Bush Hog Trail TH420 Operator'S Manual Download Page 3

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BUSH HOG

Trail Series Utility Vehicles

TABLE OF CONTENTS

SECTION

PAGE

Retail Customer’s Responsibility

Warranty

Dealer Preparation Check List

Safety Alert Symbols

Safety Precautions

I INTRODUCTION AND DESCRIPTION

Introduction

Description

Specifications

II OPERATION

General Safety

Pre-Operation Checklist

Vehicle Break-In Period

Starting The Engine

Driving The Vehicle

Braking

Stopping The Engine

Using The Cargo Box

Load Distribution

Driving Safely

Driving On Slippery Surfaces

Driving Uphill

Sidehilling

Driving Downhill

Driving Through Water

Driving Over Obstacles

Driving In Reverse

Parking On An Incline

Hauling Cargo

Emptying The Cargo Box

Towing Loads

Parking The Vehicle

4-Wheel Drive

Disengaging 4-Wheel Drive

Noise Emission Control System

Spark Arrestor

SECTION

PAGE

III MAINTENANCE

Periodic Maintenance Schedule

Lubrication Recommendations

Engine Oil

Engine Oil Filter Change

Transaxle

Front Differential

Right Angle Drive

Constantly Variable Transmission

Vehicle Immersion

Engine Air Filter

CVT Enclosure Air Filter

Fuel filter

Spark Plugs

Spark Arrestor

Throttle System

Brake Inspection

Parking Brake Adjustment

Steering Wheel Inspection

Seat Belts

Tires

Wheel Lug Nuts

Wheel Installation

Lights

Cleaning Your Vehicle

Storage

Removal From Storage

Battery

Replenishing Battery Fluid

Battery Removal

Battery Installation

Battery Storage

IV ASSEMBLY

Attaching Occupant Protection
Structure

Optional Equipment

Items To Check

Seat Belt Installation

Rubber Bumper Pad Adjustment

Troubleshooting CheckList

Safety Decals

Torque Specifications

Summary of Contents for Trail TH420

Page 1: ...107 10 00 50044549 Trail Series OFF ROAD UTILITY VEHICLES Operator s Manual MODELS TH420 TH440 TH4200 TH4400 ASSEMBLY OPERATION MAINTENANCE BUSH HOG ...

Page 2: ...r we stock genuine Bush Hog parts which are manufactured with the same precision and skill as our orig inal equipment Our trained service personnel are well informed on methods required to service Bush Hog equipment and are ready and able to help you Should you require additional information or assistance please con tact us YOUR AUTHORIZED BUSH HOG DEALER BECAUSE BUSH HOG MAINTAINS AN ONGOING PROG...

Page 3: ...Disengaging 4 Wheel Drive 44 Noise Emission Control System 45 Spark Arrestor 46 SECTION PAGE III MAINTENANCE 46 Periodic Maintenance Schedule 47 Lubrication Recommendations 50 Engine Oil 51 Engine Oil Filter Change 52 Transaxle 52 Front Differential 53 Right Angle Drive 54 Constantly Variable Transmission 55 Vehicle Immersion 56 Engine Air Filter 57 CVT Enclosure Air Filter 57 Fuel filter 58 Spark...

Page 4: ...to have any part s repaired or replaced when continued operation would cause damage or excessive wear to other parts or cause a safety hazard It is the Retail Customer s responsibility to deliver the product to the authorized Bush Hog Dealer from whom he purchased it for service or replacement of defective parts which are covered by warranty Repairs to be sub mitted for warranty consideration must...

Page 5: ...Bush Hog dealer during regular working hours Bush Hog reserves the right to inspect any equipment or parts which are claimed to have been defective in material or workmanship DISCLAIMER OF IMPLIED WARRANTIES CON SEQUENTIAL DAMAGES Bush Hog s obligation under this limited warranty to the extent allowed by law is in lieu of all warranties implied or expressed INCLUDING IMPLIED WARRANTIES OF MER CHAN...

Page 6: ... reliability 5 To normal maintenance service and normal replacement items such as gearbox lubricant or to normal deterioration of such things as belts and exterior finish due to use or exposure 6 To expendable or wear items such as teeth chains sprockets belts springs and any other items that in the company s sole judge ment is a wear item NO EMPLOYEE OR REPRESENTATIVE OF BUSH HOG IS AUTHORIZED TO...

