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Owner`s Manual - Massimo Motor

1. A WARNING The enclosure cannot protect occupants in all foreseeable accidents including rollover 1 2 A WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH OPERATING TIRE PRESSURE Set with tires cold RECOMMENDED FRONT 70kPa 70kgf cm 10psi REAR 70kPa 70kgf crn 10psi FRONT 63kPa 64kgflcm 9psi 63kPa 64kgticm 9psi Never set tire pressure below minimum Tire may dislodge from rim Gross Vehicle Weight Rating 907 kg 2000 b maximum including weight of operator passenger accessories cargo and if applicable trailer tongue weight MINIMUM REAR A WARNING hz e Keep hands body other Severe INJURY or DEATH can result Ka Persons away when closing bed if you ignore the following Do not operate the vehicle e Maximum Load in Cargo Bed 50 kg 110lb with bed up e Max loading weight is 150 kg 3301b when No passenger in Rear seat e Never carry passengers in cargo bed e Cargo can affect handling and stability Read Owner s Manual before loading or towing e When loading with cargo or towing a trailer Reduce speed and allow more room to stop Avoid hills and rough terrain e Be sure cargo is secured a loose load could change handling unexpectedly e Keep weight in the cargo bed centered and as low and far forward as possible Top heavy loads increase the ris
2. Cd 4 5 The multi function meter unit is equipped with the following Speedometer which shows the riding speed Odometer which shows the total distance traveled Two trip meters which show the distance traveled since they were last set to zero Clock Hour meter which shows the total time the key has been turned to ON Fault code meter To display the faults of Electronic Fuel Injection system Odometer and Trip Meter Modes Pushing the TRIP ODO button switches the display between the odometer mode ODO and the trip meter modes A and B in the following order ODO gt TRIP A gt TRIP B ODO To reset a trip meter select it by pushing the TRIP ODO button and then push the TRIP ODO button for at least three seconds The trip meters can be used to estimate the distance that can be traveled with a full tank of fuel This information will enable you to plan future fuel stops NOTE Holding in the TRIP ODO button and then turning the key to ON switches the display between mph and km h 4 6 Clock Mode Pushing the k button switches the display between the clock mode CLOCK and the hour meter mode HOUR in the following order CLOCK HOUR CLOCK To Set the Clock 1 Set into the clock mode 2 Press the watch button for 3 5 seconds 3 Press the KM MILE button to set the hours 4 Press th
3. INITIAL 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 Check coolant leakage Cooling system Repair if necessary O O O O e Replace coolant every 24 months Air filter elements Clean Every 20 40 hours engine and air intake duct Replace if necessary More often in wet or dusty areas Engine oil e Replace warm engine before draining O O O O Engine oil filter cartridge e Replace O O O O Final gear oil Check oil lever oil leakage o O Differential gear oil e Replace Accelerator pedal Check operation and free play O O O O O halt Check operation Vepel Check for wear cracks or damage 9 E Check balance damage runout Wheels e Replace if necessary Q E O Check operation brake pad wear fluid leakage se Front brake e page 8 6 QO O O O O Correct if necessary Replace pads if worn to the limit Check operation brake pad wear fluid leakage se Rear brake e NOTE page 8 6 O O Q O O e Correct if necessary Replace pads if worn to the limit nne Check operation and for leakage Front and rear suspension Check toe in Adjust if necessary 9 O PNPA Check bearing assemblies for looseness damaged Wheel bearings Repair if damaged 8 5 INITIAL EVERY Whichever Month 1 3 6 6 12 ITEM ROUTINE Comes first Km 320 1 20
4. 7 9 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 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 A 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 Before starting down hill make sure the vehicle is in low range 4WD On most slopes this will let you use engine braking to help you go downhill slowly Go as slowly as possible If you are starting to go too
5. Install the bulb holder cover and the cover at the rear of the headlight CAUTION Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly 9 Close the hood 10 Adjust the headlight beam if necessary Headlight beam adjustment CAUTION It is advisable to have a dealer make this adjustment To raise the beam turn the adjusting screw in direction To lower the beam turn the adjusting screw in direction 1 Headlight beam adjusting screw Tail brake light bulb replacement If a tail orake light bulb burns out replace it as follows 1 Remove panel A if replacing the left tail orake bulb or panel B if replacing the right tail orake bulb by removing the quick fasteners and bolts 1 PanelA the bulb by turning it counterclockwise 1 Panel B 1 Tail brake light bulb holder 3 Push the defective bulb in and turn it counterclockwise to remove it from the bulb holder 4 Push a new bulb in and turn it clockwise to install in the bulb holder 5 Install the bulb holder together with the bulb by turning it clockwise 1 Quick fastener x8 2 Bolt x2 6 Install the panel by installing the quick 3 Panel A fasteners and bolts and then tighten the bolts to the specified torque 2 Remove the bulb holder together with 8 49 Tightening torque Panel bolt 6 5N m 0 65 m kgf 4 7 ft lbf T
6. Type Tubeless Size front 25x8 12NHS rear 25x10 12NHS Model 7OOUTV 5 Brakes System Front and rear unified Type front Dual disc brake rear Single disc brake Operation Foot operation Suspension Front suspension Rear suspension Double wishbone Double wishbone Shock absorber Front shock absorber Rear shock absorber Coil spring oil damper Coil spring oil damper Wheel travel Front wheel travel Rear wheel travel 185mm 7 3 in 185mm 7 3 in Electrical Ignition system Generator system Battery type Battery capacity DC CDI AC magneto U1L 11 12V3 2 0Ah Headlight type Krypton bulb 10 5 Model 7OOUTV 5 Bulb voltage wattage x quantity Headlight Tail brake light 12V30 3W 30 0W x 2 12V5 0W 21 0W x 2 Indicator lights Neutral indicator light LED Reverse indicator light LED Coolant temperature warning light LED Parking brake indicator light LED On Command four wheel drive differential gear lock indicator LED On Command differential gear lock indicator light LED High range indicator light LED Low range indicator light LED Specified fuses Main fuse 30 0A Headlight fuse 15 0A Ignition fuse 10 0A Auxiliary DC jack fuse 10 0A Four wheel drive motor fuse 3 0A Signaling system fuse 10 0A Backup fuse 10 0A 10 6 10 7 Fault Code of Eleclronic Injection System DTC DTC Descrip
7. cover by unho oking the holders 1 Holder x4 2 Air filter case cover 4 Remove the air filter element 5 Remove the sponge material from its frame 1 Air filter element 1 Air filter frame 3 Element retaining plate 2 Sponge material 6 Wash the sponge material gently but thoroughly in solvent A WARNING POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the sponge material WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the sponge material 7 Squeeze the excess solvent out of the sponge material and let it dry CAUTION Do not twist the sponge material when squeezing it 8 Inspect the sponge material and replace it if damaged 9 Thoroughly apply foam air filter oil or other quality liquid foam air filter oil not spray type to the sponge material NOTE The sponge material should be wet but not dripping 10 Pull the sponge material over its frame 11 Install the air filter element 12 Install the air filter case cover and be sure the crankcase breather hose is connected 1 Crankcase breather hose 13 Install the console 14 Install the seats NOTE The air filter element should be cleaned every 20 40 hours It should be cleaned and lubricated more often if the vehicle is operated in extremely dusty areas Each time air filter element mai
8. drive select lever along the shift guide NOTE Make sure that the drive select lever is completely shifted into position 6 4 Low High Neutral L 4 H 4 N R Reverse 1 Drive select lever 3 Release the brakes and press the accelerator pedal gradually Shifting Neutral to Reverse 1 Stop the vehicle Keep your foot off the accelerator pedal Apply the brake pedal Shift from neutral to reverse or vice versa by moving the drive select lever along the shift guide 2 3 NOTE Please kick the brake pedal first before place gearshifts lever to reverse position In the brake pedal there is a cadle which is connected to a position pin of gearshift assembly Only when the brake pedal is kicked the position pin will go back and gearshifts can be removed to reverse position 1 Position pin 2 Cadle 3 Adjnst L Low Sy H High N Neutral R Reverse 1 Drive select lever NOTE e When in reverse the reverse indicator light should be on If the light does not come on ask a dealer to inspect the reverse indicator light electrical circuit e Due to the synchronizing mechanism in the engine the light may not come on until the vehicle starts moving 4 Check behind for people or obstacles then release the brake pedal 5 Press the accelerator peoal gradually and continue to watch to the rear while backing POTENTIAL HAZARD Improperly operating in reve
9. 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 an carefully if the vehicle starts to tip gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance gradually steer again in the direction you want to go CROSSING THROUGH SHALLOW WATER If you must cross shallow slow moving water up to the depth of the vehicle s floorboards choose your path carefully to avoid sharp drop offs large rocks or slippery surfaces that could cause the vehicle to overturn Never operate through water deeper than 33 cm 13in 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 A 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 33cm 13in Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary ap
10. level Use only the recommended quality brake fluid Otherwise the rubber seals may deteriorate causing leakage and poor braking performance Recommended brake fluid DOT 4 Refill with the same type of brake fluid Mixing fluids may result a harmful chemical reaction and lead to poor braking performance Be careful that water does not enter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock Brake fluid may deteriorate painted surfaces or plastic parts Always clean up spilled fluid immediately Have a dealer inspect the brake system if the brake fluid level goes down Brake fluid replacement Complete fluid replacement should be done only by trained service personnel Have a dealer replace the following components during periodic maintenance or when they are damaged or leaking Replace the oil seals every two years Replace the brake hoses every four years Checking the brake pedal Have a dealer check the brakes at the intervals specified the periodic maintenance and lubrication chart There should be no free play in the brake pedal The brakes should operate smoothly and there should be no brake drag If the brakes feel soft or spongy this could indicate air in the brake system Have a dealer check the brake system if necessary in 1 Brake pedal A WARNING POTENTIAL HAZARD Operating with impro
11. operates correctly It must operate smoothly and fully spring back to the idle position when released Have a dealer repair as necessary for proper operation A WARNING Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal Immediately contact your dealer service if throttle problems arise for Always check the pedal for free movement and return before starting the engine and occasionally during operation 5 8 Throttle Freeplay If the throttle pedal has excessive play due to cable stretch or mis adjustment it will cause a delay in throttle response especially at low engine speed The throttle may also not open fully If the throttle pedal has no freeplay the throttle may be hard to control and the idle speed may be erratic Check the throttle pedal freeplay Adjust the freeplay If necessary Throttle Freeplay Inspection 1 2 3 Lift the parking brake to the top to park the car Apply the brakes Start the engine Allow it to warm up thoroughly Measure the distance the throttle pedal moves before the engine begins to pick up speed Freeplay should 1 16 to 1 8 inches 1 5 3mm Throttle Freeplay Ajustment li 2 Remove both seats Remove the middle cover of the engi
12. play AGjUSTMENL ser eee essere eee eeeeeecee eee eee 8 34 Brake light switch adjustment 8 35 Cable inspection and lubrication 8 36 Brake pedal and accelerator pedal lubrication se rerssseeeeeeees 8 37 Rear knuckle upper and lower pivot lubrications ssseeeeeeseeeeees 8 37 Steering shaft lubrication 8 38 Wheel removal sssrrcer reece ceeeeeeeeees 8 39 Wheel installation etette eeeeee eseese ee 8 39 Battery ELETT ETTETTETTETTETTETTETTETTETTETTETT 8 40 Battery maintenance ETETTETTETTETTETTETT 8 42 Fuse replacement ETETTETTETTETTETTITIETT 8 43 Replacing a headlight bulb 8 45 Headlight beam adjustment 8 48 Tail brake light bulb replacements eee AN eeeeeececee eee QB AQ Troubleshooting Sis bveeieie o d 0 e 6 eGie e sie ATTA 8 50 Check and solution to Common Problems in Vehicles sss s s 6 8 54 CLEANING AND STORAGE 9 1 A Cleaning PERNE LALIT E TET 9 1 B Storage AE EE E T T E N 9 3 SPECIFICATIONS cee cee eee cee renee ee 10 1 FAULTCODE OF ELECLRONIC INJECTION SYSTEM s es9 2999 11 1 LOCATION OF THE WARNING AND SPECIFICATION LABELS Ake a U7 dU j AISA i aA i Read and understand all of the labels on your vehicle They contain important information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or comes off a replacement label is available from your dealer
