BRISTERS CHUCK WAGON Operator'S Manual Download Page 1

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Brister’s Utility Vehicles

2 Wheel & 4 Wheel Drive Models

Operator’s Manual

January 1, 2007

Summary of Contents for CHUCK WAGON

Page 1: ...Brister s Utility Vehicles 2 Wheel 4 Wheel Drive Models Operator s Manual Copyright January 1 2007 ...

Page 2: ...ge 13 Seat Base page 13 Section 4 Operating Instructions page 14 Section 5 Maintenance pages 15 22 Fuel Valve Lever page 15 Air Cleaner Page 16 Engine Oil page 17 Transaxle Oil page 18 Drive Belt page 19 Section Troubleshooting pages 20 28 6 Troubleshooting Chart page 26 ection 7 Parts Diagrams pages 29 64 S Wiring Diagram page 30 11hp 2 wheel drive pages 31 42 265cc 2 wheel drive pages 43 53 13hp...

Page 3: ...omplete control Only p you can prevent an accident from happening Using This Manual Prior to any vehicle operation it is absolutely essenti that you read and compreh m for your safety After reviewing this manual store it in dry and easily accessible place for future reference you with safety assembly operation adjustments troubleshooting and ma and follow your au Brister s Design Manufacturing Co ...

Page 4: ...o ATV Like an ATV the Brister Utility Vehicle has a short wheelbase narrow stance and high center clearance a which provide for narrow and difficult trail access This combination of short wheelbase e to mid sized pickups for t The Brister Utility Vehicle s ground compaction and is very gentle on the ground and surrounding vegetation The highly energized four wheeled independent suspension system p...

Page 5: ...Passenger and any Bystanders Close adult supervision is required at all times Pay close attention to all Caution and Warning labels Located on the Utility Vehicle IMPORTANT When transporting any Brister Utility Vehicle with an installed windshield or Color matched top DO NOT reach high speeds Assumption Of Risk The owner or operator assumes all the risks incident to or arising out of the operation...

Page 6: ...Section 2 Safety It is very important to read understand and follow all instructions and warnings located on the decals on your rister Utility Vehicle B 6 ...

Page 7: ... exhaust pipe and or muffler while th Some conditions may warrant extra safety gear to be orn such as safety helmets and or goggles w Keep hands arms feet and all bodily a ppendages d tree limbs and brush ill f of control may result evice to e bject causing serious injury ull gently Always stay clear of the go nd ever make turns at full speed Reduce peed when turning empty and reduce speed even sa...

Page 8: ...r other stunts drive recklessly Always operate your vehicle at a s speed that will allow you to maintain control engine to exceed 25 MPH vehicle speed Never modify any parts on the vehicle without authorization Unauthorized modifications will void warranty to all parts di th Always make sure the vehicle pathway is clear o objects when backing up Know location of a Take extra precautions when rear ...

Page 9: ... filled in and check list checke off or initialed by individuals p D form seller s signature custome signing dates are also required Below is a list of the information that q ompleted and checked off c V Model No _______ __ Date ___________ al No ___________ Seri Engine Serial No ealer Service and Inspection List charged ts nuts are tightened to 90 l at the dipstick Add SAE ark on the dipstick nd ...

Page 10: ...eviewed and understood warranty policy ies __ Check steering response There should be no free play __ Customer has inspected the vehicle and it meets customer satisfaction __ Check forward neutral and reverse shifting __ Customer understands the importance of following the owner s manual instructions re __ Chec a _ __ Make sure the suspen s IMPORTANT NOTICE __ Make su WHEN TRANSPORTING ANY BRISTER...

Page 11: ...Item 1 8 black screw steering cap 3 x 1 Hex head bolts 7 nylock nuts 4 x carriage bolts 4 flat washers 8 5 16 x 2 socket head bolts 12 5 16 curved washers 10 5 16 nylock nuts 4 5 16 x 2 hex head bolts 2 5 16 center lock nuts Qty Item 2 5 8 x 4 Hex bolt 2 5 8 nylock nuts 1 set of keys 1 Steering wheel with cap 1 Bumper 2 Rear fenders 2 Rear frame stubs 1 Seat back 1 Cage 1 Cargo Bed with tailgate 1...

