BO250 UTV - Baja Motorsports
Contents
1. 55 NOTICE TO USERS Please read this manual and follow all instructions carefully To emphasize the special information the symbol A and the words WARNING or CAUTION have some special meanings Pay attention to the messages A WARNING Indicates a potential hazard that could result in death or injury CAUTION Indicates a potential hazard that could result in vehicle damage NOTE Indicating special information which is to make maintenance easier or instructions clearer WARNING and CAUTION are arranged like this A WARNING or CAUTION The first part will identify a POTENTIAL HAZARD The second part will describe WHAT COULD HAPPEN if you ignore the WARNING or CAUTION The third part will describe HOW TO AVOID THE HAZARD This user s manual contains important safety and maintenance information Read it carefully before riding Failing to follow the warnings contained in this manual could result in INJURY or DEATH It is important that this manual remain with the vehicle when you transfer it to another user or owner All information illustrations photographs and specifications contained in this manual are based on the latest product information available at the time of publication Due to improvements or other changes there will be some discrepancies in this manual We reserve the right to make product changes at any time without notice and without incurring any obligation to make the same or simila2. Never operate this UTV at excessive speeds Always operate at a speed that is proper for the terrain visibility operating conditions and the operator s skill experience Never attempt jumps or other stunts Always inspect the UTV each time before use to ensure it is in a safe operating condition Always follow the inspection and maintenance procedures and schedules described in this manual Always as an operator keep both hands on steering wheel Operator and passenger should always keep hands arms legs and feet inside UTV while in operation Always go slow and be extremely careful when operating on unfamiliar terrain Always be alert to the changing terrain conditions when operating the UTV Never operate on excessively rough slippery or loose terrain until you have learned and practiced the necessary skills to control the UTV on such terrain Never operate the UTV on hills that are too steep for the UTV or for the operator s ability Practice on smaller hills before attempting larger hills Never attempt climbing hills greater than a 15 degree incline Check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Never go over the top of a hill at high speeds Check the terrain carefully before starting to go down any hill Never go down a hill at an angle that would cause the vehicle to lean sharply to one side Go straight down the hill if possible Always use pr
3. Operating this UTV without wearing an approved DOT motorcycle helmet eye protection and protective clothing could be hazardous Operating without an approved DOT motorcycle helmet or eye protection increases your chances of a severe head injury or death in an accident Operating without protective clothing also increases your chances of severe injury in an accident Always wear an approved DOT motorcycle helmet which fits properly Always wear eye protection goggles or face shield You should also wear gloves boots long sleeve shirt or jacket and long pants You should wear eye protection when you ride If a rock a branch hits your eyes you could be severely injured Wear goggles or a face shield Wear proper clothing when you ride The proper clothes can protect you from injury Wear a good pair of gloves strong boots that are over the ankle long pants and a long sleeve shirt 24 OPERATING YOUR UTV BREAK IN The first 10 hours is the most important in the life of your vehicle Proper operation during this break in period will be helpful for assuring maximum life and performance of your new vehicle The following guidelines explain proper break in procedures Maximum Throttle Opening Recommendation During the first 10 hours of operation you should always use less than gt throttle opening Vary the Engine Rotating Speed Vary the engine rotating speed during the break in period This allows the parts to lo
4. On slopes greater the 12 Degrees ALWAYS Ayoid paved surfaces paved surfaces can adversly Use proper riding techniques to avoid overtuming on hills rough terrain or while turning This vehicle handles differently than other vehicles Start out slow and practice on flat obstacle free terrain This vehicle will handle differently when a load is placed in the cargo bed Unsecure cargo cargo stacked too high or cargo overloading could adversly affect vehicle handling which could result in loss of control andor vehicle overtum Make aure cargo is secure stacked low as possible and moved to the front of the cargo bed Always allow more stopping distance Never try to climb or traverse a slope greater than 15 degrees This could result in vehicle overtum Refer to hill climbing instructions in owners manual Read and understand Owners manual before operating this vehicle VEHICLE OVER could cause severe injury or death i The cab frame is not intended or designed to provide rollover nr amp ection ALWAYS USE YOUR SEAT and keep eee and lega Inside cf vehicle at all times 12 LOCATION OF WARNING LABELS IMPROPER TIRE PRESSURE OR OVERLOADING can cause lass of control resulting in SEVERE INJURY OR DEATH Maximum operating cold tire Pressure Front 24 Rear 24 psi Minimum operating cold tire Pressure Front 14 psi Rear 14 psi Never set tire pressure below min
5. cora Fut 72x60 Compression ratio 10 1 7 9 0 6 0 7 024 028 TRANSMISSION Drive system Shaft drive Truro X 10 39 BRAKING FeO ING ORAM m Hydraulic disc D aKO Hydraulic disc TIRES Front Ure m 22xT 10 MINS SIZE OEIL 23 8 5 12 CAPACITIES giat 3 9 gal 15L 91 Octane or higher EDdIDe oll 1qt 1L TEANSIMIS OI sos papas v UR SV CU Du Dit epa 22 ounces Rear aierentlalssosatiiu d EROR PHI EY 16 ounces EMISSION CONTROL SYSTEM WARRANTY BAJA MOTORSPORTS EMISSION CONTROL SYSTEM WARRANTY YOUR WARRANTY RIGHTS AND OBLIGATIONS The emission control system warranty period for this vehicle begins on the date the vehicle is delivered to the first purchaser other than an authorized dealer or the date it is first used as a demonstrator lease or company vehicle whichever comes first and continues for 60 months after that date or 10 000km whichever comes first provided there has been no abuse neglect or improper maintenance of your vehicle Where a warrantable condition exists the Distributor will repair your vehicle at no cost to you including diagnosis parts and labor If an emission related part on your vehicle is defective the part will be repaired or
6. battery cover see figure 30 Secure battery with battery strap see figure 31 A WARNING NEVER REMOVE THE STRIP OF CAPS NOR ADD ANY WATER OR ELECTROLYTE Battery Replacement Remove old battery Mark which cable is connected to the positive terminal and which cable is connected to the negative terminal Clean cable connectors with wire brush or sandpaper to remove oxidation After charging install new battery Put dielectric grease on the battery terminals to avoid corrosion Connect cables to the proper terminals Positive cable to positive terminal and negative cable to negative terminal y Positive cable is red and larger in diameter Negative y cable is black and smaller of the two in diameter CONNECT NEGATIVE CABLE LAST Torque terminal bolts to 40 inches pounds Securely fasten battery to the vehicle using cover and strap A WARNING DO NOT open sealed caps to add water to battery Always wear safety glasses and charge in a ventilated area If battery gets hot to the touch discontinue charging and allow battery to cool down Do not use fast charging unless it is an emergency At the beginning or end of charging turn off the charger first in order to prevent electric spark and explosion Charge in a well ventilated area DO NOT smoke around batteries and keep away from open flame A WARNING To avoid possibility of explosion always connect battery cable in the order speci