13. prevent clutch slippage since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher 1 90L 1 67Imp at 2 01 US qt 2 00L 1 76lmp qt 2 11 US qt 10 2 Model 7OOUTV 5 Final gear case oil Type SAE80 API GL 4 Hypoid gear oil Quantity 0 25L 0 22 Imp qt 0 26 US qt Differential gear case oil Type SAE80 API GL 5 Hypoid gear oil Quantity 0 32L 0 28 Imp qt 0 34 US qt Radiator capacity including all routes 2 50L 2 20 Imp qt 2 64 US qt Air filter Engine Wet element Intake duct Dry element Fuel Type Unleaded gasoline only Fuel tank capacity 30 0L 6 60 Imp gal 7 93 US gal Throtlle valve Type quantity Spark plug Type DR8EA DPR8EA 9 DPR8EA 9 Spark plug gap 0 8 0 9 mm 0 031 0 035 in Clutch type Wet centrifugal automatic 10 3 Model 7OOUTV 5 Transmission Primary reduction system Secondary reduction system Secondary reduction ratio Transmission type Operation Reverse gear V belt Shaft drive 41 21x24 18x33 9 9 544 V belt automatic Right hand operation 25 14 1 471 Sub transmission ratio low 35 17 2 058 High 28 19 1 473 Chassis Frame type Steel tube frame Caster angle 5 0 Trail 26 0mm 1 02 in Tire
14. system makes affricate noise or the brake discs go 2 Check if the calipers hydraulic cylinders get stuck or the fixing parts of calipers are deformed 8 52 S N Problems Solutions 1 Check if left amp right brake force deviation of front brake is withi specified limit 2 Check if the brake force of front brke go down which Vehicle go deflected cause the rear wheels are locked up before the front 4 when braked at high wheels when braked speed 3 Check if spring force s deviation of shock absorbers in front left amp right suspension are within specified limit 4 Check if the damper rubber sleeves connecting front suspension rock and frame are damaged Table 3 Check and Solution of Common Problems in Electrical System S N Problems Solutions 1 check if the headlight switch functions well 1 Lamps don t work 2 Check if the wires are broken 3 Check if the lamps or bulbs are broken 1 Check if the control switch on meter board works well 2 Vehicle cannot go into 4 2 Check if the differential lock control magneto plug in rear drive mode bridge reduction gear box are broken 3 Check if the wire is broken Be ls differential wont 4 Check if the control switch on meter board works well 8 53 S N Problems Solutions rear differential won t work 2 Check if the differential lock control magneto plug in rear bri
15. 0 2 400 2 400 4 800 gt mi 200 750 1 500 1 500 3 000 hours 20 75 150 150 300 Stabilizer bushings Check for cracks or damage O O O Fittings and fasteners Check all chassis fittings and fasteners O O O o O Check if necessary hear upper and lower e Lubricate with lithium soap based grease knuckle pivots Drive shaft universal joint e Lubricate with lithium soap based grease O Check operation and for looseness Replace if Steering system damaged O O O O O Check toe in Adjust if necessary Z Check for cracks or damage Engine mount Check bolt tightness 2 S 2 Front and rear axle boots Sot operation Q O e Replace if damaged NOTE Recommended brake fluld DOT4 Brake fluid replacement e When disassembling the master cylinder or caliper replace the brake fluid Normality check the brake fluid level and add fluid as required e On the inner parts of the master cylinder and caliper replace the oil seals every two years e Replace the brake hoses every four years or if cracked or damaged 8 6 Hood To open Unhook the hood latches and then slowly tilt the hood up until it stops 1 Latch x2 8 7 To close CAUTION Lower the hood slowly to its original position Make sure that all cables and wires are and then hook the hood latches in place when closing the hood Secure projections on the underside of Do not drive the vehicle with the hoo
16. 352 Cylinder 2 Ignition Coil Malfunction KsDGDM_EST_B Fault 352 850 P0505 Idle Speed Control Error KsDGDM_lIdleControl 505 1285 P0562 System Voltage Low KsDGDM_SysVoltLow 562 1378 P0563 System Voltage High KsDGDM_SysVoltHigh 563 1379 P0650 MIL Circuit Malfunction KsDGDM_MIL_Circuit 650 1616 P1693 Tachometer Circuit Low Voltage KsDGDM_TAC_ Circuit_Low 1693 5779 11 2 P1694 Tachometer Circuit High Voltage KsDGDM_TAC_ Circuit_High 1694 5780 P0137 O28 2 Circuit Low Voltage KsDGDM_O2_2_ShortLow 137 311 P0138 O28 2 Circuit High Voltage KsDGDM_O2_2_ShortHigh 138 312 P0038 O2S Heater 2 Circuit High Voltage KsDGDM_O2_HeaterShortHigh 38 56 P0037 O2S Heater 2 Circuit Low Voltage KsDGDM_O2_HeaterShortLow 37 55 P0500 VSS No Signal KsDGDM_VSS_NoSignal 500 1280 P0850 Park Neutral Switch Error KsDGDM_ParkNeutralSwitch 850 2128 P0445 CCP short to high KsDGDM_CCP_CircuitShortHigh 445 1093 P0444 CCP short to low open KsDGDM_CCP_CircuitShortLow 444 1092 P0171 BLM Max Adapt Kohler Special KsFDIAG_BLM_MaxAdapt 171 369 P0172 BLM Min Adapt Kohler Special KsFDIAG_BLM_MinAdapt 172 370 P0174 PE System Lean Kohler Special KsFDIAG_PESystLean 174 372 11 3
17. D 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 A WARNING POTENTIAL HAZARD Carrying a passenger in the cargo bed WHAT CAN HAPPEN The passenger could fall or be struck by objects in the cargo bed HOW TO AVOID THE HAZARD Never carry a passenger in the cargo bed The cargo bed is designed to carry cargo only 7 2 The total weight of operator passenger accessories cargo trailer tongue weight and the vehicle itself must not exceed 998Kg 2 200 Ib See Loading on page 6 11 Carrying a passenger and cargo can affect vehicle handling A WARNING The driver and passenger must always wear POTENTIAL HAZARD a seat belt and an approved motorcycle Overloading this vehicle or carrying or helmet Also wear eye protection and towing cargo improperly protective clothing including over the ankle WHAT CAN HAPPEN _ boots gloves a long sleeved shirt or jacket Could cause changes in vehicle handling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this vehicle Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking Always follow the instructions in your Owner s Manual for carrying cargo or pulling a trailer and long pants Keep hands and fe
18. EHICLE 7 1 Getting to know your vehicle 7 1 Learning to operate your vehicle 7 5 Turning your vehicle eee 7 6 Brakingerssssstrcrr see eee eee see cee eee cee eee 7 7 Going UPNill eeeeee eee eeeeeeeeeeee ees 7 8 Going Gownhill eeeeeeee eee 7 10 Crossing through shallow water 7 12 Riding over rough terrain 7 15 Riding in brush or wooded ALCS roc cecee cece ete ccc cee cec cee cesceseee 7 1 6 Encountering obstacles on the trail POO ETUETIOUTELIPTTETTE TIE TIE Teer Te reer erry 7 1 7 EJ PERIODIC MAINTENANCE AND ADJUSTMENT CRE so Periodic maintenance chart for The emission control system 8 4 General maintenance and lubrication chart seeeeeeeeeeeseeseecceceee 8 5 Conos ee ccc eee ceecee 8 9 Engine oil and oil filter aS 8 10 Final gear ojleteeeeeereeeeereeeeeeeeeees 8 14 Differential gear Oil 8 16 Coolant Poe c cr ccc ccc cec ccc ccccce cee cceccccce 8 18 Axle oleic Cee 8 19 Spark plug inspection 8 20 Cleaning the air filter elements 8 23 V belt cooling duct check hose 8 27 V belt case drain pluges s 8 27 Cleaning the spark arrester 8 28 Valve clearance errr ere errr reer eer ee eee ee 8 30 Front brake pad check 8 30 Rear brake pad Checke s s eee e 8 31 Checking the brake fluid level 8 31 Brake fluid replacement etete 8 32 Checking the brake pedales 8 33 Parking brake lever free
19. MASSIMO ALLIGATOR 700 4 amp MSU 700 4 _ Owner s Manual A Mtei eg This UTV should not be ridden by anyone under 16 years of age INTRODUCTION Congratulations on your purchase of the Massimo Alligator 700 4 or MSU 700 4 It represents the result of many years of experience in the production of fine sporting touring and pacesetting racing machines With the purchase of this UTV you can now appreciate the highest degree of craftsmanship and reliability This manual will provide you with a good basic understanding of the features and operation of this UTV This manual includes important safety information It provides information about special techniques and skills necessary to ride your UTV It also includes basic maintenance and inspection procedures If you have any questions regarding the operation or maintenance of your UTV please consult the dealer AN IMPORTANT SAFETY MESSAGE e READ THIS MANUAL TOGETHER WITH TIPS FOR THE UTV RIDER CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR UTV MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS e PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE UTV e NEVER OPERATE AN UTV WITHOUT PROPER TRAINING OR INSTRUCTION e THIS UTV AND ANY OTHER UTV OVER 90cc SHOULD NOT BE RIDDEN BY ANY ONE UNDER 16 YEARS OF AGE WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm I
20. MPORTANT NOTICE The Massimo Alligator 700 4 and MSU 700 4 series UTV s have three kind of appearances with the same methods for using inspection and maintenance With the details of using inspection and maintenance the instruction is suitable for all 700 4 series UTV s 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 A The Safety Alert Symbol means ATTENTION YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or A WARNING death to the machine operator a bystander or a person inspecting or repairing the machine A CAUTION indicates special precautions that must be taken to avoid CAVON damage to the machine NOTE ANOTE provides key information to make procedures easier or clearer IMPORTANT NOTICE Curve speed must be smaller than 30km h 19miles h This UTV is designed and manufactured OFF ROAD use only It is illegal and unsafe to operate this UTV on any public street road or highway This UTV complies with all applicable OFF ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture Please check your local riding laws and regulations before operating this UTV When the temperature is below 20 C 4f please park the UTV in the place
21. assembly adjusting ring O00 NO Ol CoN 0 12 13 14 15 16 17 19 20 21 22 Cargo bed Tail brake lights Spark arrester Fuel tank cap Passenger seat Oil filter cartridge Engine oil dipstick Battery Fuses Coolant reservoir Radiator cap 23 24 25 26 27 28 29 30 31 32 Light switch Steering wheel Brake pedal Main switch On Command four wheel drive and differential lock switches Multi function meter unit Auxiliary DC jack Drive select lever Parking brake lever Accelerator pedal NOTE The vehicle you have purchased may differ slightly from those in the figures of this manual 3 2 Identification Number Records Record the key identification number vehicle identification number and model label information in spaces provided for assistance when ordering spare parts from a dealer or for reference in case the vehicle is stolen 1 KEY IDENTIFICATION NUMBER 2 VEHICLE IDENTIFICATION NUMBER 3 MODEL LABEL INFORMATION O 3 3 Key Identification Number The key identification number is stamped on the key as shown in the following illustration This number can be used for ordering a new key 1 Key identification number Vehicle identification number The Vehicle identification number is stamped into the frame 1 Vehicle identification number NOTE The vehicl
22. cked up when go acrossing the field Covers are cracked up 1 when go acrossing the 2 Change for new plastic covers ield 3 Re paste the stickers and re rivet the warning lables 1 Check if the reduction gear box and differential in front and rear bridge are damaged or if there is any oil Vehicle s bottem protect leakage 2 tion plate is damaged by 2 Check if the bottem of engine is damaged or if there is any prominence on ground oil leakage 3 Change for new bottem protection plate 8 51 Table 2 Check and Solution of Common Problems in Brake System S N Problems Solutions 1 Check if the handle of parking brake ruturn to its position 1 prake system is locked 2 Check if the brake discs are deformed p 3 Check if the calipers hydraulic cylinders get stuck or the fixing parts of calipers are deformed 1 Check if the the brake dics are over worn 2 Check if the brake block in calipers are over worn or contaminated by stuffs which can reduce friction 3 Check if there is any leakage in brake system s oil lines or k f conjunctions 2 pra AE T RRR 4 Check if the post rod in brake master cylinder is deformed 5 Check if there is any air go into the oil lines and drain the air with special equipment 6 Check if the remain oil in master cylinders of front and rear brake is still above the lowest level Front or rear brake 1 Check if the brake discs are deformed 3
23. cks or can start fires HOW TO AVOID THE HAZARD Turn off the engine when performing maintenance unless otherwise specified Have a dealer perform service if you are not familiar with vehicle service cause 1 Owner s tool kit 2 Tire pressure gauge 8 2 The service information included in this manual is intended to provide you the owner with the necessary information for completing your own preventive maintenance and minor repairs The tools provided in the Owner s tool kit are sufficient for this purpose except that a torque wrench is also necessary to properly tighten nuts and bolts NOTE If you do not have a torque wrench available during a service operation requiring one take your vehicle to dealer to check the torque settings and adjust them as necessa ry A WARNING POTENTIAL HAZARD Operating this vehicle with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident HOW TO AVOID THE HAZARD Never modify this vehicle through improper installation or use of accessories All parts and accessories added to this vehicle should be genuine or equivalent components designed for use on this vehicle and should be installed and used according to instructions If you have questions consult an authorized vehicle dealer 3 8 3 Periodic maint
