BMS APU08E Owner'S Manual Download Page 124

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124

1.Fuel

Check if there is fuel
in the fuel tank.

2.Compression

Use the electric

starter to see if

there is compression

3.Ignition

Remove the
spark plug and
check the electrodes.

4. Battery

Use the electric starter

There is fuel.

No fuel.

Remove the fuel hose
from the fuel pump.

Check the
fuel flow.

No fuel.

Fuel pump
is clogged.

Supply fuel.

Restart the engine.

No compression.

There is compression.

Compression normal.

Wipe clean with dry cloth.

Attach spark plug cap and
ground to chassis.

Wet

Dry

Use the electric

starter.

Spark is weak.

Spark is good.

No spark.

Ignition system
is normal.

Adjust the spark
plug gap or replace
the spark plug.

Ask an dealer to
inspect.

Check the connections
rechatge.

Battery is good.

Engine turn over
quickly.

Engine turn over
slowly.

Troubleshooting charts

Starting problems or poor engine performance

Summary of Contents for APU08E

Page 1: ...TV Important safety information Your UTV can provide many years of service and pleasure if you take responsibility for your own safety and understand the challenges you can meet while riding There is much that you can do to protect yourself when you ride You ll find many helpful recommendations throughout this manual The following are a few that we consider most important Follow the age recommenda...

Page 2: ...ed and manufactured for off road use only The tires are not made for pavement and the UTV does not have turn signals and other features required for use on public roads If you need to cross a paved or public road get off and walk your UTV across Take time to learn practice Even if you have ridden other UTVs take time to become familiar with your skills and get accustomed to the UTV is size and wei...

Page 3: ...lly read the terrain for unexpected turns drop offs rocks ruts and other hazards Always keep your speed low enough to allow time to see and react to hazards Ride within your limits Pushing limits is another major cause of UTV accidents Never ride beyond your personal abilities or faster than conditions warrant Remember that alcohol drugs fatigue and inattention can significantly reduce your abilit...

Page 4: ...e condition It s important to keep your UTV properly maintained and in safe riding condition Having a breakdown can be difficult especially if you are stranded off road far from your base To help avoid problems inspect your UTV before every ride and perform all recommended maintenance Your UTV comes with a hangtag and several labels containing important safety information Anyone who rides the vehi...

Page 5: ... off or becomes hard to read contact your dealer for replacements GUIDELINES ON SAFE DRIVING 1 when approaching corners or bends to reduce speed Upon the completion of turn may gradually increase the speed 2 when crossing the vehicles parked in front of to be very careful Because the ...

Page 6: ...g End after walking ago should check all brake system INTRODUCTION Congratulations on your purchase of the UTV It represents the result of many years of experience in the production of fine sporting touring and pace setting racing vehicles With the purchase of this you can now appreciate the high degree of craftsmanship and reliability that have made a leader in these fields ...

Page 7: ...NING Please read this manual carefully before operating this vehicle Do not attempt to operate this vehicle until you have attained adequate knowledge of its controls and operating features Regular inspections and careful maintenance along with good operating techniques will help ensure that you safely enjoy the capabilities and reliability of this vehicle IMPORTANT MANUAL INFORMATION FAILURE TO F...

Page 8: ...G instructions could result in severe injury or death to the vehicle operator a bystander or a person inspecting or repairing the vehicle CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the vehicle NOTE A NOTE provides key information to make procedures easier or clearer WARNING The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED ...

Page 9: ...treet road or highway Such use is prohibited by law Check the laws and regulations in force before choosing where to operate this vehicle It is illegal to operate this vehicle on public lands where vehicles its size are prohibited This vehicle complies with almost all state off highway noise level and spark arrester laws and regulations ...

Page 10: ... or to trace your vehicle in the event of loss These numbers are required by the authorized UTV dealer to complete warranty claims properly No warranty will be allowed by if the engine identification number EIN or vehicle identification number VIN is removed or mutilated in any way We strongly recommend that you take note of all the serial number on you vehicle and supply them to your insurance co...

Page 11: ... 11 Engine and Vehicle Identification Number Location ...

Page 12: ...ICAL 1 EIN Engine Identification Number on left side under of the crankcase 2 VIN Vehicle Identification Number on right side under of the frame 3 ENGINE NUMBER LOCATION OF THE WARNING AND SPECIFICATION LABELS ...

Page 13: ...ls on you 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 ...

Page 14: ... 14 1 3 ...

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Page 18: ... and all labels carefully and follow the operating procedures described This vehicle is designed to carry the driver and one passenger Never carry passengers in the cargo bed Always be sure the driver and passenger are wearing seat belts Never give a ride to a passenger who is too small to reach and hold the handgrip on the enclosure Always avoid operating the vehicle on any paved surfaces includi...

Page 19: ...e or while operating this vehicle Never operate at speeds too fast for your skills or the conditions Always go at a speed that is proper for the terrain visibility operating conditions and your experience Never attempt jumps or other stunts Always inspect your vehicle each time you use it to be sure it is in safe operating condition Always follow the inspection and maintenance procedures and sched...

