0.64kgf/ cm2,

63kpa)

11psi

(0.77kgf/ cm2,

77kpa)

Rear

10psi

(0.70kgf/ cm2,

70kpa)

9psi

(0.64kgf/ cm2,

63kpa)

11psi

(0.77kgf/ cm2,

77kpa)

1. Tire pressure gauge

Pre Operation Checks 5-14

Tire Wear Limit

When the tire groove decreases to 0.12 in (3

mm) due to wear, replace the tire

a. Tire wear limit

6-1 Operation

WARNING

POTENTIAL HAZARD

Operating vehicle without being familiar

with all controls.

WHAT CAN HAPPEN

Loss of control, which could cause an

accident or injury.

HOW TO AVOID THE HAZARD

Read the Owner’s Manual carefully. If

there is a control or function you do not
understand, ask your service center.

Starting a cold engine

WARNING

POTENTIAL HAZARD

Freezing control cables in cold weather.

WHAT CAN HAPPEN

You could be unable to control the

vehicle, which could lead to an accident

or collision.

HOW TO AVOID THE HAZARD

When riding in cold weather, always

make sure all control cables work

smoothly before you begin riding.

1. Apply the brake.

2. Shift the drive select lever into the

neutral position.

Operation 6-2

NOTE:

● When the drive select lever is in the

neutral position, the neutral indicator
light should come on. If the neutral
indicator light does not come on, ask a
service center to inspect the electric
circuit.

● The engine can be started in any gear if

the brake is applied. However, it is
recommended to shift into neutral before
starting the engine.

3. Use the starter (choke) in reference to

the figure:

Position①: Cold engine start ambient

temperature below 41°F (5℃)

Position②: Cold engine start ambient

temperature at 32°F - 86°F
(0℃ - 30℃).

Position③: Cold engine start ambient

temperature above 86°F (30

℃)

a. Choke knob 1. Fully open

2. Half open 3. Closed

4. With your foot off the accelerator pedal,

start the engine by turning the key to

“START”.

6-3 Operation

NOTE:

If the engine fails to start, release the key,
and then try starting again. Wait a few
seconds before the next attempt. Each
cranking should be as short as possible to
preserve battery energy. Do not crank the
engine more than 5 seconds on each
attempt.

5. If the engine is started with the starter

(choke) in position ①, the choke should
be returned to Position ② to warm up
the engine. If the engine is started with
the choke in Position ②, keep the choke
in this position to warm up the engine.

6. Continue warming up the engine until it
idles smoothly and return the choke to
position ③ before riding.

CAUTION:

See the “Engine break-in”section prior to
operating the engine for the first time.

Starting a warm engine

To start a warm engine, refer to the“Starting
a cold engine”section. The choke should not

be used. Press the accelerator pedal slightly.

Jump-starting

Jump-starting the vehicle should be avoided.

The battery should be removed and charged

instead. However, if the vehicle must be

jumpstarted, proceed as follows.

1. Turn the key to“OFF”.

2. Open the hood. (See pages 8-6 - 8-7for

hood opening and closing procedures.)

3. Remove the battery compartment cover.

4. Using a charged 12V battery, connect
the positive lead of the jumper cable to
the positive terminal of the battery in the
vehicle and the other end of the positive
lead to the positive terminal of the
charged battery.

Operation 6-4

1. Jumper cable positive lead

2. Jumper cable negative lead

5. Connect the negative lead of the jumper
cable to the negative terminal of the
charged battery and the other end of the
negative lead to an unpainted metal
surface of the vehicle.

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
electrical system may occur.

6. Start the engine. (Refer to“Starting a
cold engine”on pages 6-1—6-3.)

7. After the engine starts, disconnect the
negative lead of the jumper cable from
the vehicle and charged battery, and
then disconnect the positive lead of the
jumper cable from the charged battery
and the battery in the vehicle.

8. Install the battery compartment cover.

6-5 Operation

9. Close the hood.

Warming up

To get maximum engine life, always warm up
the engine before starting off. Never
accelerate hard with a cold engine! To see
whether or not the engine is warm, check if it
responds to the throttle normally with the
choke turned off.

Drive select lever operation and reverse
driving

CAUTION:

Before shifting, you must stop the vehicle

and take your foot off the accelerator pedal.

Otherwise, the transmission may be

damaged.

Shifting: Neutral to Forward

1. Stop the vehicle. Keep your foot off the

accelerator pedal.