24. d the hood into slots on the back of the open unlatched or removed instrument panel Secure slots on the side of the hood around projections on the frame 1 Projection x2 2 Slot x2 3 Slot x2 4 Projection x2 8 8 Console To remove 1 Remove the seats See pages 4 16 4 17 for seat removal and installation procedures Remove the parking brake lever boot Pull the console upward the drive select lever boot will come loose 1 Console 8 9 To install 1 2 3 Place the console in its original position Install the parking brake lever boot Install the seats CAUTION When installing the console be sure not to pinch the cables or wires Make sure that the groove 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 Engine oil and oil filter cartridge The engine oil level should be checked before each operation In addition the oil must be changed and the oil filter cartridge replaced at the intervals specified in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the vehicle on a level surface 2 Remove the console See page 8 9 for console removal and _ installation procedures Check the engine oil level on a cold engine NOTE If the engine was started before checking the oil level be sure to warm up the engine suff iciently and
25. d fuel will cause engine to work abnormally and exhaust to be deteriorated A WARNING POTENTIAL HAZARD Improper care when refueling WHAT CAN HAPPEN Engine oil Make sure the engine oil is at the specified level Add oil as necessary See pages 8 10 8 13 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 5 5 CAUTION In order to prevent clutch slippage since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGYCONSERVING II or higher Make sure that no foreign material en ters the crankcase Recommended engine oil type and quantity See page 10 2 Coolant Check the coolant level in the coolant reservoir when the engine is cold The coolant level will vary with engine temperature The coolant level is satisfactory if it is between the minimum and maximum level marks on the coolant reservoir If the coolant level is at or below the minimum level mark add additiona
26. d get out to 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 get over the obstacle at as close to a right angle as possible to minimize vehicle tipping Go only fast enough to maintain your momentum but still 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 you have the room or back up until you find a less difficult path A 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 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 owner The most important points of vehicle inspection adjustment and lubrication are explained on the following pages 8 1 A 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 sho
27. d out if they are broken 1 Check the bearing in rear bridge bearing seat to find out if they are broken 2 Check the aeng bearing connecting rear bridge and packs to find out if they are worn or loose 5 J 3 Check the inner splines of rear wheel hubs and outer Rear wheels shake 3 seriously in running PTS of rear wheel axles to find out if they are worn or 4 Check the lock screws of rear wheels and axles to find out if they are loose or broken 5 Check rubber bushs between the rear suspension rock and frame to find out if they are broken __ 1 Check if the rims are deformed 4 Wheels jump seriously in gt Check if the rear wheel axles are bent running 3 Check if the tyres are worn or deformed 8 55 S N Problems Solutions 1 Check if overloaded Shock absorbers beco 2 Check if the springs are two soft after after long time 5 me soft and not comfort running table in running 3 Check if the shock absorbers lose their damping force in their travel 1 Check if the spline of intermediate driving shaft is broken 2 Check if the splines in left amp right drive shafts of front amp rear bridges are broken e Front bridge makes 3 Check if the gears in rear bridge reduction gear box and noise in running differential are over worn 4 Check the dust cover of constant velocity universal joint in right amp left drive shafts 8 56 Table5 Check and Solution
28. dge reduction gear box are broken 3 Check if the wire is broken Moler display abnormal y 1 Check if the sensor is broken 2 Check if the meter is broken 3 Check if the surface of speed sensor is contamniated with iron dust Start switch on meter board won t work 1 Check if the switch is broken 2 Check if the wire is broken 3 Check if the ECU in electrical injection system is broken Table 4 Check and Solution of Common Problems in Running System S N Problems Solutions 1 Check the fix screws connecting steering rod to steering stem and knuckle to find out if they are loose or broken 1 Swing clearance of stee 2 Check the bulds on the ends of steering rod to find out if ring wheel is too big they are broken 3 Check m clearance between gears of steering machine if it is too big a Erontwheels shake seri 4 Check the bearings in knuckles if they are broken ously in running 8 54 S N Problems Solutions Front wheels shake seri 2 Check the main ball pins to find out if they are broken 3 Check the lock screws of front wheels and axles to find out if they are loose or broken 2 4 Check the inner splines of front wheel hubs and outer ously in running splines of front wheel axles to find out if they are worn or broken 5 Check rubber bushs betweenthe front suspension rocks and frame to fin
29. drive switch 2WD AWD and a differential gear lock switch AWD LOCK Select the appropriate drive according to terrain and the conditions Two wheel drive 2WD Power is sup plied to the rear wheels only 4 9 Four wheel drive 4WD Power is supplied to the rear and front wheels Four wheel drive with the differential gear locked 4WD LOCK Power is supplied to the rear and front wheels when the differential gear is locked DIFF LOCK Unlike the 4WD mode all wheels turn at the same speed regardless of traction A WARNING POTENTIAL HAZARD Changing from 2WD to 4WD or from 4WD to 4WD LOCK DIFF LOCK or vice versa while the vehicle is moving WHAT CAN HAPPEN The vehicle handles differently in 2WD than in 4WD and in 4WD LOCK in some circumstances Changing from 2WD to 4WD or from 4WD to 4WD LOCK or vice versa while moving may cause the vehicle to unexpectedly handle differ ently This could distract the operator and increase the risk of losing control and an accident HOW TO AVOID THE HAZARD Always stop the vehicle before chang ing from 2WD to 4WD or from 4WDto 4WD LOCK or vice versa On Command four wheel drive switch 2WD 4WD 1 Select lever 2 On Command four wheel drive switch 2WD 4WD To change from 2WD to 4WD stop the vehicle and then set the switch to AWD When the vehicle is in 4WD the AWD indicator twill co
30. e TRIP ODO button to set the minutes 5 Press the watch button for 3 5 seconds and then release it the clock will begin to work Fault Codes Display Of Electronic Injection System When the faults come out meter will display the fault codes to guide the repair See attachment for faults code page 11 1 When the fault code is confirmed and has been repaired you just need to press the button meter will go back to clock mode 4 7 Fuel meter The fuel meter will indicate the fuel volume As the fuel is running out the indicator will turn green into red Vice versa 1 Fuel level warning indicator 2 Fuel meter Switches 1 Light switch OFF OS Light switch OFF 8S 9 Set the switch to O8S to turn on the low beam and the taillights Set the switch to to turn on the high beam and the taillights Set the switch to OFF to turn off all the lights 4 8 CAUTION Do not use the headlights with the engine turned off for an extended period of time The battery may discharge to the point that the starter motor will not operate properly If this should happen remove the battery and recharge it On Command four wheel drive and diff erential gear lock switches 1 On Command four wheel drive switch 2WD 4 WD 2 Differential gear lock switch LOCK 4WD This vehicle is equipped with an On Com mand four wheel
31. e Operation Checks on pages 5 1 5 11 Set the parking brake shift to neutral and follow the instructions on page 6 1 to start the engine Once it has warmed up and you have turned the choke off you are ready to begin driving your vehicle With the engine idling shift the drive select lever into low or high Then release the parking brake Press the accelerator pedal slowly and smoothly The centrifugal clutch will engage and you will start to accelerate Avoid higher speeds until you are thoroughly familiar with the operation of your vehicle When slowing down or stopping take your foot off the accelerator pedal and smoothly press the brake pedal Improper use of the brakes can cause the tires to lose traction reducing control and increasing the possibility of an accident CAUTION Do not shift from low to high or vice versa without coming to a complete stop and waiting for the engine to return to normal idle speed Damage to the engine or drive train may occur TURNING YOUR VEHICLE The vehicle is easier to steer in two wheel drive 2WD than four wheel drive 4WD Steering takes the most effort in 4WD with the differential locked DIFF LOCK It is possible for the vehicle to roll over or go out of control if you attempt sharp high speed turns You should also be careful making sharp turns on rough terrain Do not attempt to turn around or make abrupt maneuvers on slope 7 6 Position your hands on the steering wheel s
32. e identification number is used to identify your vehicle 3 4 CONTROL FUNCTIONS Main switch 1 Main switch 4 1 Functions of the respective switch positions are as follows ON All electrical circuits are supplied with power and the headlights and taillights come on when the light switch is on OFF All electrical circuits are switched off The key can be removed in this position START The electric starter is engaged by turning and holding the key in this position Release the key when the engine starts CAUTION Indicator and warning lights e 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 e Do not turn the key to the START position with the engine running or damage to the electric starter can result e See starting instructions prior to starting the engine See pages 6 1 6 3 for details 1 High range indicator light H 2 Parking brake indicator light P 3 Low range indicator light L 4 Four wheel locked showing light 5 Neutral indicator light N 6 Reverse indicator light R 7 On Command four wheel drive differential gear lock indicator i 8 8 Coolant temperature warning light amp 9 Far light indicator 10 Position indicator 11 Emergency indicator 12 On Command differential gear loc
33. e oil filler bolt and then tighten it to the specified torque Tightening torque Final gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf 7 Check for oil leakage If oil leakage is found check for the cause Differential gear oil Checking the differential gear oil level 1 Place the vehicle on a level surface 2 Remove the differential gear oil filler bolt and check the oil level It should be up to the brim of the filler hole If the level is low add sufficient oil of the recommended type to raise it to the specified level 1 Differential gear oil filler bolt 2 Correct oil level 3 Differential gear oil CAUTION Z OZO OoOo o Be sure no foreign material enters the differential gear case 3 Install the differential gear oil filler bolt and then tighten it to the specified torque Tightening torque Differential gear oil filler bolt 23Nm 2 3 m k gf 17 ft lbf Changing the differential gear oil 1 Place the vehicle on a level surface 2 Place a container under the differential gear case to collect the used oil 3 Remove the differential gear oil filler bolt and differential gear oil drain bolt to drain the oil Recommended oil SAE 80 API GL 5 Hypoid gear oil Oil quantity 0 32 L 0 28 Imp qt 0 34 US qt CAUTION Be sure no foreign material enters the differential gear case 6 Install the differential gear oil filler bolt a and t
34. ecified rating Never use a material in place of the proper fuse Replacing a headlight bulb 3 Remove the headlight bulb holder cover If a headlight bulb bums out replace it as by pulling it off follows 1 Lift the hood up See pages 8 7 8 8 for hood opening and closing procedures 2 Remove the cover at the rear of the headlight by pulling it off 1 Headlight bulb holder cover 4 Remove the headlight bulb holder by pushing it in and turning it counterclock wise 1 Cover at the rear of the headlight 1 Headlight bulb holder 5 Remove the defective bulb by pulling it out A WARNING POTENTIAL HAZARD A headlight bulb is hot when it is on and immediately after it is turned off WHAT CAN HAPPEN You can be burned or a fire could start if the bulb touches flammable HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it something 6 Insert a new headlight bulb into the bulb holder by pushing it in 1 Do not touch the glass part of the bulb CAUTION Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner 7 Install the bulb holder by pushing it is and turning it clockwise 8
