Catvic 350ATV User manual

YOUR SAFETY IS INVO LVED!
Failur e to follow warning instructions could r esult in aever e
FAILURE TO FOLLOW THE W ARNINGS CONTAINED IN THIS MANUAL CAN
RESULT IN SERIOUS INJURY OR DEATH.
Particularly important information is distinguished in this manual by the following notations:
A CAUTION indicates special pr ecautions that must be taken to
avoid damage to the machine
A NOTE provides key information to make procedures easier or clearer.
injury or death to the machine operator, a bystander or a person
The Safety Aler t Symbol means A TTENTION! BECOME ALERT!
IMPORTANT MANUAL INFORMATION
inspecting or r epairing the machine.
NOTE:

Vehicleidentificationnumber.....................12
Indicates a potential hazard that could r esult
in serious injury or death.
CONTENTS
1 LOCATION OF THE W ARNING
AND SPECIFICATION LABELS................ 1
2SAFETY INFORMATION..........................5
3 DESCRIPTION AND MACHINE
IDENTIFICATION.....................................11
4
CONTROL FUNCTIONS.......................... 13
Mainswitch...............................................13
Indicatorandwarninglights.........
..............14
5 PRE-OPERATIONCHECKS..........................33
Handlebarswitches......................................17
Throttlelever...............................................20
Speedlimiter................................................21
Frontbrakelever..............................................22
Brake pedal and rear brakeleve....................22
Parkingbrake..............................................23
Driveselectlever..........................................24
Recoilstarter..................................................24
Fueltankcap................................................25
Fuelcock.......................................................26
Starter(choke)................................................27
Seat...............................................................28
Storagebox....................................................29
Frontcarrier..................................................30
Rearcarrier...................................................30
Front shock absorber adjustment.....................30
Rearshockabsorberadjustment........................31
Frontandrearbrakes.........................................34
Fuel......................................................................36
Engineoil............................................................38

Batterymaintenance..........................................137
Fusereplacement..............................................137
Replacingaheadlightbulb................................139
Headlightbeamadjustment..............................142
Tail/brakelightbulbreplacement......................143
Roubleshooting.................................................143
Troubleshootingchart........................................145
Dif ferentialgearoilreplacement....................110
Axleboots........................................................113
Sparkpluginspection......................................113
Airfilterelementcleaning...............................116
V-beltcoolingductcheckhose.......................119
V-beltcasedrainplug.......................................119
Sparkarrestercleaning...................................120
Carburetoradjustment.....................................121
Idlespeedadjustment.....................................122
Valveclearanceadjustment............................122
Throttleleveradjustment................................123
Frontbrakepadcheck.....................................124
Rearbrakeshoeinspection.............................125
Brakefluidlevelcheck....................................125
Brakefluidreplacement..................................127
Frontbrakeleverfreeplay...............................127
Rear brake pedal and lever adjustment...........128
Adjustingtherearbrakelightswitch..............131
Cableinspectionandlubrication.....................132
Lubricating the brake levers and
brakepedal......................................................133
Wheelinstallation............................................134
Battery.............................................................136
9 CLEANING AND STORAGE..........................146
A.Cleaning........................................................146
B.Storage..........................................................148
10 SPECIFICATIONS...........................................150
11 NOISE REGULATION....................................156

LOCATION OF THE W ARNING A N D
SPECIFICA TION LABELS
1111 1-111111
1

3

AN A T V IS NOT A TO Y AND CAN BE HAZARDOUS TO OPERATE. An A T V handles dif ferently
from other vehicles including motorcycles and cars. A collision or rollover can occur quickly , even
during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take
proper precautions.
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.
Never operate an A T V without proper training or instruction. T ake a T raining Course. Begin-
ners should receive training from a certified instructor . Contact an authorized A T V dealer.
Always follow the age recommendation:
- A child under 16 years old should never operate an A T V with engine size greater than 90cc.
Never allow a child under age 16 to operate an A T V without adult supervision, and never allow
continued use of an A T V by a child if he or she does not have the abilities to operate it safely .
Never carry a passenger on an A T V.
Always avoid operating an A T V on any paved surfaces, including sidewalks, driveways, park-
inglotsandstreets.
Never operate an A T V on any public street, road or highway, even a dirt or gravel one.
SAFETY INFORMATION
5