Page 20: ...ring 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 he skills necessary to control the vehicl...

Page 21: ...engine braking to help you go slowly If necessary use the brakes gradually to help you go slowly Always check terrain carefully before going down hills Go as slowly as possible Never go down a hill at high speed Always check for obstacles before operating in a new area Never operate the vehicle in fast flowing water or water deeper than the floorboards on this model Remember that wet brakes may ha...

Page 22: ... 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 ...

Page 23: ...icinity of sparks open flames and clothes dryers When transporting the vehicle in another vehicle be sure it is kept in an upright position or other sources of ignition such as the pilot lights of water heaters Otherwise fuel may leak out of the 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 gaso...

Page 24: ... 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 ...

Page 25: ...25 DESCRIPTION AND VEHICLE IDENTIFICATION 1 2 3 4 5 6 7 8 10 14 11 13 12 9 15 16 17 18 19 20 ...

Page 26: ...ck 3 Front shock absorber assembly adjusting ring 4 Brake fluid reservoir 5 Parking brake lever 6 Steering wheel 7 Drive select lever 8 Driver seat 9 Air filter element engine and air intake duct 10 Cargo bed push rod switch 11 Rear shock absorber assembly adjusting ring 12 Tail brake lights 13 Engine exhaust pipe 14 Cargo bed 15 Cargo bed push rod ...

Page 27: ... 20 Batter 21 2WD 4WD switch 22 Switch combination 23 Indicators Display 24 MP3 switch 25 Auxiliary DC jack Cigarette lighter 26 Glove compartment lock 27 Accelerator pedal 28 Brake pedal CONTROL FUNCTIONS Mains switch Functions of the respective switch positions are as follows ...

Page 28: ...he headlights and taillights come on when the light switch is on START The electric starter is engaged by turning and holding the key in this position Release the key when the engine starts CAUTION Do not operate the electric starter continuously for more than 5 seconds or starter damage could occur Wait at least 5 seconds between each operation of the electric starter to let it cool 1 2 3 ...

Page 29: ...gine running or damage to the electric starter can result See starting instructions prior to starting the engine Switches combination 1 Horn switch 2 Winch switch Release wire rope Contraction wire rope 3 Dangerous warning lights switch Switches combination ...

Page 30: ...30 1 Direction indicator 2 Headlamp Switch 3 Lighting Switch 4 Wiper Switch On Command four wheel drive and differential gear lock ...

Page 31: ... button 2 On Command differential gear lock switch 4WD LOCK 4WD push the button LOCK Pop up the button This vehicle is equipped with an On Command four wheel drive switch 2WD 4WD and a differential gear lock switch 4WD LOCK Select the appropriate drive according to terrain and conditions 1 2 ...

Page 32: ...cargo box 1 The switch is automatic hold the switch upward the cargo box will be up stop the holding the cargo box will be stopped 2 hold the switch downward the cargo box will be down stop the holding the cargo box will be stopped ...

Page 33: ...33 ...

Page 34: ...34 Indicators Display ...

Page 35: ...35 ...

Page 36: ...display in the odograph and be switched betweens the figure of speed will display and update synchronous while switching between KM H and MPH in unit of pedometer Press the button of Time Set the user can set the hour and minute Then adjust hours or minute by ascending or descending by continuing press button of mode of Set Reset user can clean the record to zero for particular period of working m...

Page 37: ... temperature of coolant If the temperature is above 102 stop engine immediately Check coolant lever and add if low see authorized dealer if temperature indicator stay on and overflow tank is full of coolant 2 quantity of fuel indicator light When the last segment clears a low fuel warning is activated the fuel gauge will blink refuel immediately otherwise the vechile will be stopped and can not st...

Page 38: ...ngine If the lamp is on while the engine working it indicates that the system failed When some electric jet parts are found fault check engine indicator lamp will also be ON the vehicle still can keep running the driving performance is getting worse which reminds the driver should send the vehicle to repair 4 2WD 4WD indicator 2WD 4WD 4WD LOCK ...

Page 39: ...39 ...

Page 40: ...r 6 Direction Indicator Turn Left Turn Right 7 Parking Indicator Means the vehicle is in the parking before start driving remind the driver to release the park brake and move the lever downward then start driving 8 Headlight Indicator Means headlight is in the working ...

Page 41: ...xiliary DC jack should only be used when the engine is running 1 Set the light switch to OFF 2 Start the engine Cigarette lighter Auxiliary DC jack 3 Pull out the cigarette lighter and then insert the accessory power plug into the jack 4 When the auxiliary DC jack is not being used put back the Cigarette lighter Maximum rated capacity for the auxiliary DC jack DC 12V 120W 10A CAUTION ...

Page 42: ...starting may become difficult Accelerator pedal Press the accelerator pedal down to increase engine speed Spring pressure returns the pedal to the rest position when released Ways check that the accelerator pedal returns normally before starting the engine 1 Accelerator pedal Before starting the engine check the accelerator pedal to be sure it is operating smoothly Make sure the accelerator pedal ...