35. en the On Command four wheel drive switch is set to the 4WD position The On Command differential gear lock indi cator in the On Command four wheel drive indicator also comes on when the On Command differential gear lock switch is set to the LOCK position NOTE e Due to the synchronizing mechanism in the differential gear case the four wheel drive indicator may not come on until the vehicle starts moving e When the on command differential gear lock switch is set to LOCK the indicator will flash until the differential gear is locked Coolant temperature warning light amp When the coolant temperature reaches a specified level this light comes on to warn that the coolant temperature is too hot If the light Comes on during operation stop the engine as soon as it is safe to do so and allow the engine to cool down for about 15 minutes See page 8 54 CAUTION The engine may overheat if the vehicle is overloaded If this happens reduce the load to specification After restarting make sure that the light is out Continuous use while the light is on may cause damage to the engine Multi Function Display Gauge OMNAORWND Left turn indicator Speedometer Tachometer Right turn indicator Metric mile button TRIP ODO button Clock Hour fault code meter Odometer Trip meter A Trip meter B Clock Hour fault code reset button nye
36. enance chart for the emission control system NOTE For vehicles not equipped with an odometer or hour meter follow the month maintenance intervals For vehicles equipped with an odometer or an hour meter follow the km mi or hours maintenance intervals However keep in mind that if the vehicle isn t used for a long period of time the month maintenance intervals should be followed items marked with an asterisk should be performed by dealer as they require special tools data and technical skills INITIAL EVERY Whichever Month 1 3 6 6 12 ITEM ROUTINE c first Km 320 1 200 2 400 2 400 4 800 pe KR mi 200 750 1 500 1 500 3 000 hours 20 75 150 150 300 Valves e Check valve clearance o o o o Adjust if necessary Fuel line Check fuel hose for cracks or damage o o o e Replace if necessary Check condition Spark plug Adjust gap and clean O O O O O e Replace if necessary Check for leakage Exhaust system Tighten if necessary O O O e Replace gasket s if necessary Carburetor e Check idle speed starter operation o O o o e Adjust if necessary Crankcase breather Check breather hose for cracks or damage O o o system e Replace if necessary Spark arrester Clean O O O Sensor e Clean to clean for each 500km 312ml 8 4 General maintenance and lubrication chart
37. ended lubricant Lithium soap based grease Steering shaft lubrication Lubrication of Drive Shaft Bearing Block Lubricate the pivot points Recommended lubricant Lithium soap based grease all purpose grease 1 Bearing block Lubricate the bearing block Recommended lubricant Lithium soap based grease all purpose grease Wheel Removal Wheel installation Loosen the wheel nuts 1 Install the wheel and the nuts Elevate the vehicle and place a suitable stand under the frame Remove the nuts from the wheel Remove the wheel NOTE e The arrow mark X on the tire must point toward the rotating direction of the wheel e Tapered nuts are used for both the front and rear wheels Install the nut with its tapered side towards the wheel 1 Nut x4 1 Arrow mark 1 Tapered nut 2 Lower the vehicle so that the wheel is on the ground 3 Tighten the wheel nuts to the specified torque Wheel nut torque Front 55Nm 5 5 m kgf 40 ft lbf Rear 55Nm 5 5 m kgf 40 ft lbf 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 a dealer CAUTION Do not try to remove the sealing caps of the battery cells You may damage the battery A WARNING POTENTIAL HAZARD Failure to hand
38. er at the intervals specified in the periodic maintenance and lubrication chart NOTE e Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant have a dealer check the antifreeze content of the coolant as soon as possible e The radiator fan is automatically switched on or off according to the coolant temperature in the radiator If your vehicle overheats see page 8 45 for details Axle boots Check the protective boots for holes or tears If any damage is found have them replaced by a dealer 1 Front axle boot x2 each side Spark plug inspection Removal 1 Lift the cargo bed up See pages 4 20 4 22 for cargo bed lifting and lowering procedures 2 Remove the spark plug cap 1 Rear axle boot x2 each side 1 Spark plug cap 3 Use the spark plug wrench in the tool kit to remove the spark plug as shown 1 Spark plug wrench Inspection The spark plug is an important engine component and is easy to inspect The condition of the spark plug can indicate the condition of the engine The ideal color of the porcelain insulator around the center electrode is a medium to light tan for a vehicle that is being ridden normally Do not attempt to diagnose such problems yourself Instead take the vehicle to a dealer You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to
39. erse lock out cable and make sure that they are not frozen 2 Start the engine see P6 2 Starting The Engine CAUTION See the Engine Break In section prior to operating the engine for the first time 1 Turning the key to ON the light in the display will turn on and electronic injection system s fuel pump will start to work wait for 10 second before the following operation Apply the brake Shift the drive select lever into the neutral position NOTE e When the drive select lever is in the neutral position N the neutral indicator light should come on If the neutral 6 2 indicator light does not come on ask a dealer to inspect the electric circuit The engine can be started in any gear if the brake is applied However it is recommended to shift into neutral N before starting the engine With your foot off the accelerator pedal start the engine by turning the key to START NOTE If the engine fails to start release the key and then try starting again Wait a few seconds before the next attempt Each cranking should be as short as possible to preserve battery energy Do not crank the engine more than 5 seconds on each attempt 5 Continue warming up the engine until it idles smoothly before riding A WARNING POTENTIAL HAZARD Engine idle speed exceeds the regulated speed WHAT CAN HAPPEN Will make it difficult to select gear and lose control
40. essure gauge NOTE The tire pressure gauge is included as stan dard equipment Make two measurements of the tire pressure and use the second reading Dust or dirt in the gauge could cause the first reading to be incorrect Set pressure with tires cold Set tire pressures to the following specifica tions Recommended Minimum Maximum pressure 70kpa 63kpa 77kpa Front 0 70kgf cm 0 64kgf cm 0 77kgf cm 10pai 9pai 11 pai 70kpa 63kpa 77kpa Rear 0 70kgf cm 0 64kgf cm 0 77kgf cm 10pai 9pai 11pai Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire 1 Tire pressure gauge a Tire wear limit OPERATION A WARNING POTENTIAL HAZARD Operating vehicle without being familiar with all controls WHAT CAN HAPPEN Loss of control which could cause an accident or injury HOW TO AVOID THE HAZARD Read the Owner s Manual carefully If there is a control or function you do not understand ask your dealer 6 1 Starting The Engine In Low Temperatures POTENTIAL HAZARD Freezing control cables in cold weather WHAT CAN HAPPEN You could be unable to control the vehicle which could lead to an accident or collision HOW TO AVOID THE HAZARD When riding in cold weather always make sure all control cables work smoothly before you begin riding 1 Check the throttle cable parking cable and the rev
41. et inside the vehicle at all times 7 3 A WARNING POTENTIAL HAZARD Operating this vehicle without wearing an approved motorcycle helmet eye protection and protective clothing WHAT CAN HAPPEN Operating without coining 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 Gloves Boots HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket long pants event of an accident LEARNING TO OPERATE YOUR VEHICLE You should become familiar with the performance characteristics of the vehicle in a large flat area that is free of obstacles and other vehicles Practice control of the accelerator pedal brakes steering and drive select lever Drive first at slow speed and become comfortable at that speed before gradually increasing your speed Become familiar with the way the vehicle feels in low and high ranges first in two wheel drive 2WD and then in four wheel drive 4WD and four wheel drive with the differential locked DIFF LOCK Also practice driving in reverse Take the time to learn basic operation before attempting more difficult maneuvers 7 5 Perform the Pr
42. everse gear Use engine braking to help you go slowly If necessary use the brakes gradually to help you go slowly Always check terrain before going down hills Go as slowly ad 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 2 3 A WARNING POTENTIAL HAZARD Improper handling of gasoline WHAT CAN HAPPEN Gasoline can catch fire and you could be burned HOW TO AVOID THE HAZARD Always turn off the engine when refueling Do not refuel right after the engine
43. f 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 out 1 Battery compartment cover 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 Main fuse 2 Spare main fuse Headlight fuse Auxiliary DC jack fuse Four wheel drive motor fuse Signaling system fuse Backup fuse for odometer and clock Carburetor warmer fuse 10 Spare fuse x3 4 Ignition fuse O 0 a Specified fuse Main fuse 30 0A Headlight fuse 15 0A Ignition fuse 10 0A Auxiliary DC jack fuse 10 0A Signaling system fuse 10 0A Carburetor warmer fuse 10 0A Four wheel drive motor Fuse 3 0A Backup fuse 10 0A 4 Turn the key to ON and turn on the electrical circuit in question to check if the device operates 5 If the fuse immediately blows again have a dealer check the electrical system 6 Install the battery compartment cover 7 Close the hood A WARNING POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire HOW TO AVOID THE HAZARD A ways use a fuse of the sp
44. finally causing serious injury or even death HOW TO AVOID THE HAZARD Because of electronic injection system the idle speed will be speed up when the voltage of battery is low Place the gear on position N and press the throttle pedal to make the engine run at 2500RPM to charge the battery for 5 10 minutes when the voltage of battery is over 12V the idle speed will be normal If the idle speed is still high please contact your dealer 6 3 Warming Up To get maximum engine life always warm up the engine before driving Never accelerate hard with a cold engine To see whether or not the engine is warm check if it responds to the throttle normally 1 Release the brakes and press the accelerator pedal gradually 2 If the rotation rate of the engine accelerates with pedal steadily the warming up procedure has been ready and the vehicle can been ridden Otherwise go on with the third step 3 Continue warming up the engine until it idles smoothly CAUTION See the Engine break in section prior to operating the engine for the first time Drive Select Lever Operation And Driving In Reverse CAUTION Before shifting you must stop the UTV and return the throttle lever to the closed position otherwise the transmission may be damaged Shifting Neutral to High and High to Low 1 Stop the vehicle Keep your foot off the accelerator pedal 2 Apply the brakes then shift by moving the
45. 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 or other sources of ignition such as the pilot light of water heaters and clothes dryers When transporting the vehicle in anot 2 4 her vehicle be sure it is kept in an upright position 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 A WARNING POTENTIAL HAZARD Starting or running the engine in a closed area WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time HOW TO AVOID THE HAZARD Always operate your vehicle in an area with adequate ventilation 2 5 DESCRIPTION AND VEHICLE IDENTIFICATION OO OO QWBS 0 00 0O00 0 HOO Headlights Front shock absorber assembly adjusting ring Brake fluid reservoir Air filter element engine and air intake duct Spark plug V belt case Driver seat belt Driver seat Passenger seat belt Cargo bed release levers Rear shock absorber
46. he temporary build up of heat If any abnormality is noticed during this period consult a 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 25 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 Brake System Break in Apply only moderate braking force for the first 50 stops Aggressive or overly forceful braking when the brake system is new could damage brake pads and rotors CVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and better performance Break in the clutches and belt by operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggressive acceleration and high speed operation during the break in period Accessories and loading Accessories Accessories can affect the handing and control of your vehicle Keep the following in mind when considering an accessory or operating a vehicle which has accessories e 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 t
47. hen tighten it to the specified 1 Differential gear oil drain bolt 4 Install the differential gear oil drain bolt gas and tighten it to the specified torque Tightening torque Tightening torque Differential gear oil filler bolt Differential gear oil drain bolt ese AU a 9 8Nm 0 98 m kaf 7 1 ft lbf 7 Check for oil leakage If oil leakage is 5 Fill the differential gear case with the ounid enek Ione Cause recommended oil Coolant The coolant level should be checked before each ride Checking the coolant level 1 Place the vehicle on a level surface 2 Open the hood See pages 8 7 8 8 for hood opening and closing procedures 3 Check the coolant level in the coolant reservoir when the engine is cold as the coolant level varies with engine temperature NOTE The coolant should be between the minimum and maximum level marks 1 2 4 Coolant reservoir cap 3 Minimum level mark If the coolant is at or below the minimum level mark remove the reservoir cap add coolant to the maximum level mark install the reservoir cap and then close the hood Maximum level mark Coolant reservoir capacity up to the maximum level mark 0 35L 0 31 Imp qt 0 37 US qt CAUTION Mix anti freeze with distilled water only However if distilled water is not available soft water may be used for refilling Changing the coolant The coolant must be changed by a deal