Page 7: ...ers torqued to specifications given in Torque Chart r 8 All decals in place and readable See decal page r 9 Overall condition good i e paint welds r 10 Parking brake checked and adjusted if necessary r 11 Steering checked and adjusted if necessary r 12 Check tire pressure r 13 Operators manual has been delivered to owner and he has been instructed on the safe and proper use of the utility vehicle ...

Page 8: ...ich if not avoided could result in death or serious injury This signal word indicates a poten tially hazardous situation exist which if not avoided may result in minor or moderate injury It may also be used to alert against unsafe practices 6 This Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED This symbol is used to call attention to safety pre cautions that should be fol...

Page 9: ...tructions to operators who cannot read or under stand the instructions Only allow vehicles to be operated by trained persons Allow no persons younger than 16 years old to operate Do not operate under the influence of alcohol or drugs Inspect vehicle for safe operating condition DURING OFF ROAD UTILITY USE Fasten seat belt Use vehicle only for off road operations Avoid sudden starts stops turns or ...

Page 10: ...ippery and uneven terrain AVOID FUEL FIRE AND EXPLOSIONS Stop engine and allow to cool before refueling Do not smoke while refueling Never fill fuel tank indoors Clean up spilled fuel before starting engine Only use approved Underwriter s Laboratory U L or American Society for Testing Material ASTM non metal portable fuel containers Remove fuel containers from vehicle beds or trunks and placing on...

Page 11: ...argo box and all bystanders away from vehicle Do not dump or unload vehicle parked on an incline slopes hills or with rear wheels at an edge of a drop off The cargo box weight may shift and cause the vehicle to tip or rollover Fully lower cargo box before operating vehicle TOWING OPERATIONS Do not exceed vehicle s Gross Vehicle Weight GVW rating This includes vehicle operating weight material load...

Page 12: ...ated SAFETY SURVEY The Controlling Party should conduct an operating area safety survey to identify possible hazards Steep Grade Hazards Restrict vehicle operations to designated pathways in steep grade areas Erect steep grade warning signs State Warning steep grade descend slowly on signs Loose Terrain Hazards Keep vehicle traction steering stability and braking under control by avoiding loose te...

Page 13: ...ator s competency to comply with these practices MAINTENANCE AND INSPECTION PROCEDURES Review and perform vehicle manufacturer s recommended procedures Use a scheduled preventive maintenance lubrication and inspection program Use trained and authorized personnel to maintain repair adjust and inspect vehicles Conduct recommended procedures in a properly ventilated work area Use original vehicle man...

Page 14: ...ing system Electrical system Transmission system Exhaust system Warning system Switches and devices Follow vehicle manufacturer s recommended inspection main tenance procedures Keep vehicle clean to reduce fire hazards and allow ease of vehicle inspection VEHICLE INSTRUCTION AND SAFETY DECALS Keep clean and legible Replace illegible decals VEHICLE MODIFICATION AND ADDITIONS Contact vehicle manufac...

Page 15: ...hill If you lose forward speed Apply the brakes Lock the parking brake after fully stopped If you begin rolling backwards Never apply engine power Apply the brake gradually When fully stopped lock parking brake In the event of an accident have a qualified service dealer check the complete vehicle for possible damage including but not limited to brakes throttle and steering ...

Page 16: ...the vehicle on pavement If you must operate on a paved surface travel slowly and do not make sudden turns or stops POTENTIAL HAZARD Operating this vehicle without proper instruction WHAT CAN HAPPEN Loss of control accident HOW TO AVOID THE HAZARD The risk of an accident is greatly increased if the operator does not know how to operate the vehicle properly in different situa tions and on different ...

Page 17: ...POTENTIAL HAZARD Operating this vehicle after consuming alcohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and perception Could result in an accident HOW TO AVOID THE HAZARD Driving this vehicle requires your full attention DO NOT drink alcohol or use drugs or medications before or while driving They will reduce your...

Page 18: ...OTENTIAL HAZARD Attempting jumps and other stunts WHAT CAN HAPPEN Loss of control accident and or vehicle overturn HOW TO AVOID THE HAZARD Never attempt jumps and other stunts Avoid exhibition driving WARNING POTENTIAL HAZARD Operating on frozen bodies of water WHAT CAN HAPPEN Severe injury or death can result if the vehicle and or the oper ator fall through the ice HOW TO AVOID THE HAZARD Never o...

