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INTRODUCTION - Expressatvs.com

1. 4J Seats 7 Seat belts Glove compartment Cargo bed Opening and closing the tailgate Lifting and lowering the cargo bed HH 47 Trailer hitch bracket Safe driving precautions 9 e bi Parking Adjustment 25 Gear Shift Adjustment 99999999999 Auxiliary DC jack ss ssessseccccccccccccsccccccccccccccccscscscscscses G4 PRE OPERATION CHECKS Front and rear brakes
2. qs Battery oe 6 Battery maintenance sesesesecececscccccceccccccccccscececscseeeees 3 Recommended Fuses eeseesecscccccccccccccccccccccccccccsccsesel G Tail brake light bulb replacement 06 Troubleshooting 1 8 Engine overheating CLEANING AND STORAGE 3 CLENANING 1 3 STORAGE 15 NOISE REGULATION e0e0000000000090000000900000009000000090000009900000099996 17 ENGINE eccecee eee eo eooeooooosoocoosoccococcecccccccccccececeec 18 Engine Oil hehehe Engine Coolant heh 122 Air Filter 2
3. 7 Engine and Vehicle Identification Number Location 18 LOCATION OF THE WARNING AND SPECIFICATION LABELS gt 19 SAFETY INFORMATION DESCRIPTION AND VEHICLE IDNTIFICATION 630 Aes CONTROL FUNCTIONS 0000000009090909999090909090909090900009090900900000000000000099 37 Mains switch 06000000090909099090909090909090900000000000000000000000000909999999999 2 Switches 0600000000909090909090009000000000000000000000000009999999999999999J On Command four wheel drive and differential gear lock switches 34 Indicators amp Display 35 Odometer 36 Accelerator pedal OO 3 Brake pedal Drive Select lever Fuel tank cap
4. IS YOUR VEHICLE READY TO DRIVE Before each drive it is important to inspect your UTV800 and make sure any problems you find are corrected A predrive inspection is a must not only for safely but because having a breakdown or even a flat tine can be a major inconvenience If your UTV800 has overturned or has been involved in a collision do not drive it until your UTV800 has been inspected by your dealer There maybe damages or other problems you can not see WARNING Improperly maintaining this UTV800 or failing to correct a problem before driving can cause a crash in which you can be seriously hurt or even dead Always perform a reprieve inspection before every drive and correct any problems Pre drive Inspection Check the following items before you get on the UTV800 e Engine oil Check the level and add oil if needed Check for leaks e Coolant Check the coolant add coolant if 78 needed Check for the leaks e Fuel Check the level and add fuel if needed Also make sure the fuel cap is securely fastened Check for leaks e Tires Use a gauge to check the air pressure Adjust if needed Also look for signs of damages or excessive wear e Nut amp Bolts Check the wheels to see that the axle nuts are tightened use a wrench to make sure all accessible nuts bolts and fasteners are tight e Underbody amp Exhaust System Check for and remove any dirt 79 vegetation ot
5. To protect from damage do not put metal products like tools or sharply edged products directly in the glove compartment If they must be stored wrap them in appropriate cushion material a Unlock b Open 70 Cargo bed Opening and closing the tailgate 1 Cargo bed 2 Tailgate 1 Tailgate 2 Latch x2 3 Cargo hook x4 To open Unhook the latches and then lower the tailgate To close Place the tailgate in the original position and then hook the latches Tis Lifting and lowering the cargo bed 1 Cargo bed rele se lever To lift Push down the cargo bed release lever on the left or right side of the vehicle and then slowly lift up the cargo bed until it stops To lower Lower the cargo bed slowly to its original position and be sure the it is locked into place Maximum load limit 50kg 110lbs WARNING POTENTLAL 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 the pinch points between the bed and the frame 72 WARNING POTENTLAL 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
6. Battery This vehicle is equipped with a sealed type battery Therefore it is not necessary to check the electrolyte or add distilled water in the battery If the battery seems to have discharged consult dealer 1 Tapered nut CAUTION 2 Lower the vehicle so that the wheel Do not try to remove the sealing is on the ground caps of the battery calls You may 3 Tighten the wheel nuts to the damage the battery specified torque WARNING Wheel nut to Rear rque POTENTIAL HAZARD Front amp Rear Failure to handle batteries or battery 64 Nm 6 4 m kgf 47 ft Ibf electrolyte carefully WHAT CAN HAPPEN You could be poisoned You could be severely burned by the sulfuric 102 acid in battery electrolyte Batteries produce explosive gases HOW TO AVOID THE HAZARD Avoid contact with skin eyes or clothing Always shield eyes when working near batteries Keep out of reach of children Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Get prompt medical attention EYES Flush with water for 15 minutes and get prompt medical attention Keep batteries away from sparks flames Ventilate when charging or using in a closed space Battery maintenance 1 When the vehicle is not used for a month or longer remove the battery and store it in a cool dark place Completely recharge
7. 6 Fuel eeeeeescecececccccseecoccccccseeeooccoccceeceoceccccceecececee 7 Gasohol seeeeccccccecoccccccceseooceccccseceooceccccceeeeceeeceeo7 Accelerator pedal esseecescecceccecceccccccccccccccccccceccescecceses 68 Seat belts eeeeececcccceeocccccccseeeooceccccseeeooceccccccececec 68 Steering 60 Fittings and fasteners 599599969 Switches esseeececccccceecoccccccseeeooccccccceeeocececcccececeeeceGO Tiras eeeceescsecocccccccseeoocccoccceseeocecoccceeecoceeccccceeceecce Tire wear limit eeeeseeecececccccceecocccccccseecosecoccceeccooccee O Jump starting 73 Warming Up 74 Engine break in 76 Parking on a slope 78 6 Accessories and loading 79 Loading 0e000000000909099090909090909090090000000000000000000000000000000999999 Q Braking 86 Go
8. drain plug and replace the vehicle on the ground Refill gearbox using XP S chaincase oil or an equivalent CAUTION Do not use other unrecommended types of oil when servicing Do not mix with other types of oil The oil should be level with the bottom of the oil level hole Refill as required through the breathe pipe until gearbox oil level flows through oil level hole 1 breathe pipe Reinstall oil level plug 129 MAINTENANCE CHART The maintenance is very important if you are not familiar with safe service practices and adjustment procedures see your authorized dealer PERIODIC MAINTENANCE CHART A ADJUST INITIAL INSPECTION 10 HOURS OR 300 KM OR 300 km C CLEAN The initial maintenance is very important and must not to be neglected 25 HOURS 750 L LUBRICATE 50 HOURS OR 1500 KM R REPLACE 100 HOURS OR 3000 KM OR 1 YEAR 200 HOURS OR 6000 KM OR 2 YEAR TO BE PERFOMED BY 130 ENGINE Engine oil level 2 EVERY RIDE Customer Engine bilan R R Customer filter Valve adjustment ILA Dealer Engine mount Dealer fasteners Air filter 2 C 4 R 4 Customer Exhaust system Dealer Spark arrester C Customer Condition of Dealer engine seals Coolant 2 I 3 Customer Cooling system Dealer pressure test radiator condition cleanliness Customer radiator fins 4 2
9. Arrester drive belt The muffler must be periodically purged CVT Cover Drain Screw of accumulated carbon Any time you suspect that water has WARNING Never run engine in entered the CVT cover drain the CVT snclosed area Never perform housing by removing the drain screw this operation immediately after the engine has been run because exhaust system is very hot Make sure that there are no combustible materials in the area Wear eye protection and gloves Never stand behind the vehicle while purging exhaust system Respect all applicable laws and regulations Valve Adjustment See an authorized ODES dealer for valve adjustment Select a well ventilated area and make sure the muffler is cool Place transmission on PARK position 126 Remove the cleanout plug of the muffler Block the end of the muffler with a shop rag and start engine Momentarily increase engine RPM several times to purge accumulated carbon out of the muffler Stop engine and allow muffler to cool Reinstall the cleanout plug Radiator Periodically check the radiator area for cleanliness 1 Coolant reservoir 2 Radiator Inspect radiating fins They must be clean free of mud dirt leaves and any other deposit that would prevent the radiator to cool properly Remove as much deposits as you can with your hands If water is available in proximity try rinsing the radiating fans If available use a garden hose to
10. 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 88 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 On most slopes this will let you use engine braking to help you go downhill slowly Go as slowly as possible If you are starting to go too fast apply the brakes gently 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 89 Crossing through shallow WATER I
11. be able to operate an UTV safely Parents should always supervise their child s use of the UTV at all times Parents should permit continued use of the UTV only if they have determined that the child has the ability to operate the UTV safely and responsibly All of the information in this manual is based on the latest product data and specifications available at the time of printing the manufacturers of UTV s reserve the right to make product changes and improvements which may effect the illustrations or explanations without notice If you have any other questions regarding our UTV s operation or maintenance any authorized dealer can readily answer them Enjoy your UTV And if you respect your UTV respect the environment the local and state laws and act responsibly You will gain the respect of others XP roduct and specifications are subject to change without notice Table of Contents PAY ATTENTION TO YOUR SAFETY GUIDELINES ON SAFE DRIVING eeccc0000999909099000000900090000000000999 3 INTRODUCTION e0e0000000000000000009000000090000009090000009900000090900cccccc IMPORTANT MANUAL INFORMATION 15 IMPORTANT NOTICE 16 HOW TO IDENTIFY YOUR UTV
