Crossfire 1100GT User Manual Download

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MAINTENANCE

CVT System

Usage and maintenance

Belt Assembly

：

After the belt assembly is finished, the belt tension should be appropriate. Too

loose or too tight will obvious effect the operating life of belt. So the verticality of loose edge

should be checked after the belt assembly is finished, the drooping height is 10~~15mm, refer

to picture 3-1-2

1100GT

User Manual

Summary of Contents for 1100GT

Page 1: ...rtant safety information OWNER S MANUAL 1100 UE 1100UEL 4 4 READ THIS MANUAL CAREFULLY It contains important safety information This UTV should not be ridden by anyone under 16 years of age OWNER S MA...

Page 2: ...lso includes basic maintenance and inspection procedures If you have any questions regarding the operation or maintenance of your UTV please consult you dealer AN IMPORTANT SAFETY MESSAGE READ THIS MA...

Page 3: ...notations NOTE A NOTE provides key information to make procedures easier or clearer The Safety Alert Symbol means ATTENTION BECOME ALERT Failure to follow WARNING instructions could result in severe...

Page 4: ...egal and unsafe to operate this UTV on any public street road or highway This UTV complies with all applicable OFF ROAD noise level and spark arrester laws and regulations in effect at the time of man...

Page 5: ...ls 21 Component Locations 21 Indicator and warning lights 23 Switch 24 Seats 25 Seat Belts 25 Seat Belt Inspection 26 Fuel cap 27 Ignition Switch 28 Gear Selector 29 Brake Pedal 30 Throttle Pedal 30 O...

Page 6: ...36 Parking the vehicle 36 New operator driving procedures 37 Driving with a passenger 39 Driving on slippery surface 40 Driving uphill 42 Driving on a sidehill 43 Driving downhill 43 Driving through...

Page 7: ...48 Engine oil 51 Transmission main gearcase 55 Spark plugs 56 CVT system 57 Filter system 66 Cooling system 68 Throttle system 69 EFI system 71 Brakes 72 Steering wheel inspection 74 Shock spring adj...

Page 8: ...Battery 77 Clearing and storage 80 Malfunction analysis and elimination 82 WARRANTY 96 SPECIFICATIONS 99 Circuit Diagram 106...

Page 9: ...ckly even during routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions Read this owner s manual Understand all safety warnings precautions and ope...

Page 10: ...e identification number and engine number in the spaces provided for assistance when ordering spare parts from your dealer or for reference in case the vehicle is stolen NOTE The vehicle identificatio...

Page 11: ...any equipment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes Any modifications to the original equipment of the vehicle create a...

Page 12: ...4 SAFETY Safe Riding Gear Always wear appropriate clothing when riding this vehicle Wear protective clothing for comfort and to reduce the chance of injury 1100GT User Manual 4...

Page 13: ...f Transportation DOT label Eye Protection Do not depend on eyeglasses or sunglasses for eye protection Whenever riding a vehicle always wear shatterproof goggles or use a shatterproof helmet face shie...

Page 14: ...safety Operating Without Instruction Operating this vehicle without proper instruction increases the risk of an accident The operator must understand how to operate the vehicle properly in different s...

Page 15: ...in safe operating condition before operating increases the risk of an accident Always inspect the vehicle before each use to make sure it s in safe operating condition Always follow the inspection an...

Page 16: ...at belt increases the risk of serious injury in the event of an accident or sudden stop Riders must wear seat belts at all times Seat belts reduce the severity of injury in the event of a sudden stop...

Page 17: ...idewalks paths Parking lots and driveways may seriously affect handling and control of the vehicle and may cause the vehicle to go out of control This vehicle s tires are designed for off road use onl...

Page 18: ...r at sharp angles Never turn at high speeds Practice turning at slow speeds before attempting to turn at faster speeds Physical Control of the Vehicle Removing hands from the steering wheel or hand ho...

Page 19: ...w proper procedures for driving down a hill as described in the owner s manual Always drive down a hill with the transmission in forward gear Never drive down a hill with the transmission in neutral N...

Page 20: ...a hill could cause an overturn Maintain a steady speed when climbing a hill If you lose all forward speed Apply the brakes gradually until the vehicle is fully stopped Place the transmission in rever...