Page 12: ...the bolt should be on the outside of the vehicle Put a curved washer on the threaded end of the bolt Place a 5 16 nylock nut on the bolts Tighten all 6 nuts including step 3 Bumper Installation 1 Align the holes in the front bumper with the mounting holes in the front frame tubes Insert the four 5 16 x 2 bolts through the bumper bracket and then into the frame tubes Put a curved washer on the thre...

Page 13: ...ment slot shown in upper right photo 6 Close the bed and position the latch pin bolt so to prevent rattles Tighten the latch pin that it is at the bottom of the latch slot 7 Fenders installation if Equipped no fenders on TW265 Tilt the cargo bed up Line up the holes in the rear fenders with the square holes in the bed The raised rectangular surface on the fender should be completely hidden under t...

Page 14: ...onsole located between the Driving is as pull rope s st in case y ju the battery down The drive system means there i into either forward or reverse when the stopped and press the throttle pedal to while the vehicle is moving rak B pedal that is located on the floorboard left of the accelerator A lever action parking brake control is mounted o operator and passenger seats Depress the button on the ...

Page 15: ...ng more than 10 ethanol because the damaged Do NOT mix oil with gasoline Using a fuel stabilizer conditioner in the vehicle can provide benefits such as Keeps gasoline fresh during storage of 90 days or less For longer storage drain the fuel tank Cleans the engine during operation Eliminates gum like A s directions for be perator s man fuel tank Checkin Engine Maintenance General Information Detai...

Page 16: ...elements to make sure they en damaged during cleaning Never run an w le fi B have not be engine without the filters installed Figure 5 2 Spark Plugs HONDA NGK BPR6ES CHAMPION RN9YC UTOLITE 4263 63 UBARU A DENSO W20EPR U S RLH6C NGK BR6HS HAMPION C Air Filter Elements Replacement Parts Description Part No Honda Paper Filter Element 17210 ZE3 000 010 e monthly for cracks ge Replace immediately if an...

Page 17: ... level surface set park brake turn off ignition switch and remove switch key tch and then reinstall and tighten drain plug securely at is Running engine low on oil can cause ine damage and void engine warranty Overf e Oil Fill and Drain Locations er to Figure 5 4 E SEAT and plastic tray if equipped FOR Y ACCESS Filler c Drain plug location At rear end of engine Type of Lubrication SAE 30 with API ...

Page 18: ...on SAE 30W oil xle Lubrication Capacity 20 oz xle Oil Maintenance Schedule eck transaxle housing for damage and possible oil after each use transaxle oil leve rs hichever comes first can be a a er or similar object insert into fille es the bottom of gear case Remov driver il visib o w Transaxle Oil Change Refer to Figure 5 5B Warm oil drains quickly and completely Therefore drain used transaxle oi...

Page 19: ...gnition switch and remove switch key 2 Remove the upper belt covers It is not tom cover own in ark vehicle on a level surface set park necessary to remove the bot 3 Walk the belt off of the rear pulley as sh Figure 5 6 Figure 5 6 4 Install the new belt on the front pulley first and walk it onto the rear pulley 5 Reinstall the belt guards Figure 5 7 rds may void your warranty Attention Failure to r...

Page 20: ...of the park plug hole 7 roperly replace the spark plug back into the r head move the vehicle away from any pilled fuel If there is fuel on the vehicle itself performing the activity below Gasoline is EXTREMELY FLAMABLE 1 Move the vehicle to a well ventilated area awa from sparks or flame 2 Pa turn off ignition switch and remove switch key 3 Next remove the wire connected to the spar plug And remov...

Page 21: ...rs the addi ration and maintenance of th atures 13 hp 390cc Honda engine Electric 4x4 selection Auto Locking front differential Manual locking rear differential 4 wheel hydraulic brakes o Front disk o Rear drum Long travel strut front suspension O F T differential lo d d b m N s To switch to four wheel drive the front wheels are engaged simply by flipping the dashboard switch to 4WD In 4WD mode po...

Page 22: ... s part 20848 note do not use any other type of oil in this system or the 4WD will not 3 Be sure to clean off any debris on the dr operate properly mble the oil fill plug into the gearcase 6 Reassemble the and torque to 10 1 Locate set screw on front gear box 2 Turn clockwise until you feel re 3 Turn back counter clockwise turn ansaxle Gear Box It is recommended that e changed once a year or after...