Page 19: ... procedures and schedules described in the Operator s Manual POTENTIAL HAZARD Failure to use extra caution when operating this vehicle on unfamiliar terrain WHAT CAN HAPPEN Loss of control vehicle overturn HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfa miliar terrain always be alert to changing terrain conditions when operating the vehicle May come upon hidden c...

Page 20: ...cles are recommended he or she may not have the skills abilities or judgement needed to operate the vehicle safely and may be involved in a serious accident POTENTIAL HAZARD Operating this vehicle with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Loss of control accident and or overturn HOW TO AVOID THE HAZARD Always use the size and type of tires specified in the Operat...

Page 21: ...d result in a fire WARNING Gasoline is highly flammable and is explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always stop the engine when refueling Always refuel outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the refueling area or where gasoline is stored Do not over fill the tank Do not fill the tank neck...

Page 22: ...ormation is needed contact your authorized Bush Hog dealer DESCRIPTION Trail Hunter shown on next page 1 Occupant Protection Structure O P S 2 Hand hold 3 Gear Selector 4 Steering wheel 5 Seat 6 Seat Belt 7 Fuel Tank Cap 8 Battery Under Hood 9 Headlights 10 Front Bumper Brush Guard 11 Power Winch Optional 12 Cargo Light Optional 13 Cargo Box 14 Hitch Receiver 15 Winch Wiring Pigtail 16 Cup Holder ...

Page 23: ...1 8 10 11 9 2 6 5 7 27 28 24 22 23 18 17 19 29 4 3 30 31 32 16 25 26 21 20 34 14 15 33 13 12 NOTICE LOCATIONS OF CON TROLS AND FEATURES MAY VARY SLIGHTLY ON DIFFERENT MODELS 21 ...

Page 24: ...DER HOOD AREA WITH CARGO TRAY REMOVED UNDER SEAT AREA Battery Brake Fluid Reservoir Fuses and Relays Grease Fitting Engine Air Intake Engine Oil Filler Cap Engine Oil Dipstick CVT Enclosure Air Cleaner 22 ...

Page 25: ...Assembly Front Strut Assembly Winch Optional CARGO BED RAISED SHOWING ENGINE COMPARTMENT Engine Air Cleaner Housing with Evacuator Valve Transfer Gearbox Trailing Arm Pivot Grease Fitting Grease Fitting For Pillow Block Hidden From View 23 ...

Page 26: ... property damage observe the precautions on page 43 Seat Belts The Bush Hog Trail Series is equipped with lap style seat belts for the operator and passengers 24 WARNING Falling from a moving vehicle could result in serious injury or death Always fasten your seatbelt securely before operating or riding in the vehicle Passengers under five years of age require special restraints which are not avail...

Page 27: ...LWAYS REMOVE THE IGNITION KEY WHEN THE VEHICLE IS NOT IN USE Light Switch Turn the headlights and tailights on by flipping the rocker switch up the ignition switch must be in the ON position Flip the switch down to turn the lights off Cargo Bed Light Switch Optional Flip the rocker switch up to turn on and down to turn off Power Bed Lift Switch Optional Push and hold the spring loaded rocker switc...

Page 28: ...ted under the dash and is rotated back and upward to engage and pushed down and forward to release Make sure the parking brake is working properly before each opera tion Gear Selector The transmission gear selector is located on the console to the right of the steering wheel It has four positions high low neutral and reverse NOTE Low gear is the primary driving range on this vehicle High is intend...

Page 29: ...ical Systems 12 volt DC with 20 amp alternator CHASSIS Suspension Front MacPherson strut single A Arm coil over shock Suspension Rear Independent trailing arm coil over shock Wheel travel Frt Rr 5 7 inches 4 4 inches 5 7 inches 6 0 inches Steering Rack and Pinion Turning Radius 13 ft Front Tires AT 23 x 8 0 12 NHS AT 25 x 10 0 12 NHS Rear Tire AT 23 x 10 0 12 NHS AT 25 x 11 0 12 NHS Brakes 4 wheel...

Page 30: ... Ground Speed 0 25 mph 4WD True On Demand 4 wheel drive switch engage 4wd models only DIMENSIONS Dry Weight 1 270 lbs 1 320 lbs 1 450 lbs 1 500 lbs Wheel Base 72 inches 76 inches Vehicle 1 250 lbs 1 500 lbs Load Capacity Cargo Box 750 lbs 1 000 lbs Load Capacity Towing Capacity 1 500 lbs Fuel Capacity 7 gallons Seating Capacity 2 3 Lights Dual 37 watt halogen headlights tail lights and brake light...

