Chironex SPARTAN 600 EFI Owner'S Manual Download Page 1

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SPARTAN

600

EFI

SPARTAN

600

EFI

OWNER’S

MANUAL

Summary of Contents for SPARTAN 600 EFI

Page 1: ...SPARTAN 600 EFI SPARTAN XT 600 EFI OWNER S MANUAL ...

Page 2: ...NG OR INSTRUCTION THE SPARTAN SHOULD NOT BE RIDDEN BY ANYONE UNDER 16 YEARS OF AGE INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH Particularly important information is distinguished in this manual by the following symbols NOTE IMPORTANT NOTICE The Spartan is designed and manufactured for OFF ROAD use only It is illegal and unsafe to operat...

Page 3: ...arrying a Passenger 10 Carrying Multiple Passengers 10 Operating on Pavement 10 Operating on Public Roads 10 Operating at Excessive Speeds 10 Turning Improperly 11 Physical Control of the Vehicle 11 Jumps and Stunts 11 Driving Downhill Improperly 11 Improper Hill Climbing 12 Stalling While Climbing a Hill 12 Crossing Hillsides 12 Operating in Unfamiliar Terrain 12 Operating on Sand or Slippery Ter...

Page 4: ...nent Locations 17 Indicator and Warning Lights 18 Switches 19 Seats 20 Fuel Cap 21 Ignition Switch 21 Gear Shifter 22 Parking Brake 22 Brake Pedal 22 Throttle Pedal 22 OPERATION 23 Vehicle Break in Period 23 Pre Ride Inspection 24 Safe Operation Practices 24 Starting the Engine 25 Stopping the Engine 25 Braking 25 Parking the Vehicle 25 New Operator Driving Procedures 26 Driving with a Passenger 2...

Page 5: ...tenance Chart 32 Engine Oil 34 Transmission Main Gear case 36 Spark Plugs 36 CVT System 37 Filter System 38 Cooling System 39 Throttle System 39 EFI System 40 Steering Wheel Inspection 40 Brakes 41 Tires 42 Vehicle Immersion 43 Battery 43 Cleaning and Storage 45 Malfunction Analysis and Elimination 46 WARRANTY 53 SPECIFICATIONS 54 WIRING DIAGRAM 56 ...

Page 6: ...s and operating procedures before driving the vehicle Keep this manual with the vehicle Never operate this vehicle without proper instruction Always follow the age guidelines for your vehicle Operation is prohibited for anyone age 16 and under Never operate with a passenger age 12 and under Identification number records Record the vehicle identification number and engine number in the spaces provi...

Page 7: ... been made to the vehicle that increase its speed or power The addition of certain accessories may change the handling characteristics of the vehicle Use only our company approved accessories and familiarize yourself with their function and effect on the vehicle Safe Riding Gear Always wear appropriate clothing when riding this vehicle Wear protective clothing for comfort and to reduce the chance ...

Page 8: ...e risk of an accident The operator must understand how to operate the vehicle properly in different situations and on different types of terrain Age Restrictions Operation is prohibited for anyone less than 16 years of age Never operate with a passenger under 12 years of age Make sure any passenger is tall enough to comfortably and safely reach the hand holds and place feet flat on the floor Rider...

Page 9: ...an approved helmet and protective eyewear increases the risk of serious injury in the event of an accident The operator and passenger must always wear an approved helmet that fits properly as well as eye protection goggles or face shield Seat Belts Riding in this vehicle without wearing the seat belt increases the risk of serious injury or death in the event of an accident or sudden stop Riders mu...

Page 10: ...is vehicle s tires are designed for off road use only Avoid operating the vehicle on pavement If you must operate on a paved surface travel slowly and do not make sudden turns or stops Operating on Public Roads Operating this vehicle on public streets roads or highways could result in a collision with another vehicle Never operate this vehicle on any public street road or highway including dirt an...