12. coolant in cooling system when engine is hot 122 Remove access panel 1 Coolant reservoir With vehicle on a level surface liquid should be between MIN and MAX level marks of coolant reservoir NOTE When checking level at temperature lower than 20C itm ay be lightly lower than MIN mark Add coolant up to MAX mark if required Use a funnel to avoid spillage Do not overfill Properly reinstall and tighten filler cap and reinstall access panel If the coolant is added in the coolant reservoir check the level in the radiator too Add coolant if necessary i WARNING In order to avoid getting burned do not remove the radiator cap if the engine is hot NOTE cooling system that frequently requires coolant is the indication of leaks or engine problems See an authorized dealer Coolant Replacement i WARNING In order to avoid potential burns do not remove the radiator cap or loosen the coolant drain plug if the the engine is hot Open the front access panel and remove the radiator cap Unscrew the coolant drain plug and drain the coolant into a suitable container 1 Coolant drain plug NOTE Do not unscrew the coolant drain plug completely Unscrew the bleeding screw on the top of thermostat housing 124 Drain the system completely and reinstall the coolant drain plug radiator Pinch hose between and thermostat housing with a large pincher or an
13. element engine and air intake duct V belt case Driver seat Driver seat belt Spark plug Cargo bed Tail brake lights Rear shock absorber assembly adjusting ring 30 Cargo bed release levers Spark arrester Passenger seat belt Passenger seat Oil filter cartridge Battery Fuses Fuel tank cap NOTE The vehicle you have purchased may differ slightly from those shown in the figures of this manual 20 Light switch 21 Hazard warning lamp switch 22 Steering wheel 23 Auxiliary DC jack 24 Mains switch 25 2WD 4WD switch 26 Indicators amp Display 27 Parking brake lever 28 Accelerator pedal 29 Brake pedal 31 CONTROL FUNCTIONS Mains switch e Se 1 Mains switch Functions of the respective switch positions are as follows D All electrical circuits are supplied with power and the headlights and taillights come on when the light switch is on S All electrical circuits are switched off The key can be removed in this position Q The electric starter is engaged by turning and holding the key in this position Release the key when the engine starts 2130 5 CAUTION Do not operate the electric starter continuously for more than 5 seconds or starter damage could occur Wait at least 5 seconds between each operation of the electric starter to let it cool Do not turn the key to the D position with the engine running o
14. equivalent CAUTION Do not use vise grip pliers to pinch hose Fill the radiator until the coolant comes out by the thermostat housing hole Complete the radiator filling Check the level in the coolant reservoir and refill if necessary Run engine at idle with the radiator cap off Slowly add coolant if necessary As this point wait until engine reaches normal operating temperature Depress the throttle level two or three times then add coolant if required Install radiator cap Inspect all connections for leaks and check coolant level in the reservoir Air Filter Removal CAUTION never remove or modify any component in the air filter housing Otherwise engine performance degradation or damage can occur The engine is calibrated to operate specifically with these components Remove access panel Loosen clamp and remove air filter 125 1 Clamp 2 Air filter Cleaning Pour cleaning solution or an equivalent into a bucket Put the filter in to soak While filter soaks clean inside the air filter housing Rinse the filter with warm water until all cleaning solution disappears Then let the filter dry completely Installation Properly reinstall removed parts in the reverse order of their removal Insufficient clearance will cause loss of Drive Belt power and possibly damage the valves See and authorized ODES dealer to Excessive clearance will cause noise check the width and the condition of Spark
15. follow proper procedures for going uphill If you lose momentum 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 26 Always check terrain carefully 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 them 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 maintain 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 27 WARNING POTENTIAL HAZARD Improper handling of gasolin
16. in these fields This manual will provide you with a good basic understanding of the features and operation of this vehicle It also includes basic maintenance and inspection procedures If you have any questions regarding the operation or maintenance of your vehicle please consult an dealer WARNING Please read this manual carefully before operating this vehicle Do not attempt to operate this vehicle until you have attained adequate knowledge of its controls and operating features Regular inspections and careful maintenance along with good operating techniques will help ensure that you safely enjoy the capabilities and reliability of this vehicle 14 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 BECOME ALERT YOUR SAFETY IS INVOLVED WARNING Failure to follow WARNING instructions could result in severe injury or death to the vehicle operator a bystander or a person inspecting or repairing the vehicle CAUTION CAUTION indicates special precautions that must be taken to avoid damage to the vehicle NOTE A NOTE provides key information to make procedures easier or clearer Product and specifications are subject to change without notice 15 IMPORT
17. maintenance procedures and schedules described in the Owner s Manual 65 Front and rear brakes Brake fluid leakage Check to see if any brake fluid is leaking out of the pipe joints or the brake fluid reservoir Apply the brakes firmly for one minute If there is any leakage have the vehicle inspected by an dealer Brake operation Test the brakes at slow speed after starting out to make sure they are working properly If the brakes do not provide proper braking performance inspect the brake system WARNING POTENTLAL 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 problem with the brakes If a problem cannot be corrected by the adjustment procedures provided in this manual have the vehicle inspected by an dealer 66 Fuel Gasohol Make sure there is sufficient gasoline There are two types of gasohol gasohol in the tank containing ethanol and that containing CAUTION methanol Gasohol containing ethanol Use only unleaded gasoline The use can be used if ethanol content does not of leaded gasoline will cause severe exceed 10 Gasohol containing damage to internal engine parts methanol is not recommended by such as the valves and piston rings because it may cause fuel system as
18. oil eReplace warm engine before draining Engine oil filter cartridge eReplace Final gear oil eCheck oil level oil leakage 95 INTIAL EVERY Whichever month 1 3 6 6 12 ITEM ROUTINE Comes first Km 320 1 200 2 400 2 400 4 800 gt mi 200 750 1 500 1 500 3 000 hours 20 75 150 150 300 eCheck operation brake pad wear fluid leakage Front brake eCorrect if necessary Replace pads if worn to the limit o o o eCheck operation brake pad wear fluid leakage Rear brake eCorrect if necessary Replace pads if worn to the limit o o Accelerator pedal eCheck operation and free play O R eCheck balance damage runout Wheels eRepair if necessary eCheck bearing assemblies for looseness damage Wheel bearings eReplace if damaged o o Front and rear eCheck operation and for leakage Suspension eCorrect if necessary eCheck operation and for looseness Replace if damage Steering system eCheck toe in Adjust if necessary Rear upper and lower knuckle pivots Lubricate with lithium soap based grease Q O O Drive shaft universal joint eLubricate with lithium soap based grease Q eCheck for cracks or damage Engine mount eCorrect bolt tightness o o Front and rear axle boots eChec operation eReplace if damage Stabilizer
19. rinse the radiating fins i WARNING Never ciean radiator with your hands when it is hot Let the radiator cool down before cleaning 127 CAUTION Be careful not to damage the radiating fins when cleaning Do not use any object tool that could damage the parts to allow efficient cooling When hosing use low pressure only never use a high pressure washer See an authorized ODES dealer to check the performance of the cooling system Gearbox Oil Recommended Oil Use XP S chaincase oil or an equivalent CAUTION Do not use unrecommended other types of oil when servicing Do not mix with other types of oil Gearbox Oil Level CAUTION Check level and refill if necessary Do not overfill Operating the gearbox with an improper level may severely damage gearbox Wipe off any spillage Place the vehicle on a level surface Select NEUTRAL position then apply parking brake Check the gearbox oil level by removing the gearbox oil level plug 128 1 Oil level plug 2 Oil drain plug The oil should be level with the bottom of the oil level bole Refill as required until gearbox oil level flows through oil level hole Gearbox Oil Change Place the vehicle on a level surface Clean drain plug area and oil level plug then remove the gearbox drain plug NOTE to completely drain the gearbox place a jack under the left footrest and tilt the vehicle toward the right side When the gearbox is empty install the