7. check the amount of engine oil before starting the engine 40 ENGINE OIL ENGINE OIL CHANGE 1 COON OS GW Turn engine on and let it idle for at least 5 minutes to warm up turn engine off and remove key Place oil pan or any suitable container under engine to drain oil Remove engine drain bolt Let oil drain Remove clean and inspect oil filter cap spring and oil filter If damaged replace Reinstall oil filter spring and oil filter cap Reinstall the drain bolt and torque to 25 ft Ibs Fill 1 qt of API classification see CHART Start engine and check for any leaks Turn engine off and check the oil level see ENGINE OIL LEVEL CHECK Min Ma Oil filter cap 1 Transmission fill Engine oilfillldipstick plug Spring Oil filter Engine drain bolt Transmission drain plug TRANSMISSION OIL CHANGE 1 CON OC engine on and let it idle for at least 5 minutes to warm up turn engine off and remove key Place oil pan or any suitable container under rear of engine to drain oil Remove transmission drain plug Let oil drain Remove fill plug on the right rear of engine casing Inspect fill plug Reinstall drain plug and torque to 256 165 Fill transmission through fill plug with 22 ounces of SAE 80W 90 oil Reinstall fill plug and start engine Be sure to change the gear oil after the first 3
8. operator experience 27 OPERATING YOUR UTV A WARNING Failing to use extra care when operating on excessively rough slippery or loose terrain could be hazardous Failing to use extra care could cause loss of traction This could result in an accident including an overturn Do not operate under these conditions until you have learned and practiced the skills necessary to control the UTV on such terrain Always be especially cautious on this kind of terrain A WARNING Failing to use extra care when operating this UTV on unfamiliar terrain could be hazardous You could come upon hidden rocks bumps or holes without enough time to react This could cause the UTV to overturn or go out of control Go slow and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the UTV 28 OPERATING YOUR UTV A WARNING The UTV may start moving as soon as you release the parking brake Unexpected movement could cause you to lose control of the UTV Make sure to apply the foot brake before you release the parking brake Brake pedal Accelerator pedal When you are sure that the engine is Release the brake pedal and slowly warm release the parking brake depress the accelerator pedal to move forward A WARNING Opening the throttle suddenly could be hazardous The front wheels could leave the ground and cause loss of control of the UTV Always open th
9. or person could be on the other side of the hill To climb a hill with the UTV follow the directions below 1 Speed up and maintain a steady speed before reaching the top of the hill Remember that you must ride at a steady speed all the way to the top of the hill 2 Maintain a steady speed while climbing the hill 3 Slow down gradually when you reach the top of the hill 31 OPERATING YOUR UTV DESCENDING A HILL A WARNING Going down a hill improperly could be hazardous Going down a hill improperly could cause loss of control or cause the UTV to overturn Always follow the proper procedures for going down hills as described in this section To ride down a hill with the UTV follow the instructions below 1 Point UTV straight down the hill Ride down the hill slowly with the throttle released Apply brake to control speed Avoid going down a hill at an angle that would cause vehicle to lean sharply to one side Go AR N Check the terrain carefully for any obstacles before you go down the hill straight down the hill if possible OPERATING OVER OBSTACLES A WARNING Operating this UTV over obstacles improperly could be hazardous Improperly crossing obstacles could cause loss of control or a collision It would also cause the UTV to overturn If you come to an obstacle that you cannot avoid you may be able to cross over it by using the following procedure 1 If th
10. replaced by the Distributor This is your emission control defects warranty OWNER S WARRANTY RESPONSIBILITIES As the vehicle owner you are responsible for the performance of the required maintenance You should main tain a record of all maintenance performed on your vehicle and retain all receipts covering maintenance on your vehicle You may not be denied a warranty claim solely because of your failure to ensure the performance of all scheduled maintenance or lack of maintenance records or receipts You are responsible for presenting your vehicle to an authorized dealer as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days As the vehicle owner you should be aware that you may be denied your warranty coverage if your vehicle or a part has failed due to abuse neglect improper maintenance or unapproved modifications WARRANTY COVERAGE The Distributor warrants that each new 2008 and later vehicle is designed built and equipped so as to conform at the time of initial retail purchase with all applicable regulations of the United States Environmental Protection Agency and the California Air Resources Board and is free from defects in material and workmanship which cause such vehicle to fail to confirm with ap plicable regulations of the United States Environmental Protection Agency or the California Air Resources Board for the periods specified above Your e
11. vehicle to from the authorized dealer The Distributor is not liable to any person for incidental consequential or special damages of any description whether arising out of express or implied warranty or any other contract negligence or other tort or otherwise No express emission control system warranty is given by the Distributor except as specifically set forth herein Any emission control system warranty implied by law including any warranty of merchantability or fitness for a particular purpose is limited to the express emission control system warranty terms stated in this warranty The foregoing statements of warranty are exclusive and in lieu of all other remedies All express warranties not stated in this warranty are disclaimed Some states do not allow limitations on how long an implied warranty lasts so the above limitations may not apply if it is inconsistent with the controlling state law No dealer is authorized to modify this Emission Control System Warranty If you have any questions regarding your warranty rights and responsibilities you should contact BAJA MOTORSPORTS 56 Motorsports Baja INC P O Box 61150 Phoenix AZ 85082 Tel 602 443 9180 Toll Free 888 863 2252 57
12. 0 hours of use 41 REAR DIFFERENTIAL OIL Rear differential drain plug BOTTOM VIEW REAR DIFFERENTIAL OIL CHANGE Place oil pan or any suitable container under rear differential case Remove differential drain bolt Let drain Reinstall the differential drain bolt and torque to 25 ft lbs Remove differential oil fill plug and add 16 ounces of SAE80W 90 oil in differential fill plug A NS Rear differential fill plug TOP VIEW 42 FUELING INSTRUCTIONS A WARNING Overfilling the fuel tank could be hazardous If you overfill the fuel tank fuel may overflow when it expands Expanding is due to heat from engine or sun Overheated fuel could easily catch fire Stop adding fuel when the fuel level is one inch from the top of the fuel tank A WARNING Improper fueling of the UTV could be hazardous Failing to follow safety precautions when refueling could result in a fire or let you to breathe toxic fumes Refuel in a well ventilated area Make sure the engine is off and avoid spilling fuel on a hot engine Do not smoke and make sure there are no open flames or sparks in the area Avoid breathing gasoline vapors Keep children and pets away when you are refueling the UTV The fuel tank is located under the passenger seat 1 Remove fuel tank cap and begin to fill the fuel tank with unleaded gasoline only DO NOT OVERFILL 2 Replace fuel tank cap and make sure the cap is secure Fuel ta