Always follow proper procedures for climbing hills as described in this manual. Check the ter -
rain carefully before you start up any hill. Never climb hills with excessively slippery or loose
surfaces. Shift your weight forward. Never open the throttle suddenly. Never go over the top of
a hill at high speed.
Always follow proper procedures for going down hills and for braking on hills as described in
this manual. Check the terrain carefully before you start down any hill. Shift your weight back-
ward. Never go down a hill at high speed. A void 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.
Always follow proper procedures for crossing the side of a hill as described in this manual.
A void hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the
A T V. Never attempt to turn the A T V around on any hill until you have mastered the turning
technique described in this manual on level ground. A void crossing the side of a steep hill if
possible.
Always use proper procedures if you stall or roll backwards when climbing a hill. Maintain a
steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for
braking described in this manual. Dismount on the uphill side or to a side if pointed straight up-
hill. T urn the A T V around and remount, following the procedure described in this manual.
Always check for obstacles before operating in a new area. Never attempt to operate over large
obstacles, such as lar ge rocks or fallen trees. Always follow proper procedures when operating
7

POTENTIAL HAZARD
Improper handling of gasoline.
W H AT CAN HAPPEN
Gasoline can catch fir e and you could
be burned.
HOWT O AV OID THE HAZARD
Always turn of f the engine when r efuel-
ing.
Do not r efuel immediately after the en-
gine has been running and is still very
hot.
Do not spill gasoline on the engine or
exhaust pipe/muf fler when r efueling.
Never r efuel while smoking, or inthevi-
cinity of sparks, open flames, or other
sour ces of ignition such as the pilot
lights of water heaters and clothes dry-
ers.
When transporting the A T V in another
vehicle, be sur e it is kept upright and
that the fuel cock is in the “OFF” posi-
tion. Otherwise, fuel may leak out of the
carburetor or fuel tank.
W H AT CAN HAPPEN
Gasoline is poisonous and can cause
injuries.
HOWT O AV OID THE HAZARD
If you should swallow some gasoline or
inhale a lot of gasoline vapor, or get
some gasoline in your eyes, see your
If you should swallow some gasoline or
doctor immediately.
If gasoline spills on your skin, wash with
soap and water. If gasoline spills on
your clothing, change your clothes.
9

1. R ea r sho ck a bso rb er a sse mbly
spring preload adjusting ring
2.Spark arrester
3.Storage box and t o
ol kit
4. Sp ar k plu g
5. F ro nt sho ck a bso rbe r as sem bl y
spring preload adjusting ring
6. Bra ke pe da l
7. V-belt case
8. F ue l co ck
9. Air filter case
1 0. F us es
11
.T ail/brake light
1 2. F ro nt sho ck a bso rbe r as sem bl y
spring preload adjusting ring
13. V -b el t co ol in g d uct ch eck h o se
14.Oil filter
cartridge
15.Engine oil dipstick
16 . Re ar b rak e le ve r
17 . Le ft h an dl eb ar s wit ch e s
18.Starter (choke)
19.Drive sele ct lever
20 . Mai n sw it ch
21 . Fu e l t an k cap
22 . Ri gh t h an d le ba r s wi tc h
23. Throttle lever
24. Front b rakelever
NOTE:
The machine you have purchased may dif ferslightly
from those shown in the figures of this manual.
DESCRIPTION AND MACHIN IDENTIFICATION
11

CONTROL FUNCTIONS
Indicates a potential hazard that could
result in serious injur y or death.
Main switch
Functions of the respective switch positions
are as follows:
ON:
The engine can be started only at this position
and the headlights and taillight come on when
the light switch is on.
OFF:
All electrical circuits are switched of f.The key
can be removed in this position.
1. Main switch
13