20. to maintain your balance and control of the UTV800 Removing hands or feet away from the controls can reduce your ability to react and control the off highway recreational vehicle 82 WARNING Removing hand from steering wheel or feet from foot controls during operation can reduce your ability to control the UTV800 Always keep both hands on the steering wheel and both feet on the foot controls of your UTV800 during operation the capability of your UTV800 the terrain visibility and other operating conditions plus your own skills and experience WARNING Control speed Driving at excessive speed increases the chance of an accident In choosing a proper speed you need to consider 83 Operating this UTV800 at excessive speeds increases your changes of losing control of the UTV800 which can result in an accident Always drive at a speed that is proper for your UTV800 the terrain visibility and other operating conditions and your experience Take Care on Unfamiliar or Rough Terrain Before driving in a new area always check the terrain thoroughly Don t drive fast on unfamiliar terrain or when visibility is limited It s sometimes difficult to see and react obstructions such as hidden rocks bumps or holes Never drive past the limit of visibility Maintain a safe distance between your and other off road vehicles Always exercise caution and take extra care on ro
21. 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 81 DRIVING YOUR VEHICLE GETTING TO KNOW YOUR VEHICLE This off highway utility vehicle will handle and maneuver differently from 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 the operation of the controls 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 passengers in the cargo bed WARNING POTENTLAL 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 82 WARNING WARNING POTENTIAL HAZARD Carrying a passenger in the cargo bed W
22. well as to the exhaust system damage or vehicle performance problems 61 WARNING POTENTLAL 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 Accelerator pedal Check to see that the accelerator pedal operates correctly It must operate smoothly and fully spring back to the idle position when released Have an dealer repair as necessary for proper operation Seat belts Make sure that both seat belts are not frayed or damaged The seat belt must move smoothly when pulled 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 an dealer repair as necessary for proper operation Steering Park on level ground Turn the steering wheel right and left Check for excessive free play abnormal noises or a rough feeling Have an dealer repair as necessary for proper operation Fittings and fasteners Always check the tightness of chassis fittings and fasteners before a ride Take the vehicle t
23. 1 Brake pedal 65 Parking brake lever Pull the parking lever up so that the unit can engage park brake To release the unit press button in the front end of parking lever then push the parking lever to the bottom CAUTION e Never use parking brake lever then the vehicle don t stop fully e Adjust the parking cable if necessary e Be sure to fully release the parking brake lever before starting the vehicle Parking level Not on parking Release button _ On parking Drive select lever The drive select lever is used to shift your vehicle the L H N R P and reverse positions CAUTION e Never start the vehicle at N or R lever e Stop the vehicle fully when shifting to reverse 66 Fuel tank cap Remove the tank cap by turning it counterclockwise 1 Driver seat 2 Passenger seat 3 Seat lock lever x2 1 Fuel tank cap Seats To remove a seat pull its seat lock lever upward lift the front of the seat and then slide the seat forward and up 61 To install a seat insert the projections on the rear of the seat into the holders and push down on the seat at the front WARNING POTENTIAL HAZARD A loose seat WHAT CAN HAPPEN The operator could lose control or the operator or passenger could fall if the seat is loose during operation HOW TO AVOID THE HAZARD Make sure the seat is securely latched Seat belts This vehicle is equ
24. 5 Drive 1 6 CVT Cover Drain Screw Oe 70 8 Valve Adjustment eeesessecesccccccscccccccccccccscccccsccccscssce 2 Gearbox Oil 00000000909999090909090909000000000000000000000000000999999 5 2O MAINTENANCE CHART e0e0000000099990990909090909090909000009090909009009000000000999913 SPECIFICATIONS e00000000000000000000000000000000000099999999999999996 3A4 PAY ATTENTION TO YOUR SAFETY This section presents some of the most important information and recommendations to help you ride your UTV safely Please take a few moments to read these pages This section also includes information about the location of safety labels on your UTV Important safety information Your UTV can provide many years of service and pleasure if you take responsibility for your own safety and understand the challenges you can meet while riding There is much that you can do to protect yourself when you ride You ll find many helpful recommendations throughout this manual The following are a few that we consider most important Follow the age recommendation The minimum recommended age of this UTV model is 16 Children under age 16 should never operate this vehicle Always wear a helmet It s a proven fact helmets significantly reduce the number and severity of head injuries So always wear an approved motorcycle helmet Protection sturdy boots gloves and other protective gear 10 Ride off road only Your UTV is designed and manufactured for
25. ANT NOTICE This vehicle is designed and manufactured for off road use only It is illegal to operate this vehicle on any public street road or highway Such use is prohibited by law Check the laws and regulations in force before choosing where to operate this vehicle It is illegal to operate this vehicle on public lands where vehicles its size are prohibited This vehicle complies with almost all state off highway noise level and spark arrester laws and regulations HOW TO IDENTIFY YOUR UTV The main components of your vehicle engine and frame are identified by different serial numbers It may sometimes become necessary to locate these numbers for warranty purposes or to trace your vehicle in the event of loss These numbers are required by the authorized UTV dealer to complete warranty claims properly No warranty will be allowed by if the engine identification number EIN or vehicle identification number VIN is removed or mutilated in any way We strongly recommend that you take note of all the serial number on you vehicle and supply them to your insurance company Engine and Vehicle Identification Number Location TYPICAL 1 EIN Engine Identification Number on left side under of the crankcase 2 VIN Vehicle Identification Number on right side under of the frame LOCATION OF THE WARNING AND SPECIFICATION LABELS Read and understand all of the labels on you vehicle They contain impo
26. HAT 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 POTENTIAL HAZARD Overloading this vehicle orcarrying or towing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle hand ling 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 carry cargo or pulling a trailer 83 The driver and passenger must always wear a seat belt and an approved motorcycle helmet Also wear 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 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 Al
27. Pre ride inspection item 3 Every 100 hours check coolant strength 4 More often under severe use such dusty area sand snow wet or muddy conditions 131 ENGINE MANAGEMENT SYSTEM A ADJUST INITIAL INSPECTION 10 HOURS OR 300 KM OR 300 km C CLEAN The initial maintenance is very important and must not to be neglected INSPECT 25 HOURS OR 750 KM 50 HOURS 1500 R REPLACE 100 HOURS OR 3000 KM OR 1 YEAR 200 HOURS OR 6000 KM OR 2 YEAR TO BE PERFOMED BY SUSPENSION Trailing arms Dealer Trailing arm Dealer bearings Shock absorbers A arms IL Customer Ball joints Dealer 132 BRAKES siepe al R 2 Pre ride inspection item Blake pads 4 Customer 4 More often under Brake system severe use such dusty discs hoses Customer amp sand snow wet etc or muddy conditions BODY FRAME ica lC Customer compartment 4 More often under Frame Dealer severe use such dusty Chassis area sand snow wet ieee Customer or muddy conditions Seat fasteners EVERY RIDE Customer 133 SPECIFICATIONS Model UTV800 Overall length 2850mm Overall width 1610mm Dimen Overall height 1880mm Seat height 850mm Wheelbase 1900mm Ground clearance 285mm Basic weight With oil and full fu
28. UTV800 4x4ES OWNER S MANUAL WARNING e Operation of this UTV by children under the age of 16 Increase of the risk of severe injury or death e An adult supervision required always e Never permit children under age 16 to operate this UTV e Overloading can adversely affect vehicle handling e Operator use only passengers prohibited e This vehicle is designed and manufactured for OFF ROAD use only e Driving on public streets roads or highways is illegal e Always wear helmet and other protective equipment e Do not operate this vehicle after consuming Alcohol or Drugs e Gasoline is flammable when refueling Pis shut off engine to avoid sparks and open flame e Read owner s manual carefully before riding Keep owner s manual with vehicle Sis FOREWORD Dear Customer Congratulations and thank you for your purchase our All Terrain Vehicle UTV It was designed and built to provide you with a superior ride comfort reliability utility and safety Your UTV was designed as a recreational UTV for off road use by one rider only This Operator s Manual is furnished to familiarize the operator of all proper operating procedures It also includes information about the general care and maintenance of your UTV Most importantly carefully read the following pages regarding safety warnings and active riding skills and precautions Children and adults differ in skills physical abilities and judgment Some children may not