13. BSERVE ALL WARNING PRECAUTIONS STORING THE UTV A DANGER Do not drain gasoline when engine is hot or running Clean any spilled gasoline before operating the vehicle Store gasoline in an approved container only Store in a well ventilated area away from sparks open flames heaters etc Keep gasoline out of reach of children Do not siphon gasoline from vehicle OPERATION INSTRUCTIONS A WARNING Remove the key and set the parking brake Do not charge a frozen battery or batteries with bulging cases Discard batteries according to state and local environmental legal guidelines for battery disposal Frozen batteries may explode CAUTION Batteries with low charge will freeze at low temperatures PREPARATION FOR EXTENDED STORAGE Make sure there is no load in the cargo bed Store in a cool dry place This will help prevent the battery from loosing charge Drain all gasoline from fuel tank and seal Run engine until all fuel in carburetor and fuel lines are gone and the engine stalls Loosen but do not remove the carburetor drain screw allowing the remaining fuel to drain into a container then pour the fuel from container into the vehicle fuel tank Fill the fuel tank 1 inch from the top of fuel tank and add fuel stabilizer Disconnect fuel tank line from fuel tank vent nipple Plug the fuel tank vent line air tight Disconnect battery cables making sure to disconnect the negative cable first 0
14. IFT 15 ACCELERATOR PEDAL cha curi 15 he rH Cia Sem at t DTI 15 PARKING BRAKE EEVER 15 OPERATION INSTRUC TIONS prox uai iuis 16 TING THE UU Ae 16 STOPPING THE 16 PARKING THE UTM Merc 16 BED LATO H a 16 LOADING AND UNLOADING CARGO BED 17 TOWING WITH THE U M 18 TRANSPORTING THE 18 Jed cELISUR 18 PREPARATION FOR EXTENDED STORAGE 19 RETURNING STORED UTV TO 20 OPERATING TOUR UTV ie het 21 WHAT YOU SHOULD KNOW BEFORE RIDING 21 INSPECTION BEFORE RIDING 22 SAFETY GEAR c 24 BREAKIN RET 25 STARTING 26 BRAKING 30 OPERATION ON D EE 31 OPERATING OVER OBSTACLES eene 32 OPERATING THROUGH WATER eene 33 OPERATING IN COLD WEATHER eee 34 DRESSING FOR COLD WEATHER RIDING s 35 OPERAT
15. ING YOUR UTV ON SNOW 36 4 TABLE OF CONTENTS PERIODIC MAINTENANCE SCHEDULE ees 37 PERIODIC LUBRICATION SCHEDULE 37 gl R onen 38 RADIATOR ME 39 ENGINE OI 39 ENGINE OIL LEVEL CHECK inicia tds Gao 39 ENGINE DIECHANGE in adn ors toma 41 TRANSMISSION OIL CHANGE eene 41 REAR DIFFERENTIAL OIL CHANGE eene 42 FUELING INSTRUC TIONS 43 44 PREPARING THE BATTERY netus t 45 HOW TO INITIALLY CHARGE THE BATTERY 46 BATTERY REPLACEMENT a 47 ADJUSTMENT S cert errr ere terres 48 SUSPENSION 48 SPARR PLUG ND 48 DIM apa MUN E 90 VEHIGEEGDBEANING stitit didum d t errr err 91 CLEANING PROCEDURE oiii testet na Eois 91 PREPARATION FOR CLEANING enne 91 IROUBLESHOOTING 5 iin ASIE S GEI 92 SERIAL NUMBER EOCATIONO u rU 53 SPEGCIFICATIONS 54 EMISSION CONTROL SYSTEM
16. Make sure the battery is clean and free of corrosion Wash the terminals with baking soda and water 1 cup baking soda per 1 gallon water Rinse the solution be sure the solution does not enter the battery Make sure the terminals are tight let them dry and coat with Battery Terminal Protector Spray 11 Remove the spark plug and pour 1 2 of SAE 10 weight oil into the engine through the spark plug hole and manually turn the crankshaft several times and reinstall the spark plug 12 Adjust tires to the recommended tire pressure 13 Perform any semi annual periodic lubrication including the front suspension 14 Thoroughly clean the vehicle 15 Do not set the parking brake To prevent the vehicle from rolling choke the wheels N OPERATION INSTRUCTIONS RETURNING STORED UTV TO SERVICE Restore the fueling system to operational standards Remove plug from fuel tank vent Connect fuel vent line to fuel tank vent Connect the battery cables making sure to connect the positive cable first Engage the parking brake and crank the engine until fuel has pumped into the carburetor and fuel lines and the engine starts Turn the engine NOTE Engine may smoke for awhile when running it the first time after storage 6 Adjust the tires to recommended tire pressure a OPERATING YOU UTV WHAT YOU SHOULD KNOW BEFORE RIDING Before riding you should read all the following informat
17. Motorsports BO250 UTV Read this manual carefully It contains important safety information No one under the age of 16 should operate this UTV OWNER S MANUAL Minimum Age Requirement 16 Rev C 021309 Always wear a helmet It could save your Life Please obtain review and follow provincial municipal government acts and regulations pertaining to owning and operating an off road vehicle Motorsports Congratulations on your purchase of the Baja Motorsports UTV It is warranted to be free of manufacturing defects in the material of workmanship for a period of 90 days from the date of purchase During the warranty period BAJA INC will at its option repair provide replacement parts or replace your Baja Motorsports UTV at no charge This warranty does not cover normal wear items or damage caused by neglect or misuse of the product Engine Warranty 90 days Frame Warranty 90 days Warranty is void if Frame is bent or broken due to abuse Wheels are bent or broken Fender bent or broken due to abuse Any sign of impact accident jumping spin outs or roll over BAJA INC is not liable for any damage claim or liability claim person or otherwise resulting from the operation of this product in any way Should you experience a problem or need to return your Baja Motorsports UTV for repair please call the BAJA MOTORSPORTS customer service department TOLL FREE at 1 888 863 BAJA 2252 between th
18. ad and then unload allowing the parts to cool Although it is essential to place some stress on the engine components during break in you must be careful not to load the engine too much Avoid Constant Low Rotating Speed Operating the engine at constant low rotating speed light load can cause parts to glaze and not seal properly Allow the engine to accelerate freely without exceeding the maximum throttle limit Allow the Engine Oil to Circulate Before Riding Allow enough idling time after warm or cold engine starting This allows the lubricating oil to reach all critical engine components Observe Your Initial and Most Critical Service The initial service break in maintenance is the most important service that your vehicle will receive Observing a proper break in operation will help engine components seal properly Maintenance required as part of the initial service includes proper adjustments tightening of all bolts amp nuts and replacement of dirty oil Timely performance of this service will help you get the best service life and performance of the engine 25 OPERATING YOUR UTV STARTING THE ENGINE Before attempting to start the engine make sure to follow these steps Any maintenance checks have been made Parking brake is applied Driver and passenger if any is seated with seat belt on Brake pedal is applied A GN gt A WARNING The UTV could start moving as soon as you start the eng
19. d fall into the cold water Check with local authorities to verify the thickness of the ice and areas to avoid A WARNING Failing to use extra care when operating on slippery surfaces such as hard packed snow and ice could be hazardous Failing to use extra care could cause loss of traction or loss of vehicle control This could result in an accident including an overturn Do not operate on slippery surfaces until you have learned and practiced the skills necessary to control the UTV on such terrain Always use extra care on slippery surfaces Avoid riding on snow or ice covered hills whenever possible Practice operating your UTV in an open snow or ice covered area at slow speeds before handling out on snow or ice covered trails Learn how your UTV responds to steering and braking on the type of terrain you will encounter on your ride Your eyes may be sensitive to sunlight when you ride over snow or ice on a bright sunny day Snow and ice reflects more light into your eyes than dirt or grass Tinted eye protection will reduce the amount of light reaching your eyes On overcast days you may find it helpful to use yellow tinted eye protection 36 PERIODIC MAINTENANCE SCHEDULE REGULARINTERVAL SERVICE o Monthly service by owner or Check engine oil level change if trained technician necessary see periodic lubrication schedule Check engine cooling air intake visually inspect unshrouded area around engine exhaust fo