Page 11: ...th hands securely grasping the hand holds Always keep hands and feet inside the vehicle at all times Jumps and Stunts Stunt driving increases the risk of an accident or overturns DO NOT perform power slides donuts jumps or other driving stunts Avoid stunt driving Driving Downhill Improperly Driving downhill improperly could cause loss of control or overturn Always follow proper procedures for driv...

Page 12: ... on a hill is not recommended Improper procedure could cause loss of control or overturn Avoid crossing the side of any hill unless absolutely necessary Operating in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn Trave...

Page 13: ...or sliding can cause loss of control or overturn if tires regain traction unexpectedly Always follow proper procedures for operating on slippery surfaces as described in the owner s manual When operating on slippery surfaces such as ice or loose gravel reduce your speed and use extra caution to reduce the chance of skidding or sliding Do not operate on excessively slippery surfaces Operating Throu...

Page 14: ...n frozen bodies of water can result in the vehicle and riders falling through the ice Never operate this vehicle on a frozen body of water Handling Gasoline Gasoline is highly flammable and is explosive under certain conditions Always exercise extreme caution whenever handling gasoline Never allow a child to refuel or handle gasoline Always stop the engine when refuelling Always refuel outdoors or...

Page 15: ...ve been placed on the vehicle for your protection Read and follow the instructions on each label carefully If any of the labels shown in this manual differ from the labels on your vehicle always read and follow the instructions of the labels on the vehicle If an informational or graphic label becomes illegible or comes off contact your dealer to purchase a replacement Warning Labels WARNING Improp...

Page 16: ...vehicle WARNING VEHICLE OVERTURN could cause severe injury or death The cab frame is not designed or intended to provide rollover protection MAXIMUM WEIGHT CAPACITY 660 lbs 300 Kg THIS INCLUDES THE WEIGHT OF THE OPERATOR PASSENGER AND ACCESSORIES REFER TO THE OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS IF OWNER S MANUAL IS MISSING CONTACT YOUR DEALER FOR A REPLACEMENT ...

Page 17: ...17 FEATURES AND CONTROLS Component Locations ...

Page 18: ...ndicator 4 Fuel indicator 5 High beam indicator 6 Odometer 7 Speedometer 8 2WD 4WD 4WD locked indicator 9 Low brake fluid indicator 10 Reverse speed override indicator 11 Parking brake indicator 12 Low engine oil indicator 13 Check engine indicator 14 Check battery indicator 15 Tachometer ...

Page 19: ...ch is in the 2WD position power will go to the 2 rear wheels When in the 4WD position power will go to all 4 wheels When in the 4WD locked position power will go to all 4 wheels and the front differential will lock 8 Radio and MP3 Player control This is used to control the Radio and USB MP3 player The USB socket used to plug in your USB device is located under the dashboard 9 Cigarette lighter The...

Page 20: ... the belt is not twisted 2 Push the latch plate into the buckle until it clicks 3 Press the red release button on the buckle to release the seat belt Seat Belt Inspection Inspect all seat belts for proper operation before each use of the vehicle 1 Push the latch plate into the buckle until it clicks The latch plate must slide smoothly into the buckle A click indicates that it s securely latched 2 ...

Page 21: ...rnoff except emergency light electric fan and cigarette lighter 2 ACC position lights MP3 horn windshield wiper 3 ON open position All circuits except engine are connected and they could start at any moment or make engine keep running status 4 ST start position Connect engine and ignition circuit and start engine Handle returns to ON position automatically after engine starts Note You can start th...

Page 22: ... the parking brake apply the brakes and push the lever toward the passenger seat and downward Tip Always engage the parking brake whenever the vehicle is left unattended Operating the vehicle while the parking brake is engaged could cause an accident resulting in serious injury or death It could also result in driveline or engine damage Always be sure to disengage the parking brake before operatin...

Page 23: ... Never substitute or mix oil brands Vehicle Break in Period Engine and Drivetrain Break in 1 Fill the fuel tank with gasoline Always exercise extreme caution whenever handling gasoline Never allow a child to handle gasoline 2 Check the oil level See page 34 Add the recommended oil as needed to maintain the oil level in the safe operating range 3 Complete the New Operator Driving Procedures outline...