2. Apply the brakes, and then shift by

moving the drive select lever along the

shift guide.

NOTE:

Make sure that the drive select lever is

completely shifted into position.

1. Drive select lever

Operation 6-6

3. Release the brakes and press the

accelerator pedal gradually.

Shifting: Neutral to Reverse

1. Stop the vehicle. Keep your foot off the
accelerator pedal.

2. Depress the brake pedal.

3. Shift from neutral to reverse or vice
versa by moving the drive select lever
along the shift guide.

NOTE:

4. Depress the brake pedal before shifting
to “reverse”position.

5. 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.

1. Drive select lever

NOTE:

● When in reverse, the reverse indicator

light should be on. If the light does not
come on, ask a service center to inspect
the reverse indicator light electrical
circuit.

● Due to the synchronizing mechanism in

the engine, the light may not come on
until the vehicle starts moving.

6-7 Operation

4. Check behind for people or obstacles,

and then release the brake pedal.

5. Press the accelerator pedal gradually

and continue to watch to the rear while

backing.

WARNING

POTENTIAL HAZARD

Improperly operating in reverse.

WHAT CAN HAPPEN

You could hit an obstacle or person

behind you, resulting in serious injury.

HOW TO AVOID THE HAZARD

When you shift into reverse, make sure

there are no obstacles or people behind

you. When it is safe to proceed, go

slowly.

Vehicle Break-in Period

The break-in period for your new UTV

vehicle is the first 25 hours of operation, or

the time it takes to use the first three tanks

full of gasoline. No single action on your part

is as important as a proper break-in period.

Careful treatment of a new engine and drive

components will result in more efficient

performance and longer life for these

components. Perform the following

procedures carefully.

CAUTION:

● Excessive heat build-up during the

first three hours of operation will

damage close-fitted engine parts and

drive components. Do not operate at

full throttle or high speeds during the

first three hours of use.

Operation 6-8

● Use of any engine oil not recommended

in this manual will cause severe damage
to the engine。

Engine Break-In

There is never a more important period in the
life of your vehicle than the period between
zero and 25hours.
For this reason, we ask that you carefully
read the following material. Because the
engine is brand new, you must not put an
excessive load on it for the first several
hours of running.
During the first 25 hours, the various parts in
the engine wear and polish themselves to
the correct operating clearances.
During this period, prolonged full throttle
operation or any condition that might result in
excessive engine heating must be avoided.
However, momentary (2-3 seconds

maximum) full throttle operation under load
does not harm the engine.
Each full throttle acceleration sequence
should be followed with a substantial rest
period for the engine by cruising at lower
rpm’s so the engine can rid itself of the
temporary build up of heat. If any
abnormality is noticed during this period,
consult a service center.

0-10 Hours:

Avoid continuous operation above half
throttle. Allow a cooling off period of five to
ten minutes after every hour of operation.
Vary the speed of the vehicle from time to
time. Do not operate it at one set throttle
position.

10-25 Hours:

Avoid prolonged operation above 3/4 throttle.

Rev the vehicle freely but do not use full

6-9 Operation

throttle at any time.

After Break-In:

The vehicle can now be operated normally.

Brake System Break-in

Apply only moderate braking force for the

first 50 stops. Aggressive or overly forceful

braking when the brake system is new could

damage brake pads and rotors.

CVT Break-in (Clutches/Belt)

A proper break-in of the clutch and drive belt

will ensure a longer life and better

performance. Break in the clutch and belt by

operating at slower speeds during the

break-in period as recommended. Pull only

light loads. Avoid aggressive acceleration

and high speed operation during the break-in

period.

Parking

When parking, stop the engine and shift the

drive select lever into the neutral position.

Apply the parking brake to help prevent the

vehicle from rolling.

1. Parking brake pedal

2. Parking brake pedal release lever

Operation 6-10

Parking on a slope

WARNING

POTENTIAL HAZARD

Parking on a hill or other incline.

WHAT CAN HAPPEN

The vehicle could roll out of control,

increasing the chance of an accident.

HOW TO AVOID THE HAZARD

Avoid parking on hills or other inclines. If

you must park on an incline, apply the

parking brake, and block the front and

rear wheels with rocks or other objects.

Do not park the vehicle at all on hills that

are so steep you could not walk up them

easily.