20. e hours of 7am and 5pm Monday thru Friday PST and Saturday 8am to 4pm PST During DST hours change to MT You will be instructed how to proceed A COPY OF THE SALES RECEIPT IS REQUIRED 2 WARNING This manual should considered as a permanent part of the vehicle and should remain with the vehicle when resold or otherwise transferred to a new user or operator The manual contains important safety information and instructions which should be read carefully before operating the vehicle A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm CALIFORNIA PROPOSITION 65 TABLE OF CONTENTS NOTICE TO USEISS ucc bicc 6 DW WA dign 10 LOCATION OF WARNING LABELS eene 11 CONTROLS AND INDICATORS ener 14 Mele ERES 14 HEADLIGHT iusti 14 EMERGENCY SHUT OFF SWITCH ess 14 14 REVERSE INDICATOR 14 NEUTRAL INDICATOR 14 FORWARD INDICATOR LIGHT nee 14 FUEL INDIGAT OR uas aa oria baia dbi ciu 14 TEMPERATURE INDICATOR LIGHT sess 14 TRANSMISSION GEAR SH
21. e obstacle is in front of you approach at walking speed Remember that some obstacles are too high for your UTV or for your abilities If you are not sure that you can safely cross over an obstacle back up and ride around the obstacle 32 OPERATING YOUR UTV OPERATING THROUGH WATER You can ride the UTV through shallow water Make sure it is not more than 10cm 4 inches deep and is not moving fast Choose a good place to cross before you ride through the water Look for a spot where the banks are gently sloped on both sides and the bottom of the stream is hard If you are unfamiliar with the area park the UTV and inspect the stream first to find a suitable spot for crossing When crossing operate the UTV at a slow steady speed Be careful not to damage banks when crossing A WARNING Operating this UTV through deep or fast flowing water could be hazardous The UTV tires may float losing traction and then loss of control This could lead to an accident Never operate this UTV in fast flowing water or in water deeper than described in this section Remember that wet brakes may reduce the stopping ability Test your brakes after leaving the water If necessary apply the brakes several times to let friction dry out the linings CAUTION Operating the UTV in water sand or mud causes rapid brake wear Excessive brake wear could cause the brakes to be less effective After repeated operation of the UTV in these conditions b
22. e throttle gradually when you want to accelerate 29 OPERATING YOUR UTV BRAKING Brake pedal Accelerator pedal To stop the UTV first release the accelerator pedal then depress the brake pedal smoothly A WARNING Braking while turning the UTV could be hazardous Use of the brake when turning could cause the UTV to slide or roll over Use the brake to slow down before you begin to turn A WARNING Braking hard on slippery surfaces could be hazardous The UTV could skid and go out of control if you brake too hard Apply the brakes lightly and carefully on slippery surfaces 30 OPERATING YOUR UTV OPERATION ON HILLS A WARNING Operating this UTV on hills over 15 degrees could be hazardous The UTV could overturn more easily on extremely steep hills than on level surfaces or small hills Never operate the UTV on hills which are too steep for the UTV or for your abilities Practice on smaller hills before trying larger hills CLIMBING A HILL A WARNING Climbing hills improperly could be hazardous Climbing hills improperly could cause loss of control or cause the UTV to overturn Always follow the proper procedures for climbing hills as described in this section Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Never go over the top of any hill at a high speed An obstacle a sharp drop or another vehicle
23. eats Use this lever whenever parking the machine especially on a slope Apply the parking brake by pulling up Release by pressing button on end of lever and lower completely Parking Brake Lever OPERATION INSTRUCTIONS STARTING THE UTV Read warning and loading labels be sure to secure load if any Study and understand all controls and indicators Fasten seat belt including passenger if any Depress the brake pedal turn ignition key clockwise and hold Keeping the brake pedal depressed select the direction of travel placing the drive select lever in either forward or reverse Release the parking brake 6 Release the brake pedal and slowly depress the accelerator pedal NOTE Never shift from forward to reverse or vice versa until the vehicle is completely stopped ee ee ee STOPPING THE UTV Driving through water may affect the brakes Check the effectiveness of the brakes after driving through water by gently depressing the brake pedal If the vehicle does not slow down continue to depress the brake pedal until the brakes dry out PARKING THE UTV 1 Always engage the parking brake when stopping to ensure the vehicle will not roll 2 Turn the ignition key switch to the off position and remove key 3 Wheel chocks are recommended if parking on an incline BED LATCH To lift the bed pull the latch handle upward and the hydraulic stand will secure the bed A WARNING Be sure to keep hands and all body part
24. fied RED first BLACK last An exploding battery can cause serious injury or death Batteries contain sulfuric acid Always shield eyes with protective eye wear when working around battery acid Battery acid is poisonous and can cause severe burns DO NOT smoke around batteries and keep away from open flame 47 ADJUSTMENTS SUSPENSION The left and right front suspension can be adjusted to different pre loaded positions The suspension adjustment is needed to match the load and driving conditions Make sure to adjust the left and right shock absorbers to the same position or severe injury or death may occur SPARK PLUG Your UTV is equipped with a NGK DPR7EA 9 spark plug To determine if the standard spark plug is in good condition check the color of the plug s center electrode insulator after vehicle operation A brown color indicates that the plug is correct A white or dark insulator indicates that the engine may need adjustment or another plug type may be needed Consult your authorized dealer or Baja Motorsports if your plug insulator is not a light brown color CAUTION Failing to use the proper spark plug could damage your UTV An improper spark plug may have an incorrect fit or heat range for your engine This may cause severe engine damage which may not be covered under warranty Use only the spark plug recommended for this engine Call Baja Motorsports if you are not sure which spark plug is correct for you vehic
25. fter you have found a good place to practice review the control system on your UTV before riding Learn to find these controls without looking for them because you will not have time to look for them when you are riding Canadian residents must obtain review and follow all provincial and municipal government acts and regulations pertaining to owning and operating an off road vehicle 21 OPERATING YOUR UTV INSPECTION BEFORE RIDING ITEM TO CHECK CONTENT Steering Smoothness No restriction of movement No play or looseness Proper brake lever free play enough brake force Parking brake effectiveness Tires Proper air pressure Enough tread depth No cracks rips or other damages Enough fuel for the intended trip Fuel hose connected securely No damage to fuel tank or cap Fuel tank cap closed securely Proper level Check the oil Make sure it is full Throttle Proper free play of gas pedal Smooth response Quick return to idle position General condition Bolts and nuts are tight No rattle from any parts of the engine when running No visible evidence of Damage A WARNING Failing to inspect the UTV before operating could be hazardous Failing to perform proper maintenance could also be hazardous Failing to inspect and maintain your UTV could increase the chances of an accident or equipment damage Always inspect your each time before riding and make sure it is in a safe operating condition Refer