48. ht up hills and avoid crossing the side of a hill which increases your chance of rollover Practice first on gentle slopes before attempting steeper hills Always check the terrain carefully before attempting any hill Use common sense and remember that some hills are too steep for you to climb Maximum slope angle 15 71 8 15 Maximum 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 A WARNING Before climbing the hill first be sure you are POTENTIAL HAZARD operating in low range 4WD or if necessary Operating on excessively steep hills with 4WD Diff Lock To climb a hill you need WHAT CAN HAPPEN The vehicle can over turn more easily on extremely steep hills than on level surfaces or small hills HOW TO AVOID THE HAZARD Never operate your vehicle on hills too traction momentum and steady throttle Travel fast enough to keep your momentum going but not so fast that you cannot react to changes in the terrain as you climb Slow down when you reach the crest of the hill if steep for it or your abilities Never you cannot clearly see what is on the other operate vehicles on hills steeper than side there could be another person an 15 obstacle or a sharp drop off Do not drive across the face of a hill Go straight up the hill Practice on smaller hills before attempting large hills
49. ial wrench can be obtained at a dealer to make this adjustment Standard position B A Minimum soft E Maximum hard A WARNING POTENTIAL HAZARD Improper shock absorber adjustment WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability which could lead to an accident HOW TO AVOID THE HAZARD Always adjust the shock absorbers on the left and right side to the same setting Trailer hitch bracket This vehicle is equipped with a 5 cm 2 in receiver bracket for a standard trailer hitch Trailer towing equipment can be obtained at a dealer See pages 6 11 6 13 for precaut ion information 1 Trailer hitch bracket Auxiliary DC jack The auxiliary DC jack is located at the right side of the front panel The auxiliary DC jack can be used for suitable work lights radios etc The auxiliary DC jack should only be used when the engine is running 1 Auxiliary DC jack cap 1 Set the light switch to OFF 2 Start the engine See pages 6 1 6 3 3 Open the auxiliary DC jack cap and then insert the accessory power plug into the jack Auxiliary DC jack Maximum rated capacity for the auxiliary DC jack DC 12V 120W 10 A 4 When the auxiliary DC jack is not being used cover it with the cap CAUTION Do not use accessories requiring more than the above maximum capacity This may overload the circuit and cause the fu
50. ight display 4 2 A 8 Light Indicator Check for light indicator operation 4 2 4 8 5 1 A WARNING POTENTIAL HAZARD Failure to inspect the vehicle before operating Failure to properly maintain the vehicle WHAT CAN HAPPEN Increases the possibility of an accide nt or equipment damage HOW TO AVOID THE HAZARD Always inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the Owner s Manual 5 2 Front and rear brakes Brake pedal Check for correct brake pedal free play If the brake pedal free play is incorrect have a dealer adjust it See pages 8 35 8 36 Check the operation of the brake pedal It should move smoothly and there should be a firm feeling when the brakes are applied If not have the vehicle inspected by a dealer Brake fluid level Check the brake fluid level Add fluid if necessary See pages 8 34 8 35 Recommended brake fluid DOT 4 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 a 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 b
51. ing in a humid or salt air atmosphere coat all exposed metal surfaces with a light film of oil Do not apply oil to any rubber parts or the seat covers 8 Remove the battery and charge it Store it in a dry place and recharge it once a month Do not store the battery in an excessively warm or cold place less than 0 C 82F or more than 30 C 86F NOTE Make any necessary repairs before storing the vehicle 9 4 SPEIFICATIONS Model 7OOUTV 5 Dimensions Overall length 3 950 mm 155 5 in Overall width 1 430 mm 56 3 in Overall height 1 900 mm 74 8 in Seat height 818 mm 82 2 in Wheelbase 2 840mm 111 8 in Ground clearance 280 mm 11 0 in Minimum turning radius 5 000 mm 196 8 in Basic weight 688 0 kg 1 517 Ib With oil and full fuel tank Engine Engine type Liquid cooled 4 stroke Water cooled Cylinder arrangement Forward inclined single cylinder Displacement 686cm Bore x stroke 100x84mm Compression ratio 9 10 1 Starting system Electric starter Lubrication system Wet sump 10 1 Model 7OOUTV 5 Engine oil Type Recommended engine oil classification Quantity Without oil filter cartridge replacement With oil filter cartridge replacement 4 14 32 50 68 86 104 122 F i SAE 20W40 w SAE 10W30 SAE 5W30 a ae 20 10 o 140 20 30 40 50 C API service SG type or higher JASO standard MA CAUTION In order to
52. 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 A WARNING POTENTIAL HAZARD Overloading the cargo bed WHAT CAN HAPPEN Could cause changes in vehicle handl ing which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated maximum load limit for this cargo bed Cargo should be properly distributed and securely attached Reduce speed when carrying cargo Al low greater distance for braking A WARNING POTENTIAL HAZARD Carrying a passenger in the cargo bed WHAT CAN HAPPEN The passenger could fall be thrown out or be struck by objects in the cargo bed HOW TO AVOID THE HAZARD Never carry a passenger in the cargo bed This cargo bed is designed to carry cargo only Front and rear shock absorber adjustment The spring preload can be adjusted to suit the operating conditions You can reduce preload for a softer ride or increase preload if frequent bottoming occurs CAUTION Frequent or severe bottoming can cause increased wear or damage to the vehicle Adjust the spring preload as follows To increase the spring preload turn the adjusting ring in direction To decrease the spring preload turn the adjusting ring in direction 1 Spring preload adjusting ring 2 Position indicator NOTE A spec
53. k indicator light DIFF LOCK 4 2 On Command differential gear lock indic ator light DIFF LOCK This indicator light and the On Command differential gear lock indicator in the display come on when the On command differential gear lock switch is set to the LOCK position NOTE When the switch is set to LOCK the On Command differential gear lock indicator light will flash until the differential gear is locked Low range indicator light L This indicator light comes on when the drive select lever is in the L position High range indicator light H This indicator light comes on when the drive select lever is in the H position 4 3 Neutral indicator light N This indicator light comes on when the drive select lever is in the N position Reverse indicator light R This indicator light comes on when the drive select lever is in the R reverse position Furthermore this indicator light flashes when the engine is being raced for 10 seconds or more NOTE If the indicator light flashes under any other circumstances or the speedometer does not show the speed while riding have a dealer check the speed sensor circuit Parking brake indicator light P This indicator light comes on when the parking brake is applied On Command four wheel drive differential gear lock indicator enn A The On Command four wheel drive indic ator ia comes on wh
54. k of overturn 1 3 A WARNING Improperly loading a trailer and failure to use extra care when pulling trailer can cause an accident or injury Never MAX 7 3 INCH load more than 50kg 110 Ibs tongue weight on the towin 1 85MM Sa sce tow more ian 550kg 1212 Ibs rolling weight trailer plus cargo Operate in low range gears only allow for increased braking distance and use extreme caution when operating on inclines Read carefully the loading information and trailer hitch sections in the owner s manual 1 4 A WARNING Turning the off road vehicle in 4WD LOCK DIFF LOCK takes more effort Operate at a slow speed and allow extra time and distance for maneuvers to avoid loss of control 1 5 Improper use can result in Severe INJURY or DEATH This off highway utility vehicle will handle and maneuver differently from an ordinary passenger car or other vehicle Gross Vehicle Weight Rating 2200 Ib 998 kg maximum including operator passenger accessories cargo and trailer tongue weight This vehicle is recommended only for operators 16 and older with a valid motor vehicle license Adults must supervise use by minors Check state laws for minimum age requirements The vehicle is designed for one driver and three passengers one driver and one psaaenger on front seats and two passengers on rear seats No passenger shall be allowed in cargo box e You could be severely injured if
55. ke lever The parking brake lever is located at the right side of the driver s seat It will help hold the vehicle from moving while parked To set the parking brake pull the lever up completely To release the parking brake pull up on the lever press the release button and then push the lever all the way down Spring pressure helps return the lever to the released position Be sure to fully release the parking brake before starting out Failure to do so may result in poor performance and premature wearing of the rear brake and V belt 1 Parking brake lever 2 Release button Drive select lever Fuel tank cap The drive select lever is used to shift you Remove the fuel tank cap by turning it vehicle into the low high neutral and counterclockwise reverse positions Refer to pages 6 5 6 7 for the drive select lever operation ILII SSS ee 1 Fuel tank cap 1 Drive select lever Front Seats rear of the seat into the seat holders and To remove a seat pull its seat lock lever PUSh down on the seat at the front upward lift the front of the seat and then A WARNING slide the seat forward and up POTENTIAL HAZARD A loose seat WHAT CAN HAPPEN The operator could lose control or the operator or passenger could fall if the seat is loose during operation HOW TO AVOID THE HAZARD Make sure the seat is securely latched 1 Driver seat 2 Passenger seat 3 Seat l
56. l coolant to bring the level up to maximum level mark If coolant is not available add distilled water Change the coolant every two years See pages 8 18 8 19 for details CAUTION Hard water or salt water is harmful to the engine You may use soft water if you cannot get distilled water Coolant reservoir capacity up to the maximum level mark 0 35L 0 31lmp qt 0 37US qt 5 6 A WARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap Always use a thick rag over the cap Allow any remaining pressure to escape before completely removing the cap Final gear oil Make sure the final gear oil is at the specified level Add oil as necessary See pages 8 14 8 15 for details Recommended oil SAE 80 API GL 4 Hypoid gear oil If desired an SAE 80W90 hypoid gear oil may be used for all conditions NOTE GL 4 is a quality and additive rating GL 5 or GL 6 rated hypoid gear oils may also be used Differential gear oil Make sure the differential gear oil is at the specified level Add oil as necessary See pages 8 16 8 17 for details Recommended oil SAE 80 API GL 5 Hypoid gear oil 5 7 Throttle Pedal Check to see that the accelerator pedal
57. le batteries or battery electrolyte carefully WHAT CAN HAPPEN You could be poisoned You could be severely burned by the sulfuric acid in battery electrolyte Batteries produce explosive gases HOW TO AVOID THE HAZARD Avoid contact with skin eyes or clothing Always shield eyes when working near batteries 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 cigarettes or other sources of ignition 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 rechar ge the battery before reinstallation CAUTION A special battery charger constant voltage ampere or constant voltage is required for recharging a sealed type battery Using a conventional battery charger may shorten the battery life 2 Always make sure the connections are correct when putting the battery back in the vehicle 1 Negative battery lead 2 Positive battery lead Fuse replacement The main fuse and the fuse box are located under the hood See pages 8 7 8 8 for hood opening and closing procedures If a fuse is blown turn of
58. mbs and fingers around the steering wheel This is particularly important when driving in rough terrain The front wheels will move right and left as they respond to the terrain and this movement will be felt in the steering wheel A sudden jolt could wrench the steering wheel around and your thumbs or fingers could be injured if they are in the way of the steering wheel spokes Always go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when driving the vehicle Never operate on excessively rough slippery or loose terrain until you have learned and practiced the skills necessary to control the vehicle on such terrain Always be especially cautious on these kinds of terrain Never turn at excessive speed Practice turning at slow speeds before attempting to turn at faster speeds Do not attempt turns on steep inclines Never operate the vehicle on hills that are too steep for it or for your abilities Go straight up and down hills where possible Maximum slope angle 12 Max climbing capacity when fully loaded and towing a trailer with a weight of 550KG 8 2 2 Never operate on hills that are slippery or ones where you will not be able to see far enough ahead of you Never go over the top of a hill at speed if you cannot see what is on other side Always follow proper procedures for going uphill If you lose control and cannot continue up a hill back down the hill with the engine in r