1. Bring the vehicle to a stop by applying
the brakes.

2. Stop the engine.

3. With the brakes applied, set the parking
brake.

NOTE:

Like many other vehicles, the parking brake
acts on the rear wheels. For the parking
brake to have the effect of braking all four
wheels, shift to 4WD before stopping the
engine.

6-11 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. Other

accessories may also be available on the

market. However, it is not possible to test

all nonstandard accessories, nor have

any control over the quality or suitability

of them. Choose a genuine accessory, or

one that is equivalent in design and

quality.

● Accessories should be rigidly and

securely mounted. An accessory that

can shift position or come off while you

are operating could affect your ability to

control the vehicle.

● Do not mount an accessory where it

could interfere with your ability to control

the vehicle. Examples include (but are

not limited to) an object that limits your

ability to turn the steering wheel or one

that limits your view.

● Use extra caution when driving a vehicle

with accessories. The vehicle may

handle differently than it does without

accessories.

Loading

Cargo or a trailer can change the stability

and handling of a vehicle.

You must use common sense and good

Operation 6-12

judgment when carrying cargo or towing a

trailer. Keep the following points in mind:

● Never exceed the weight limits shown.

An overloaded vehicle can be unstable.

MAXIMUM LOADING LIMIT

● Vehicle loading limit (total weight of

cargo, operator, passenger and
accessories, and tongue weight):

882 lb (400 Kg)

● Cargo bed: 350 lb (159Kg)

● Trailer hitch:

Pulling load (total weight of trailer
and cargo): 1212 lb (550Kg)
Tongue weight (vertical weight on
trailer hitch point):110 lb (50Kg)

● Choose a trailer hitch drawbar designed

for use with a 1 ¼ in receiver. (See page

4-29 for more information)

● Do not exceed the maximum tongue

weight. You can measure tongue weight

with a bathroom scale. Put the tongue of

the loaded trailer on the scale with the

tongue at hitch height. Adjust the load in

the trailer, if necessary, to reduce the

weight on hitch. If you are carrying cargo

and towing a trailer, include the tongue

weight in the maximum vehicle load limit.

● Load cargo in the cargo bed as close to

the center of the vehicle as possible and

tie it down using the cargo hooks

equipped on the cargo bed.

● Tie down cargo securely in the trailer.

Make sure cargo in the trailer cannot

move around. A shifting load can cause

an accident.

● Make sure the load does not interfere

6-13 Operation

with controls or your ability to see where

you are going.

● Drive slower than you would without a

load. The more weight you carry, the

slower you should go. Although

conditions vary, it is good practice not to

exceed low range whenever you are

carrying heavier loads or when towing a

trailer.

● Allow more braking distance. A heavier

vehicle takes longer to stop.

● Avoid making sharp turns unless at very

slow speeds.

● Avoid hills and rough terrain. Choose

terrain carefully. Added weight affects

the stability and handling of the vehicle.

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.

Cargo should be properly distributed and

securely attached.

Reduce speed when carrying cargo or

pulling a trailer. Allow greater distance

for braking.

Your Vehicle 7-1

DRIVING YOUR VEHICLE

GETTING TO KNOW YOUR VEHICLE

This off-highway utility vehicle will handle

and maneuver differently form an ordinary

passenger car or other vehicle.

Before you begin to use your vehicle, be sure
you have read this Owner’s Manual

completely and understand all of the controls.

Pay particular attention to the safety

information on pages 2-1 - 2-5. Please also

read all caution and warning labels on your

vehicle.

This vehicle is designed for the operator and

one passenger. The driver and passenger

must always wear a seat belt. Never carry

passenger in the cargo bed.

WARNING

POTENTIAL HAZARD

Not wearing the seat belt.

Wearing the seat belt improperly.

WHAT CAN HAPPEN

There is increased risk of being killed or

seriously injured in an accident.

HOW TO AVOID THE HAZARD

Always wear your seat belt when riding in

the vehicle.

Be sure the seat belt is close fitting

across your hips and chest and is latched

securely.

7-2 Your Vehicle

WARNING

POTENTIAL HAZARD

Carrying a passenger in the cargo bed.

WHAT CAN HAPPEN

The passenger could fall or be struck by

objects in the cargo bed.

HOW TO AVOID THE HAZARD

Never carry a passenger in the cargo bed.

The cargo bed is designed to carry cargo

only.