Page 24: ...Engine exhaust fumes are poisonous Never start the engine or let it run in an enclosed area 4 Never install accessories not approved by our company for use on this vehicle 5 Never operate the vehicle on pavement or on any public street road or highway including dirt and gravel roads 6 Drive in a manner appropriate for your skills and operating conditions Never operate at excessive speeds DO NOT at...

Page 25: ... until the engine idles smoothly 8 Release the parking brake before driving Stopping the Engine 1 Release the throttle pedal completely and brake to a complete stop 2 Place the transmission in neutral 3 Set the parking brake 4 Stop the engine Braking 1 Release the throttle pedal completely When the throttle pedal is released completely and engine speed slows to near idle the vehicle has no engine ...

Page 26: ...ce the transmission in neutral 11 Start the engine 12 Apply the brakes and shift into gear 13 Release the parking brake 14 Check your surroundings Make sure the area is clear of people and obstacles 15 Keeping both hands on the steering wheel slowly release the brakes and press the throttle with your right foot to begin driving 16 Drive slowly at first Practice starting stopping turning using the ...

Page 27: ...Never carry more than one passenger in this vehicle 7 Never allow a passenger to ride on the back of the vehicle Allow a passenger to ride only in the passenger seat 8 Make sure the passenger is wearing appropriate riding gear including an approved helmet and eye protection See page 7 9 Make sure the passenger secures the seat belt 10 Tell your passenger to always keep hands and feet inside the ve...

Page 28: ...r loose gravel slow down and use extra caution to help prevent skidding or sliding Always use extra caution when operating on sand or on rough slippery or loose terrain Do not operate on excessively rough slippery or loose terrain Follow these precautions when driving in slippery conditions 1 Slow down before entering slippery areas 2 Be alert watch the path ahead and avoid quick turns which can c...

Page 29: ...nded This could cause loss of control or an overturn If crossing a hill is unavoidable follow these precautions 1 Drive slowly and use extreme caution 2 If the vehicle begins to overturn or if it feels as if it may overturn immediately turn downhill 3 Avoid obstacles and changes in terrain that may lower or raise one side of the vehicle or cause the vehicle to slide 4 If the vehicle begins to slid...

Page 30: ...ated in water deeper than the floor level take it to your dealer for service before starting the engine If it s impossible to bring the vehicle to your dealer before starting the engine perform the service outlined on page 43 and take the vehicle to your dealer as soon as possible Driving Over Obstacles Follow these precautions when driving over obstacles 1 Always check for obstacles before drivin...

Page 31: ...le suddenly 3 Reverse slowly 4 Apply the brakes lightly to stop 5 Avoid making sharp turns Parking on an Incline A rolling vehicle can result in serious injury Avoid parking on an incline If parking on an incline is unavoidable follow these precautions 1 Place the transmission in neutral 2 Set the parking brake 3 Stop the engine 4 Always block the rear wheels on the downhill side ...

Page 32: ... qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately ten 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Is Defined As Frequent immersion in mud water or sand Racing or high RPM use Prolonged low speed operation Exten...

Page 33: ...0 Monthly 160 100 Inspect periodically Idle speed 10 Monthly 160 100 Check adjust as needed Front Suspension 50 6 months 800 500 Lubricate Rear Suspension 50 6 months 800 500 Lubricate Spark plugs 100 12 months 1000 600 Inspect replace as needed Wheel bearings 100 12 months 1000 600 Inspect replace as needed Shift Linkage 50 6 months 800 500 Inspect lubricate adjust Battery 25 Monthly 400 250 Chec...

Page 34: ...tute or mix oil brands Oil Check Maintain the oil level within the safe range on the dipstick Do not overfill 1 Position the vehicle on a level surface 2 Remove the dipstick Wipe it dry with a clean cloth 3 Reinstall the dipstick completely 4 Remove the dipstick and check the oil level Tip A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture c...