26. imum recommended level Setting tire pressure below minimum recommended level could cause tire to dislodge from rim Maximum Load capacity including cargo trailer and tongue weight 660 Lbs 299kg Crush Area Can cause severe injury Stay away when closing bed Excessive speed can cause severe injury or death Do not tamper with engine govemor adjustment 13 HOT SURFACES Hot Manifold Hot Muffler Negative frame ground Can cause severe injury Do not contact postive battery post or cable to frame Disconnect negative battery lead first GASOLINE EXPLOSION ARE CAN CAUSE SEVERE INJURY OR DEATH KO SMOKING SPARKS OF OPEN FLAME STOP ENGINE ALLOW TO COOL BEFORE REFUELING DO NOT ALL ANK ABOVE THE BOTTOM EDGEOFTHE SIDE FILL CONTROLS AND INDICATORS KEY SWITCH To start the vehicle turn key switch right CW and hold until engine is running smoothly The engine should now idle Turn key switch left CCW to turn engine off NOTE Key can only be removed when engine is off EMERGENCY SHUT OFF SWITCH For engine to run the Emergency shut off switch needs to be placed in the ON position HEADLIGHT SWITCH To turn headlights on press the headlight button Headlights should be off when engine is not running to prevent the battery from loosing life HOUR METER The hour meter located under driver seat only operates when the engine is running It tracks accumulative operating time of
27. ine Unexpected movement could cause you to lose control of the UTV Be sure to set the parking brake before you start the engine A WARNING Running your UTV indoors where there is little or no ventilation could be hazardous Breathing in exhaust gases from the UTV could cause severe injury Always run your UTV outdoors where there is fresh air 26 OPERATING YOUR UTV A WARNING Operating this UTV on paved surfaces including sidewalks paths parking lots driveways and streets could be hazardous UTV tires are designed for off road use Paved surfaces may seriously affect handling and control of the UTV and may cause the vehicle to lose control Avoid operating the UTV on paved surfaces if possible If you must ride on a paved surface go slow and do not make sudden turns or stops A WARNING Operating this UTV on public streets roads or highways could be hazardous You may collide with another vehicle if you ride on the public roads Never operate this UTV on any public street road or highway even dirt or gravel street roads or highway In many states is it illegal to operate UTVs on public streets roads and highways A WARNING Operating this UTV at excessive speeds could be hazardous Riding at excessive speeds increases your chances of losing control of the UTV which could result in an accident Always go at a speed that is proper for the terrain visibility operating conditions operator skills and
28. ion carefully If you are properly prepared you will have a more enjoyable ride Before riding you should find a good place to practice the skills Find a flat open area with enough space to practice the new skills 20 OPERATING YOUR UTV A WARNING Operating this UTV without proper instruction could be hazardous The risk of riding could increase greatly if you do not know how to operate the UTV properly under different situations and in different types of terrain Beginners and inexperienced operators should complete a certified training course You should regularly practice the skills learned in the course and the operating techniques described in this user s manual For more information about the training course visit www svia org or call 800 887 2887 For more information on UTV safety and other provincial and municipal governmental acts and regulation pertaining to owning and operating an off road vehicle visit one of the following web sites www svia org WWW CpSC gov www mmic ca CAT V Make sure that it is legal to ride in the area you selected Review the local laws and make sure you are not trespassing Call the police if you don t know where you can ride Protect your riding areas When you are riding remember to keep the terrain in good condition Don t destroy plants trees or other vegetation Don t litter and don t bother wildlife With your help your riding area can remain open for use in the future A
29. le ADJUSTMENTS NOTE This UTV uses resistor type spark plug to avoid jamming electronic parts Improper spark plug selection may cause electronic interference with your UTVs ignition system resulting in the vehicle performance problems Use recommended spark plugs To install a spark plug turn it in as far as possible with your fingers then tighten it with a wrench do not over tighten CAUTION Improper installation of the spark plug could damage your UTV An overly tight or cross threaded spark plug will damage the aluminum threads of the cylinder head Carefully turn the spark plug by hand into the threads If the spark plug is new tighten it with a wrench about 7 turn past finger tight If you are reusing the old spark plug tighten it with a wrench about 1 8 turn past finger tight To maintain a proper functioning spark plug keep the plug free of carbon Remove carbon from the plug with a wire or pin and adjust the gap to 0 6 0 7mm 024 028in for good ignition Use a thickness gauge to check the gap CAUTION Dirt could damage your UTV if it entered an open spark plug hole of cylinder head Dirt could damage engine parts that move Cover the spark plug hole while the spark plug is out of the hole 49 ADJUSTMENTS TIRES The UTV is equipped with low pressure tubeless tires of the size and type listed below Size AT22x7 10 AT23x8 5 12 A WARNING Operating this UTV with improper tires or even i
30. ll Fill battery to upper level mark located on front of battery Repeat step for each of the 6 cells see figure 22 After each cell is filled with electrolyte to upper level remove tube from battery Figure 21 Vent cap Discard empty electrolyte bottles in a waste area that is inaccessible to children and animals After filling let battery stand for at least 30 minutes before charging This allows the electrolyte to penetrate plates for optimum performance and ensures longer battery life After 30 minutes the battery is ready for its initial charge Place caps loosely over battery cell holes see figure 23 Figure 23 45 BATTERY How to Initially Charge the battery 1 Connect the red positive cable to the red positive pole of the battery see figure 24 2 Connect the black negative cable to the black negative pole of the battery see figure 25 Note The red positive cable has a larger diameter than the black negative y cable 3 Charging rate Charge battery 0 7 Amps for 5 10 hours After charging is complete install securely cap strip see figure 26 Install battery into battery tray located under driver seat see figure 27 Once battery is firmly seated in tray attach red positive wire to positive terminal on battery see figure 28 then attach black negative wire to negative terminal on battery see figure 29 Install
31. lude numbness in the extremities hands feet arms and legs and shivering Damp clothing contributes to hypothermia because cold water on your skin will drain heat from your body s core We strongly recommend that if you do any cold weather riding that you familiarize yourself with the symptoms treatment and prevention of hypothermia Information is available at libraries and through government agencies Plan your winter rides with safety and comfort in mind Dress for the worst conditions you might encounter Be prepared for bad weather and UTV breakdowns Wear warm water resistant clothing such as thermal underwear snowmobile suits lined gloves and boots and wool socks A WARNING Wearing loose clothing when riding your UTV could be hazardous Loose clothing such as a long scarf or shawl could get caught in an UTV s moving parts Never wear loose clothing when riding your UTV 35 OPERATING YOUR UTV OPERATING YOUR UTV ON SNOW AND ICE A WARNING Riding on snow covered terrain even with care could be hazardous The snow may be covering rocks holes ice or other hazards that can cause loss of control Severe injury or death could occur if you lose control of the UTV Go slowly and be careful when riding on snow covered terrain Always be alert to changing terrain conditions A WARNING Riding on a frozen lake or river could be hazardous Serious injury or death could occur if the ice breaks and you coul