Oil temperatur e warning light “ ”
When the oil temperature reaches a specified
level, this light comes on to warn that the en-
gine oil 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 en-
gine to cool down for about 10 minutes.
The engine may over heat if the A T V is
overloaded. If this happens, r educe
the load to specification.
Restar t after making sur e that the light
is out. Continuous use while the light
is on may cause damage to the en-
gine.
15
Left turning indicator light
After open left turning light cntrol,left turning
indicator light is on.
Speed de men stration
Speed demenstration is moving speed of the ATV.
Total course demenstration
T otal course demenstration is total moving course of A T V
and can keeps memory.
Right turning indicator light
After open righ t turning light cntrol,righ t turning
indicator light is on.
Metric system demenstration indicator light
Metric system demenstration indicator light is on, it indicates
that vehhicle speed demenstraton is KM/h .
Metric-English system transfer indicator button
Metric-English system transfer indicator button can control
transfer indicator between meric and English in meter.
High beam indicator light
High beam indicator light is on, it indicates large headlight source
English system demenstration indicator light
English system demenstration indicator light is on, it indicates
that vehhicle speed demenstraton is mph .
Small course demenstration
Small course table demenstration only records course number
before closing electrical source.If restart electrical source after
closing it,small course demenstration will record again.

Handlebar switches
Do not use the headlights with the engine
turned off for more than thirty minutes.
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.
17
1. High and low beam switch
2.Engine flame out ¡° ¡±
3.Horn switch
4.Electrical starter switch¡± ¡±
5.Turning light switch
6.light switch¡± ¡ñ¡ñ
¡ñ¡ñ
¡ñ ¡±
T urning light switch contr ol
Press turnng light switch left,left front turning light,
left rear turning light and meter left turning indicator
lightarelit.
Press turnng light switch right,right front turning light,
right rear turning light and meter right turning indica-
torlightarelit.
Press turning light switch middle,all turning light and
turning indicator light are out.
When light switch is pushed to “ ” of the first
gear, taillight, front light and meter light will light.
When light switch is pushed to “¡ ”of the second
gear, taillight, front light, large headlight and meter
lightwilllight.
When light switch is pushed to “ ” of the second
gear, and press down the button of high & low beam
switch, and high & low beam of large headlight will shift
correspondingly, and indicator light” ” on the meter
plate also will light or be out correspondingly.
When change vehicle lines or turn each time on the
move, must form the habit of sending signal. After fin-
ishing changing vehicle lines or turning operation,
must close turning light.

POTENTIAL HAZARD
Changing from 2WD to 4WD or from
4WD to 2WD while the A T V is moving.
W H AT CAN HAPPEN
The A T V handles dif fer ently in 2WD
than in 4WD in some circumstances.
Changing from 2WD to 4WD or from
the A T V to unexpectedly handle dif fer
ently. This could distract the operator
and increase the risk of losing control
and an accident.
HOWT O AV OID THE HAZARD
Always stop the A T V befor e changing
from 2WD to 4WD or vice-versa.
19
Emergency light switch
When AT V happens to be troublesome or
other conditions do, need stop the vehicle
right away to warn other drivers
On-Command four-wheel drive
switch“2WD/4WD”
To change from two-wheel drive (2WD) to
four -wheel drive (4WD), stop the A T V and
set the switch to the 4WD position.
T o change from four -wheel drive (4WD) to
two-wheel drive (2WD), stop the A T V andset
the switch to the 2WD position.
1. Four-wheel drive switch “2WD/4WD”
2. Emergency light switch ¡ ° / ¡ñ¡±

Speed limiter
The speed limiter keeps the throttle from fully
opening, even when the throttle lever is pushed
to the maximum. T urning in the adjusting screw
limits the maximum engine power available and
decreases the maximum speed of the A T V.
1.Locknut 2. Adjusting screw
a. 12 mm (0.47 in)
POTENTIAL HAZARD
Improper adjustment of the speed limit-
er and thr ottle.
W H AT CAN HAPPEN
The thr ottle cable could be damaged.
Im pr oper thr ottle operation could r esult.
Y ou could lose contr ol, have an acci-
dent or be injur ed.
HOWT O AV OID THE HAZARD
Do not turn the adjusting scr ew out
m o r e than 12 mm (0.47 in). Always make
sur e the thr ottle lever fr ee play is adjust-
ed to 3 5 mm (0.12 0.20 in). See page
122.
21