The total weight of operator, passenger,

accessories, cargo, trailer tongue weight,

and the vehicle itself must not exceed
1880lbs (853Kg).

Your Vehicle 7-3

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.
Cargo should be properly distributed and
securely attached.
Reduce speed when carrying cargo or
pulling a trailer. Allow greater distance
for braking.
Always follow the instructions in your
Owner’s Manual for carrying cargo or
pulling a trailer.

The driver and passenger must always wear

a seat belt, an approved motorcycle helmet,

eye protection and protective clothing,

including over-the-ankle boots, gloves, a

long-sleeved shirt or jacket, and long pants.

Keep hands and feet inside the vehicle at all

times.

7-4 Your Vehicle

WARNING

POTENTIAL HAZARD
Operating this vehicle without wearing an
approved motorcycle helmet, eye
protection, and protective clothing.
WHAT CAN
HAPPEN
Operating without
an approved
motorcycle helmet
increases your
chances of a severe
head injury or death
in the event of an
accident. Operating
without eye protection can result in an
accident and increases your chances of a
severe injury in the event of an accident.

HOW TO AVOID THE HAZARD

Always wear an approved motorcycle

helmet that fits properly. You should also

wear:

Eye Protection

(Goggles or Face Shield)

Gloves

Boots

Long-Sleeved Shirt or Jacket

Long Pants

Your Vehicle 7-5

LEARNING TO OPERATE YOUR VEHICLE

You should become familiar with the
performance characteristics of the vehicle in
a large, flat area that is free of obstacles and
other vehicles. Practice control of the
accelerator pedal, brakes, steering, and drive
select lever. Drive at slow speed and become
comfortable at that speed before gradually
increasing your speed. Become familiar with
the way the vehicle feels in low and high
ranges, first in two-wheel drive (2WD) and
then in four-wheel drive (4WD) and
four-wheel drive with the differential locked
(DIFF. LOCK). Practice driving in reverse.
Take the time to learn basic operation before
attempting maneuvers that are more difficult.

Perform the Pre-Operation Checks on pages
5-1 - 5-14. Set the parking brake, shift to

neutral, and follow the instructions on page
6-1 to start the engine. Once it has warmed
up and you have turned the choke off, you
are ready to begin driving your vehicle. With
the engine idling, shift the drive select lever
into low or high. Then release the parking
brake. Press the accelerator pedal slowly
and smoothly. The centrifugal clutch will
engage and you will start to accelerate. Avoid
higher speeds until you are thoroughly
familiar with the operation of your vehicle.
When slowing down or stopping, take your
foot off the accelerator pedal and smoothly
press the brake pedal. Improper use of the
brakes can cause the tires to lose traction,
reducing control and increasing the
possibility of an accident.

7-6 Your Vehicle

CAUTION:

Do not shift from low to high or vice versa
without coming to a complete stop and
waiting for the engine to return to normal idle
speed. Damage to the engine or drive train
may occur.

TURNING YOUR VEHICLE

The vehicle is easier to steer in two-wheel
drive (2WD) than four-wheel drive (4WD).
Steering takes the most effort in 4WD with
the differential locked (DIFF. LOCK).
It is possible for the vehicle to roll over or go
out of control if you attempt sharp,
high-speed turns. You should also be careful
making sharp turns on rough terrain. Do not
attempt to turn around or make abrupt
maneuvers on slope.

Position your hands on the steering wheel so

that your thumbs and fingers do not wrap

around the wheel. This is particularly

important when driving in rough terrain. The

front wheels will move right and left as they

respond to the terrain, and this movement

will be felt in the steering wheel. A sudden jolt

could wrench the steering wheel around, and

your thumbs or fingers could be injured if

they are in the way of the steering wheel

spokes.

Your Vehicle 7-7

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. Apply the throttle lightly. Never open the

throttle suddenly.

3. Back up slowly.

4. Apply the brakes lightly for stopping.

5. Avoid making sharp turns.

Before shifting into reverse gear, always

check for obstacles or people behind the

vehicle. When it is safe to proceed, back up

slowly.

7-8 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.

GOING UPHILL

Do not attempt to climb hills until you have
mastered basic maneuvers on flat ground.
Use proper driving techniques to avoid
overturns on hills and slopes. Drive straight
up hills, and avoid crossing the side of a hill,
which increases your chance of rollover.
Practice first on gentle slopes before
attempting steeper hills. Always check the
terrain carefully before attempting any hill.
Use common sense and remember that

Your Vehicle 7-9

some hills are too steep for you to climb.