Page 31: ...s 6 Check battery fluid level 7 Check tire pressure Trail Hunter models require 18 psi in all four tires Trail Hand models require 12 psi in all four tires 8 Clean the air intake screen on the engine if necessary 9 Perform any other maintenance as it becomes necessary See Maintenance section VEHICLE BREAK IN PERIOD The break in period for your new Bush Hog Utility Vehicle is defined as the first 2...

Page 32: ...ecome fouled 1 Place the transmission in neutral and lock the parking brake 2 Sit in the driver s seat with the seat belt fastened 3 Turn the ignition key to START 4 If the engine has cooled and does not readily start intermittent use of the choke knob pulled half way out may be necessary 5 If the engine is over choked when warm depress the throttle pedal fully while cranking to aid in starting 6 ...

Page 33: ...erator is released completely and the engine speed drops to near idle the vehicle has no engine braking 1 Release the throttle pedal completely 2 Press on the brake pedal evenly and firmly Stopping The Engine 1 Release the throttle pedal completely 2 Place the transmission selector lever in neutral 3 Apply the parking brake to help prevent the vehicle from rolling 4 Turn the ignition key to the of...

Page 34: ...Models with the electric power lift feature only require pushing the rocker switch on the dash Manual models require pulling the release handle located under the front left corner of the cargo box upward Refer to photograph on next page CAUTION NEVER EXCEED THE LOAD CAPACITY LISTED IN THE SPECIFICATIONS CHART FOR YOUR PARTICULAR VEHI CLE AN OVERLOADED CARGO BOX CAN CAUSE INSTA BILITY DURING OPERAT...

Page 35: ...t the cargo box latch on manual lift models is secure ly latched before loading and operating Unintentional box tilting may result if weight is place in the rear of the box and the latch is not secured WARNING Manual Cargo Box Release Handle Electric Cargo Box Power Lift Actuator 33 NEVER OPERATE THIS VEHICLE WITH THE CARGO BOX IN THE RAISED POSITION THE CARGO BOX COULD CLOSE UNEXPECTEDLY WHILE DR...

Page 36: ...cked surfaces with light loads Driving on Slippery Surfaces When driving on slippery surfaces such as wet trails loose gravel or ice be alert for the possibility of skidding and sliding Under these conditions follow these precautions 1 Slow down when entering slippery areas 2 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 3 Correct a skid ...

Page 37: ...G AND HANDLING ARE GREATLY AFFECTED WHEN OPERATING IN HILLY TERRAIN IMPROPER PROCEDURE COULD CAUSE LOSS OF CONTROL OR OVERTURN AND RESULT IN SERIOUS INJURY OR DEATH AVOID CLIMBING STEEP HILLS 15 MAXIMUM USE EXTREME CAUTION WHEN OPERATING ON HILLS AND FOLLOW PROPER OPERATING PROCEDURES OUTLINED IN THE OPERATOR S MANUAL NEVER CLIMB HILLS WITH EXCESSIVELY SLIPPERY OR LOOSE SURFACES NEVER ACCELERATE S...

Page 38: ... EXTREME CAUTION AVOID OPERATING ON STEEP HILLS 15 MAXIMUM WARNING TRAVELING DOWNHILL IMPROPERLY COULD CAUSE LOSS OF CONTROL OR VEHICLE OVERTURN ALWAYS CHECK TERRAIN CAREFULLY BEFORE DESCENDING A HILL NEVER DESCEND A HILL AT HIGH SPEED EXCESSIVE SPEED MAY RESULT IN LOSS OF VEHICLE CONTROL AND LEAD TO SERIOUS INJURY OR DEATH ALWAYS OPERATE SLOWLY WHEN TRAVELING DOWNHILL AVOID DESCENDING A HILL AT A...

Page 39: ... you per form the services outlined in the Maintenance section on page 47 Give special attention to engine oil transmission oil front and rear gearcases and all grease fittings CAUTION IMMERSION CAN RESULT IN MAJOR DAMAGE IF THE VEHICLE ISN T SERVICED CORRECTLY AND PROMPTLY AFTER IMMERSION ALWAYS TAKE THE VEHICLE FOR YOUR DEALER TO SERVICE DO NOT START THE ENGINE IF IT IS NOT POSSIBLE TO TAKE THE ...

