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Maintenance & Adjustments

5

14

Engine Coolant

Checking Engine Coolant Level 

(EFI & Diesel Powered Units Only!)

Before each use, the engine coolant level in the overflow 
reservoir should be checked to ensure it is within the operating 
range. Engine coolant absorbs heat from the engine and 
transfers the heat to the air flowing through the radiator. If the 
coolant level becomes low, the engine may overheat and could 
cause severe damage to the engine.
Use a permanent type antifreeze containing corrosion and rust 
inhibitors. Dilute the antifreeze with water at a 1 : 1 ratio to mix 
the coolant solution (50% antifreeze : 50% water).

NOTE: 

Distilled water is recommended for the coolant solution 

IF your tap water has a high mineral content. Minerals cause 
scaling in the engine and the radiator coolant passages. System 
efficiency will be greatly reduced over time and severe engine 
damage may result. Refer to the antifreeze manufacturer’s 
instructions for additional information on dilution procedures.
1. 

Check the coolant level when the engine is cold and the 
utility vehicle is on a level surface.

2. 

Raise the hood and check the coolant level in the overflow 
reservoir on the right side of the radiator.

3. 

If the coolant level is below the “LOW” mark, remove the 
cap from the reservoir and add coolant solution to the 
“FULL” mark. Refer to Figure 5-2.

NOTE: 

The cooling system is a closed type. Normally, to prevent 

air from entering the system, the radiator cap should not be 
removed.

Figure 5-2

If the overflow reservoir is empty, the radiator cap should be 
removed and the coolant level in the radiator checked before 
adding coolant to the reservoir. If necessary, first refill the system 
through the radiator filler neck as follows:

Engine

Air Filter 

(Air-Cooled, Gas Powered Units Only!)

The engine air filter should be changed every 50 hours. Change 
more frequently if operated in extremely dusty conditions.
1. 

The air filter is located on top of the engine. To access, 
simply remove wing nut securing plastic cover, remove 
wing nut securing filter, inspect and replace if excessively 
dirty or damaged. See your Kohler engine manual for more 
detailed instructions.

2. 

Reattach cover and secure with latch.

Read the Kohler engine operator’s manual for any other service 
or maintenance information pertaining to the engine.

Air Filter 

(EFI & Diesel Powered Units Only!)

The engine air filter should be changed every 50 hours. Change 
more frequently if operated in extremely dusty conditions.
3. 

Pull up on latch and turn counter-clockwise to release air 
cleaner cover. See Figure 5-1.

Cover

Dust 

Valve

Element

Latch

Figure 5-1

4. 

Remove cover. Remove and inspect air cleaner element. If 
excessively dirty or damaged, replace element.

5. 

Reattach cover and secure with latch.

IMPORTANT: 

When reattaching cover, make certain that 

dust valve is pointing downward. See Figure 5-1 inset.

Read the Kohler engine operator’s manual for any service or 
maintenance information pertaining to the engine.

Summary of Contents for Volunteer

Page 1: ...s Set Up Operation Maintenance Service Troubleshooting Warranty WARNING READ AND FOLLOW ALL SAFETY RULES AND INSTRUCTIONS IN THIS MANUAL BEFORE ATTEMPTING TO OPERATE THIS MACHINE FAILURE TO COMPLY WIT...

Page 2: ...l operate the machine carefully follow the recommended safety practices at all times Failure to do so could result in personal injury or property damage All information in this manual is relative to t...

Page 3: ...iver and one passenger only No riders are allowed in cargo box or anywhere else on vehicle except in the driver and passenger seats 11 Keep all body parts i e head arms hands legs feet inside vehicle...

Page 4: ...on 31 Do not touch engine or muffler while engine is running or soon after it is stopped They will be hot and can cause a burn 32 Always inspect your vehicle each time you use it to make sure it is in...

Page 5: ...and the dangers Never assume that children will remain where you last saw them Avoid run over accidents a Keep children out of the immediate area of the vehicle and in watchful care of a responsible a...

Page 6: ...onmental Protection Agency Recycling centers are established to properly dispose of materials in an environmentally safe fashion 13 Use proper containers when draining fluids Do not use food or bevera...

Page 7: ...Read understand and follow all instructions in the manual s before attempting to assemble and operate WARNING HOT SURFACE Hot Surface Do not touch WARNING GAS CONTAINER Avoid injury from explosion Do...

Page 8: ...ence IMPORTANT Refer to the Engine operator s manual before operating this vehicle to familiarize yourself with the engine controls and adjustments A F G I J K H L M E B N O C D A 4x4 Switch all 4X4 u...

Page 9: ...nel Depressing the accelerator pedal will move the vehicle in the direction selected on the gearshift As the pedal is depressed speed will increase to the maximum selected range Releasing the pedal re...

Page 10: ...lowest possible lap position before riding To adjust the position of the seat belts 1 Loosen the seat belt mounting bolts 2 Reposition both the buckle an retractor Tighten the mounting bolts Cargo Bo...