Page 43: ... 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 an dealer if you can t find or solve the problem yourself Brake pedal Press the brake pedal to slow or stop the vehicle 1 Brake pedal ...

Page 44: ...44 Parking brake leve Pull the parking lever up so that the unit can engage park brake To release the unit press button in the front end of parking lever then push the parking lever to the bottom ...

Page 45: ...release the unit press button in the front end of parking lever then push the parking lever to the bottom CAUTION Never use parking brake lever then the vehicle don t stop fully Adjust the parking cable if necessary Be sure to fully release the parking brake lever before starting the vehicle ...

Page 46: ...46 Drive select lever The drive select lever is used to shift the vehicle gear CAUTION Never start the vehicle at N or R lever Stop the vehicle when shifting to reverse ...

Page 47: ...seat best 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 secur 1 Buckle 2 Latch plate ...

Page 48: ...4 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 5 To release the buckle firmly press the release button 1 Buckle 2 Release button WARNING POTENTIAL HAZARD Not wearing the seat belt Wearing the seat belt improperly WHAT CAN HAPPEN ...

Page 49: ...ing in the vehicle Be sure the seat belt is close fitting across your hips and chest and is latched securely Glove compartment 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 appropriate cushion material a b a Unlock b Open ...

Page 50: ...et ARE YOU READY TO DRIVE Before each drive you need to make sure you and your UTV are both ready to drive To help get you prepared this section discusses how to evaluate your driving readiness what items you should check on your UTV and adjustments to make for your comfort convenience or safety Protective apparel For your safety we strongly recommit end that you always wear an approved ...

Page 51: ... proper driving gear Helmets and eyes protection Your helmet is your most important piece of driving gear because it offers the beat protection against head injuries A helmet should fit your head comfortably and securely An open face helmet offers some protection but a full face helmet offers more Regardless of the style look for a DOT Department of Transportation sticker in any helmet you buy Alw...

Page 52: ...e training Developing your driving skills is an on going process Even if you have driven other UTVs take time to become familiar with hoe this UTV in a safe area WARNING Operating this without wearing an approved motorcycle helmet eye protection and protective clothing could increase your chances of head or eye injury possibly death in the event of severe accident Always wear approved motorcycle h...

Page 53: ...he off highway recreational vehicle will turn over Age Recommendation It is strongly recommended that is not one under the age of 16 be permitted this UTV without adult supervision No Alcohol or Drugs WARNING Operating UTV without proper instruction could increase your risk of an accident which could lead to serious injury or death WARNING A child driving a UTV that is not recommended for his her ...

Page 54: ...er taking medication IS YOUR VEHICLE READY TO DRIVE Before each drive it is important to inspect your UTV and make sure any problems you find are corrected A predrive inspection is a must not only WARNING Operating this UTV after consuming alcohol or drugs can seriously affect your judgment cause you to react more slowly affect your balance and perception and could result in serious injury or deat...

Page 55: ... Pre drive Inspection Check the following items before you get on the UTV Engine oil Check the level and add oil if needed Check for leaks Coolant Check the coolant add coolant if needed Check for the leaks Fuel Check the level and add fuel if WARNING mproperly maintaining this UTV or failing to correct a problem before driving can cause a crash in which you can be seriously hurt or even dead Alwa...

Page 56: ...t Underbody Exhaust System Check for and remove any dirt vegetation or other debris that could be fire hazard or interfere with the proper operation of the UTV Air Cleaner Check the air filter Replace it if needed Leaks Loose Part Walk around your UTV and look for anything that appears unusual such as a leak or loose cable Lights Make sure the headlight brake light and tail light are working prope...

Page 57: ...he cable housing for wear Check the fittings are tight Replace or tighten as needed Tie rod Check the tie rod housing for wear Check the fittings are tight Replace Safe driving precautions Off road use only You re UTV and its tires are designed and manufactured for off road use only not for pavement Driving on pavement can affect handling and control You should not drive your UTV on pavement ...

Page 58: ...ghways even if they are not paved Drivers of street vehicles may have difficulty seeing and avoiding you which could lead to a collision In many states it is illegal to operate UTV on public streets roads and highways WARNING Operating this UTV on paced surfaces may seriously affect handling and control of the UTV and may cause the vehicle to go out of control Never operate the on any paved surfac...

Page 59: ...ntrol the off highway recreational vehicle WARNING Operating this UTV on paced surfaces may seriously affect handling and control of the UTV and may cause the vehicle to go out of control Never operate the on any paved surfaces including sidewalks Operating this UTV on paced surfaces may seriously affect handling and control of the UTV and may cause the vehicle to go out of control Never operate t...

Page 60: ...ughly Don t drive fast on unfamiliar terrain or when WARNING Removing hand from steering wheel or feet from foot controls during operation can reduce your ability to control the UTV Always keep both hands on the steering wheel and both feet on the foot controls of your UTV during operation WARNING Operating this UTV at excessive speeds increases your changes of losing control of the UTV which can ...