59. me on in the multi function meter unit display To change from 4WD to 2WD stop the vehicle be sure the select lever is set to position and then set the switch to 2WD lock On Command __ differential switch 4WD LOCK gear 1 On Command differential gear lock switch 4WD LOCK 2 Select lever To lock the differential gear in 4WD stop the vehicle make sure the On Command four wheel drive switch is set to 4WD move the select lever to position and then set the switch to LOCK When the differential gear is locked the differential gear lock indicator light DIFF LOCK will come on along with the differential gear lock indicator Win the multifunction meter unit display To release the differential gear lock stop the vehicle and set the switch to 4WD A WARNING POTENTIAL HAZARD Riding too fast while the vehicle is in A4WD LOCK WHAT CAN HAPPEN All wheels turn at the same speed when the differential is locked so it takes more effort to turn the vehicle The amount of effort required is greater the faster you go You may lose control and have an accident if you cannot make a sharp enough turn for the speed you are traveling HOW TO AVOID THE HAZARD Always ride at a slow speed when the vehicle is in 4WD LOCK and allow extra time and distance for maneuvers NOTE Accelerator pedal When the switch is set to LOCK the Press the accelerator
60. nd cargo 550kgf 1 21 2lbf Tongue weight vertical weight on trailer hitch point 50kgf 11 Olbf Please distribute loaded weight of front amp rear seats adequately make sure whole weight of loaded vehicle is not above 998kg NOTE Max loading weight is 150Kg 330Ib when No passenger in Rear seat e Choose a trailer hitch drawbar designed for use with a 5 cm 2in receiver See page 4 25 for more information e Do not exceed the maximum tongue weight You can measure tongue weight with a bathroom scale Put the tongue of the loaded trailer on the scale with the tongue at hitch height Adjust the load in the trailer if necessary to reduce the weight on hitch If you are carrying cargo and towing a trailer include the tongue weight in the maximum vehicle load limit Load cargo in the cargo bed as close to the center of the vehicle as possible and tie it down using the cargo hooks equipped on the cargo bed Tie down cargo securely in the trailer Make sure cargo in the trailer cannot move around A shifting load can cause an accident Make sure the load does not interfere with controls or your ability to see where you are going Drive more slowly than 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 heavie
61. ne see PAGE 8 6 Loose the nut of throttle rope on the valve Spin the throttle rope inside outside to increase the throttle pedal s moving distance to 1 5 3 mm Accelerator Cable column nut Fix the nut Resume the center cover and seat to their position 5 9 Steering Wheel Inspection Check the steering wheel for specified freeplay and smooth operation 1 Position the vehicle on level ground 2 Lightly turn the steering wheel left and right 3 There should be 0 8 of freeplay If there is excessive freeplay or strange noises or the steering feels rough or 1 0 20 25 mm catchy have the steering system inspected by an authorized dealer Seat belts Make sure that both seat belts are not frayed or damaged The seat belt must move smoothly when pulled out and retract on its own when released The latch plate should click securely into the buckle and release when the release button is pushed firmly Wash off any dirt or mud which could affect operation Have a 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 to a dealer or refer to the Service Manual for correct tightening torque Lights Check the headlights and tail orake lights to make sure they are in working condition Repair as necessary for proper operation Switches Check the operation of all switches Ha
62. nstall the console Final gear oil Checking the final gear oil level 1 Place the vehicle on a level surface 2 Remove the oil filler bolt and then check the oil level in the final gear case 1 Speedometer sensor 2 final gear oil 3 Correct oil level NOTE The oil level should be at the brim of the filler hole 3 If the oil is below the brim of the filler hole add sufficient oil of the recommended type to raise it to the correct level CAUTION s 1 Be sure no foreign material enters the final gear case 2 Please clean the sensor every 500km period 4 Install the oil filler bolt and then tighten it to the specified torque Tightening torque Final gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf Changing the final gear oil 1 Place the vehicle on a level surface 2 Place a container under the final gear case to collect the used oil 3 Remove the oil filler bolt and the drain bolt to drain the oil is 4 Final gear oil drain bolt Install the drain bolt and then tighten it to the specified torque Tightening torque Final gear oil drain bolt 20 Nm 2 0 m kgf 14 ft lbf 5 Add the recommended final gear oil up to the brim of the filler hole Recommended oil SAE 80 API GL 4Hypoid gear oil Oil quantity 0 25 L 0 22 Imp qt 0 26 US qt CAUTION Be sure no foreign material enters the final gear case 6 Install th
63. ntenance is performed check the air inlet to the air filter case for obstructions Check the air filter element rubber joint to the carburetor and manifold fittings securely to avoid the possibility of unfiltered air entering the engine CAUTION Never operate the engine with the air filter element removed This will allow unfiltered air to enter causing rapid engine wear and possible engine damage Additionally operation without the air filter element will affect carburetor jetting with subsequent poor performance and possible engine overheating V belt cooling duct check hose The V belt cooling duct check hose is located under the driver seat See pages 4 16 4 17 for seat removal and installation procedures If dust or water collects in the V belt cooling duct check hose remove the hose and clean it 1 V belt cooling duct check hose V belt case drain plug The V belt case drain plug is located under the driver seat See pages 4 16 4 17 for seat removal and installation procedures After riding in water deep enough to allow water to enter the V belt case remove the drain plug to drain any water from the case NOTE If water drains from the V belt case after removing the drain plug have a dealer inspect the vehicle as the water may affect other engine parts 1 V belt case drain plug Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool before cleaning the spark ar
64. o 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 Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or person Always follow proper operating procedures Follow these precautions when operating in reverse 1 Always check for obstacles or people behind the vehicle 2 Apply the throttle lightly Never open the throttle suddenly 3 Back slowly 4 Apply the brakes lightly for stopping 5 Avoid making sharp turns Before shifting into reverse gear always check for obstacles or people behind the vehicle When it s safe to proceed back slowly 7 7 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 straig
65. o test all non accessories nor have any control over the quality or suitability of them Choose a genuine accessory or one that is equivalent in design and quality e 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 common sense and good judgment when carrying cargo or towing a trailer Keep the following points in mind e Never exceed the weight limits shown An overloaded vehicle can be unstable MAXIMUM LOADING LIMIT e Vehicle loading limit total weight of cargo operator passengers and accessories and tongue weight e 998kg 2200 Ib e The max load capacity of packing case while 4 passenger 50kg 110lb e The max load capacity of packing case while 2 passenger 150kg 330Ib e Front seat load weight 75 x 2 150kg 330 Ib Rear seat load weight 55 x 2 110kg 242 Ib Trailer hitch Pulling load total weight of trailer e a
66. ock lever x2 To install a seat insert the projection on the 4 16 Rear Seats Seat Belt For Front Seats This vehicle is equipped with three point seat belts for both the operator and passenger Always wear the seat belt while riding in the vehicle 1 Rear seat To remove the rear seats you need to pull it up from back and then push it back 1 Seat belt x2 2 Latch plate x2 3 Buckle x2 Seat Belt For Rear Seats To wear the seat belt properly do the following 1 Hold the latch plate as you pull the belt across your lap and chest Make sure the belt is not twisted and is not caught on any portion of the vehicle your clothing or any equipment you are carrying 2 Push the latch plate into the buckle until it clicks Pull up on the latch plate to make sure it is secure 1 Driver seat 2 Passenger seat 3 Seat lock lever x2 Three point belt is provided on the vehicle two passengers on rear seats Please wear it during the process of running 1 Buckle 2 Latch plate 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 across your hips Position the shoulder belt over your shoulder and across your chest The shoulder belt should fit against your chest If it is loose pull the belt out all the way and then let it retract To release the buckle firmly press the relea
67. of Common Problems in Engine System S N Problems Solutions 1 Check the throttle cable for seizure 2 Check the adjustment knob of carburetor for damage or 1 Idle speed can not be wear adjusted ona 3 Check the needle of carburetor to see if it can be placed to the bottom 1 Check the battery voltage for Within specified value 2 Idle speed is not stable Zonak the rectifier output voltage for within specified value 3 Check MEUI for failure 1 Check if there is one cylinder not working 3 Power performance is 2 Check gasoline nozzle for block falling 3 Check and clean core of air cleaner 4 Check muffler for partly block and clean spark arrestor 1 Check air cleaner and admission line for leak vay i 2 Check the connection joint of exhaust pipe with engine 4 Popping in engine or muffler for leak 3 Check the grade of gasoline to see if it s too low 1 Check if the battery voltage goes down when 5 Engine is difficult to start temperature goes down atlow temperature 2 lf the temperature is under 18 C have the vehicle placed in warmer place for start 8 57 S N Problems Solutions Coolant boils 1 Check the cooling fin of radiator for blocked by soil or dirt 2 Check the speed sensor of radiator for damage and Check fan for failure 3 Check if antifreeze can meet the requirement stated in the owner manual 4 Check the coolant loop for mi
68. operly a 6 O ring Install the new oil filter cartridge with an oil filter wrench and then tighten it to the specified torque with a torque wrench Tightening torque Oil filter cartridge 17Nm 1 7m kgf 12 ft lbf 1 Oil filler cartridge 2 Torque wrench 7 Install the engine oil drain bolt and then tighten it to the specified torque Tightening torque Engine oil drain bolt 30Nm 3 0m kgf 22 ft lbf 8 Add the specified amount of recomm ended engine oil and then install the engine oil filler cap and tighten it Recommended engine oil See page 10 2 Oil quantity Without oil filter cartridge replacement 1 9 L 1 67 Imp qt 2 01 US qt With oil filter cartridge replacement 2 0 L 1 76 Imp qt 2 11 US qt CAUTION In order to prevent clutch slippage since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign material enters the crankcase 9 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause 10 Turn the engine off wait at least ten minutes and then check the oil level and correct it if necessary 11 I
69. p sec ce cece cee ccc ccc ccccccces 4 15 Front Seats eee cer ccc ccc cce ccc ccc ces ccccce 4 16 Rear Seats eee ccc cee ccc cee ccc cce ccs ccccee 4 17 Seat Belt For Front Seats 4 17 Seat Belt For Reat Seats 4 18 Glove compartment eee ccc cee ccc cccccccce 4 20 Cargo bed Peer cece crc cce ccc cce ccc ccscccces 4 20 Front and rear shock absorber Trailer hitch bracket e 4 25 Auxiliary DC jack ccc cc ccc ccc ccc cccccccce 4 26 PRE OPERATION CHECKS 5 1 Front and rear brakes 5 2 FUC err reece cee cee cee cette eceeeeeeeeeneeee eee A Engine Oilssrsserrcrr eee teecee eee eee eee B25 Final gear Oilsss srssreeeser essere eeecee ees 5 7 Differential gear Oil s eeeeeee e829 5 7 Seat beltseercrecercre reece sree eee cee eee eee 5 Fittings and fasteners seee 5 10 Lights s rssseeeeeeeeeeeeeeeceeeeecee ees 5 10 How to measure tire pressure 5 12 Tire Wear lirtiterss eere cere ee eee eee ee eens 5 13 OPERATION ceccece creer ceecce reser ces 6 1 Starting The Engine In Low Temperatures ssrrrreeseeseeeeeeeseeeees 6 1 Starting The Engine 6 2 Warming Upersssrssteeerreseeceseeeeeeeee ees 6 3 Drive select lever operation and Driving In Reverser sssserrsreeeeee ees 6 4 Parking srsrrrrr cee eee see cee eee cee eee eee eee 6 6 Parking on a Slopers ss ssererreeeeee ee 6 7 Engine Break In eee eereeTrerrerre ree reer yy 6 9 Accessories and loading 6 10 DRIVING YOUR V
70. parts coated with grease after wash and reassemble 1 V belt cooling duct check hose 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 accident Avoid jumping the vehicle as injury loss of control and damage to the vehicle could occur A 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 1 V belt case drain plug be alert to changing terrain conditions when operating the vehicle 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 an