29. are properly installed 2 If the engine case is excessively greasy apply degreaser with a paint brush Do not apply degreaser to the wheel axles 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job CAUTION Excessive water pressure may cause water seepage and deterioration of wheel bearings brakes transmission seals and electrical devices Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin operated car washers 113 4 Once the majority of the dirt has been hosed off wash all surfaces with warm water and mild detergent type soap An old toothbrush or bottle brush is handy for hard to get at places 5 Rinse the vehicle off immediately with clean water and dry all surfaces with a chamois clean towel or soft absorbent cloth 6 Clean the seats with a vinyl upholstery cleaner to keep the cover pliable and glossy 7 Automotive type wax may be applied to all painted and chrome plated surfaces Avoid combination cleaner waxes Many contain abrasives which may scratch the paint or protective finish When finished start the engine and let it idle for several minutes WARNING POTENTIAL HAZARD Operation with wet brakes after washing WHAT CAN HAPPEN Wet brakes may have reduced stopping ability increasing the chance of an accident HOW TO AVOID THE HAZARD Test the brak
30. bushings eCheck for cracks or damage Fittings and fasteners eCheck all chassis fittings and fasteners 8 eCorrect if ne ry NOTE e Recommended brake fluid DOT4 e Brake fluid replacement Replace the brake hoses every four years or if cracked or damaged When disassembling the master cylinder or caliper replace the brake fluid Normally check the brake fluid level and add fluid as required On the inner parts of the master cylinder and caliper replace the oil seals every two years 96 HOOD Unhook the hood latches and then Ps slowly tilt the hood up until it stops 1 Hood To close Lower the hood slowly to its original position and then hook the hood 1 Latch x2 latches Secure projections D on the underside of the hood into slots on the back of the instrument panel Secure slots 3 on the side of the hood around projections on the frame 97 CAUTION Make sure that all cables and wires are in place when closing the hood Do not drive the vehicle with the hood open unlatched or removed 1 Projection x2 3 Slot x2 2 Slot x2 4 Projection x2 Console To install 1 Place the console in its original position 2 Install the parking brake lever boot 3 Install the seats CAUTION When installing the console be sure not to pinch the cables or wires Make sure that the g
31. dent Avoid jumping the vehicle as injury loss of control and damage to the vehicle could occur WARNING POTENTIAL HAZARD Failure to use extra care when operating this vehicle on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the vehicle overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the vehicle 91 Riding in brush or wooded areas When operating in areas with brush or trees watch carefully on both sides and above the vehicle for obstacles such as branches that the vehicle might hit causing an accident or for brush that might enter the vehicle as you pass and strike the driver or passenger Never hold onto the enclosure so your hand is outside the vehicle Hold only onto the handgrip inside the enclosure Encountering obstacles on the trail If you cannot go around an obstacle such as a fallen tree trunk or a ditch stop the vehicle where it is safe to do so Set the parking brake and get out to 92 inspect the area thoroughly Look from both your approach side and the exit side If you believe you can continue safely decide the path that will allow you to a right angle as possible to minimize vehicle tipping Go only fast enough to maintain your momentum but s
32. e 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 muffler when refueling Never refuel while smoking or while in the vicinity of sparks open flames and clothes dryers When transporting the vehicle in another vehicle be sure it is kept in an upright position or other sources of ignition such as the pilot lights of water heaters Otherwise fuel may leak out of the carburetor 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 28 WARNING POTENTIAL HAZARD Starting or running the engine ina 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 29 eee ovoo0 o0o0naomwma DESCRIPTION AND VEHICLE IDNTIFICATION Headlights Front shock absorber assembly adjusting ring Brake fluid reservoir Air filter
33. e Otherwise 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 25 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 he 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 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 sped if you cannot see what is on the other side Always
34. el tank 550kg Wet tank lubrication oil filters can be Final gear Type case oil changed Quantity 2 2L Fuel Type Unleaded gasoline only 93 or higher Fuel tank capacity 25 0 L Spark plug Type manufacturer DCPR8E Transmission type Four speed amp one reverse Transmission Operation Manual 134 Model UTV800 Frame type Steel tube frame Chassis Caster angle 5 0 Trail 26 0mm 1 02in Type Tubeless Tire Size Front 25x8 12 Size Rear 25x10 12 System Front and rear unified Biss Type Front pua disc brake Type Rear Single disc brake Operation Foot operation Front suspension Double wishbone Suspension Rear suspension Double wishbone Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber Coil spring oil damper Wheel travel Front wheel travel 185 0 mm 7 28 in Rear wheel travel 185 0 mm 7 28 in 135 Model UTV800 Engine model 2V91 Two cylinder overhead cam SOHC water yp cooling Cylinder diameter 91 Piston stroke 61 5 mm Compression ratio 10 3 1 Displacement 7 97 Maximum torque 73N m 5000 RPM Idle speed 1250rpm 136
35. enance intervals e For vehicles equipped with an odometer or an hour meter follow the km mi or hours maintenance intervals However keep in mind that if the vehicle isn t used for a long period of time the month maintenance intervals should be followed e Items marked with an asterisk should be performed by a dealer as they require special tools data and technical skills engine and air intake duct eReplace if necessary INTIAL EVERY Whichever month 1 3 6 6 12 ITEM ROUTINE Comes first Km 320 1200 2 400 2 400 4 800 gt mi 200 750 1 500 1 500 3 000 hours 20 75 150 150 300 Valves eCheck vale clearance Adjust if necessary eCheck coolant leakage Cooling system eRepair if necessary eReplace coolant every 24 months eCheck condition Spark plug Adjust gap and clean o o o o o Air filter elements eClean Every 20 40 hours More often in wet or dusty areas eCheck idle speed starter operation Differential gear oil eReplace Carburetor up Adjust if necessary Crankcase breather system eCheck breather hose for cracks or damage eReplace if necessary eCheck for leakage Exhaust system eTighten if necessary eReplace gasket s if necessary Spark arrester eClean O rd eCheck fuel hose for cracks or damage Fuel line eReplace if necessary i o o o Engine
36. er x8 2 Bolt x2 3 PanelA 2 Push the defective bulb in and turn it counterclockwise to remove it from the bulb holder 3 Push a new bulb in and turn it clockwise to install in the bulb holder 4 Install the bulb holder together with the bulb by turning it clockwise 5 Install the panel by installing the 107 quick fasteners and bolts and then tighten the bolts to the specified torque Tightening torque Panel bolt 6 5 N m 0 65 m kof 4 7 Troubleshooting Although vehicles receive a rigid inspection before shipment from the factory trouble may occur during operation Any problem in the fuel compression or ignition systems can cause poor starting and loss of power The troubleshooting chart describes a quick easy procedure for making check If your vehicle requires any repair take it to dealer The skilled technicians at dealership have the tools experience and know how to properly service your vehicle Use only genuine parts on your vehicle Imitation parts may look like parts but they are often inferior Consequently they have a shorter service life and can lead to expensive repair bills WARNING POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame WHAT CAN HAPPEN Fuel can ignite or explode causing severe injury or property damage HOW TO AVOID THE HAZARD Do not smoke when checking the fuel system Make sure there are no open f
37. es after washing Apply the brakes several times at slow speeds to let friction dry out the linings 114 STORAGE container by loosening the drain bolt Long term storage 60 days or more of this will help prevent fuel deposits your vehicle will require some from building up Pour the drained fuel preventive procedures to guard onto the fuel tank against deterioration After thoroughly Specified amount cleaning the vehicle prepare for 1 oz of stabilizer to each gallon of fuel storage as follows or 7 5 cc of stabilizer to each liter of fuel 1 Fill the fuel tank with fresh fueland NOTE add the specified amount of Fuel of fuel stabilizer and conditioner Stabilizer and Conditioner or eliminates the need to drain the fuel equivalent product Operate system Consult an dealer if the fuel treated fuel through the fuel system needs to be drained instead system 3 Remove the spark plug pour about 2 Drain the fuel from the carburetor one tablespoon of SAE 10W30 or float chamber into a clean 20W40 motor oil in the spark plug 115 Ground the spark plug wire and turn the engine over several times to coat the cylinder wall with oil 4 Lubricate all control cables 5 Block up the frame to raise all wheels off the ground 6 Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering 7 If storing in a humid or salt air atmosphere coat all exposed metal surfaces with a ligh