Page 61: ...trol which could result in an accident including an overturn Do not operate on excessively rough slippery or loose terrain until you have learned and practiced the skills necessary to control the UTV on such terrain Always be especially cautious on these kinds of terrain Do Not Perform Stunts You should always operate your UTV in a safe and reasonable manner When WARNING Failure to take extra care...

Page 62: ...he first month is most important in the life of your vehicle Proper operation during this break in period will help assure maximum life and performance from your new vehicle The following guidelines explain proper break in procedures 1 After the engine starts the engine is not allowed in high speed in the neutral gearshift 2 Drive vehicle from stop to low speed slowly 3 Avoid braking strongly 4 Do...

Page 63: ... of this UTV is small and agile so the centrifugal force is very high when turning at high speed Slow down to a more controllable speed when turning to prevent the UTV from rolling over To prevent vehicle from rolling over be sure to only turn the vehicle at a slow more controllable speed PRE OPERATION CHECKS Before using this vehicle check the following points WARNING POTENTIAL HAZARD Failure to ...

Page 64: ...ner s Manual Front and rear brakes Brake fluid leakage Check to see if any brake fluid is leaking out of the pipe joints or the brake fluid reservoir Apply the brakes firmly for one minute If there is any leakage please send the vehicle inspected by an dealer Brake operation Test the brakes at slow speed after starting out to make sure they are working properly If the brakes do not provide proper ...

Page 65: ...ded in this manual have the vehicle inspected by an dealer Fuel Make sure there is sufficient gasoline in the tank 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 Gasohol There are two types of gasohol gasohol containing ethanol and that containing methanol Gasohol c...

Page 66: ...mance problems Accelerator pedal Check to see that the accelerator pedal operates correctly It must operate smoothly and fully spring back to the idle position when released Have an dealer repair as necessary for proper operation ...

Page 67: ... ground Turn the steering wheel right and left Check for excessive free play abnormal noises or a rough WARNING POTENTIAL HAZARD Improper care when refueling WHAT CAN HAPPEN Fuel can spill which can cause a fire and severe injury Fuel expands when it heats up If the fuel tank is overfilled fuel could spill out due to heat from the engine or the sun HOW TO AVOID THE HAZARD Do not overfill the fuel ...

Page 68: ...working condition Repair as necessary for proper operation Switches Check the operation of all switches Have an dealer repair as necessary for proper operation Tires 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 ...

Page 69: ... 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 pressure gauge NOTE The tire pressure gauge is included as standard equipment Make two measurements of the tire pressure and use the second reading Dust or dirt in the gauge could cause the first reading to be incorrect Recommende d pressure Mi...

Page 70: ...m 0 12 in due to wear replace the tire a Tire wear limit OPERATION WARNING POTENTIAL HAZARD Operating vehicle without being familiar with all controls WHAT CAN HAPPEN Loss of control which could cause an accident or injury HOW TO AVOID THE HAZARD Read the Owner s Manual carefully ...

Page 71: ...en the hood Remove the battery compartment cover 3 Using a charged 12V battery connect the positive lead of the jumper cable to the positive terminal of the battery in the vehicle and the 4 Connect the negative lead of the jumper cable to the negative terminal of the negative lead to an unpainted metal surface of the vehicle 1 Jumper cable positive lead 2 Jumper cable negative lead WARNING Do nor ...

Page 72: ...nd charged battery and then disconnect the positive lead of the jumper cable from the charged battery and the battery in the vehicle 7 Install the battery compartment cover 8 Close the hood Warming up To get maximum engine life always warm up the engine before starting off Never accelerate hard with a cold engine To see whether or not the engine is warm check if it responds to the throttle normall...

Page 73: ...r while backing WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN You could hit an obstacle or person behind you resulting in serious injury HOW TO AVOID THE HAZARD When you shift into reverse make sure there are no obstacles or people behind you When it is safe to proceed go slowly Engine break in There is never a more important period in the life of your vehicle than the p...

Page 74: ...cessive 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 engine by cruising at lower r min so the engine can rid itself of the temporary build up of heat If any abnormality is noticed during this period consult an dealer 0 10...

Page 75: ...king brake to help prevent the vehicle from rolling Parking on a slope WARNING POTENTIAL HAZARD Parking on a hill or other incline WHAT CAN HAPPEN The vehicle could roll out of control increasing the chance of an accident HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines If you must park on an incline apply the parking brake and block the front and rear wheels with rocks or other ob...

Page 76: ...rking brake Accessories and loading Accessories Accessories can affect the handling and control of your vehicle Keep the following in mind when considering an accessory or operating a vehicle which has accessories Choose only accessories designed for your vehicle Your dealer has a variety of genuine accessories Other ...

Page 77: ...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...