Parking brake
Use the parking brake when you have to start
the engine or park the machine, especially on
a slope. Apply the rear brake lever and push
down the lock plate to apply the parking
brake. Squeeze the rear brake lever to re-
lease the parking brake.
1. Lock plate
ing the engine. This could of control or a
collision.
The brake could over heat if you ride the A T V
without r eleasing the parking brake. Y ou could
lose braking perfor -mance which could cause
an accident.
Y ou could also wear out the brakes pr e-
maturely.
HOWT O AV OID THE HAZARD
Always set the parking brake before
starting the engine.
Always be sure you have released the
parking brake before you begin to ride.
23
POTENTIAL HAZARD
Improper use of the parking brake.
W H AT CAN HAPPEN
The A T V could star t moving unexpect-edly if the
parking brake is not applied before start-
1.seeerign lock
Steering locd
turn the steering bar left,and rnscrew the
lock cover,then insert the key into the
lockstitch,turnitforacompleteroundwith
force, then the steering mechanism can be
locked.

Fuel tank cap
Remove the fuel tank cap by turning it coun-
terclockwise.
1. Fuel tank cap
POTENTIAL HAZARD
Starting the engine without shifting into
the neutral position.
W H AT CAN HAPPEN
The A T V could star t to move unexpect-
edly, which could cause an accident.
HOWT O AV OID THE HAZARD
Shift the drive select lever into the neu-
tral position and apply the parking brake
befor e star ting the engine.
25

Starter (choke) “ ”
Starting a cold engine requires a richer air -fuel
mixture. A separate starter circuit supplies this
mixture.
Move in direction a to turn on the starter
(choke).
Move in direction b to turn of f the starter
(choke).
Refer to “Starting a cold engine” for proper op-
eration. (See page 43.)
1. Arrow mark pointing to “RES”
27
1. Starter (choke) “ ”

Storage box
Maximum load limit: 2 kg (4.4 lb)
T o pr otect fr om damage, do not put metal
pr oducts, like tools or sharply edged pr od-
ucts dir ectly in the storage box. If they
must be stor ed, wrap them in appropriate
cushion material.
1. Storage box
NOTE:
There is a check hose at the bottom of the
storage box. If any water collects in this hose,
remove the hose, empty it, and then install it.
1. Storage box check hose
29

Rear shock absorber adjustment
The spring preload can be adjusted to suit the
rider’s weight and riding conditions.
Adjust the spring preload as follows:
T o increase the spring preload, turn the ad-
justing ring in direction a .
T o decrease the spring preload, turn the ad-
justing ring in direction b .
1. Spring preload adjusting ring
2. Position indicator
POTENTIAL HAZARD
Improper shock absorber adjustment.
W H AT CAN HAPPEN
Uneven adjustment can cause poor
handling and loss of stability, which
could lead to an accident.
HOWT O AV OID THE HAZARD
Always adjust the shock absorbers on
the left and right side to the same set-
ting.
31

PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE 111111 PAGE
Fr ont brake Check operation, free play, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.
Check operation, condition and free play.
Rear brake
Check fuel level.
Fuel Fill with fuel if necessary.
Check oil level.
Engine oil Fill with oil if necessary .
Check for leakage.
Fina l gear oil/
differ ential gear oil
Check for proper throttle cable operation.
Throttle
Check tire pressure, wear and damage.Wheels and tir es
Check all fittings and fasteners.
Fittings and fasteners
Check for proper operation.
Lights and switches
Check for damage.
Axle boots
Adjust if necessary.
33
34-35
123-126
34-35
124 127-129
36-37
38 102-107
107-111
36-37
37 122-123
38-41
132-133
37
37 129-130
138-142
112