71. pedal down to increa differential gear lock indicator and se engine speed Spring pressure returns indicator light will flash until the the pedal to the rest position when released differential gear is locked Always check that the accelerator pedal When the indicator and indicator light are returns normally before staring the engine flashing turning the steering wheel back and forth will help the differential gear lock to engage Riding before the differential gear lock is properly engaged e g when the indica tor and indicator light are flashing will cause the engine speed to be limited until engagement is complete 1 Accelerator pedal Before starting the engine check the accele Brake pedal rator pedal to be sure it is operating smoothly Press the brake pedal to slow or stop the Make sure the accelerator pedal fully returns i me vehicle to the idle position as soon as it is released A WARNING POTENTIAL HAZARD Malfunction of the accelerator pedal WHAT CAN HAPPEN The accelerator pedal could de hard to operate making it difficult to speed up or slow down when you need to This could cause an accident HOW TO AVOID THE HAZARD Check the operation of the accelerator pedal before you start the engine If it does not work smoothly check for the cause Correct the problem before operating the vehicle Consult a dealer if you can t find or solve the problem yourself 1 Brake pedal Parking bra
72. perly serviced or adjusted brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the brake pedal position is correct Make sure the brakes do not drag All air must be bled from the brake system Replacement of brake components requires professional knowledge These procedures should be performed by a dealer Parking brake lever free play adjustment Periodically check the parking brake lever free play and adjust it if necessary 1 Shift the drive select lever into low gear L f Remove the seats See page 4 16 4 17 for seat removal and installation procedures Remove the console See page 8 9 for console removal and installation procedures Check the parking brake lever free play The maximum free play is equal to one click of the parking brake lever If necessary adjust the free play as follows 1 Parking brake lever free play NOTE The parking brake lever must be released when checking and adjusting the parking brake lever free play 5 Loosen the locknut oo Locknut 2 Adjusting nut Turn the adjusting nut in direction to increase the free play or in direction to decrease the free play Tighten the locknut Install the console Install the seats Brake light switch adjustment The brake light switch which is activated b
73. ply them several times to let friction dry out the linings CAUTION After riding your vehicle in water be sure to drain the trapped water by removing the check hose at the bottom of the air filter case the V belt cooling duct check hose the drive select lever box check hose and the V belt case drain plug Wash the vehicle in fresh water if it has been operated in salt water or muddy conditions Vehicle Immersion CAUTION If your vehicle becomes immersed major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine If it s impossible to take your vehicle to a dealer before starting it follow the steps outlined below 1 Move the vehicle to dry land Check the air box If water is present dry the air box and replace the filter with a new filter Remove the spark plugs Turn the engine over several times e 5 Dry the spark plugs and reinstall them or install new plugs 6 Attempt to start the engine If necessary repeat the drying procedure Take the vehicle to your dealer for service as soon as possible whether you succeed in starting it or not If water has been ingested into the CVT make sure inspect the hole without water left inside If it is muddy water open the CVT cap and wash the parts before reassemble 9 check the gearshift release the water inside Wash it if it is necessary CAUTION Make sure all motion
74. r vehicle takes longer to stop Avoid making sharp turns unless at very slow speeds Avoid hills and rough terrain Choose terrain carefully Added weight affects the stability and handling of the vehicle A WARNING POTENTIAL HAZARD Overloading this vehicle or carrying or towing cargo improperly WHAT CAN HAPPEN Could cause changes handling which could 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 in vehicle lead to an DRIVING YOUR VEHICLE GETTING TO KNOW YOUR VEHICLE This off highway utility vehicle will handle and maneuver differently form an ordinary passenger car or other vehicle Before you begin to use your vehicle be sure you have read this Owner s Manual completely and understand of the controls Pay particular attention to the safety information on pages 2 1 2 5 Please also read all caution and warning labels on your vehicle This vehicle is designed for the operator and one passenger The driver and passenger must always wear a seat belt Never carry passengers in the cargo bed 7 1 A WARNING POTENTIAL HAZARD Not wearing the seat belt Wearing the seat belt improperly WHAT CAN HAPPEN There is increased risk of being killed or seriously injured in an accident HOW TO AVOID THE HAZAR
75. rake system See pages 8 32 8 36 5 3 A WARNING POTENTIAL HAZARD Driving with improperly operating brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride Do not operate the vehicle if you find any problem with the brakes If a problem cannot be corrected by the adjustment procedures provided in this manual have the vehicle inspected by a dealer Fuel Make sure there is sufficient gasoline in the tank Recommended fuel Unleaded gasoline only Fuel tank capacity 30 0L 6 60Imp gal 7 93US gal CAUTION Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system 5 4 Your engine has been designed to use regular unleaded gasoline with a pump octane number R M 2 of 86 or higher or research octane number of 91 or hither If knocking or pinging occurs use a different brand of gasoline or premium unleaded fuel Unleaded fuel will give you longer spark plug life and reduced maintenance cost Gasohol The UTV uses an electric fuel injection system and its emissions completely meet the requirements of relevant rule of the United States and Europe But mixed fuel is forbidden to use on the UTV because its injection quantity is different from gasoline The mixe
76. re the spark plug and all filler Caps 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 9 1 CAUTION _ _ S 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 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 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 9 2 A WARNING POTENTIAL HAZARD Operation with wet washing WHAT CAN HAPPEN Wet brakes may have reduced stopping ability increasing the chance of an accident HOW TO AVOID THE HAZARD Tes
77. rester 1 Remove the bolts 1 Bolt x3 2 Remove the tailpipe by pulling it out of the muffler 3 Tap the tailpipe lightly and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing 1 Tailpipe 2 Spark arrester 4 Insert the tailpipe into the muffler and align the bolt holes 5 Install the tailpipe by installing the bolts and then tighten the bolts to the specified torque Tightening torque Tailpipe bolt 9 5 Nm 0 95 m kgf 6 9 ft lbf A WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester Hot exhaust system WHAT CAN HAPPEN Could injure the eyes Could cause burns Could cause carbon monoxide poisoning possibly leading to death Could start a fire HOW TO AVOID THE HAZARD When cleaning the spark arrester Always let the exhaust system cool prior to touching exhaust components Do not start the engine when cleaning the exhaust system Valve clearance The correct valve clearance changes with use resulting in improper fuel air supply or engine noise To prevent this the valve clearance must be adjusted regularly This adjustment however should be left to a professional service technician Front brake pad check Each brake pad is provided with wear indicator grooves which allow you to check the brake pad wear without having to disassemble the brake To check the brake pad
78. roubleshooting 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 checks If your vehicle requires any repair take it to a dealer The skilled technicians at a dealer ship have the tools experience and know how to properly service 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 A 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 on open flames or sparks in the area including pilot lights from water heaters of furnaces Check and solution to Common Problems in Vehicle Here you can see some tables on the common problems which may come up when you are driving a UTV which will help to solve these problems To repair a UTV requires technical skills if you cannot fix it up yourself please contact your dealer Table1 Check and Solution of Common Problems in Appearance parts and impact fittings S N Problems Solutions 1 Covers are cra
79. rse 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 6 6 Parking a When parking stop the engine and shift the drive select lever into the neutral position b Push the brake pedal down and pull the parking brake to top position to park the vehicle 1 Parking handbar Parking On a Slope A WARNING POTENTIAL HAZARD Parking on a hill or other incline WHAT CAN HAPPEN The vehicle could roll out of control increasing the chance of an accident HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines If you must park on an incline apply the parking brake and block the front and rear wheels with rocks or other objects Do not park the vehicle at all on hills that are so steep you could not walk up them easily 6 7 Bring the vehicle to a stop by applying the brakes Stop the engine With the brakes applied set the parking brake NOTE Like many other vehicles the parking brake acts on the rear wheels For the parking brake to operate all four wheels shift to 4WD before stopping the engine 6 8 Vehicle Break in Period The break in period for your new UTV vehicle is the first 25 hours of operation or the time it takes to use the fir
80. se button 1 Buckle 2 Release button A WARNING POTENTIAL HAZARD Not wearing the seat belt Wearing the seat belt improperly WHAT CAN HAPPEN There is increased risk of being killed or seriously injured in an accident HOW TO AVOID THE HAZARD Always wear your seat belt when riding in the vehicle Be sure the seat belt is close fitting across your hips and chest and is latched securely Glove compartment Cargo bed CAUTION 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 appropria te cushion material 1 Cargo bed 2 Tailgate 3 Cargo hook x4 a Unlock b Open Opening and closing the tailgate Lifting and lowering the cargo bed 1 Tailgate 2 Latch x2 1 Cargo bed release lever To open To lift Unhook the latches and then lower the Push down the cargo bed release lever on tailgate the left or right side of the vehicle and then To close slowly lift up the cargo bed until it stops Place the tailgate in the original position and To lower then hook the latches Lower the cargo bed slowly to its original po sition and be sure the it is locked into place Maximum load limit 150kg 830Ib A WARNING POTENTIAL HAZARD Pinch points WHAT CAN HAPPEN You or someone else could be pinched between the cargo bed and the frame when the bed
81. se to blow If accessories are used without the engine running or with the headlights turned on the battery will lose its charge and engine starting may become difficult Do not use an automotive cigarette lighter or other access with a plug that gets hot because the jack can be damaged PRE OPERATION CHECKS Before using this vehicle check the following points ITEM ROUTINE PAGE Check operation free play fluid level and fluid leakage Brakes Fill with DOT 4 brake fluid if necessary 5 2 5 3 8 26 8 30 Parking brake Check for proper operation condition and free play 6 6 6 7 Check fuel level Fuel Fill with fuel if necessary 5 4 5 5 Check oil level Engine Geat boxoil Fill with oil if necessary 5 6 Check coolant level Coolant reservoir 5 6 8 15 8 16 Final gear oil Differential gear oil Check for leakage 5 7 Accelerator pedal Check for proper accelerator pedal operation 5 8 5 10 Seat belts Check for proper operation and belt wear 5 10 Steering Check for proper operation 5 8 5 10 Fittings and fasteners Check all fittings and fasteners 5 11 e e e e e e e e e Fill with coolant if necessary e e e e e e e e Lights and switches Check for proper operation 5 11 Wheels and tires Check tire pressure wear and damage 5 2 5 15 8 35 8 36 Axle boots Check for damage 8 17 Instrument Check for compelete and r
82. slowly break down and erode If electrode erosion becomes excessive or if carbon and other deposits are excessive you should replace the spark plug with the specified plug Specified spark plug DPR8EA 9 NGk Installation 1 Measure the electrode gap with a wire thickness gauge and if necessary adjust the gap to specification Spark plug gap 0 8 0 9mm 0 031 0 035 in a Spark plug gap 2 Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spark plug threads 3 Install the spark plug and tighten it to the specified torque Tightening torque Spark plug 17 5 Nm 1 75 m kgf 12 7 ft lbf NOTE If a torque wrench is not available when you are installing the spark plug a good estimate of the correct torque is 1 4 to 1 2 turn past finger tight Have the spark plug tightened to the specified torque as soon as possible 4 Install the spark plug cap 5 Lower the cargo bed Cleaning the engine air filter element NOTE There is a check hose at the bottom of the air filter case If dust or water collects in this hose empty the hose and clean the air filter element and air filter case 1 Air filter check hose e Remove the seats See pages 4 16 4 17 for seat removal and installation procedures e Remove the console See page 8 9 for console removal and installation proced ures 3 Remove the air filter case