Page 21: ...rn Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions Operating on Sand or Slippery Terrain Operating on sand or on excessively rou...

Page 22: ...fore operating in a new area check for obstacles Never attempt to operate over large obstacles such as rocks or fallen trees Always follow the proper procedures outlined in this manual when operating...

Page 23: ...ibed in the owner s manual Wet brakes may have reduced stopping ability After leaving water test the brakes Apply them lightly several times while driving slowly The friction will help dry out the pad...

Page 24: ...ident have a qualified service dealer inspect the entire vehicle for possible damage including but not limited to brakes throttle and steering systems Operating on Frozen Bodies of Water Operating on...

Page 25: ...refueling area or where gasoline is stored Never refuel while a person is in the vehicle Do not over fill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately was...

Page 26: ...e any grass or debris clinging to the vehicle Unauthorized Use of the Vehicle Leaving the keys in the ignition can lead to unauthorized use of the vehicle which could result in an accident or overturn...

Page 27: ...ontrol With non approved accessories they may seriously affect stability At speeds that are too fast for the operator s skills the conditions and or the terrain ALWAYS require operator and passenger t...

Page 28: ...G VEHICLE OVERTURN could cause severe injury or death The cab frame is not designed or intended to provide rollover protection TIRE PRESSURE IN PSI KPa Front 12 0 5 83 3 5 Rear 12 0 5 83 3 5 MAXIMUM W...

Page 29: ...21 FEATURES AND CONTROLS Component Locations 1100GT User Manual 21...

Page 30: ...22 FEATURES AND CONTROLS Component Locations 1100GT User Manual 22...

Page 31: ...warming light 4 Low battery and Over Voltage 5 Fuel indicator 6 turning indicator 7 Engine malfunction warming light 8 Fuel warming light 9 Water temperature warming light 10 High beams indicator 11 G...

Page 32: ...turn switch 3 Turning switch 4 Light switch 5 Low beams High beams turn 6 Horn switch 7 Warning indicator light switch 8 Wiper switch optional 9 Spot light optional 10 Cigarette lighter 11 winch swit...

Page 33: ...desired position then release the lever 3 Slide the seat forward and rearward to ensure the latch is engaged Before operating the vehicle always make sure both seats are securely installed Seat Belts...

Page 34: ...t clicks The latch plate must slide smoothly into the buckle A click indicates that it s securely latched 2 Push the red release latch in the middle of the buckle to make sure it releases freely 3 Ins...

Page 35: ...el Tank Cap Never allow a child to refuel or handle gasoline The fuel tank filler cap is located on the right hand side of the vehicle behind the passenger seat When refueling always use unleaded gaso...

Page 36: ...position the engine will turn off When turn the key switch to OFF position the electric was cut off and the key can be removed Cigarette Lighter The cigarette lighter installed on the vehicle The soc...

Page 37: ...t to assure proper transmission function See your dealer if you experience any shifting problems NOTICE Do not attempt to shift the transmission while the vehicle is moving or damage to the transmissi...

Page 38: ...edal to slow or stop the vehicle Apply the brakes while starting the engine Throttle Pedal Push the pedal down to increase engine speed Spring pressure returns the pedal to the rest position when rele...

Page 39: ...No single action on your part is as important as a proper break in period Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these com...

Page 40: ...at sustained idle 6 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page33 7 Change the engine oil at 10 hours or one month Brake Sys...

Page 41: ...tion Item Remarks Page Brake Ensure proper operation 72 Steering Ensure free operation 74 Engine oil Ensure proper levels 51 52 53 54 Air filter Inspect clean 66 67 Seat Belts Check length of belt for...

Page 42: ...ds 7 Drive in a manner appropriate for your skills and operating conditions Never operate at excessive speeds DO NOT attempt to do power slides donuts jumps or other driving stunts Keep both hands on...

Page 43: ...ine does not start within five seconds return the ignition switch to the ON position and wait five seconds Repeat steps 5 and 6 until the engine starts Tip If a warm engine has cooled to a point where...

Page 44: ...Press on the brake pedal evenly and firmly Practice starting and stopping using the brakes until you re familiar with the controls Parking the Vehicle 1 Stop the vehicle on a level surface When parki...