Page 40: ...aveling on Watch for hazards such as logs rocks and low hanging branches WARNING SEVERE INJURY OR DEATH CAN RESULT IF YOUR VEHICLE SUDDENLY COMES IN CONTACT WITH A HIDDEN OBSTACLE NOT ALL OBSTACLES ARE IMMEDIATELY VISIBLE REDUCE SPEED AND TRAV EL WITH CAUTION IN UNFAMILIAR TERRAIN 38 ...

Page 41: ...l 5 Never open the throttle suddenly while backing 6 Always inspect left and right fields of vision before backing WARNING 39 FAILURE TO USE CAUTION WHEN OPERAT ING IN REVERSE CAN RESULT IN SERIOUS INJURY OR DEATH BEFORE SHIFTING INTO REVERSE ALWAYS CHECK FOR OBSTA CLES OR PEOPLE BEHIND THE VEHICLE AND FOLLOW THE REVERSE OPERATION PROCEDURES OUTLINED IN THIS MANUAL ALWAYS BACK SLOWLY ...

Page 42: ...NG 40 A ROLLING VEHICLE CAN CAUSE PROPERTY DAMAGE AND SERIOUS INJURY ALWAYS APPLY THE PARKING BRAKE AFTER STOP PING THE ENGINE ALWAYS BLOCK THE DOWNHILL SIDE OF THE WHEELS IF LEAVING THE VEHICLE ON A HILL OR PARK THE VEHI CLE IN A SIDEHILL POSITION INSTEAD OPERATING THE VEHICLE WHILE THE PARK ING BRAKE IS ENGAGED COULD CAUSE LOSS OF CONTROL AND RESULT IN SERIOUS INJURY OR DEATH ALWAYS DISENGAGE TH...

Page 43: ...O IMPROPERLY CAN ALTER VEHICLE HANDLING AND MAY CAUSE LOSS OF CONTROL OR BRAKE INSTABILITY WHICH CAN RESULT IN SERIOUS INJURY OR DEATH ALWAYS FOLLOW THESE PRE CAUTIONS WHEN HAULING CARGO ALWAYS LOAD THE CARGO BOX WITH THE LOAD AS FAR FORWARD AS POSSIBLE ALWAYS OPERATE THE VEHICLE WITH EXTREME CARE WHEN HAULING OR TOWING LOADS SLOW DOWN AND DRIVE IN LOW GEAR WARNING 41 DRIVING WITH PASSENGERS IN TH...

Page 44: ...NG OPERTATING THE VEHICLE WHILE THE CARGO BOX IS RAISED COULD RESULT IN SEVERE INJURY THE BOX COULD CLOSE UNEXPECTEDLY AND CAUSE INJURY TO THE DRIVER OR PASSENGER NEVER OPERATE THIS VEHICLE WITH THE CARGO BOX IN THE RAISED POSITION WARNING Cargo Box Release Lever ON MANUAL LIFT MODELS IF THE WEIGHT DISTRIBUTION ON THE BOX IS LOCAT ED TOWARD THE REAR OF THE BOX WHEN THE RELEASE LEVER IS PULLED UPWA...

Page 45: ...IOUS INJURY OR DEATH ALWAYS FOLLOW THESE PRECAUTIONS WHEN TOWING NEVER LOAD MORE THAN 150 LBS 68 1 kg TONGUE WEIGHT ON THE TOWING BRACKET DO NOT OPERATE VEHICLE FASTER THAN 10 MPH 16 km h WHEN TOWING TOWING A TRAILER INCREAS ES BRAKING DISTANCE DO NOT TOW MORE THAN THE RECOMMENDED 1 500 LB WEIGHT FOR THE VEHICLE ATTACH A TRAILER TO THE HITCH BRACKET ONLY DO NOT ATTACH A TRAILER TO ANY OTHER LOCATI...

Page 46: ...he front hubs are driving they will not release until the rear wheels regain traction Disengaging 4 Wheel Drive Under certain conditions it may be possible for one or both hubs to remain engaged unnecessarily This condition causes increased steering effort and some vehicle speed restriction Take the following steps to disengage the 4 wheel drive system 1 Stop the vehicle 2 Shift to reverse and bac...