Page 23: ...ehicle to not shift properly and it may affect starting since the ehicle must go to neutral to start Before attempting to adjust the cables there are several steps at can be taken to insure the cables are operating properly Lubricate the cables Behind the dash board there are two cables attached to the gear this several times as the oil soaks into the o the next step Remove the center console with...

Page 24: ... to roll the rear wheels a little until it clicks in 7 Pull the slack out of the rear most cable under the dash but do not stretch the spring and tighten the adjuster nuts If you have tried all of this and it is still not operating correctly you may need new cables and a shifter update kit Please call Brister s Customer Service at 1 866 646 5278 Have your serial number handy when you call icles wi...

Page 25: ...eutral 4 Make sure the transmission is in neutral You can check by turning the key to Start The engine will only turn over if the transmission is in neutral 5 Pull the slack out of both cables but do not stretch the springs and tighten the adjuster nuts If you have tried all of this and it is still not operating correctly you may need new cables Please call Brister s Customer Service at 1 866 646 ...

Page 26: ...Section 6 Troubleshooting 26 ...

Page 27: ...ed excessive idling or running unit with choke engaged can cause plugs to foul or engine oil may be low Possible Remedy Make sure fuel valve is on Replace spark plug and try to restart Check oil level with unit on level ground Adding more oil or making sure the oil is completely full can help to not alert the low oil sensor Engine will not start and does not turn over with electric starter Probabl...

Page 28: ... units Clean the rotors with brake cleaner and test A stiff pedal is normal for our 4x4 unit A stiff pedal means good pressure in the brake lines Check brake pads and front calipers 2wd units The 2wd units have an automatic brake adjuste Put the unit in reverse back up at low speed and step hard on the brakes This should give enough br e adjustment If you continue to have problems discontinue use ...

Page 29: ...els Wiring Diagram All Mod 29 ...

Page 30: ...Terminal Block Wiring 30 ...

Page 31: ...Section 7 Parts Brister s 2 wheel drive Utility Vehicle Parts Breakdown 31 ...

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Page 35: ...ck 1 50168 5 16 x 2 1 4 USS Socket Head bolt 2 50007 nut 5 16 nylock 2 50702 bent washer 5 16 2 6 45404 A arm upper CW black left or right 2 51100 suspension bushings 4 ea 50262 bolt 5 8 x 9 1 ea 50254 Bolt 5 8 x 3 5 bolt 1 ea 50015 Nut 5 8 nylock 2 ea 7 45405 A arm Lower CW black left or right 2 51100 suspension bushings 4 ea 50262 bolt 5 8 x 9 1 ea 50254 Bolt 5 8 x 3 5 bolt 1 ea 50015 Nut 5 8 ny...

Page 36: ... 10593 Rack Pinion Boots 2 10590 Rack Pinion Rod 2 50171 Bolt 5 16 x 3 USS 4 50005 Nut 5 16 keps 4 50063 Nut SAE nylock 2 21 10524 Rod end 2 50078 Nut SAE jam 2 22 10522 Steering Shaft w u joints 1 50402 Bolt 10mm x 30mm 1 50066 Nut 10mm Tri Lock Jam 1 50403 Bolt 8mm x 30mm 1 50780 Lock washer 8mm 1 23 ck 45422 Steering Stub Shaft Assembly CW Bla 1 24 45400 Steering support CW black 1 51100 suspen...

Page 37: ... 8 x 1 2 50010 nut 3 8 ny lock 2 37 embly black built after 2 1 05 11085 Shifter control ass 1 11083 Knob 1 11082 Cable shifter built after 2 1 05 2 11080 Shifter Cable and Shifter Control built before 2 1 05 1 50053 nut 10 24 Keps nut 2 50616 screw 10 24 X Pan Head Phillips 2 50770 Washer 10 flat 2 38 l assembly with cable and knob 11086 Differential Contro 1 11083 Knob 11090 Differential Control...