Page 45: ...inspection page 33 4 Wear appropriate riding gear including an approved helmet and eye protection goggles or face shield 5 Select a level open area to practice driving 6 Sit in the driver s seat and...

Page 46: ...topping turning using the throttle and brakes and driving in reverse Learn how the vehicle handles when making both left and right turns at a slow speed 17 Increase speed only after mastering all mane...

Page 47: ...ience with this vehicle 4 Never operate with a passenger age 12 and under Make sure the passenger is tall enough to comfortably and safely sit in the passenger seat with the seat belt secured put both...

Page 48: ...Avoid unexpected or aggressive maneuvers that could cause discomfort or injury to a passenger 13 Always follow all operating guidelines as outlined on safety labels and in this manual Driving on Slipp...

Page 49: ...onditions 1 Slow down before entering slippery areas 2 Be alert watch the path ahead and avoid quick turns which can cause skids 3 Correct a skid by turning the steering wheel in the direction of the...

Page 50: ...teady rate of speed Never press the throttle suddenly 6 Avoid unnecessary changes in speed or direction 7 Never go over the crest of a hill at a high speed An obstacle a sharp drop or another vehicle...

Page 51: ...he vehicle to slide 4 If the vehicle begins to slide downhill immediately turn downhill to stop the slide Driving Downhill Whenever driving down a hill follow these precautions 1 Avoid steep hills 15...

Page 52: ...dry out the pads NOTICE Major engine damage can result if the vehicle is not thoroughly inspected after operation in water Perform the services outlined in the maintenance chart See page 49 50 Give s...

Page 53: ...gs rocks and low hanging branches 3 Drive slowly and use extra caution when driving on unfamiliar terrain Obstacles are not always clearly visible 4 Do not drive over large obstacles such as rocks and...

Page 54: ...autions when driving in reverse 1 Always check for obstacles or people behind the vehicle 2 Apply the throttle lightly Never apply the throttle suddenly 3 Back slowly 4 Apply the brakes lightly for st...

Page 55: ...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 b...

Page 56: ...r 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...

Page 57: ...Wheels fasteners Daily Frame fasteners Daily Engine oil level Daily Check each day before driving the vehicle Make adjustments as needed See the Pre Ride Checklist on page33 Engine oil change break i...

Page 58: ...00 Check terminals clean test Toe adjustment Inspect periodically adjust when parts are replaced Headlight aim Adjust as needed Choke 10 Monthly 100 160 Check for proper operation see dealer for adjus...

Page 59: ...eck and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 49 Oil may need to be changed more frequently if the recommended oil is not used Oil Recomme...

Page 60: ...h 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...

Page 61: ...ean the area around the drain plug CAUTION Hot oil can cause burns to skin Do not allow hot oil to contact skin 4 Place a drain pan under the engine crankcase 5 Remove the drain plug Allow the oil to...

Page 62: ...0 Reinstall the sealing washer on the drain plug 11 Reinstall the drain plug Add the recommended engine oil 12 Place the transmission in PARK Apply the brakes 13 Start the engine Allow it to idle for...

Page 63: ...as needed 5 Reinstall the fill plug Oil Change The drain plug is located on the bottom of the gearcase 1 Remove the fill plug 2 Place a drain pan under the drain plug Front Gearcase 3 Remove the drai...

Page 64: ...ition should be read after the engine is warmed up and the vehicle is driven at higher speeds Immediately check the spark plug for correct color A hot exhaust system and engine can cause burns Wear pr...

Page 65: ...o code Name Spe Torque N m Assembly position Thread fastening agent 1 GB T5789 1986 Plate bolt 10 9 level M6x16 11 1 Torque cam 2 GB T 5783 2000 Plate bolt 10 9 level M6x45 11 1 Driving wheel cover 3...

Page 66: ...the operating life of belt and performance of vehicle So after pulley assembly you should use exclusive check tool to check whether the CVT driving plate is accord with the center of driven plate The...

Page 67: ...stem Usage and maintenance If there is space between CVT and check tool use the gasket to adjust between input shaft of gearbox and CVT The thickness of every gasket is 0 5mm refer to picture 3 1 1 2...

Page 68: ...is finished the belt tension should be appropriate Too loose or too tight will obvious effect the operating life of belt So the verticality of loose edge should be checked after the belt assembly is...