Page 47: ...chaser or while it is in use or 2 The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPER ING ARE THE ACTS LISTED BELOW 1 Removal or alteration or the puncturing of the muffler or any engine component which conducts removal of engine exhaust gases 2 Removal or alteration or the puncturing of...

Page 48: ...service and adjustment procedures have a qualified dealer perform these operations Inspect clean lubricate adjust or replace parts as necessary When inspection reveals the need for replacement parts always use gen uine Bush Hog parts available from you Bush Hog dealer Maintenance Chart Key s s Perform these operations more often under severe use such as in dirty or wet conditions to purge water or...

Page 49: ...tor when replaced Taillamp Daily Inpect daily apply dielectric grease to socket when replaced s Air Filter Main Weekly Inspect replace if necessary H Element s Transmission Oil 25 hrs Check level change oil annually Battery 25 hrs Check terminals clean check fluid level n Brake pad wear 25 hrs Inspect periodically s Engine breather 25 hrs Inspect replace annually H filter and as needed s General 2...

Page 50: ...age n Throttle Cable 50 hrs Inspect adjust lubricate replace if necessary H Choke Enricher 50 hrs Inspect adjust replace if Cable necessary Shift Linkage 50 hrs Inspect adjust n Drive Belt 50 hrs Inspect adjust replace if necessary n Steering 50 hrs Inspect lubricate s Front Suspension 50 hrs Inspect lubricate tighten Fasteners s Rear Suspension 50 hrs Inspect tighten fsteners Engine Mounts 300 hr...

Page 51: ...s Clean out s Front Gearcase Oil 100 hrs Check monthly change annually n Clutches drive 100 hrs Inspect clean and driven n Brake Fluid 200 hrs Change every two years n Front Wheel 300 hrs Inspect replace if necessary Bearings H Idle Speed As required Adjust Engine Side Cover As required Drain moisture after driving in water n Toe Adjustment As required Periodic inspection adjust when parts are rep...

Page 52: ...ddle of Check monthly w LSD additive sight window change every 100 hrs Front Differential Mobil 424 Refill to check plug Every 100 hrs Right Angle SAE 80W 90 Refill to middle of Every 100 hrs Drive w LSD additive sight window Lube Fittings Lithium Based Grease with grease Every 25 hrs Top of Front Grease gun Struts Swing Arm Pivots Pillow Block on Driveshaft MIXING BRANDS OR USING A NON RECOMMENDE...

Page 53: ...n 10 F and 30 F if most trips are slow speed and less than five miles Always change the oil filter when changing oil Oil Check The engine oil can be checked and or refilled by folding the bottom seat cushion up and forward exposing the engine 1 Position the vehicle on a level surface 2 Start the engine and let it idle for 20 30 seconds 3 Stop the engine and fold the seat forward 4 Remove the dipst...

Page 54: ...ck and fill the engine with approximately 1 1 2 quarts of SAE 10W 30 API SJ motor oil Replace the dipstick 9 Start the engine and check for leaks at the drain plug and oil filter 10 Stop the engine and check the oil level on the dipstick 11 Dispose of used oil and filter properly Transaxle The transaxle oil should be changed every 100 hours 1 Park the vehicle on a level surface 2 Remove the drain ...

Page 55: ... a level surface remove the fill plug and check the lubricant level Oil should be filled until it overflows from the fill plug 2 Replace the fill plug and tighten Oil Change 1 Support the vehicle securely with a jack stand 2 Remove the front tire on the driver s side 3 Remove the fill plug 4 Remove the drain plug located on the bottom right hand side and drain the oil into a drain pan Discard the ...

Page 56: ...ditive to the mid dle of the sight window Oil Change 1 Remove the combination breather fill plug from the top of the case 2 Remove the drain plug from the bottom of the case and drain the oil into a pan Discard the used oil properly 3 Clean and replace the drain plug and fill the right angle drive with Mobilube HD LS 80W 90 or equivalent Refill to the center of the sight window 4 Replace the breat...

Page 57: ...ler if required This CVT system is intended for use on the Bush Hog utility vehicle Do not install it on any other product Always make sure the CVT housing is securely in place during operation CVT Drying There may be some instances when water is accidently ingested into the CVT system Use the following instructions to dry it out before operating 1 Shift the transmission into neutral and apply ful...