Page 35: ... or scratches 6 Using a cap style oil filter wrench turn the oil filter cartridge to remove it 7 Using a clean dry cloth clean the filter sealing surface on the crankcase 8 Lubricate the O ring on the new filter with a film of fresh engine oil Check to make sure the O ring is in good condition 9 Install the new oil filter cartridge with an oil filter wrench and then tighten it to the specific torq...

Page 36: ... hole Do not overfill 8 Reinstall the fill plug 9 Check for leaks 10 Discard used fluid properly Spark Plugs Spark Plug Gap Torque Spark Plug Gap Plug Tightening Torque Specified Spark Plug 0 8 0 9 mm 0 032 0 035 in 12 5 ft lbs 17 5 Nm DPR7EA 9 NGK NOTICE Using non recommended spark plugs can result in serious engine damage Always use our company recommended spark plugs Spark plug condition is ind...

Page 37: ...l shorten the life of the CVT engine and transmission Belt Assembly After installing or replacing the belt check for up and down free play CVT Drying 1 There may be some instances when water enters the CVT system Use the following instructions to dry it out before operating 2 Remove the CVT cover Allow the water to drain Reinstall the CVT cover 3 Shift the transmission to neutral Set the parking b...

Page 38: ...er element 4 from the air box 4 Wash the filter element in warm soapy water then rinse and let dry If the filter element is damaged install a new filter 5 Clean any oil or sediments in the air box 6 Reinstall the filter element 4 7 Tighten the screw 3 8 Reinstall the cover 2 and secure the latches 1 NOTICE Never operate the vehicle with the filter element removed Dirt will enter the engine causing...

Page 39: ... lead to serious injury or death if the throttle pedal sticks during operation Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal Immediately contact your dealer for service if throttle problems arise Always check the pedal for free movement and return before starting the engine Throttle Free play If the throttle pedal has excessive play or maladjustmen...

Page 40: ...ake to the ECU The ECU utilizes the throttle position information as well as rpm to provide the correct fuel air ratio NOTE The idle speed limit screw does not allow the adjustment the engine idle speed depend on the EFI system adjustment completely does not hand adjust the idle speed limit screw Steering Wheel Inspection 1 Position the vehicle on level ground 2 Lightly turn the steering wheel lef...

Page 41: ... worn to 3 64 1 mm Brake Fluid Inspect the level of the brake fluid before each operation If the fluid level is low add DOT 3 or DOT 4 brake fluid After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to dro...

Page 42: ...roper tire pressure When replacing tires always use original equipment size and type Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations All service must be performed by your authorized dealer Wheel Removal 1 Position the vehicle on a level surface 2 P...

Page 43: ...cessary to check the electrolyte or add distilled water in the battery If the battery seems to have discharged consult your dealer CAUTION Do not try to remove the sealing caps of the battery cells You may damage the battery Failure to handle batteries or battery electrolyte carefully could result in severe burns Batteries produce explosive gases Contact with skin eyes or clothing must be avoided ...

Page 44: ... 5A 11 Fuel pump fuse 10A 12 High beam fuse 10A 13 Low beam fuse 10A 14 Windshield wiper fuse 15A 15 MP3 player fuse 5A When the machine is not used for a month or longer removes the battery and stores it in a cool dark place Completely recharge the battery before reinstallation Always make sure the connections are correct when putting the battery back in the machine WARNING Do not use an improper...

Page 45: ...pe washing cloth cleaning the upper body first and the lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Storage Long term storage 60 days or more of your machine will require some preventive procedures to guard against deterioration After thoroughly cleaning the machine prepare for storage as follows 1 Drain the fuel system 2 Remove the spar...

Page 46: ...n or change Clean or change fuel pump Clean or change Miscellaneous Gear is not in neutral Put gear on neutral Erratic idle or won t idle Mechanical reasons 1 Valve gap is incorrect 2 Worn or leaking valve 3 Blocked exhaust 4 Incorrect idle adjustment Adjust Repair or replace Replace Adjust Electric parts problem 1 Fouled or dirty spark plug 2 Gap of plug not correct 3 Ignition switch problem 4 EC...