38. f 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 33 cm 13 in 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 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 33 cm 13 in Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings 90 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 drive select button Wash the vehicle in fresh water if it has been operated in salt water or muddy conditions Riding over rough terrain Operating over rough terrain should be done with caution Look for obstacles that could cause damage to the vehicle or could lead to a rollover or acci
39. he 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 on the enclosure 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 a dirt or gravel one Never operate this vehicle without wearing an approved motorcycle helmet that fits properly You should also wear eye protection goggles or a face shied gloves over the ankle boots long sleeved shirt or jacket and long pants 24 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 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 both hands arms feet and legs in side the vehicle at all times during operation Keep your feet on the floorboard Never hold onto the enclosure except when using the handgrip inside the enclosur
40. he 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 some hills are too steep for you to climb 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 WARNING Maximum slope angle 15 15 Maximum POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn move easily on extremely steep hills than on lever 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 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 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
41. her debris that could be fire hazard or interfere with the proper operation of the UTV800 e Air Cleaner Check the air filter Replace it if needed e Leaks Loose Part Walk around your UTV800 and look for anything that appears unusual such as a leak or loose cable e Lights Make sure the headlight brake light and tail light are working properly e Throttle Check the free play and adjust if needed Press the throttle to make sure it moves smoothly without sticking and snaps back automatically when it is released e Clutch pedal Check the free play of clutch pedal and adjust if needed Press the clutch cable to make sure it moves smoothly without sticking and snaps back automatically when it is released e Brakes Press the brake pedal several times check for proper brake pedal free play Make sure there is no brake fluid leakage e Engine stop When engine is running turn the switch key counterclockwise Make sure engine stops e Steering Wheel Check that the wheels turn properly as you turn the steering wheel eCable Check the cable housing for wear Check the fittings are tight Replace or tighten as needed eTie rod Check the tie rod housing for wear Check the fittings are tight Replace or tighten ad needed 80 Safe driving precautions Off road use only You re UTV800 and its tires are designed and manufactured for off road use only not for pavement Driving on pavement can affect handling a
42. icle and the other end of the positive lead to the positive terminal of the charged battery 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 negative lead to an unpainted metal surface of the vehicle 2335 WARNING Do nor 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 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 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 starter choke turned off 74 Shifting Neutral to Reverse 1 Stop the vehicle Keep your foot off the accelerator pedal 2 Apply the brake pedal 3 Shift from neutral to reverse or vice versa by mo
43. important piece of driving gear because it offers the beat protection against head injuries A helmet should fit your head comfortably and securely An open face helmet offers some protection but a full face helmet offers more Regardless of the style look for a DOT Department of Transportation sticker in any helmet you buy Always wear a face shield or goggles to protect your eyes and help your vision 75 WARNING Operating this without wearing an approved motorcycle helmet eye protection and protective clothing could increase your chances of head or eye injury possibly death in the event of severe accident Always wear approved motorcycle helmet that fits properly and wear eye protection goggle or face shield gloves boots long sleeved shirt or jacket and long pants Additional driving gear In addition to a helmet and eye protection we also recommend sturdy off road motorcycle boots to help protect your feet ankles and lower legs Off road motorcycle gloves to help protect your hands driving pants with knee and hip pads a driving jersey with padded elbows chest shoulder protector Drive training Developing your driving skills is an on going process Even if you have driven other UTVs 800 take time to become familiar with hoe this UTV800 in a Safe area to build your skills Do not drive in rough terrain you get accustomed to the UTV800 s controls and feel comfortable with
44. ing uphill BG Going downhill BB Crossing through shallow 00 Encountering obstacles on the trail nre 2 PERIODIC MAINTENANCE AND ADJUSTMENT rrr Periodic maintenance lubrication Q5 OPEN 7 Toclose 0 Console 08 Changing 99 Rear knuckle upper and lower pivot lubrication ee t 100 Steering shaft lubrication 100 Wheel removal Wheel installation
45. ipped with three point seat belts for both the operator and passenger Always wear the seat belt while riding in the vehicle SEAL dell 3 Buckle x2 To wear the seat best belt properly do the following 1 Hold the latch plate as you pull the belt across your lap and chest Make 68 Latch plate X sure the belt is not twisted and is not across your hips caught on any portion of the vehicle 4 Position the shoulder belt over your your clothing or any equipment you shoulder and across your chest The are carrying shoulder belt should fit against your 2 Push the latch plate into the buckle chest If it is loose pull the belt out all until it clicks Pull up on the latch the way and then let it retract plate to make sure it is secure 5 To release the buckle firmly press the release button 1 Buckle 2 Latch plate 1 Buckle 2 Release button 3 Put 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 69 WARNING POTENTLAL 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 Glove compartment CAUTION
46. itched betweens the figure of speed will display and update synchronous while switching between KM H and in unit of pedometer Press the button of Time Set the user can set 36 the hour and minute Then adjust hours or minute by ascending or descending by continuing press button of mode of Set Reset user can clean the record to zero for particular period of working mileage and time by pressing the mode of Set Reset while showing mode of TRIP A and HRA the speedometer 1 Speed meter 2 Time 3 Trip meter m 000070 Km h amp mph mode change Press the MODE button choose either Km h or mph needed mph km h 37 Other indicator light Coolant temperature indicator light It indicates the temperature of coolant If the temperature is above 102 C stop engine immediately Check coolant lever and add if low see authorized dealer if temperature indicator stay on and overflow tank is full of coolant Oil pressure indicator light It indicates low high oil pressure when illuminated see authorized dealer if necessary Check engine indicator lamp t 500 Ss Check engine indicator lamp After
47. its size and weight WARNING Operating UTV800 without proper instruction could increase your risk of an accident which could lead to serious injury or death WARNING Attempt supporting with your hands to the ground then the off highway recreational cubicle turning over could lead to serious injury or death Never support with your hands to ground when the off highway recreational vehicle will turn over i76 Age Recommendation It is strongly recommended that is not one under the age of 16 be permitted this UTV800 without adult supervision WARNING A child driving a UTV800 that is not recommended for his her age could lose UTV800 control and result in server injury or death A child under 16 years holed have adult supervision when operate on the UTV800 impair your ability to operate a UTV800 safely Likewise drugs even if prescribed by a physician can be dangerous whiles operating a UTV800 consult your to be sure it is safe to operate a vehicle after taking medication WARNING No Alcohol or Drugs Alcohol drugs and driving don t mix Even a small amount of alcohol can sq Operating this UTV800 after consuming alcohol or drugs can seriously affect your judgment cause you to react more slowly affect your balance and perception and could result in serious injury or death Never consume alcohol or drugs before or while operating this UTV800
48. kes 2 Stop the engine 3 With the brakes applied set the parking brake 78 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 Accessories and loading Accessories Accessories can affect the handling and control of your vehicle Keep the following in mind when considering an accessory or operating a vehicle which has accessories Choose only accessories designed for your vehicle Your dealer has a variety of genuine accessories Other accessories may also be available on the market However it is not possible for to test all 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 which 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 co