Page 11: ...lease parking brake IMPORTANT DO NOT run the starter continuously for more than 5 seconds otherwise the battery may discharge quickly NOTE On air cooled gas powered models if the engine surges after s...

Page 12: ...face and parking brake is locked before raising cargo box Manual Lift 1 Park the vehicle safely on level ground and set parking brake 2 Empty cargo by hand and unlatch cargo box by pulling up on the c...

Page 13: ...nd hitch point provided for the utility vehicle Do not modify the hitch in any way Transporting Vehicle IMPORTANT Never tow the vehicle Transmission damage will occur if vehicle is towed Haul the vehi...

Page 14: ...e Normally to prevent air from entering the system the radiator cap should not be removed Figure 5 2 If the overflow reservoir is empty the radiator cap should be removed and the coolant level in the...

Page 15: ...ation Check for loose hose connections Replace any damaged hoses and tighten any loose connections Replace a worn or damaged water pump belt Servicing the Fuel Filter DieselModelsOnly WARNING Do not s...

Page 16: ...tween the fuel tank and the filter 1 Place a suitable container beneath the filter drain 2 Clamp the fuel line just to the rear of the fuel filter See Figure 5 4 3 Open the filter drain and drain the...

Page 17: ...rate properly 6 Reassemble the oil fill plug into the gearcase and torque to 10 ft pds Battery WARNING The battery produces a flammable and explosive gas Do not smoke near battery Wear eye protection...

Page 18: ...re Check tire pressure before driving the vehicle Operator Protective Structure OPS Periodically at least every six months visually inspect the OPS and seat belts need to be inspected for damage and p...

Page 19: ...ay comes in contact with intake openings or any other electrical components i e at instrument cluster or under dash CVT Inlet Filter A CVT Inlet Filter 751 12642 is installed in the inlet pipe of the...

Page 20: ...t the passenger seat forward and locate the adjustment in the throttle cable running along the right side of the unit below the passenger seat See Figure 5 13 1 Loosen the locking nut and thread the a...

Page 21: ...light assembly 2 Turn the bulb socket assembly approximately a quarter turn counterclockwise to align its tabs with the notches of the reflector then remove from the reflector See Figure 6 16 Figure 6...

Page 22: ...Brake Pads WARNING Using an unstable lifting device and vehicle support may result in bodily injury Use a safe lifting device and supports to work on raised vehicle To gain access to the brake pads re...

Page 23: ...UnitsOnly P Change Fuel Filter EFI DieselUnitsOnly P Inspect OPS and Seat Belts P Inspect Front and Rear Shocks P Inspect Ball Joints P Lubricate Rear Knuckles P Inspect CV Boots P Inspect Tires P Ins...

Page 24: ...Tires Black Steel Rims Set of 4 Mile Marker 3500 Lb Winch Digital Speedometer Fuel Gauge Hood Rack Warn 4000 Lb Winch Electrical Accessory Harness 22 Cubic Foot Dump Cart Front Receiver Warn Winch Ki...

Page 25: ...h Standard 2 Rear Receiver Dual Cup Holders Standard Additional Storage Dash Box Power Port 12V Dash Mounted Front Bumper Standard Front Brush Guard Standard Front bumper required Electric Bed Lift Op...

Page 26: ...rd 2 Rear Receiver Dual Cup Holders Standard Additional Storage Dash Box Power Port 12V Dash Mounted Front Bumper Standard Front Brush Guard Standard Front bumper required Electric Bed Lift Optional R...

Page 27: ...2 Rear Receiver Dual Cup Holders Standard Additional Storage Dash Box Power Port 12V Dash Mounted Front Bumper Standard Front Brush Guard Standard Front bumper required Electric Bed Lift Optional Rub...

Page 28: ...t in wiring Engine is difficult to start 1 Engine is cold 2 Plugged fuel filter 3 Carburetor not adjusted properly or dirty Air Cooled Gas Powered Units Only 4 Engine oil viscosity too heavy 5 Spark p...

Page 29: ...umes are colored Black Diesel Units Only 1 Fuel quality is poor 2 Too much oil 3 The air cleaner is clogged Engine fumes are colored Blue white Diesel Units Only 1 The inside of exhaust muffler is dum...

Page 30: ...olenoid 2 Key switch not turned to STOP position 3 Sulfated or worn out battery Battery light comes on when engine is running 1 Low engine speed 2 Faulty voltage regulator 3 Faulty battery 4 Faulty al...

Page 31: ...Notes 11 31...

Page 32: ...32 Notes...

Page 33: ...33 Notes...

Page 34: ...to that part as described in MTD Consumer Group Inc s application for certification The warranty period begins on the date the outdoor equipment engine is delivered to an ultimate purchaser or first p...

Page 35: ...ill eligible for warranty coverage Further the coverage under this warranty extends only to parts that were present on the off road engine and equipment purchased The following emission warranty parts...

Page 36: ...may carry a separate manufacturer s warranty Refer to applicable manufacturer s warranty for terms and conditions b Routine maintenance items such as lubricants filters tune ups brake adjustments clu...

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