Page 78: ... cargo bed as close to the center of the vehicle as possible and tie it down using the cargo hooks equipped on the cargo bed The down cargo securely in the trailer Make sure cargo in the trailer cannot move around A shifting load can cause an accident Make sure the load does not interfere with controls or your ability to see where you are going Drive more slowly than you would without a load The m...

Page 79: ...ZARD Overloading this vehicle or carrying or towing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this vehicle Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking DRIVING YOUR VEH...

Page 80: ...our vehicle This vehicle is designed for the operator and one passenger The driver and passenger must always wear a seat belt Never carry passengers in the cargo bed WARNING 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 ri...

Page 81: ...designed to carry cargo only WARNING POTENTIAL HAZARD Overloading this vehicle orcarrying or towing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle hand ling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this vehicle Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Al...

Page 82: ... or jacket and long pants Keep hands and feet inside the vehicle at all times WARNING POTENTIAL HAZARD Operating this vehicle without wearing an approved motorcycle helmet eye protection and protective clothing WHAT CAN HAPPEN Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident Operating without eye protection can resu...

Page 83: ...reful making sharp turns on rough terrain Do not attempt to turn around or make abrupt maneuvers on slopes Position your hands on the steering wheel so that your thumbs and fingers do not wrap around the wheel This is particularly important when driving in rough terrain The front wheels will move right and left as they respond to the terrain and this movement will be felt in the steering wheel A s...

Page 84: ...l Do not attempt to climb hills until you have mastered basic maneuvers on flat ground Use proper driving techniques to avoid overturns on hills and slopes Drive straight up hills and avoid crossing the side of a hill which increases your chance of rollover Practice first on gentle slopes before attempting steeper hills Always check the terrain carefully before attempting any hill Use common sense...

Page 85: ...85 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 ...

Page 86: ...t Release the brake and begin to coast down the hill Use engine braking as much as possible gently applying the WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn move easily on extremely steep hills than on lever surfaces or small hills HOW TO AVOID THE HAZARD Never operate your vehicle on hills too steep for it or your abilities Never operate v...

Page 87: ... and drive no faster than you will be able to react to obstacles that may appear WARNING POTENTIAL HAZARD Going down a hill improperly WHAT CAN HAPPEN Could cause loss of control or cause the vehicle to overturn HOW TO AVOID THE HAZARD Always check the terrain carefully before you start down any hill Never go down a hill at high speed Avoid going down a hill at an angle that would cause the vehicl...

Page 88: ...st turn on the hill to avoid an obstacle do so slowly and carefully If the vehicle starts to tip gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance gradually steer again in the direction you want to go CrossingthroughshallowWATER If you must cross shallow slow moving water up to the depth of the vehicle s floorboards choose your path caref...

Page 89: ...89 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 ...

Page 90: ... could lead to a rollover or accident Avoid jumping the vehicle as injury loss of control and damage to the vehicle 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 o...

Page 91: ...91 could occur ...

Page 92: ...y 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 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 ...

Page 93: ... 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 have the room or back up until you find a less difficult path WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or a c...

Page 94: ...p your vehicle in the safest and most efficient condition possible Safety is an obligation of the vehicle inspection adjustment and lubrication are explained in the following pages WARNING POTENTIAL HAZARD Servicing an engine while it is running WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body causing injury Electrical components can cause shocks or can start fires ...

Page 95: ...95 HOW TO AVOID THE HAZARD Turn off the engine when performing maintenance unless otherwise specified Have an dealer perform service if you are not familiar with vehicle service ...

Page 96: ...hicles 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 a dealer as they require special tools data and technical skills ...

Page 97: ...ndition Adjust gap and clean Air filter elements engine and air intake duct Clean Replace if necessary Every 20 40 hours More often in wet or dusty areas Crankcase breather system Check breather hose for cracks or damage Replace if necessary Exhaust system Check for leakage Tighten if necessary Replace gasket s if necessary Spark arrester Clean Fuel line Check fuel hose for cracks or damage Replac...

Page 98: ...o the limit Rear brake Check operation brake pad wear fluid leakage Correct if necessary Replace pads if worn to the limit Accelerator pedal Check operation and free play Wheels Check balance damage runout Repair if necessary Wheel bearings Check bearing assemblies for looseness damage Replace if damaged Front and rear Suspension Check operation and for leakage Correct if necessary Steering system...

Page 99: ...asteners Correct if necessary NOTE Recommended brake fluid DOT4 Brake fluid replacement Replace the brake hoses every four years or if cracked or damaged When disassembling the master cylinder or caliper replace the brake fluid Normally check the brake fluid level and add fluid as required On the inner parts of the master cylinder and caliper replace the oil seals every two years ...

Page 100: ...100 ...

Page 101: ...ng 1 Park the UTV on level ground 2 Place an oil drain pan under the oil drain plug 1 3 Remove the oil filler cap 2 and the drain plug 1 oil drain plug 2 oil filler cap Gearbox Oil Level The oil should be level with the Type Hypoid gear oil Viscosity weight SAE 85w 90 Suggested oil Shaft drive oil of original manufacturer or equivalent ...