32. mission control system warranty covers components whose failure would increase an engine s emission including electronic controls fuel injection system carburetor the ignition system catalytic converter or any other system utilized in this vehicle to control emission if it is originally equipped Also included may be hoses connectors and other emission related assemblies Replacing or repairing other components including parts labor and other costs not covered by this emission control system warranty or the standard warranty is the responsibility of the owner Coverage of repairs under this warranty applies only when repairs are completed at an authorized dealer or repair facility The Distributor will not cover repairs performed outside of an authorized dealer or repair facility The use of replacement parts not equivalent to the original parts may impair the effectiveness of your vehicle s emission control system If such a replacement part is used and an authorized dealer determines it is defective or causes a failure of a warranted part your claim for repair to bring your vehicle into compliance with applicable standards may be denied 55 EMISSION CONTROL SYSTEM WARRANTY This Emission Control System Warranty is in addition to the standard Limited Warranty EXCLUSIONS AND LIMITATIONS This warranty does not cover the following Failures malfunctions of the emission control systems caused by abuse alteration accident
33. misuse the use of leaded gasoline Replacement of expendable maintenance items unless they are original equipment defective in mate rial or workmanship under normal use and the first required replacement interval for the item has not been reached Expendable maintenance items include but not limited to spark plugs filters coolant lubricants gaskets hoses and belts Replacements of parts and other services and adjustments for required maintenance Any vehicle equipped with an odometer or hour meter where the reading is altered so that actual mileage cannot be readily determined Repairs or replacements as a result of Accident 0 Misuse 0 Use of replacement parts or accessories not conforming to original specifications which adversely affect performance Physical damage corrosion or defects caused by fire explosions or similar causes beyond the control of the Distributor Failures not caused by a defect in material or workmanship Use of the vehicle in any type of competitive racing or related events immediately and completely voids this and all other warranties LIMITED LIABILITY The liability of the Distributor under this Emission Control System Warranty is limited solely to the remedying of defects in material workmanship by an authorized dealer at its place of business during customary business hours This warranty does not cover inconvenience or loss of use of the vehicle or transportation of the
34. mproper tire air pressure could be hazardous If you use improper tires or improper tire air pressure you may lose control of the UTV Always use the size and type tires specified Always maintain proper tire air pressure as described in this section Tire Tread Condition 4 0 mm 0 16 inches A WARNING Using worn tires could be hazardous The traction of the vehicle will be decreased This increases your risk of having an accident Replace the front and rear tires when the depth on the tread is 4 0 mm 0 16 inches or less Tire Air Pressure Check the air pressure in all tires before riding Improper air pressure would effect handling steering response traction tire life and rider comfort Be sure that the tires are inflated to the pressures shown below Tire pressure should only be measured or adjusted when the tires are cold COLD TIRE AIR PRESSURE 50 VEHICLE CLEANING CLEANING PROCEDURE A thorough cleaning of your UTV is a necessary part of maintenance It will help keep your UTV looking and performing best Proper cleaning can also extend the life of your UTV It is important to clean and inspect your UTV after every ride especially if it is used in mud brush grass water salt water or very dusty conditions The build up of mud brush grass etc especially on the engine and exhaust system can reduce engine cooling ability conceal damage or increase wear of certain parts It is important to rem
35. nk under passenger seat BATTERY INSTALLATION INITIAL SERVICE AND INSTALLATION OF BATTERY Ni moto battery 2 SAN TANG BATT x ze An LL NETS A WARNING The following procedure is very dangerous and should be performed with the utmost care and attention Wear protective eye wear rubber gloves and have water available should electrolyte come in contact with skin or eyes KEEP ALL CHILDREN AWAY FROM THE AREA WHILE THIS PROCEDURE IS BEING PERFORMED POISON CAUSES SEVERE BURNS Contains sulfuric acid Avoid contact with skin eyes or clothing To prevent accidents rinse empty container with water ANTIDOTE External flush with water Internal Call physician immediately Drink large quantities of water or milk Follow with milk of magnesia beaten eggs or vegetable Eyes Flush with water for 15 minutes and get prompt medical attention KEEP OUT OF REACH OF CHILDREN Note The following page is for vehicles with battery s containing separate electrolyte pack Preparing the battery Place battery on level surface Remove cap strip from top of battery see figure 20 Remove Vent cap from battery vent located on top side portion of battery see figure 21 Wear eye protection and rubber gloves for this step Cut off tip of electrolyte bottle and attach tube Place other end of tube in battery and allow the electrolyte to drain in battery ce
36. om above the bottom of the cargo bed Remove cargo from bed before raising vehicle lift hoist jack etc Avoid stopping on a hill with cargo in cargo bed If it is necessary to stop on a hill avoid sudden starts or rolling backward and sudden stopping Maximum payload capacity 850165 385kg Maximum cargo capacity 400165 181kg Maximum trailer tongue weight 100165 45kg OPERATION INSTRUCTIONS TOWING WITH THE UTV Never tow a vehicle or trailer on public streets or highways Speed should be reduce when towing Use extreme caution Never allow riders in or on whatever is being towed Total vehicle capacity load weight weight of whatever is being towed should not exceed the previous weight specified Avoid sudden starts stops and tight turns Avoid stopping on a hill If it is necessary to stop on a hill avoid sudden starts or rolling backward and sudden stopping Be sure to always use the parking brake and chocks if accessible TRANSPORTING THE UTV Never allow riders on the vehicle Avoid sudden starts stops and tight turns Avoid stopping on a hill If it is necessary to stop on a hill avoid sudden starts or rolling backward and sudden stopping Reduce speed Tie down securely and set the parking brake Never transports with any load in the cargo bed USE AN APPROVED TRAILER THAT HAS A LOAD RATING OF AT LEAST 2000LBS PER VEHICLE BEING TRANSPORTED AND O
37. oper procedures if stalling while climbing a hill Place UTV in reverse and back down slowly using brakes as needed To avoid stalling maintain a steady speed when climbing a hill If you stall or roll backwards follow the special procedure for braking described in this manual NOTICE TO USERS Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as large rocks or fallen trees Always follow proper procedures when operating over obstacles as described in this manual Always be careful when skidding or sliding Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slow and be very cautious in order to avoid going out of control when skidding or sliding Never operate a UTV in fast flowing water or in water deeper than 4 inches Remember that wet brakes can reduce stopping ability Test your brakes after leaving water If necessary apply them several times to let friction linings dry out Always use the tires with proper size and type tires specified in this manual Always maintain proper tire pressure as described in this manual Never modify a UTV through improper installation of accessories Never exceed the stated load capacity for an UTV Cargo should be distributed properly and attached securely Reduce speed and follow instructions in this manual for carrying cargo Allow longe