Page 58: ... electric starter 6 Dry the spark plugs and reinstall or install new spark plugs 7 Tighten the carburetor drain screw 8 Connect the fuel pump wires 9 Attempt to start the engine If necessary repeat the drying pro cedure Briggs Stratton Engines The procedure for the Briggs Stratton engine would be the same as for the Honda except that there is no drain feature on the carburetor fuel bowl The carbur...

Page 59: ...lter elements or install new ones NOTE Service the air filter more frequently if the vehicle is operated in wet conditions or at high throttle openings for extended periods CVT Enclosure Air Filter We recommend that the air filter be cleaned every 25 hours and replaced once a year The CVT filter is accessible by folding the seat forward The filter housing is located on the driver s side above the ...

Page 60: ...e electrodes are not burned or eroded This indicates the proper type and heat range for the engine and service NOTE The tip should not be white A white tip indicates overheating caused by use of an improper spark plug or incorrect carburetion adjustments 2 Wet Fouled The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose General...

Page 61: ...the engine and allow the exhaust system to cool 4 Reinstall the spark arrestor Spark Arrestor WARNING FAILURE TO HEED THE FOLLOWING WARNINGS WHILE SERVICING THE SPARK ARRESTOR COULD RESULT IN SERIOUS INJURY OR DEATH DO NOT PERFORM SERVICE ON THE SPARK ARRESTOR WHILE THE SYSTEM IS HOT EXHAUST SYSTEM TEM PERATURES CAN REACH 1000 F ALLOW COMPO NENTS TO COOL SUFFICIENTLY BEFORE PROCEEDING REMOVE COMBU...

Page 62: ...ttle pedal moves before the engine begins to pick up speed Freeplay should be from 1 16 to 1 8 Note The throttle system is not intended to be adjusted by the owner If problems occur take the vehicle to your dealer for adjustments WARNING FAILURE TO CHECK OR MAINTAIN PROPER OPERA TION OF THE THROTTLE SYSTEM CAN RESULT IN AN ACCIDENT AND LEAD TO SERIOUS INJURY OR DEATH IF THE THROTTLE STICKS DURING ...

Page 63: ...ocedure 1 Position the vehicle on level ground 2 Inspect the brake fluid by looking at the reservoir under the hood The level should be between the upper MAX and lower MIN level lines 3 If the fluid level is lower than the lower level line add brake fluid to the upper MAX line 4 Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings WARNING AFTER OPENING A BOT...

Page 64: ... the parking brake cable passes through an equalizer bracket Hex nuts on each side of the equalizer position the brake cable Loosen the nut on the front side of the equalizer and then tighten the rear side nut to increase pressure on the brake system Test the brake system and adjust again if needed When adjustment is satisfactory tighten both nuts securely against the equalizer bracket Trail Hunte...

Page 65: ...tton to make sure it releases freely 3 Check the belt for wear cuts or damage If any irregularities are found have the seat belt system checked and or replaced by an authorized dealer The seat belt angles should be adjusted to suit the individual in that particular seat before driving Make sure the seat belt angle is adjust ed to the lowest possible lap position before riding 1 To adjust loosen th...

Page 66: ...N TROL AND AN ACCIDENT WHICH COULD RESULT IN SERIOUS INJURY OR DEATH ALWAYS REPLACE TIRES WHEN THE TREAD DEPTH MEASURES 1 8 3 CM OR LESS IMPROPER TIRE INFLATION OR THE USE OF NON STAN DARD SIZE OR TYPE TIRES MAY ADVERSELY AFFECT VEHICLE HANDLING WHICH COULD RESULT IN VEHICLE DAMAGE OR PERSONAL INJURY ALWAYS MAINTAIN PROPER TIRE PRESSURE WHEN REPLACING TIRES ALWAYS USE THE ORIGINAL EQUIPMENT SIZE A...

Page 67: ... nuts and finger tighten 3 Carefully lower the vehicle to the ground 4 Torque the lug nuts to 35 ft lbs Lights When servicing a halogen lamp don t touch the lamp with bare fin gers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp WARNING POOR LIGHTING WHILE DRIVING CAN RESULT IN SEVERE INJURY OR DEATH HEADLIGHT AND TAIL LIGHT LENSES BECOME DIRTY DURING ...

Page 68: ...arning decals Many expensive repair bills can result from using high pressure detergent systems NOTE If a high pressure car wash is used grease all zerk fittings immediately after washing Also run the vehicle to evaporate any water that may have entered the engine or exhaust system Storage If your vehicle is to be placed in extended or off season storage the following steps should be taken to pres...