49. lames or sparks in the area including pilot lights from water heaters or furnaces 109 Troubleshooting charts Starting problems or poor engine performance 1 Fuel There is fuel __ hose rS the L No fuel Le m pump Check if there is fuel rom the fuel pump uel flow is clogged in the fuel tank No fuel Supply fuel Restart the engine Ask an dealer to 2 Compression Use the clec There is compression Compression normal starter to see if there is compression Ask an dealer to No compression inspect 3 Ignition m Spark is good Ignition system is normal Wet Wipe clean with dry cloth emove the spark plug and Spark is weak check the electrodes D Attach spark plug cap and Use the electric ggl B ground to chassis starter Adjust the spark No spark plug gap or replace 4 Battery Engine turn over B iteiv3 d the spark plug quickly PES rte Use the electric starter Ask an dealer to Engine turn over Check the connections inspect slowly rechatge 110 Engine overheating WARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator sti
50. ll hot WHAT CAN HAPPEN You can be burned by hot fluid and steam blown out under pressure HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap Always use a thick rag over the cap Allow any remaining pressure to escape before completely removing the cap 111 Ask an dealer 1 Wait until the __ to inspect Level is low engine has cooled and repair the check the cooling system cooling system Check the coolant Or leakage Wait until the Add coolant Wait until the mu level in the engine has cooled nS See NOTE engine has cooled coolant reserver and or radiator Restart the engine L Levelis OK if the engine overheats afain ask an dealer to inspect and or repair the cooling system NOTE If it is difficult to get the recommended coolant tap water can be temporarily used provided that it is changed to the recommended coolant as soon as possible 112 CLEANING AND STORAGE CLENANING Frequent though cleaning of your vehicle will not only enhance its appearance but will improve its general performance and extend the useful life of many components 1 Before cleaning the vehicle a Block off the end of the exhaust pipe to prevent water entry A plastic bag and strong rubber band may be used b Make sure the spark plug and all filler caps
51. maximum load limit for this cargo bed Cargo should be properly distri buted and securely attached Reduce speed when carrying cargo Allow greater distance for braking WARNING POTENTLAL 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 293 Trailer hitch bracket This vehicle is equipped with a 5cm 2in receiver bracket for a standard trailer hitch Trailer towing equipment can be obtained at an dealer 1 Trailer hitch bracket ARE YOU READY TO DRIVE Before each drive you need to make sure you and your UTV800 are both ready to drive To help get you prepared this section discusses how to evaluate your driving readiness what items you should check on your UTV800 and adjustments to make for your comfort convenience or safety Protective apparel For your safety we strongly recommit end that you always wear an approved motorcycle helmet eye protection boots gloves long pants and long sleeved shirt or jacket whenever you drive Although complete protection is not possible wearing proper gear 74 can reduce the chance of injury then you drive The following suggestions will help you choose the proper driving gear Helmets and eyes protection Your helmet is your most
52. mmon sense and good 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 Choose a trailer hitch drawbar designed for use with a 5 cm 2in receiver 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 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 The 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 with controls or your ability to see where you are going Drive more slowly 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
53. n plug or the filter cover if the engine is hot Wait until engine oil is warm Ensure vehicle is on a level surface Remove dipstick Clean the oil drain plug area Place a drain pan under the oil drain plug area Unscrew oil drain plug 121 TYPICAL 1 Oil drain plug Allow enough time for oil to flow out of oil filter Unscrew the oil filter cover 1 Oil filter cover 2 Exhaust pipe Remove the oil filter and replace with a new filter Check the cover O ring and change it if necessary 3 1 2 Y 1 Oil filter 2 O ring 3 Oil filter cover Screw oil filter cover in place Wipe out any oil spillage on engine Change gasket on oil drain plug Clean gasket area on engine and oil drain plug then reinstall plug Refill engine at proper level with the recommended oil Refer to SPECIFICATIONS capacity Start engine and let idle for a few minutes Ensure oil filter area and oil drain plug areas are not leaking Stop engine Wait a while to allow oi to flow down to crankcase then ch eck oil level Refill as necessary Dispose of oil as per your environmental regulations Engine Coolant Recommended coolant Always use ethylene glycol antifreeze containing corrosion inhibitors specifically for internal combustion aluminum engine Cooling system must be filled with premixed coolant local Coolant level i WARNING Check coolant level with engine cold Never add
54. nd control You should not drive your UTV800 on pavement WARNING Operating this UTV800 on paced surfaces may seriously affect handling and control of the UTV800 and may cause the vehicle to go out of control Never operate the on any paved surfaces including sidewalks driveways parking lots and strata 81 When driving off road also remember to always obey local off road driving laws and regulations Obtain permission to drive on private property Avoid posted areas and obey no trespassing signs You should never drive your UTV800 on public streets roads or highways even if they are not paved Drivers of street vehicles may have difficulty seeing and avoiding you which could lead to a collision In many states it is illegal to operate UTV800 on public streets roads and highways WARNING Operating this UTV800 on paced surfaces may seriously affect handling and control of the UTV800 and may cause the vehicle to go out of control Never operate the on any paved surfaces including sidewalks Operating this UTV800 on paced surfaces may seriously affect handling and control of the UTV800 and may cause the vehicle to go out of control Never operate the on any paved surfaces including sidewalks driveways parking lots and strata Keep hands and feet on controls Always keep both hands on the steering wheel and both feet on controls When driving your UTV800 it is important
55. o an dealer or refer to the Service Manual for correct tightening torque Lights Check the headlights and tail brake lights to make sure they are in working condition Repair as necessary for proper operation Switches Check the operation of all switches Have dealer repair as necessary for proper operation Tires WARNING POTENTLAL HAZARD Operating this vehicle with improper tires or with improper or uneven tire pressure 69 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 motor Manufac turing corporation of America for this model Other tire combinations are not recommended 2 The tires should be set to the recommended pressure Recommended tire pressure Front amp Rear 25 kPa 0 25 kgf cm 10psi Check and adjust tire pressures when the tires are cold Tire pressures must be equal on both sides 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 amp Rear 22 kPa 0 22 kgf cm 3 2 psi Higher pressures may cause the tire to burst Inflate the tires very slowly and carefully Fast inflation could cause the tire to burst 70 How to measu
56. off road use only The tires are not made for pavement and the UTV does not have turn signals and other features required for use on public roads If you need to cross a paved or public road get off and walk your UTV across Take time to learn amp practice Even if you have ridden other UTVs take time to become familiar with your skills and get accustomed to the UTV is size and weight Because many accidents involve inexperienced or untrained riders we urge all riders to take a training course approved by the UTV safety institute Contact an authorized UTV dealer to find out about the training courses nearest you Be alert for off road hazards The terrain can present a variety of challenges when you ride off road Continually read the terrain for unexpected turns drop offs rocks ruts and other hazards Always keep your speed low enough to allow time to see and react to hazards ll Ride within your limits Pushing limits is another major cause of UTV accidents Never ride beyond your personal abilities or faster than conditions warrant Remember that alcohol drugs fatigue and inattention can significantly reduce your ability to make good judgments and ride safely Don t drink and ride Alcohol and riding don t mix Even one drink can reduce your ability to respond to changing conditions and your reaction time gets worse with every additional drink So don t drink and ride and don t let your friends drink and