Page 69: ...belt So before CVT assembly or change please clean it firstly Belt The belt should be changed when vehicle run more than 15000 Kilometers the abrasion and verticality of belt need to be checked if it...

Page 70: ...tenance and check the CVT as below chart maintenance Period As anyone is firstly expired Item Time h Month Distance Driving driven part 100 12 1500 Check clean change the abrasion parts Belt 100 12 15...

Page 71: ...63 MAINTENANCE CVT System Appearance installation dimension map 1100GT User Manual 63...

Page 72: ...f balance creating vibration and additional loads on components The CVT syst em rotates at high speeds creating large amounts of force on clutch components Extensive enginee ring and testing has been...

Page 73: ...ne Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds 4 Allow the engine RPM to settle to idle...

Page 74: ...Loose the air filter fixed card and remove the tail cover 5 2 Remove the filter element of the air filter 4 from the primary cover 4 Wash the filter element in warm soapy water then rinse and let dry...

Page 75: ...the air box 6 Reinstall the filter element and tail cover Secure the fixed card NOTICE Never operate the vehicle with the filter element removed Dirt will enter the engine causing rapid wear and sever...

Page 76: ...ap add coolant to the maximum level mark install the reservoir cap Don t removing the radiator cap when the engine and radiator are still hot or you could be burned by hot fluid and steam blown out un...

Page 77: ...se Always check the pedal for free movement and return before starting the engine and occasionally during operation Throttle Freeplay If the throttle pedal has excessive play or misadjustment it will...

Page 78: ...lace the transmission in neutral Set the parking brake 2 Start the engine Allow it to warm up thoroughly 3 Measure the distance the throttle pedal moves before the engine begins to pick up speed Freep...

Page 79: ...celerator back guy reduces expenses to enter engine cylinder s gas flow amount the damper opening transmits from the damper position transducer to engine control unit ECU Flows through the by pass can...

Page 80: ...including excessive pedal travel contact your dealer for proper diagnosis and repairs Operating the vehicle with a spongy brake pedal can result in loss of braking which could cause an accident resul...

Page 81: ...or severe injury Change the brake fluid every two years and any time the fluid becomes contaminated the fluid level is below the minimum or if the type and brand of the fluid in the reservoir are unk...

Page 82: ...n authorized dealer Shock Spring Adjustment The front and rear shock absorber springs are adjustable to increase or decrease spring tension Rotate the adjuster either clockwise or counterclockwise to...

Page 83: ...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...

Page 84: ...he air box If water is present dry the air box and replace the filter with a new filter Thor oughly dry the air filter See page66 3 Remove the spark plugs 4 Turn the engine over several times 5 Dry th...

Page 85: ...ectrolyte Batteries produce explosive gases So you should avoid contact with skin eyes or clothing Always shield eyes when working near batteries Keep out of reach of children If contract with you bod...

Page 86: ...ch and the switch of the circuit in question then install a new fuse of the specified amperage Turn on the main switch If the fuse immediately blows again consult your dealer Specified fuses 1 Battery...

Page 87: ...ctions are correct when putting the battery back in the machine WARNING Do not use an improper fuse because an improper fuse can cause damage to the electrical system which could lead to a fire Always...

Page 88: ...inlet and outlet ducts when washing the vehicle from the rear High water pressure may damage components We recommend washing the vehicle by hand or with a garden hose using mild soap Certain products...

Page 89: ...spark plug wire and turn the engine over several times to coat the cylinder wall with oil 3 Block up the frame to raise all wheels off the ground 4 Tie a plastic bag over the exhaust pipe outlet to p...

Page 90: ...suitable plug is loose Starting motor is too slow Air circulation is not right Gap of valve is not suitable change change change Repair or change Tighten Check electric system Adjust Adjust Start dif...

Page 91: ...t start 4 Miscellaneous Gear is not in neutral Put gear on neutral 1 Mechanic problem Valve gap no suitable Valve base is not suitable Problem on air pipe Broken on bush of swing arms IAC valve blocke...

Page 92: ...e fuel pump Change Change Clean or Change Adjust or change Adjust or change Change Clean or change Clean Change Adjust or change Exhaust blue smoke Mechanical fault too many lube Piston ring worn out...