Maximum slope angle: 15°

Choose carefully which hills you attempt to

climb. Avoid hills with slippery surfaces or

ones where you will not be able to see far

enough ahead of you.

7-10 Your Vehicle

WARNING

POTENTIAL HAZARD

Operating on excessively steep hills.

WHAT CAN HAPPEN

The vehicle can over turn more easily on

extremely steep hills than on level

surfaces or small hills.

HOW TO AVOID THE HAZARD

Never operate your vehicle on hills too

steep for it or your abilities. Never

operate vehicles on hills steeper than

15°.

Do not drive across the face of a hill. Go

straight up the hill.

Practice on smaller hills before

attempting large hills.

Before climbing the hill, first be sure you are

operating in low range 4WD or, if necessary,

with 4WD Diff. Lock. To climb a hill, you need

traction, momentum, and steady throttle.

Travel fast enough to keep your momentum

going, but not so fast that you cannot react to

changes in the terrain as you climb. Slow

down when you reach the crest of the hill if

you cannot clearly see what is on the other

side. There could be another person, an

obstacle, or a sharp drop off.

If you start to lose traction or momentum

when climbing, and you decide you will be

unable to continue, use the brakes to come

to a stop. Do not attempt to turn the vehicle

around. With your foot on the brake, look

Your Vehicle 7-11

behind you and plan your descent. Shift the

drive select lever in reverse so you can use

the engine brake if necessary to slow your

descent. Release the brake and begin to

coast down the hill. Use engine braking as

much as possible, gently applying the brakes

when necessary.

GOING DOWNHILL

Check the terrain carefully before going

down a hill. When possible, choose a path

that lets you drive your vehicle straight

downhill. Avoid sharp angles that could allow

the vehicle to pitch or roll over. Carefully

choose your path and drive no faster than

you will be able to react to obstacles that may

appear.

WARNING

POTENTIAL HAZARD

Going down a hill improperly.

WHAT CAN HAPPEN

Could cause loss of control or cause the

vehicle to overturn.

HOW TO AVOID THE HAZARD

Always check the terrain carefully before

you start down any hill. Never go down a

hill at high speed. Avoid going down a hill

at an angle that would cause the vehicle

to lean sharply to one side. Go straight

down the hill where possible.

7-12 Your Vehicle

Before starting downhill, make sure the
vehicle is in low-range 4WD. On most slopes,
this will let you use engine braking to help
you go downhill slowly. Go as slowly as
possible. If you start going too fast, gently
apply the brakes. Avoid sudden application of
the brakes, which could cause the vehicle to
start sliding.
If you are sliding or skidding, try to steer in
the direction the vehicle is sliding to help you
regain control.
If you must turn on the hill to avoid an
obstacle, do so slowly and carefully. If the
vehicle starts to tip, gradually steer in the
downhill direction if there are no obstacles in
your path. As you regain proper balance,
gradually steer again in the direction you
want to go.

CROSSING THROUGH SHALLOW WATER

If you must cross shallow, slow moving water

up to the depth of the vehicle’s floorboards,

choose your path carefully to avoid sharp

drop-offs, large rocks, or slippery surfaces

that could cause the vehicle to overturn.

Never operate through water deeper than 13

in (33 cm) or fast flowing water.

Wet brakes may have reduced effectiveness.

After leaving the water, test your brakes. If

necessary, apply the brakes several times to

let friction dry out the linings.

Your Vehicle 7-13

WARNING

POTENTIAL HAZARD
Operating this vehicle through deep or
fast-flowing water.
WHAT CAN HAPPEN
Loss of control, which could result in an
accident including overturn, which could
increase the risk of drowning.
HOW TO AVOID THE HAZARD
Never operate this vehicle in fast flowing
water or in water deeper than 13 in
(33cm).
Remember that wet brakes may have
reduced stopping ability. Test your
brakes after leaving water. If necessary,
apply brakes several times to let friction
dry out the linings.

CAUTION：

After riding your vehicle in water, be sure to

drain the trapped water by removing the

check hose at the bottom of the air filter case,

the CVT-belt cooling duct check hose, the

drive select lever box check hose and the

CVT-belt case drain plug. Wash the vehicle

in fresh water if it has been operated in salt

water or muddy conditions.