57. on applications use XP S 5W40 synthetic oil Engine Oil Recommended Oil Use 4 stroke mineral based engine oil that meets or exceeds the requirements for API service classification SM SL or SJ Always check the API service label certification on the oil container it must contain at least one of the above 118 5 SW40 Synthetic Oil XP S 10W40 Mineral Oil He 119 Oil Level CAUTION Check level frequently and refill if necessary Do not overfill Operating the engine with an improper level may severely damage engine Wipe off any spillage With vehicle on a level surface and engine cold not running check the oil level as follows 1 Unscrew dipstick then remove it and wipe clean 2 Reinstall dipstick screw in it completely TYPICAL 1 Full 2 Add 3 Operating range 3 Remove and check oil level It 120 should be near or equal to the upper mark To add oil remove the dipstick Place a funnel into the dipstick tube to avoid spillage Add a small amount of recommended oil and recheck oil level Repeat the above procedures until oil level reaches the dipstick s upper mark Do not overfill Properly tighten dipstick Oil Change and Oil Filter Replacement Oil and filter are to be replaced at the same time Oil change should be done with a warm engine WARNING The engine oil can be very hot In order to avoid potential burns do not remove the engine drai
58. ottle operation under load does not harm the engine Each full throttle acceleration sequence should be followed with a substantial rest period for engine by cruising at lower r min so the engine can rid itself of the temporary build up of heat If any abnormality is noticed during this period consult an dealer 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 20 hours Avoid prolonged operation above 3 4 throttle Rev the vehicle freely but do not use full throttle at any time After break in The vehicle can now be operated normally 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 77 Parking on a slope WARNING POTENTLAL 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 no hills that are so steep you could not walk up them easily 1 Bring the vehicle to a stop by applying the bra
59. out 2 Turn the key to OFF and turn off the electrical circuit in question CAUTION To prevent accidental short circuiting turn off the main switch when checking or replacing a fuse 3 Remove the blown fuse and then install a new fuse of the specified amperage If a fuse blows All of the electrical circuits on your UTV have fuses to protect them from damage caused by excess current flow short circuit or overload If something electrical on your UTV stops working the first thing you should check for is a blown fuse 1 Check all the fuses before looking elsewhere for another possible cause of the problem Replace any blown fuses and check component operation Recommended Fuses 1 2 3 4 5 6 7 8 9 10 1 Speed power rear brake light headlight and fan power 2 ECU and speed sensor 3 Footbrake switches 4 2WD AWD drive switch main relay 5 Supplely power 6 Spare fuse 7 Spare fuse 8 Main relay 9 Fan relay 10 Fuel pump relay NOTE Replacing a fuse with one that has a higher rating greatly increases the chance of damage to the electrical system Tail brake light bulb replacement If a tail brake light bulb burns out replace it as follows 1 Remove panel A if replacing the left tail brake bulb or panel B if replacing the right tail brake bulb by removing the quick fasteners and bolts 106 2 Panel B 1 Quick fasten
60. r damage to the electric starter can result see Starting instructions prior to starting the engine Switches Light switch O SO Set the switch to Zto turn on the low beam and the taillights Set the switch toO to turn on the high beam and the taillights 133 On Command four wheel switch 2WD 4WD and a differential drive and differential gear gear lock switch 4WD LOCK Select lock switches the appropriate drive according to terrain and conditions 1 four wheel drive switch 2WD 4WD 2 On Command differential gear lock switch 4WD LOCkK This vehicle is equipped with an On Command four wheel drive 34 Indicators amp Display Lu f A N al e Lu o 59 aE an p m ss SS ER 0 PRS HEB mcs Je LENEN ew Bh Se CJ fre s mo C lt Odometer When selected the odometer registers total distance traveled in miles while the ignition is ON A To change the display from trip meter to odometer press and release the Odometer Trip meter select button Functions switch Press the button of Mode the mode of ODO TRIP A TRIP B HRA and HRB will display in the odograph and be sw
61. re tire pressure Set pressure with tires cold Use the tire pressure gauge Set tire pressures to the following NOTE specifications The tire pressure gauge is included as standard equipment Make two measurements of the tire pressure Front 25 kPa 22 kPa 26 kPa 2 and use the second reading Dust or amp 0 25 kgf cm 0 22 0 26 NS 10 psi kgf cm kgf cm dirt in the gauge could cause the first 3 2 psi 11 psi reading to be incorrect Manufacturer size FAR EAST 25x8 12 Rear FAR EAST 25x10 12 71 OPERATION WARNING 1 Tire pressure gauge Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire POTENTLAL 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 dealer a Tire wear limit 29972 Jump starting Jump starting the vehicle should be avoided The battery should be removed and charged instead however if the vehicle must be jump started proceed as follows 1 Turn the key to OFF 2 Open the hood 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 veh
62. ride either Keep your UTV in safe condition Its important to keep your UTV properly maintained and in safe riding condition Having a breakdown can be difficult especially if you are stranded off road far from your base To help avoid problems inspect your UTV before every ride and perform all recommended maintenance Your UTV comes with a hangtag and several labels containing important safety information Anyone who rides the vehicle should read and understand this information before riding The labels should be considered permanent parts of the vehicle If a label comes off or becomes hard to read contact your dealer for replacements GUIDELINES ON SAFE DRIVING when approaching corners or bends to reduce speed Upon the completion of turn may gradually increase the speed when crossing the vehicles parked in front of to be very careful Because the driver of the vehicle may be invisible to you and the door opened the forward block in your way Brake Lining may Motorcycle rinsing wetting lose their role so when cleaning End after walking ago should check all brake system For training please call ASI at 1 800 887 2887 INTRODUCTION Congratulations on your purchase of the UTV It represents the result of many years of experience in the production of fine sporting touring and pace setting racing vehicles With the purchase of this you can now appreciate the high degree of craftsmanship and reliability that have made a leader
63. roove at the bottom of the parking brake lever boot and the drive select lever boot fits securely around the edge of the hole in the console Gear Case Oil Type Hypoid gear oil Viscosity SAE 80 weight Shaft drive oil of original Suggested oil manufacturer or equivalent Changing Oil Changing the oil with the gear case at normal operating temperature to assure complete and rapid draining 1 Park the UTV on level ground 2 Place an oil drain pan under the oil 1 oil drain plug drain plug 1 2 oil filler cap 3 Remove the oil filler cap 2 and the drain plug 99 Rear knuckle upper and lower Steering shaft lubrication pivot lubrication Lubricate the pivot points Lubricate the knuckle upper and lower pivots with a grease gun Recommended lubricant Lithium soap based grease all purpose grease Recommended lubricant Lithium soap based grease 100 Wheel removal Wheel installation 1 Loosen the wheel nuts 1 Install the wheel and the nuts 2 Elevate the vehicle and place a suitable stand under the frame NOTE 3 Remove the nuts from the wheel The arrow mark on the tire must point 4e Remove Mie wheel toward the rotating direction of the wheel Tapered nuts are used for both the front and rear wheels Install the nut with its tapered side towards the wheel 1 Nut x4 Arrow mark 101
64. rtant information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or comes off a replacement label is available from your dealer Improper use can result in Severe INJURY or DEATH This off highway utility vehicle will handle and ALWAYS keep your hands and feet inside the vehicle at all Vehicle capacity operator and 1 times watch for branches brush or other hazards must be able to reach and hold the handgrip inside that could enter the vehicle E S enclosure drive straight up and down inclines driving across the side of an incline increases the risk of overtum ALWAYS USE AN This vehicle is recommended onlyfor operators 16 and older with a valid motor vehicle license Adults must NEVER super minors Ch r minimum age des orale Ghecicetate lwe tor minimu e operate through water deeper than 13 33 cm or fast flowing water if you must cross shallow slow moving Gross Vehicle Weight Rating 1764 Ibs 800kg maximum water choose your path carefully to avoid sharp including operator passenger accessories cargo drop offs large rocks or slippery surfaces that and trailer tongue weight could cause the vehicle to overturn Passenger and cargo can affect vehicle handling aos M LOCATE AND READ THE OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS 20 25kPa mw 10psi MINIMUM FRONT 0 lat 305 Ne
65. ry Gear Shift Adjustment 3 Before operating the vehicle check the shift lever as to change gearshift from 1 to 5 and reverse smoothly The shift lever should be vertical when the gear is in neutral If not adjust the shift cable and then tighten the nuts of the shift cable 86 Break in The first month is most important in the life of your vehicle Proper operation during this break in period will help assure maximum life and performance from your new vehicle The following guidelines explain proper break in procedures 1 After the engine starts the engine is not allowed in high speed in the neutral gearshift 2 Drive vehicle from stop to low speed slowly Avoid braking strongly 4 Do not exceed the vehicle speed on the below schedule Starting and Operating Instructions 87 e Before starting the engine be sure that the driver is seated properly in the UTV800 and tighten the seat belts e Testing the UTV800 in an open place at the beginning to learn how to start turn and stop e Operate the UTV800 slowly until you are familiar with it e The turning radius of this UTV80O is small and agile so the centrifugal force is very high when turning at high speed Slow down to a more controllable speed when turning to prevent the UTV800 from rolling over e To prevent vehicle from rolling over be sure to only turn the vehicle at a slow more controllable speed Auxiliary DC jack 1 Set