Page 93: ...Engine power is not enough 3 Mechanical problem Gap of Valve is not correct The force of valve spring is weak Air circulation is not right Cylinder worn out Piston Ring worn out Valve base not correc...

Page 94: ...ange Repair or change Dredge Repair or change 4 Engine cooling system Block in water channel or radiator Air in Cooling system or coolant is not enough Water pump problem Unsuitable coolant Constant t...

Page 95: ...ne of crankshaft damaged Spline of clutch damaged Change crankshaft Change clutch Noise from Crankshaft Bearing noise Needle bearing damaged Gap too big Change Change Change Noise from CVT Belt loose...

Page 96: ...suitable Change Change Change Adjust Starting problem Blocked in muzzle Blocked in muzzle channel Leakage on connecting part of starting part Starting pin not work properly Clean Clean Tighten Adjust...

Page 97: ...ition loop problem Starting loop problem Change Change Change Change Change Change II Malfunction in transmission system Vehicle speed does not increase by engine speed Transmission system Shift belt...

Page 98: ...em suspension and steering organization Running is leaning Running system Air pressure in left and right wheel is different Load of left and right wheel is different Spring force of left and right abs...

Page 99: ...radial is too great Air pressure in tyre is too hig or too low Adjust or Change Change Check or adjust Check load Change Adjust or Change Change Adjust air pressure in tyre Front wheel shakes swing o...

Page 100: ...wheel location is wrong Steering pole pipe is blocked Mesh clearance of redirector is too small Charge the tyre to applicable air pressure Change Check and adjust Repair or Change Adjust IV Malfunctio...

Page 101: ...se Vehicle is leaning Thread abrasion of left and right wheel is different Clean or Change Repair or Change Equalize the air pressure Adjust as the stipulation Repair or Adjust Repair or adjust Repair...

Page 102: ...er Check Change Change Repair circuit Repair Change Change Only one front headlight does not illuminate Lighting system Bulb has been damaged Lead or grounding happens malfunction Change Repair circui...

Page 103: ...t is bad or complete lamplights are damaged not including headlight Lamplight circuit Switch has been damaged Bulb has been burned Circuit has been cut off linking parts contact badly Fuse has been bu...

Page 104: ...on WARRANTY COVERAGE LIMITATIONS OF WARRANTIES AND REMEDIES The limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidenta...

Page 105: ...o a company Servicing Dealer When requesting warranty service you must present your related proof form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Company su...

Page 106: ...e your vehicle to an authorized Company dealer You must show the related proof Upon verification the servicing dealer will be authorized to perform the warranty repair Notice If your vehicle is regist...

Page 107: ...Wheelbase 1830mm 72 0in 2630mm 103 5in Minimum ground clearance 340mm 13 4in Minimum turning radius 4500mm 177 2 in 5000mm 196 9 in Maximum speed 85 km h Basic weight Mass of whole equipments Not inc...

Page 108: ...c Lubrication system Pressure spray Engine oil Type Recommended engine oil classification Quantity Without oil filter cartridge replacement 3 6L 3 8 US qt With oil filter cartridge replacement 3 5L 3...

Page 109: ...l change 0 31L 0 3US qt Air filter dry element Fuel Type UNLEADED GASOLINE 93 OCTANE OR ABOVE Fuel tank capacity 35L 9 3Gal EFI System Type quantity SIMK31 Manufacturer SIEMENS VDO Spark plug Type man...

Page 110: ...ion type V belt automatic Operation Right hand operation High gear 2 66 Low gear 5 527 Reverse gear 6 80 Chassis Frame type Steel tube frame Caster angle 8 Trail Tire Type Tubeless front 26 9 14 Size...

Page 111: ...swing arm independent suspension Shock absorber Front shock absorber Coil spring Air damper Rear shock absorber Coil spring Air damper Electrical Ignition system ECU Generator system A C magneto Batt...

Page 112: ...lant temperature warning light LED 1 4WD Lock drive indicator light LED 1 Fuses Battery fuse 30A Electronic clock ECU 10A Fuel pump 20 A Fan fuse 30A Power output fuse 30A Spare heater 20A Ignition co...

Page 113: ...105 MODEL 1100UE 1100UEL Vacant EPS 30 A 2WD 4WD Brake 15 A 1100GT User Manual 105...

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