Page 102: ... gearbox oil level flows through oil level hole Rear knuckle upper and lower pivot lubrication Lubricate the knuckle upper and lower pivots with a grease gun Recommended lubricant Lithium soap based grease Steering shaft lubrication Lubricate the pivot points ...

Page 103: ...ace a suitable stand under the frame 3 Remove the nuts from the wheel 4 Remove the wheel 1 Nut x4 Wheel installation 1 Install the wheel and the nuts NOTE The arrow mark on the tire must point toward the rotating direction of the wheel Tapered nuts are used for both the front and rear wheels Install the nut with its tapered side towards ...

Page 104: ...Tighten the wheel nuts to the specified torque Wheel nut to Rear rque Front Rear 64 Nm 6 4 kgf m 47 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 ...

Page 105: ...es 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 a...

Page 106: ...e and damage may result 2 Always make sure the connections are correct when putting the battery back in the vehicle WARNING Do not connect the negative lead of the jumper cable to the negative terminal of the battery in the vehicle Be especially careful not to touch the positive lead of the jumper cable to the negative lead reverse the polarity of the jumper cables when connecting to the batteries...

Page 107: ...her possible cause of the problem Replace any blown fuses and check component operation 1 Blown fuse Fuse replacement The main fuse and the fuse boa are located under the hood If a fuse is blown turn off the main switch and install a new fuse of the specified amperage If a fuse is blown replace it as follows 1 Remove the battery compartment cover by lifting it up and pulling it out 2 Turn the key ...

Page 108: ...blem in the fuel compression or ignition systems can cause poor starting and loss of power The troubleshooting chart describes a quick easy procedure for making check If your vehicle requires any repair take it to dealer The skilled technicians at dealership have the tools experience and know how to properly service your vehicle Use only genuine parts on your vehicle Imitation parts may look like ...

Page 109: ... an open flame WHAT CAN HAPPEN Fuel can ignite or explode causing severe injury or property damage HOW TO AVOID THE HAZARD Do not smoke when checking the fuel system Make sure there are no open flames or sparks in the area including pilot lights from water heaters or furnaces ...

Page 110: ...t any protective measure To Avoid the injury and engine damage should take some proective measures when making assembly or using the engine ratation parts No maintenance or use the engine in a closed room No repair the engine in the roadside it could cause a fair Do not make modification on the engine or its parts it will resault in the human injury engine damage and warranty terminated exhaust ga...

Page 111: ... the cooling pipe and remove the air from the cooling system otherwise it will cause the engine overheated and high pressure of cooling system Use 4 stroke mineral based engine oil that meets or exceeds the requirements for API service classification SM SL or SJ Always check the API service label certification on the oil container it must contain at least one of the above standards Oil Viscosity S...

Page 112: ... Check level frequently and refill if necessary Do not overfill Operating the engine with an improper level may severely damage engine Wipe off any spillage With vehicle on a level surface and engine cold not running check the oil level as follows 1 Unscrew dipstick then remove it and wipe clean 2 Reinstall dipstick screw in it completely ...

Page 113: ...al to the upper mark To add oil remove the dipstick Place a funnel into the dipstick tube to avoid spillage Add a small amount of recommended oil and recheck oil level Repeat the above procedures until oil level reaches the dipstick s upper mark Do not overfill Properly tighten dipstick Oil Change ...

Page 114: ...tential burns do not remove the engine drain plug or the filter cover if the engine is hot Wait until engine oil is warm Ensure vehicle is on a level surface Remove dipstick Clean the oil drain plug area Place a drain pan under the oil drain plug area Unscrew oil drain plug TYPICAL 1 Oil drain plug Allow enough time for oil to flow out of oil filter Unscrew the oil filter cover ...

Page 115: ...t area on engine and oil drain plug then reinstall plug Refill engine at proper level with the recommended oil Refer to SPECIFICATIONS for capacity Start engine and let idle for a few minutes Ensure oil filter area and oil drain plug areas are not leaking Stop engine Wait a while to allow oil to flow down to crankcase the n check oil level Refill as necessa ry Dispose of oil as per your local envi...

Page 116: ...lant reservoir With vehicle on a level surface liquid should be between MIN and MAX level marks of coolant reservoir NOTE When checking level at temperature lower than 20 it may be lightly lower than MIN mark Add coolant up to MAX mark if required Use a funnel to avoid spillage Do not overfill Properly reinstall and tighten filler cap and reinstall access panel If the coolant is added in the coola...

Page 117: ...olant Replacement WARNING In order to avoid potential burns do not remove the radiator cap or loosen the coolant drain plug if the the engine is hot Open the front access panel and remove the radiator cap Unscrew the coolant drain plug and drain the coolant into a suitable container 1 Coolant drain plug NOTE Do not unscrew the coolant drain plug completely Unscrew the bleeding screw on the top of ...

Page 118: ...level in the coolant reservoir and refill if necessary Run engine at idle with the radiator cap off Slowly add coolant if necessary As this point wait until engine reaches normal operating temperature Depress the throttle level two or three times then add coolant if required Install radiator cap Inspect all connections for leaks and check coolant level in the reservoir Air Filter Removal CAUTION n...