Page 38: ...od plastic Camo 50620 X 1 Pan Head Phillips Machine screw 2 50621 X 2 Pan Head Phillips Machine screw 2 50717 SAE Flat washer 8 50001 nut nylock 4 50846 Clamp Tube vinyl coated 1 1 4 2 51 18309 Glove Box 1 50624 Screw 10 x hex black 5 52 18308 Steering Cover 1 18317 Steering Cover Bottom 1 50624 Screw 10 x hex black 1 53 18306 Center Console 1 50624 Screw 10 x hex black 14 54 18316 Access Cover Ce...

Page 39: ...seat bar CW 17 black 2 50609 14 x Pan Head Screw 6 65 10705 Seat Belt 2pt 2 50025 7 16 Nylock 4 70 45426 Cargo Bed Green 1 45420 Cargo Bed Red 1 45424 Cargo Bed Black 1 18352 Camo Bed Panel Left 1 18353 Camo Bed Panel Right 1 18354 Camo Bed Panel Tail Gate 1 50255 5 8 x 4 bolt Zinc plate 2 50015 5 8 nylock 2 18402 Bed Rubber Plug 2 73 50208 Bed latch bolt 3 8 x 2 1 2 1 50013 nut 3 8 keps 2 50740 w...

Page 40: ... 18023 Throttle Guard Laser 1 50086 1 4 20 x 1 1 4 Hex Hd Bolt 3 50082 1 4 20 x 2 1 4 Hex Hd Bolt 1 50000 4 Keps Nut 1 5 50715 1 4 Flatwasher USS 8 107 20648 TC Driver Comet 500 used before Serial Number 25658 1 20665 TC Driver CVTECH used fter Serial Number 25658 1 a 108 20649 TC Driven Comet 500 us efore Serial Number 25658 1 ed b 20666 TC Driven CVTECH used fter Serial Number 25658 1 a 109 1116...

Page 41: ...as 4 her USS 125 50730 3 4 Spacer W 6 asher 126 50280 3 4 x 2 5 SA 3 E bolt 127 500 3 20 3 4 SAE nylock 128 180 1 12 shifter lever CW black used before Serial Number 15244 500 1 84 1 4 20 x 3 4 Hex Hd Bolt 2 50000 1 4 Keps Nut 129 1 18011 shifter cable mount CW black used after Serial Number 15245 1 50084 1 4 20 x 3 4 Hex Hd Bolt 1 50000 1 4 Keps Nut 2 50715 1 4 Flatwasher USS 130 11103 Brake Cabl...

Page 42: ...1 50000 1 4 Keps Nut 2 50159 5 16 18 x 1 1 2 Hex Hd Bolt 1 50005 5 16 Keps Nut 2 133 11804 Spring 80704 Black painted 1 135 11080 Shifter Cable and Shifter Control used before Serial Number 15244 1 11082 Cable shifter used after Serial Number 15245 2 136 65500 fuel hose 3 16 dia 24 1 137 50849 hose clamps small 3 138 18313 Belt Guard Plastic UTV Front 1 139 18314 Belt Guard Plastic UTV Rear 1 140 ...

Page 43: ...Brister 265cc Utility Vehicle Parts Breakdown 43 ...

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Page 47: ...702 bent washer 5 16 4 5 45411 brshgrd seat back CW black 1 50168 5 16 x 2 1 4 USS Socket Head bolt 2 50007 nut 5 16 nylock 2 50702 bent washer 5 16 2 6 42045 A arm upper 265 black left or right 2 51100 suspension bushings 4 ea 50262 bolt 5 8 x 9 1 ea 50254 Bolt 5 8 x 3 5 bolt 1 ea 50015 Nut 5 8 nylock 2 ea 7 42046 A arm Lower 265 black left or right 2 51100 suspension bushings 4 ea 50262 bolt 5 8...

Page 48: ...ck Pinion Boots 2 Rack Pinion Rod 265 2 50171 Bolt 5 16 x 3 USS 4 50005 Nut 5 16 keps 4 50063 Nut SAE nylock 2 21 10524 Rod end 2 50078 Nut SAE jam 2 22 10522 Steering Shaft w u joints 1 50402 Bolt 10mm x 30mm 1 50066 Nut 10mm Tri Lock Jam 1 50403 Bolt 8mm x 30mm 1 50780 Lock washer 8mm 1 23 45422 Steering Stub Shaft Assembly CW Black 1 24 45400 Steering support CW black 1 51100 suspension bushing...