Page 47: ...nge Change Change Change Change Change Engine overheats Fuel system fault 1 Octane rating is too low 2 Fuel passage blocked 3 Fuel pump problem Use the correct fuel Clean the fuel passage Change Electric System problem 1 Incorrect ignition timing 2 Spark is weak or no spark Adjust ignition timing Check ignition components Intake combustion or exhaust problems 1 Compression leak 2 Air filter is dir...

Page 48: ...Driving portion of CVT damaged Change Change Noise from transmission system 1 Gear damaged 2 Input and output shaft damaged 3 Bearing worn out 4 Bushing worn out Change Change Change Change Engine lacks power Fuel system 1 Octane rating is too low 2 Fuel flow restriction Use minimum recommended octane Clean fuel lines and system Clutch slipping Transmission system 1 Pulley faces worn 2 Spring on c...

Page 49: ... battery voltage 5 Ignition switch problem Change Change Change Change or charge Change II Malfunction in transmission system Malfunction phenomenon Malfunction system Reason Solving method Vehicle speed does not increase with engine speed Transmission system 1 Belt slipping 2 Worn pulley faces 3 Moveable pulley side of CVT is binding 4 Weak spring in primary part of CVT Change Change Repair or ch...

Page 50: ...Vehicle is over loaded 5 Wheel hub bearing has been damaged or adjustment is wrong 6 Loose tie rods or ball joints 7 Improper tire pressure Adjust or Change Balance or replace wheel Adjust and align Remove weight Adjust or replace Check or adjust Tighten or replace Correct Front wheel s vibrate or shake Steering running system suspension 1 Bent wheel or tires are out of balance 2 Wheel hub bearing...

Page 51: ... running system suspension 1 Oil on pads or calipers 2 Leaking caliper 3 Uneven tire pressure 4 Front wheel adjustment is wrong 5 Vehicle frame is bent 6 Bent or crushed brake line 7 Worn brake pads or rotors 8 Suspension parts loose 9 Vehicle is leaning 10 Left and right side tires have uneven tread wear Clean or Change Replace Correct Adjust Repair Replace Replace Repair or adjust Check and corr...

Page 52: ...cuit Parking light does not illuminate 1 Faulty relay 2 Bulb is burned out 3 Grounding is bad 4 Fuse burned out 5 Switch damaged Change Change Correct Change Repair or replace Starter failure 1 Starter has been damaged 2 Starter relay has been damaged 3 Grounding of starter is bad 4 Ignition switch has been damaged Repair or replace Change Correct Repair or replace Complete electrical failure Circ...

Page 53: ...53 WARRANTY All warranty information can be obtained through your dealer or online at www chironex com ...

Page 54: ...0 US qt With oil filter cartridge replacement 1 9 L 2 01 US qt Final gear case oil Type SAE 80W 90 GL 4 Periodic oil change 0 25 L 0 26 US qt Front differential oil Type SAE 80W 90 GL 4 Periodic oil change 0 28 L 0 30 US qt Fuel Type UNLEADED GASOLINE 93 OCTANE OR ABOVE Fuel tank capacity 20 litres 5 28 gallons Spark plug Type DPR7EA 9 NGK Spark plug gap 0 8 0 9 mm 0 032 0 035 in Drivetrain Final ...

Page 55: ...shock absorber Coil over shock Dimensions Overall length 2690 mm 105 9 in 3345 mm 131 7 in Overall width 1270 mm 50 in 1290 mm 50 8 in Overall height 1820 mm 71 7 in 1865 mm 73 4 in Wheelbase 1730 mm 68 1 in 2450 mm 96 5 in Ground clearance 229 mm 9 02 in Weight 590 kg 1298 lbs 620 kg 1367 lbs Capacities Top speed 80 km h 50 mph Towing capacity 680 kg 1500 lbs Weight capacity 300 kg 660 lbs Electr...

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Chironex SPARTAN 600 EFI, Owner'S Manual

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Summary of Contents for SPARTAN 600 EFI

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