Page 119: ...aks clean inside the air filter housing Rinse the filter with warm water until all cleaning solution disappears Then let the filter dry completely Installation Properly reinstall removed parts in the everse order of their removal Drive Belt See and authorized ODES dealer to check the width and the condition of drive belt CVT Cover Drain Screw Any time you suspect that water has entered the CVT cov...

Page 120: ... hot Make sure that there are no combustible materials in the area Wear eye protection and gloves Never stand behind the vehicle while purging exhaust system Respect all applicable laws and regulations Select a well ventilated area and make sure the muffler is cool Place transmission on PARK position Remove the cleanout plug of the muffler Block the end of the muffler with a shop rag and start eng...

Page 121: ...er clean radiator with your hands when it is hot Let the radiator cool down before cleaning CAUTION Be careful not to damage the radiating fins when cleaning Do not use any object tool that could damage the parts to allow efficient cooling When hosing use low pressure only never use a high pressure washer See an authorized ODES dealer to check the performance of the cooling system Gearbox Oil Reco...

Page 122: ...level with the bottom of the oil level bole Refill as required until gearbox oil level flows through oil level hole Gearbox Oil Change Place the vehicle on a level surface Clean drain plug area and oil level plug then remove the gearbox drain plug NOTE to completely drain the gearbox place a jack under the left footrest and tilt the vehicle toward the right side When the gearbox is empty install t...

Page 123: ...x with other types of oil The oil should be level with the bottom of the oil level hole Refill as required through the breathe pipe until gearbox oil level flows through oil level hole 1 breathe pipe Reinstall oil level plug ...

Page 124: ...uel Restart the engine No compression There is compression Compression normal Wipe clean with dry cloth Attach spark plug cap and ground to chassis Wet Dry Use the electric starter Spark is weak Spark is good No spark Ignition system is normal Adjust the spark plug gap or replace the spark plug Ask an dealer to inspect Ask an dealer to inspect Ask an dealer to inspect Check the connections rechatg...

Page 125: ...radiator still hot WHAT CAN HAPPEN You can be burned by hot fluid and steam blown out under pressure HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap Always use a thick rag over the cap Allow any remaining pressure to escape before completely removing the cap ...

Page 126: ...126 NOTE If it is difficult to get the recommended coolant tap water can be temporarily used provided that it is changed to the recommended coolant as soon as possible ...

Page 127: ...127 MAINTENANCE CHART The maintenance is very important if you are not familiar with safe service practices and adjustment procedures see your authorized dealer ...

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Page 134: ...he 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 CAUTION Excessive water pressure may cause water seepage and deterioration of wheel bearings brakes transmission seals and electri...

Page 135: ...an the seats with a vinyl upholstery cleaner to keep the cover pliable and glossy 7 Automotive type wax may be applied to all painted and chrome plated surfaces Avoid combination cleaner waxes Many contain abrasives which may scratch the paint or protective finish When finished start the engine and let it idle for several minutes WARNING POTENTIAL HAZARD Operation with wet brakes after washing WHA...

Page 136: ...l the fuel tank with fresh fuel and add the specified amount of Fuel Stabilizer and Conditioner or equivalent product Operate treated fuel through the fuel system Specified amount 1 oz of stabilizer to each gallon of fuel or 7 5 cc of stabilizer to each liter of fuel NOTE Use of fuel stabilizer and conditioner eliminates the need to drain the fuel system Consult an dealer if the fuel system needs ...

Page 137: ...et to prevent moisture from entering 6 If storing 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 7 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 30 of move than 30 90 NOTE Make any neces...

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Page 139: ... 74 8 in 320 mm 12 6 in 4500mm 153 5 in 3500 mm 137 8 in 1480 mm 58 3 in 1970mm 77 6 in 2580 mm 101 6 in 280 mm 11 0in 5500 mm 216 5 in Basic weight With oil and full fuel tank 540 0 kg 1 190 lb 640kg 1 410 lb Engine Engine type Displacement Bore stroke Compression ratio Starting system Double V cylinder four stroke water cooled eight valves EFI 800 ml 91 61 5 mm 3 58 2 42 in 10 3 1 Electric start...

Page 140: ...r higher 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 0 10 30 50 70 90 110 130 F 20 10 0 10 20 30 40 50 C LUBE 4 20W40 or SAE 20W40 LUBE 4 10W30 or SAE 10W30 S...

Page 141: ... API GL 4 Hypoid gear oil 0 25 L 0 22 Imp qt 0 26 US qt Differential gear case oil Type Quantity SAE80 API GL 4 Hypoid gear oil 0 32 L 0 28 Imp qt 0 34 US qt Radiator capacity including all routes 2 50 L 2 20 Imp qt 2 64 US qt Fuel Type Fuel tank capacity UNLEADED GASOLINE ONLY 27 0 L 5 9 lmp gal 7 14 US gal Spark plug Type manufacturer Spark plug gap DCPR7E NGK 0 7 0 8 mm 0 029 0 031 in Transmiss...