Page 49: ...5 16 x NC 4 50005 Nut 5 16 keps 4 50701 Washer 5 16 flat 4 36 CW 2 black 45415 Brake equalizer 1 50215 bolt 3 8 x 1 2 50010 nut 3 8 ny lock 2 37 mbly black built after 2 1 05 11085 Shifter control asse 1 11083 Knob 1 11082 Cable shifter built after 2 1 05 2 11080 Shifter Cable and Shifter Control built before 2 1 05 1 50053 ut 10 24 Keps nut n 2 50616 crew 10 24 X Pan Head Phillips s 2 50770 Washe...

Page 50: ...TW265 1 18387 TW265 grill 1 18389 TW265 headlight bucket left 1 18388 TW265 headlight bucket right 1 50620 X 1 Pan Head Phillips Machine screw 2 50621 X 2 Pan Head Phillips Machine screw 2 50717 SAE Flat washer 8 50001 nut nylock 4 50846 Clamp Tube vinyl coated 1 1 4 2 51 18309 Glove Box 1 50624 Screw 10 x hex black 5 52 18308 Steering Cover 1 18317 Steering Cover Bottom 1 50624 Screw 10 x hex bla...

Page 51: ...609 14 x Pan Head Screw 6 65 10705 Seat Belt 2pt 2 50025 7 16 Nylock 4 70a 45420 Cargo Bed Red CW265 1 70b 45434 Flat Cargo Bed Black TW265 1 50255 5 8 x 4 bolt Zinc plate 2 50015 5 8 nylock 2 18402 Bed Rubber Plug 2 73 50208 Bed latch bolt 3 8 x 2 1 2 1 50013 ut 3 8 keps n 2 50740 asher 3 8 flat w 2 75 45421 Tail gate Red 1 50152 bolt 5 16 x 1 2 50701 washer 5 16 sae 4 50007 nut 5 16 nylock 2 702...

Page 52: ...113 50793 7 16 Lock Washer 1 114 50302 7 16 x 2 SAE Bolt 1 115 20693 Belt Com 1 et 300668 116 50239 1 2 x 2 SA 1 E 117 50722 1 2 Lock 1 Washer 50721 1 2 Uss F 1 lat Washer 118 1019 1 1 Key stock 3 16 119 1806 1 1 Tension Mount Engine 265 Black 5015 2 7 5 16x 3 4 Bolt Hex Hd NF 507 2 03 5 16 Lock Washer 507 2 04 5 16 Flatwasher 120 702 5 50 Rubber Feet Isolators 500 10 10 3 8 Nylock Nut 5 50740 3 8...

Page 53: ... 4 Flatwasher USS 2 130 11103 Brake Cables 2 50150 5 16 18 x 1 Hex Hd Bolt 2 50007 5 16 Nylock Nut 2 131 11013 Throttle Cable 265 1 135 11082 Cable shifter 2 138 18313 Belt Guard Plastic UTV Fr 1 ont 139 18314 Belt Guard Plastic UTV Re 1 ar 140 18315 Belt Guard Plastic UTV Bottom 1 50624 10 x 3 4 Blunt Point Black 7 50050 10 Speed Nut for Plastic 7 50770 10 Flat washer 7 53 ...

Page 54: ...Brister 4 wheel drive Utility Vehicle Parts Breakdown 54 ...

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Page 58: ... nut 5 16 nylock 2 50702 bent washer 5 16 2 6 43007 A arm 4x4 CW black left or right 2 51100 suspension bushings 2 ea 50266 bolt 5 8 x 9 1 2 1 ea 50015 Nut 5 8 nylock 1 ea 45150 Spacer CW A arm bushing 4x4 7 25001 Strut assembly left 1 25009 Strut assembly right 1 50028 Nut 7 16 NF jam 2 50041 Nut 3 8 NF slotted 2 50801 cotter pin 1 8 x 1 2 7a 25020 Lower ball joint 2 8 25003 strut bearing 2 50163...