38. ove all debris during cleaning PREPARATION FOR CLEANING Wash the UTV before any mud dries on the UTV Block or seal the end of the exhaust pipe muffler using a piece of plastic wrap cloth rag or another method to prevent water from entering engine With some care your UTV can be washed in a similar manner to washing an automobile Note Avoid spraying or allowing water to flow over the following places e lgnition switch e Spark plug e Fueltank cap e Carburetor e Air filter Use a garden hose at low pressure to remove the majority of dirt or other debris Hand wash your UTV with mild soap or detergent and water Try to thoroughly remove all dirt and debris without excessive water pressure even at remote areas such as between engine cooling fans linkages or mounting brackets Cloth rags washing mitts or cleaning brushes can be used Be careful with brushes as they may scratch plastic or painted surfaces Rinse the UTV thoroughly with clean water Dry all areas using a chamois or soft absorbent cloth NOTE If warning labels are damaged contact Baja Motorsports or your local service center for replacement 91 TROUBLESHOOTING PROBLEM CAUSE SOLUTION Engine turns over but Nofuel Replenish fuel won t start Clogged fuel filter Replace fuel filter Water in fuel system Drain fuel system and replenish fuel No spark Contact local service center Engine stops or looses Replenish fuel power Clogged fuel filter Re
39. place fuel filter Water in fuel system Drain fuel system and replenish fuel Engine overheat Allow to cool clean radiator screen Check radiator water level 52 SERIAL NUMBER LOCATION You need to know the frame and engine serial numbers to get title documents for your UTV You also need these numbers to help your authorized service center or Baja Motorsports order parts The frame vin number is stamped on the frame under the driver seat as shown in the photograph The engine serial number is stamped on the top of the crankcase Write down the serial numbers here for your future reference Frame No Engine No oo 53 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall I ndlll RA 2600mm 102 in Overall WIO 2 nto eoim nubit 1450mm 57 in Overall 1720mm 68 in Ground clearance me oe pU EC DNE 270mm 11 in Vehicle Weight 430Kg 948 Ibs Weight 385Kg 850 165 Type PR 4 stroke buo M CDI bb iem Qe tr eis 244cc HOoISeDOWOE cibis veiba Deiner n TK Eon E 14Hp Picture Paper element SAN UNIV kn Electric eres EL e Water cool Max 11kw 7000rpm COR UG iaceat o Fab ed cedri b 17 6Nm 500rpm Bore ANG deii rea
40. r changes to the vehicle previously built or sold NOTICE TO USERS We believe in conservation and protection of the earth s natural resources We encourage every vehicle owner and operator to do the same by obeying posted signs and riding only in areas designated and approved for off road recreational use NOTICE TO USERS THIS UTV IS NOT A TOY IT COULD BE HAZARDOUS TO OPERATE A UTV is different from other vehicles including motorcycles and cars A collision or rollover could occur quickly even during routine maneuvers such as turning and driving on hills or over obstacles if you fail to take proper precautions A WARNING SEVERE INJURY OR DEATH can result if you do not follow these instructions Read this manual and labels on the UTV carefully and follow the operations procedures as described Never operate the UTV without proper instructions Always avoid operating an UTV on paved surfaces including sidewalks paths parking lots driveways streets roads and highways Never operate this or any UTV on a public street road or highway where motor vehicles are in operation Never operate an UTV without wearing a DOT approved motorcycle helmet which fits properly Operators should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants Never use alcohol or drugs before or during operation of UTV Driver and passenger should always wear seat belts NOTICE TO USERS
41. r distance for braking Be sure to remove any all cargo before raising the cargo bed or servicing UTV Maximum load capacity in cargo bed is 400165 181kg Overloading the cargo bed will cause damage and danger Make sure all persons are clear before lowering cargo bed Do not drop the cargo bed slowly lower Failure to follow these warnings may result in severe injury or death The combined weight of the rider and any accessories or cargo must never exceed the vehicle s load capacity of 850 Ibs 385kg BAJA 250CC UTV Forward Reverse lever Headrests Brush guard Cargo bed latch Front bumper Radiator fill Brake pedals 5 i brake cap lever Left Mirror Passenger Handle Seat Belts Key switch Cargo bed Front Rear Shocks Shocks Gas tank X Rear wheel Front wheel Right 10 LOCATION OF WARNING LABELS m Es persica mum 7 Located on left and right side panels 8 LOCATION OF WARNING LABELS Improper use of this vehicle could result in severe gt Never use thi always v p Never operate tht T eye protect mand Mili EE M NEVER OPERATE many Heal At speeds too fast for your skills and or conditions With passengers in the cargo bed NEVER penni anyone under age 16 On public roads collision can occur with another im Operate thes Vehicle vehicle
42. r gases and debris and clean if necessary Tires Check air pressure and adjust as necessary General vehicle Wash engine compartment Semiannual service every 50 Clean terminals and wash dirt from hours of operation casing check electrolyte level Electrical wiring Check for tightness and damage and connections Brake system Inspect and replace any worn components Annual service every 100 Engine Check for leaks around the gaskets fill plugs etc 5 iii Annual service every 200 Transmission oil See page 41 hours of operation Periodic checks and cleaning should be done to the engine shroud and radiator Debris in these areas will cause engine failure and will void the warranty PERIODIC LUBRICATION SCHEDULE ITEM LUBRICATION METHOD FREQUENCY RECOMMENDATION Engine oil SF SG SAE 15W 40 see page 40 Change every 6 months or every 100 hours SAE 85W 140 see page 41 Change annually or every 200 hours 37 AIR FILTER The air filter element must be kept clean to provide good engine power If you use your vehicle under normal low tension conditions you should service the air filter at the intervals specified If you ride in dusty wet or muddy conditions you will need to inspect the air filter element much more frequently Use the following procedures to remove the element and clean it AIR FILTER REMOVAL AND CLEANING a Remove gear shift cover center console There are a total of 4 screws Remove lo
43. r mark on dipstick add oil until it is between the low and full level mark 4 Reinsert the dipstick into the filler tube and screw in securely 39 ENGINE OIL 20C 10C 10 C 20 C 30 40 C Use the chart to select a viscosity rating based on the SAE 40 temperature range in your area NOTE Using multi grade oils e gt will increase oil consumption ia 14F 32F 50F 68F 86F 104F Be sure to check the oil level Fu AE 10W bum AE 10W zm more frequently when using these oils A WARNING New and used oil could be hazardous Children and pets may be harmed by swallowing new or used oil Continuous contact with used oil can cause skin cancer in laboratory animals Brief contact with the used oil may irritate the skin Keep new and used oil away from children and pets To minimize your exposure to used oil wear a long sleeve shirt and moisture proof gloves such as dish washing gloves when changing oil If oil contacts your skin wash thoroughly with soap and water Launder any clothing or rags if wet with oil Recycle or properly dispose of used oil CAUTION Failure to use the correct oil could harm your UTV Be sure to use the oil specified in the ENGINE OIL section CAUTION Running the engine without an adequate amount of engine oil could cause severe engine damage which would not be covered under warranty Running the engine without any engine oil could cause engine overheating Always