83. st three tanks full of gasoline No single action on your part is as important as a proper break in period Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components Perform the following procedures carefully CAUTION e Excessive heat build up during the first three hours of operation will damage close fitted engine parts and drive components Do not operate at full throttle or high speeds during the first three hours of use e Use of any engine oil not mentioned in this manual will cause severe damage to the engine Engine Break In There is never a more important period in the life of your vehicle than the period between zero and 25hours For this reason we ask that you carefully read the following material Because the engine is brand new you must not put an excessive load on it for the first several hours of running During the first 25 hours the various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throttle operation or any condition which might result 6 9 in excessive engine heating must be avoided However momentary 2 3 seconds maximum full throttle operation under load does not harm the engine Each full throttle acceleration sequence should be followed with a substantial rest period for the engine by cruising at lower r min so the engine can rid itself of t
84. t the brakes after washing Apply the brakes several times at slow speeds to let friction dry out the linings brakes after B STORAGE Long term storage 60 days or more of your vehicle will require some preventive procedures to guard against deterioration After thoroughly cleaning the vehicle prepare for storage as follows 1 Fill the fuel tank with fresh fuel and add the specified amount of Fuel Stabilizer and Conditioner or equivalent product Operate the vehicle for at least 5 minutes to distribute treated fuel through the fuel system 2 Drain the fuel from the carburetor float chamber into a clean container by loosening the drain bolt this will help prevent fuel deposits from building up Pour the drained fuel into the fuel tank Specified amount 1 oz of stabilizer to each gallon of fuel or 7 5 ml of stabilizer to each liter of fuel 9 3 NOTE Use of fuel stabilizer and conditioner eliminates the need to drain the fuel system Consult a dealer if the fuel system needs to be drained instead 3 Remove the spark plug pour about one tablespoon of SAE 10W30 or 20W40 motor oil in the spark plug Ground the spark plug wire and turn the engine over several times to coat the cylinder wall with oil 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 stor
85. then wait at least ten minutes until the oil settles for an accurate reading 4 Remove the engine oil filler cap and wipe off the dipstick with a clean rag Insert the dipstick in the oil filler hole without screwing it in and then remove it again to check the oil level 5 NOTE The engine oil should be between the minimum and maximum level marks 2 Minimum level mark 1 Maximum level mark 3 Dipstick 4 Engine oil filler cap 6 If the engine oil is at or below the minimum level mark add sufficient oil of the recommended type to raise it to the correct level Insert the dipstick into the oil filler hole and then tighten the oil filler cap Install the console To change the engine oil with or without oil filter cartridge replacement 1 Remove the console See page 8 9 for console removal and installation procedures 2 Place an oil pan under the engine to collect the used oil and then remove the engine oil filler cap 3 Remove the engine oil drain bolt to drain the oil from the crankcase 1 Engine oil drain bolt NOTE Skip steps 4 6 if the oil filter cartridge is not being replaced 4 Remove the oil filter cartridge with an oil filter wrench 2 Oil filter wrench 1 Oil filter cartridge NOTE An oil filter wrench is available at a nearby dealer 5 Apply a light coat of engine oil to the O ring of the new oil filter cartridge NOTE Make sure the O ring is seated pr
86. tion Related Calibration HEX DEC Number P0107 MAP Circuit Low Voltage or Open KsDGDM_MAP_ShortLow 107 263 P0108 MAP Circuit High Voltage KsDGDM_MAP_ShortHigh 108 264 P0112 IAT Circuit Low Voltage KsDGDM_IAT_ShortLow 112 274 P0113 IAT Circuit High Voltage or Open KsDGDM_IAT_ShortHigh 113 275 Coolant Oil Temperature Sensor Circuit P0117 KsDGDM_CoolantShortLow 117 279 Low Voltage Coolant Oil Temperature Sensor Circuit P0118 KsDGDM_CoolantShortHigh 118 280 High Voltage or Open P0122 TPS Circuit Low Voltage or Open KsDGDM_TPS_ShortLow 122 290 P0123 TPS Circuit High Voltage KsDGDM_TPS_ShortHigh 123 291 P0131 O2S 1 Circuit Low Voltage KsDGDM_O2_1_ShortLow 131 305 P0132 O2S 1 Circuit High Voltage KsDGDM_O2_1_ShortHigh 132 306 11 1 P0031 O2S Heater Circuit High Voltage KsDGDM_O2_HeaterShortHigh 31 49 P0032 O2S Heater Circuit Low Voltage KsDGDM_O2_HeaterShortLow 32 50 P0201 Injector 1 Circuit Malfunction KsDGDM_INJ_CYL_A Fault 201 513 P0202 Injector 2 Circuit Malfunction KsDGDM_INJ_CYL_B_ Fault 202 514 P0230 FPR Coil Circuit Low Voltage or Open KsDGDM_FPP_CircuitShortLow 230 560 P0232 FPR Coil Circuit High Voltage KsDGDM_FPP_CircuitShortHigh 232 562 P0336 CKP Sensor Noisy Signal KsDGDM_CrankNoisySignal 336 822 P0337 CKP Sensor No Signal KsDGDM_CrankNoSignal 337 823 P0351 Cylinder 1 Ignition Coil Malfunction KsDGDM_EST_A Fault 351 849 P0
87. ve a dealer repair as necessary for proper operation Tires A WARNING POTENTIAL HAZARD Operating this vehicle with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires on this vehicle or operation of this vehicle with improper or uneven tire pressure may cause loss of control increasing your risk of accident HOW TO AVOID THE HAZARD 1 The tires listed below have been approved by Motor Manufac turing corporation of America for this model Other tire combinations are not recommended Type Size Front 25X8 12 6PR Rear 25 X 10 12 6PR 2 The tires should be set to the recommended pressure e Recommended tire pressure Front 70kpa 0 7 kgf cm 10psi Rear 70kpa 0 7 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 63 kpa 0 64kgf cm 9psi Rear 63 kpa 0 64kgf cm 9psi 3 Use no more than the following pressures when seating the tire beads Front 250kpa 2 5kgt cm 36psi Rear 250kpa 2 5kgf cm 36psi Higher pressures may cause the tire to burst Inflate the tires very slowly and carefully Fast inflation could cause the tire to burst How to measure tire pressure Use the tire pr
88. ver 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 shield gloves over the ankle boots long sleeved shirt or jacket and long pants Never consume alcohol or drugs before or while operating this vehicle Never operate at speeds too fast for your skills or the conditions Always go at a speed that is proper for the terrain visibility operating conditions and your experience Never attempt jumps of other stunts Always inspect your vehicle each time you use it to be sure it is in safe operating condition 2 1 Always follow the inspection and maintenance procedures and schedules described in this manual Always keep both hands arms feet and legs inside the vehicle at all times during operation Keep your feet on the floorboard Never hold onto the enclosure except when using the handgrip inside the enclosure 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 thu
89. wear check the wear indicator grooves If a brake pad has worn to the point that the wear indicator grooves have almost disappeared have a dealer replace the brake pads as a set 1 Brake pad wear indicator groove NOTE The wheels need to be removed to check the brake pads See pages 8 4 18 42 for wheel removal and installation procedures Rear brake pad check Each brake pad is provided with wear indicator grooves which allow you to check the brake pad wear without having to disassemble the brake To check the brake pad wear check the wear indicator grooves If a brake pad has worn to the point that the wear indicator grooves have almost disappeared have a dealer replace the brake pads as a set 1 Brake pad wear indicator groove Checking the brake fluid level 1 Minimum level mark Insufficient brake fluid may let air enter the brake system possibly causing the brakes to become ineffective Before riding check that the brake fluid is above the minimum level mark and replenish if necessary A low brake fluid level may indicate worn brake pads and or brake system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage The brake fluid reservoir is located under the hood See pages 8 7 8 8 for hood opening and closing procedures Observe these precautions When checking the fluid level make sure the top of the brake fluid reservoir is
90. where the temperature is higher than 20 C 4 F After the UTV has warmed up the UTV can be started Please check page 6 2 on the warming up process When the temperature is higher than 38 C 100f and when you park the UTV after it run at high speed please turn off the flameout switch firstly while make the radiator fan still work for 3 minute then turn off the power switch to save the battery When you park the UTV and cut off the engine please turn off the ignition switch to stop meter displaying With EFI system use for this UTV the electric fuel pump in the fuel tank can work when the meter displays If the fuel pump work for a long time it will result in battery power loss and failure to electric start CONTENTS 4 LOCATION OF THE WARNING AND SPECIFICATION LABELS 1 1 E SAFETY INFORMATION 2 1 EJ DESCRIPTION AND VEHICLE IDENTIFICATION errr eree ree eee ree er eee 3 1 Identification number records 3 3 Key Ldentification Number 3 3 Vehicle identification number 3 4 CONTROL FUNCTIONS reee 4 1 Main switch EEETTETTETTETTETTETTTTTETTETTETT 4 1 Indicator and warning lights 4 2 Multi function meter unites 4 5 Switches recrecee cer cec cee ceeeeeeee ses cee ees 4 8 Accelerator pedal see ccc ccc ccc ccc scccccces 4 1 2 Brake Pedalerrsrrssstereeesseeeesee eee eee 4 13 Parking brake lever see ccc ccc ccccccccccce 4 14 Drive select lever dec ccc ccc ccc ccc cccccccce 4 15 Fuel tank ca
91. xed with air Engine can not start 1 Check the battery which with low electricity may cause the motor failure 2 Check the starting motor for damage 3 Check if MEUI can work in good condition 4 Check if the ignition loop can work in good condition 5 Check if the spark plug is foulled or burned 6 Check if the ignition signal is in good condition 7 Check if the air cleaner is blocked 8 Check if the oil circuit is smooth 9 Check if the exhaust system is blocked A WARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap Always use a thick rag over the cap Allow any remaining pressure to escape before completely removing the cap NOTE eee 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 CLEANING AND STORAGE A CLEANING Frequent thorough 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 su
92. y the brake pedal is properly adjusted when the brake light comes on just before braking takes effect If necessary adjust the brake light switch as follows 1 Open the hood See pages 8 7 8 8 for hood opening and closing procedures 2 Turn the adjusting nut while holding the brake light switch in place To make the brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction To make the brake light come on later turn the adjusting nut in direction 1 Brake light switch 3 Close the hood 2 Adjusting nut Cable inspection and lubrication A WARNING POTENTIAL HAZARD Damaged control cables WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged Cables can also become frayed or kinked Operation of controls could be restricted which could cause an accident or injury HOW TO AVOID THE HAZARD Inspect cables frequently Replace damaged cables Lubricate the inner cables and the cable ends If the cables do not operate smoothly ask a dealer to replace them Recommended lubricant Engine oil Brake pedal and accelerator pedal Rear knuckle upper and lower pivot lubrication lubrication Lubricate the knuckle upper and lower pivots Lubricate the pivoting parts with a grease gun Recommended lubricant Lithium soap based grease all purpose grease Recomm
93. you try to stop a vehicle tip over using your arm or leg If vehicle starts to tip over keep arms and legs inside vehicle e Slopes uneven terrain and turning too fast or sharp increase the risk of tip over A WARNING e Max speed less than 65km h 40miles h e Turn speed less than 30km h 19miles h 1 6 A WARNING ALWAYS e Wear a seat belt when riding in the vehicle e Keep your hands and feet inside the vehicle at all times watch for branches brush or other hazards that could enter the vehicle e Dive straight up and down inclines driving across the side of an incline increase the risk of overturn NEVER e Operate through water deeper than13 33cm or fast flowing water if you must cross shallow slow moving water choose your path carefully to avoid sharp drop offs large rocks or slippery surfaces that could cause the vehicle to overturn e Make sharp high speed turns the vehicle could roll over or go out of control A SAFETY INFORMATION This off highway utility vehicle handles differently from other vehicles including cars and ATVs SEVERE INJURY OR DEATH can result you do not follow these instructions Read this manual and all labels carefully and follow the operating procedures described The vehicle is designed for one driver and three passengers one driver and one passenger on front seats and two passengers on rear seats No passenger shall be allowed in cargo box Always be sure the dri

Owner`s Manual - Massimo Motor

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