Page 59: ...x square head set 2 10184 key 3 16 x 1 3 19 g 17 inch 20804 convoluted tubin 20 10591 Rack pinion with rod ends 4x4 1 10593 Rack Pinion Boots 2 50171 Bolt 5 16 x 3 3 4 USS 4 50005 Nut 5 16 keps 4 21 10594 Rod end 4x4 2 10595 Tie rod 4x4 2 10593 Rack boot 2 22 10592 Steering Shaft w u joints 4x4 1 50402 Bolt 10mm x 30mm 1 50066 Nut 10mm Tri Lock Jam 1 50403 Bolt 8mm x 30mm 1 50780 Lock washer 8mm 1...

Page 60: ... 5 16 x 1 4 50007 nut 5 16 nylock 1 35 nt 11135 Brake hose fro 1 36 11136 Brake hose rear 1 37 11085 Shifter control assembly black 1 11083 Knob 1 11082 Cable shifter 2 50053 nut 10 24 Keps nut 2 50616 screw 10 24 X 3 4 Pan Head phillips 2 50770 Washer 10 flat 2 3 Control Assy 4x4 Diff Control w cable 8 11086 Differential 1 11083 Knob 1 11091 cable diff lock 1 50053 nut 10 24 Keps nut 2 50616 scre...

Page 61: ...t washer 8 50001 nut 1 4 nylock 4 50846 Clamp Tube vinyl coated 1 1 4 2 51 18309 Glove Box 1 50624 hex black Screw 10 x 3 4 5 52 18308 Steering Cover 1 50624 Screw 10 x 3 4 hex black 1 53 18383 Center Console 4x4 1 50624 Screw 10 x 3 4 hex black 14 54 18316 Access Cover Center Console 1 50624 Screw 10 x 3 4 hex black 4 55 rap 4x4 18382 Plastic Seat Bottom w 1 50624 Screw 10 x 3 4 hex black 5 56 18...

Page 62: ... 1 2 1 50013 nut 3 8 keps 2 50740 washer 3 8 flat 2 75 45427 Tail gate green 1 45421 Tail gate Red 1 45425 Tail gate Black 1 50152 bolt 5 16 x 1 2 50701 washer 5 16 sae 4 50007 nut 5 16 nylock 2 70230 rubber bump stops 4 78 50815 1 4 Lynch Pin tailgate latch 2 80 18312 Roof green 1 18301 Roof Red 1 18351 Roof Camo 1 18391 Roof Top Vinyl Trim 1 18390 Roof Hardware bolt kit 50847 Clamp Tube vinyl co...

Page 63: ... not used with CVTech pulley 1 115 20693 Belt Comet 300668 used before Serial Number 25663 1 20694 Belt CV TECH used after Serial Number 25663 1 116 50239 1 2 x 2 SAE 1 117 50722 1 2 Lock Washer 1 50721 1 2 Uss Flat Washer 1 118 3 16 Key stock 1 119 45431 Tension Mount Engine CW Black 1 50157 5 16x 3 4 Bolt Hex Hd NF 2 50703 5 16 Lock Washer 2 50704 5 16 Flatwasher 2 120 70250 Rubber Feet Isolator...

Page 64: ...ght angle gearbox 1 10184 Key 3 16 x 1 3 151 20852 gearbox coupling 1 152 18042 Gear box bracket torque arm long built before 10 06 1 18083 Gear box bracket short built after 10 06 1 70232 rubber washer built before 10 06 2 50163 bolt 5 16 x 3 4 NC 4 50701 Washer 5 16 flat 6 50703 Washer 5 16 lock 2 50005 Nut 5 16 keps 2 50303 Bolt 7 16 x 1 3 4 built before 10 06 1 50794 Washer 7 16 flat built bef...

Page 65: ...ty does not apply to the engine which is covered by its manufacturer s warranty Please refer to the engine manufactures warranty policy included with your BDM product American Honda Motor Co Inc 770 497 6400 Phone Two Year Limited Engine Warranty Warranty Service To obtain warranty service you must return your BDM product to the local authorized dealer you must inform them of your warranty problem...

Page 66: ... you please call Brister s Design Mfg customer service at 1 866 646 5278 or 985 748 4889 visit our website at www bristers com or contact your place of purchase Mail Customer Support c o Brister s Design Manufacturing Co LLC P O Box 649 Roseland LA 70456 0649 Telephone Customer Support Brister s Design Manufacturing Co LLC 1 866 646 5278 or 985 748 4889 Fax Customer Support Brister s Design Manufa...

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