44. ring it to your authorized service center to have the brakes inspected and cleaned 33 OPERATING YOUR UTV OPERATING IN COLD WEATHER Pre ride Inspection Check that the gas brake pedal move freely Move the UTV forward and backward to check that the wheels roll freely If you cannot move the UTV the tires may be frozen to the ground or the brakes may be frozen to the wheels If the tires are frozen to the ground pour warm water around them to melt the ice If the brakes are frozen bring the UTV to a warmer area to thaw out the brakes After the engine has warmed up check the brakes Do this inspection on level ground and do not exceed walking speed Be sure to check the operation of both front and rear brakes If the brakes do not work adequately stop riding the UTV CAUTION Using engine power to free up frozen wheels could damage your UTV Severe damage to the drive train may occur if you use engine power to free frozen wheels Before riding manually move the UTV forward and backward to make certain that all wheels roll freely Bring the UTV to a warmer area to allow the brakes to thaw out After the brakes thaw dry them by applying them several times before riding If the brakes do not regain full stopping power ask your authorized service center to check them before you continue riding your UTV Water that enters the brakes may freeze after you park your UTV The frozen water can prevent wheels from turning or
45. s away from crush area Failure to do so could result in severe injury or death Bed latch handle 16 OPERATION INSTRUCTIONS A WARNING Make certain the hydraulic stand is secure when working under the bed Failure to do so may result in severe injury or death A WARNING Do not lower cargo bed until all persons and objects are clear from cargo bed area Gently lower cargo bed do not drop bed down Failure to do so may result in severe injury or death To lower the cargo bed lift the prop rod and push rod toward the vehicle to free it from the track Gently lower bed do not drop LOADING AND UNLOADING CARGO BED Engage parking brake before loading anything Never allow riders in cargo bed When driving uphill downhill or on uneven terrain reduce the load and speed Never exceed the maximum weight capacity of the vehicle Overloading the vehicle can affect vehicle handling and cause components to fail resulting in injury or death Reduce speed and sudden stops when in reverse to prevent the vehicle from flipping backward Do not load tailgate Tailgate must be in the upright position and secure when vehicle is in motion Avoid sudden starts stops and turns to help prevent load from shifting and possibly causing the vehicle to overturn Make sure cargo is well secured to prevent is from shifting and possibly causing vehicle overturn The center of gravity should never exceed 15 inches fr
46. the brakes from working After riding through water mud snow or slush it is important to dry the brakes before parking the UTV To dry the brakes apply them several times while riding slowly Before your next ride be sure to do a Pre ride inspection as described earlier in this section A WARNING Operating the UTV without a properly functioning brake system could be hazardous Wet or frozen brakes will increase stopping distance This will increase your chance of having an accident Be sure to inspect the brakes before riding the vehicle in cold weather as described above OPERATING YOUR UTV DRESSING FOR COLD WEATHER RIDING A WARNING Operating your UTV in cold weather without proper clothing could be hazardous Continued exposure in the cold weather could lead to hypothermia Hypothermia is a condition where your body s inner temperature drops low enough to cause injury or death Always dress for the worst weather conditions you might encounter Be prepared for bad weather and UTV breakdowns Riding in cold weather can be hazardous At a temperature of 10 F 12 C the wind chill created by going just 10 mph 16km h makes you as cold as if you were standing still at a temperature of 9 F 23 C At this temperature exposed flesh will freeze in just a few minutes Continued exposure in the cold weather could lead to hypothermia Hypothermia occurs when your body s inner temperature drops Symptoms inc
47. the engine so you know when to perfo I periodic Maintenance Headlight switch Emergency shut off Switch Key Switch REVERSE INDICATOR LIGHT This light will illuminate when the UTV is in reverse Hour meter NEUTRAL INDICATOR LIGHT This light will illuminate when the UTV is in neutral FORWARD INDICATOR LIGHT This light will illuminate when the UTV is in Forward FUEL INDICATOR LIGHT This light will illuminate when fuel is low TEMPERATURE INDICATOR LIGHT This light will illuminate when engine is overheating pm EA Reverse Indicator Light Neutral Indicator Light Forward Indicator Light Temperature Fuel Indicator Light Indicator Light CONTROLS AND INDICATOR TRANSMISSION GEAR SHIFT LEVER The transmission gear shift lever is located between the driver and passenger seat cushion To put the transmission in forward place lever down To put transmission in reverse pull lever back NOTE Be sure to depress the brake pedal before shifting in any position Transmission gear shift lever ACCELERATOR PEDAL By depressing this pedal the vehicles speed will increase in either forward or reverse When the pedal is released it will return to the original position and the engine will idle BRAKE PEDAL This pedal will slow or stop the vehicle when depressed Accelerator Pedal Brake Pedal PARKING BRAKE LEVER TARNEN The parking brake lever is located between the driver and passenger s
48. to the INSPECTION BEFORE RIDING and PERIODIC MAINTENANCE SCHEDULE 22 OPERATING YOUR UTV A WARNING Operating this UTV with improper tires or improper tire air pressure could be hazardous If you use improper tires or improper air pressure you may lose control of the UTV This will cause an accident Always use the tires with size and type tires specified in this user s manual Always maintain proper tire air pressure as described in the TIRES section A WARNING Overloading could be hazardous Overloading could cause changes in vehicle handling and could lead to an accident Check the condition of the UTV to make sure that the UTV does not have mechanical problems or you could get stranded when you ride Before riding the UTV be sure to check the above items Be sure your UTV is in good condition to ensure the safety of the rider s A WARNING Checking maintenance items when the engine is running could be hazardous You could be severely injured if your hands or clothing get caught in moving UTV parts Shut the engine off when performing maintenance checks except checking the throttle 23 OPERATING YOUR UTV SAFETY GEAR A DOT approved motorcycle helmet is the most important part of you safety gear A DOT approved motorcycle helmet can help prevent a serious head injury Choose a helmet that fits snugly Motorcycle dealers can help in selecting a good quality helmet which fits properly A WARNING
49. wer portion of center console that covers parking brake and allows access to air filter box There are a total of 6 screws Locate air filter box and remove Now you have complete access to the air filter remove cover There are a total of 5 screws Remove air filter bracket 2 screws Remove foam air filter Wash foam air filter gently in water or a mild non flammable solvent Squeeze water and let dry Add a small amount of engine oil to entire surface of air filter es UE SS 10 Install in reverse order of removal Gear shift cover center console Lower portion of center console 4 Air filter Wash with D Squeeze out water E OF 35 excess water 38 RADIATOR FLUID ENGINE OIL RADIATOR FILL The Radiator fill is located behind the passenger seat Fill radiator with antifreeze Radiator fill RADIATOR DRAIN 1 Place approved container under radiator drain plug 2 Remove drain plug and let drain completely 3 Reattach drain plug ENGINE OIL LEVEL CHECK Change the engine oil monthly and for excellent performance check the oil level before each use Before checking the oil place the vehicle on a level surface 1 Remove the oil fill dipstick and wipe clean CAUTION DO NOT REMOVE OIL FILL DIPSTICK WHILE ENGINE IS RUNNING 2 Insert dipstick into filler tube and remove Do not screw the cap on when checking the oil level 3 If the oil level is at or below the lowe
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