Page 142: ...Shaft drive reduction ratio 3 667 Periodic oil change 0 4L 0 35 Imp qt 0 42 US qt Model APU08E APU08EL Tire Type Size front rear Tubeless 25 8 12NHS 25 10 12NHS Brakes System Type front Rear Operation Front and rear unified Dual disc brake Dual disc brake Foot operation Suspension Front suspension Rear suspension Double wishbone Double wishbone Shock absorber ...

Page 143: ...ng oil damper Electrical Ignition system Generator system Battery type Battery capacity ECU A C magneto Colloid free maintenance battery 12VDC 34Ah Model APU08E APU08EL Headlight type Type Bulb voltage wattage quantity Headlight Tail brake light Krypton bulb 12V35W 2 12V5W 21W 2 ...

Page 144: ...ne Family DUSTX 800LZP Importer U STORM POWER CORPORATION Manufacturer ZHEJIANG APPLESTONE VEHICLE CO LTD Model Numbers APU08E APU08EL AP08ATV AP08GK BMS800 Emission Related Parts List Part Nomenclature Part Manufacturer Name Part Number ...

Page 145: ...JIANG CFMOTO POWERCO LTD 28188405 Spark Plugs NGK SPARK PLUG SHANGHAI CO LTD DCPR7E Fuel Tank ZHEJIANG APPLESTONE VEHICLE CO LTD APSD Fuel Tank Cap Cover RUIAN CHUANLONG VEHICLE PARTS CO LTD LZ111 110300 Air Cleaner ZHEJIANG CFMOTO POWERCO LTD 291 12 8 fuel line XIAMEN JINBEIDE RUBBER SCIENCE TECHNOLOGY CO LTD EPA XJR A15 AAA 2 THE SKETCH MAP OF CRANKCASE WASTE RECYCLING ...

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Page 147: ...or company vehicle which ever comes first and continues for 60 months after that date or 10 000 which ever comes first provided there has been no abuse neglector improper maintenance of your vehicle Where a warrantable condition exists the Distributor will repair your vehicle at no cost to you including diagnosis parts and labor If an emission related part on your vehicle is defective the part wil...

Page 148: ...our vehicle You may not be denied a warranty claim solely because of your failure to ensure the performance of all scheduled maintenance or lack of maintenance records or receipts You are responsible for presenting your vehicle to an authorized dealer as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days As the vehicle owner you s...

Page 149: ...ed so as to conform at the time of initial retail purchase with all applicable regulations of the United States Environmental Protection Agency and the California Air Resources Board and is free from defects in material and workmanship which cause such vehicle to fail to confirm with applicable regulations of the United States Environmental Protection Agency or the California Air Resources Board f...

Page 150: ...cluded may be hoses connectors and other emission related assemblies Replacing or repairing other components including parts labor and other costs not covered by this emission control system warranty or the standard warranty is the responsibility of the owner Coverage of repairs under this warranty applies only when repairs are completed at an authorized dealer or repair facility The Distributor w...

Page 151: ...e denied If an emergency situation exists when a warranted part or a dealer is not reasonably available to the owner repairs may be performed at any available service establishment or by the owner using any replacement part The Distributor shall reimburse the owner for the expenses including diagnostic charges not to exceed the Distributor s suggested retail price for all warranted parts replaced ...

Page 152: ...NS This warranty does not cover the following Failures or malfunctions of the emission control systems caused by abuse alteration accident misuse the use of leaded gasoline Replacement of expendable maintenance items unless they are original equipment defective in material or workmanship under normal use and the first required replacement interval for the item has not been reached Expendable maint...

Page 153: ...Any vehicle equipped with an odometer or hour meter where the reading is altered so that actual mileage cannot be readily determined Repairs or replacements as a result of Accident Misuse Use of replacement parts or accessories not conforming to the original specifications which adversely affect performance Physical damages corrosions or defects caused by fire explosions or similar ...

Page 154: ...istributor under this Emission Control System Warranty is limited solely to the remedying of defects in material workmanship by an authorized dealer at its place of business during customary business hours This warranty does not cover in convenience or loss of use of the vehicle or transportation of the vehicle to from the authorized dealer The Distributor is not liable to any person for incidenta...

Page 155: ...xpress emission control system warranty terms stated in this warranty The foregoing statements of warranty are exclusive and in lieu of all other remedies All express warranties not stated in this warranty are disclaimed Some states do not allow limitations on how long an implied warranty lasts so the above limitations may not apply if it is inconsistent with the controlling state law No dealer is...

Page 156: ...ontact 3500 South DuPont Highway in the City of Dover County of Kent DE 19901 855 717 7416 or the California Air Resources Board 9528 Telstar Avenue El Monte CA 91731 for California registered vehicles only ...

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BMS APU08E, Owner'S Manual, Page: 124 / 158

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