Page 69: ...e as outlined in the Periodic Maintenance Schedule Battery Keep the battery terminals and connections free of corrosion If clean ing is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon of baking soda and one cup of water Rinse well with tap water and dry off with clean shop towels Coat the terminals with dielectric grease or petroleum jelly Be careful n...

Page 70: ...t page 1 Open the hood to access the battery 2 Disconnect the negative black cable first 3 Disconnect the positive red cable next 4 Remove the nuts from the battery tie down bracket and lift off the bracket 5 Lift the battery out of the vehicle being careful not to tip the battery side ways and spill electrolyte WARNING IMPROPERLY CONNECTING OR DISCONNECTING BAT TERY CABLES CAN RESULT IN AN EXPLOS...

Page 71: ...operly routed NOTE When installing a new battery make sure it is fully charged prior to its use Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance Battery Storage When the vehicle is placed in storage for three months or more the battery should be removed stored out of the sun in a cool dry place and tested...

Page 72: ...ents assembled as shown below place bottom mounting plates into position on frame and join with front frame mem bers Fasten mounting plates to frame with 5 8 x 3 bolts and lock nuts Fasten bottom panel to frame with 3 8 x 1 bolts and locknuts Once the complete cab frame is in place securely tighten all fasteners Install seat belts to mounting locations on frame as shown in illustra tions on next p...

Page 73: ... Seat Belt Outside Seat Belt 1 2 x 2 1 2 Bolt Locknut 1 2 x 1 1 2 Bolt Locknut 1 2 x 1 Bolt Locknut 1 2 x 1 Bolt 7 Locknut Seat Belt Installation Install all seat belts so that the release button will be to the outside of the occupant when fastened 71 Release Button Release Button ...

Page 74: ...follows Manual Lift Screw pads down enough so that slight down pressure on the front of the bed is needed to unlatch the lift handle Electric Lift Lower bed then screw pads down for a snug fit to pre vent rattling Bumper Pad 5 16 x 3 4 Hex Socket Button Head Bolts Seat Back Mounting Holes Use 5 16 Flatwashers Locknuts Bottom Mounting Plates Use 5 8 x3 Bolts Locknuts Cross Member Front Left Frame M...

Page 75: ...ent clogged Spark plug wire not on spark plug Spark plug fouled ENGINE STOPS No fuel in tank Water in fuel Fuel filter clogged Choke left on too long Air filter clogged or inlet blocked Fuel tank cap vent clogged Engine overheated Too much idling or low speed running not enough air flow Overloaded Fouled spark plug Engine oil low NO POWER Engine overheated Too much idling or low speed running not ...

Page 76: ...red Because damage can occur to safety decals either through shipment use or reconditioning Bush Hog will upon request provide safety decals for any of our products in the field at no charge Contact your authorized Bush Hog dealer for more information No 1 No 2 No 1 or 2 No 6 No 7 No 3 No 4 No 5 74 ...

Page 77: ...No 3 No 4 No 5 No 6 No 7 75 ...

Page 78: ...8 7 16 20 UNF 36 49 55 75 78 106 3 4 1 2 13 UNC 49 66 76 103 106 144 3 4 1 2 20 UNF 55 75 85 115 120 163 7 8 9 16 12 UNC 70 95 109 148 153 207 7 8 9 16 18 UNF 79 107 122 165 172 233 15 16 5 8 11 UNC 97 131 150 203 212 287 15 16 5 8 18 UNF 110 149 170 230 240 325 1 1 8 3 4 10 UNC 144 195 266 360 376 509 1 1 8 3 4 16 UNF 192 260 297 402 420 569 AMERICAN Bolt Head Markings Wrench Size A B o l t D i a...

Page 79: ...2 165 325 440 449 608 Proper torque for metric fasteners used on Bush Hog equipment Recommended torque in foot pounds newton Meters U se 7 5 o f th e sp e cifie d to rq u e va lu e fo r p la te d fa ste n e rs U se 8 5 o f th e sp e ci fie d to rq u e Numbers appearing on bolt heads indicate ASTM class METRIC Wrench Size A B o l t D i a m e t e r B TORQUE SPECIFICATIONS Proper torque for metric fa...

Page 80: ...NOTES ...

Page 81: ...NOTES ...

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