66. t film of oil Do not apply oil to any rubber parts or the seat covers 8 Remove the battery and charge it Store it in a dry place and recharge it once a month Do not store the battery in an excessively warm or cold place less than 0 C 30 F of move than 30 C 90 F NOTE Make any necessary repairs before storing the vehicle 116 NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc Muffler Exhaust system Exhaust pipe Silencer Air cleaner case Intake system Air cleaner element Intake duct 117 ENGINE standards Oil Viscosity SAE 5W30 mineral based oil is recommended for all seasons However during the hottest days of the summer the XP S 10W40 mineral oil can be used NOTE For improved overall performance and all seas
67. the battery before reinstallation CAUTION The carburetor was set at the factory after many tests If the settings are disturbed by someone without sufficient technical knowledge poor engine performance and damage may result 2 Always make sure the connections are correct when putting the battery back in the vehicle 103 WARNING Do nor 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 If a fuse blows All of the electrical circuits on your UTV have fuses to protect them from damage caused by excess current flow short circuit or overload If something electrical on your UTV stops working the first thing you should check for is a blown fuse 1 Check all the fuses before looking elsewhere for another possible cause of the problem Replace any blown fuses and check component operation 1 1 Blown fuse Fuse replacement The main fuse and the fuse boa are located under the hood If a fuse is blown turn off the main switch and install a new fuse of the specified amperage If a fuse is blown replace it as follows 1 Remove the battery compartment cover by lifting it up and pulling it
68. the light switch to OFF The auxiliary DC jack is located at the 2 Start the engine right side of the front panel 3 Open the auxiliary DC jack cap and The auxiliary DC jack can be used for then insert the accessory power plug suitable work lights radios etc into the jack The auxiliary DC jack should only be used when the engine is running 1 Auxiliary DC jack Maximum rated capacity for the auxiliary DC jack 1 Auxiliary DC jack cap DC 1 2V 120W 1 0A 64 4 When the auxiliary DC jack is not being used cover it with the cap CAUTION Do not use accessories requiring move than the above maximum capacity This may overload the circuit and cause the fuse to blow elf accessories are used without the engine running or with the headlights turned on the battery will lose its charge and engine starting may become difficult Do not use an automotive cigarette lighter or other accessories with a plug that gets hot because the jack can be PRE OPERATION CHECKS Before using this vehicle check the following points WARNING POTENTLAL 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
69. till give yourself plenty of time to react to changes in conditions If there is any question about your ability to maneuver safely over the obstacle you should turn around if the ground is flat and have the room or back up until you find a less difficult path WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or a collision Could cause the vehicle to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Use extreme caution when operating over large obstacles such as large rocks or fallen trees 93 PERIODIC MAINTENANCE AND ADJUSTMENT Periodic inspection adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible Safety is an obligation of the vehicle inspection adjustment and lubrication are explained in the following pages WARNING POTENTIAL HAZARD Servicing an engine while it is running WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body causing injury Electrical components can cause shocks or can start fires HOW TO AVOID THE HAZARD Turn off the engine when performing maintenance unless otherwise specified Have an dealer perform service if you are not familiar with vehicle service Periodic maintenance lubrication NOTE e For vehicles not equipped with an odometer or hour meter follow the month maint
70. turning the ignition switch on the lamp shall be on and the lamp shall be off after starting the engine If the lamp is on while the engine working it indicates that the system failed When some electric jet parts are found fault check engine indicator lamp will also be ON the vehicle still can keep running the driving performance is getting worse which reminds the driver should send the vehicle to repair Accelerator pedal Press the accelerator pedal down to increase engine speed Spring pressure returns the pedal to the rest position when released Ways check that the accelerator pedal returns normally before starting the engine 1 Accelerator pedal Before starting the engine check the accelerator pedal to be sure it is operating smoothly Make sure the accelerator pedal fully returns to the idle position as soon as it is released WARNING POTENTLAL HAZARD Malfunction of the accelerator pedal WHAT CAN HAPPEN The accelerator pedal could be hard to operate making it difficult to speed up or slow down then 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 it does not work smoothly check for the cause Correct the problem before operating the vehicle Consultan dealer if you can t find or solve the problem yourself 64 Brake pedal Press the brake pedal to slow or stop the vehicle
71. ugh slippery and loose terrain WARNING WARNING Failure to take extra care when operating this UTV800 on unfamiliar terrain could result in the UTV800 overturning or going out of control Go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the UTV800 Failure to take extra care when operating on excessively rough slippery or loose terrain could cause loss of traction or vehicle control which could result in an accident including an overturn Do not operate on excessively rough slippery or loose terrain until you have learned and practiced the skills necessary to control the UTV800 on such terrain Always be especially cautious on these kinds of terrain 84 Do Not Perform Stunts Parking Adjustment You should always operate your Parking level UTV800 in a safe and reasonable manner When driving always keep all wheels on the ground WARNING Attempting wheelies and other stunts Not on parking increases the chance of an accident including an overturn Release button _ Never attempt stunts such as wheelies or jumps Don t try to show off On parking 85 e Pull the park brake lever up so that the unit can engage park brake e To release the unit press button on front end of parking lever then push the parking lever to the bottom e Adjust the parking cable if necessa
72. ver set tire ss below minimum Tire may dislodge from rim 800 kg 1764 Ibs of operator passenger if applicable trailer tongue weight 2 Severe INJURY or DEATH can result if you ignore the following Maximum Loadin Cargo Bed 50kg 110 Ibs Never carry passengers in cargo bed Cargo can affect handling and stability Read Owner s Manual before loading or towing When loading with cargo or towing a trailer Reduce speed and allow more room to stop Avoid hills and rough terrain Be sure cargo is secured loose load could change handling unexpectedly Keep weight in the cargo bed centered and as low and far forward as possible Top heavy loads increase the risk of overturn 3 Improperly Loading a trailer Keep hands body other persons W KS away when closing bed Do not operate the vehicle with bed up w 13 INCH 22 improper use can result engine damage Before change reverse gear you must stop Please check the oil before driving the UTV the UTV eFirst step on the brake pedal then press the reverse button 7 8 Please fasten the seat belt before driving 9 23 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 t
73. ving the drive select lever along the shift guide 4 Check behind for people or obstacles then release the brake pedal 5 Press the accelerator pedal gradually and continue to watch to the rear while backing NOTE When in reverse the revere indicator light should be on If the light does not come on ask an dealer 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 WARNING POTENTLAL 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 Engine break in There is never a more important period in the life of your vehicle than the period between zero and 20 hours 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 20 hours the various parts in the engine wear and polish them selves to the correct operating clearances During this period prolonged full throttle operation or any condition which might result in excessive engine heating must be avoided However momentary 2 3 seconds maximum full thr
74. ways wear an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield long sleeved shirt or jacket gloves boots long pants 84 Protective clothing Goggles LEE Helmet TURNING YOUR VEHICLE 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 slopes 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 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 t

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