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MAINTENANCE

CVT System(1100cc)

Usage and maintenance

When assemble CVT and gearbox, if the CVT driving plate is not accord with the center of
driven plate will serious effect 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 distance between driving plate and

driven plate is

39.8±0.15

checked by exclusive check tool for CVT assembly

）

refer to

picture3-1-1:

（

Picture 3-1-1

）

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Summary of Contents for Vyper 4WD 1100cc

Page 1: ...Owner s Manual Vyper 4WD 1100cc 4 seater 2 seater GIO MOTORS ...

Page 2: ... skills necessary to ride your UTV It also includes basic maintenance and inspection procedures If you have any questions regarding the operation or maintenance of your UTV please consult your dealer AN IMPORTANT SAFETY MESSAGE Read this manual for the UTV rider carefully and completely before operating your UTV Make sure you understand all instructions Pay close attention to the warning and cauti...

Page 3: ...g 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 injury or death to the machine operator a bystander or a person inspecting or repairing the machine A CAUTION indicates special precautions that must be taken to avoid damage to the machine ...

Page 4: ...legal 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 manufacture Please check your local riding laws and regulations before operating this UTV ...

Page 5: ...ols 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 OPERATION 31 Vehicle break in period 31 Pre ride inspection 33 ...

Page 6: ...g 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 water 44 Driving over obstacles 45 Driving in reverse 46 Parking on an incline 47 ...

Page 7: ...t 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 73 Steering wheel inspection 75 Shock spring adjustment 75 Tires 76 Vehicle immersion 77 ...

Page 8: ...Battery 78 Clearing and storage 81 Malfunction analysis and elimination 83 WARRANTY 97 SPECIFICATIONS 100 Circuit Diagram 105 ...

Page 9: ...n occur quickly 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 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 Operat...

Page 10: ...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 800cc 1100cc 1100cc 800cc NOTE The vehicle identification number is used to identify your machine ...

Page 11: ...n a vehicle 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 substantial safety hazard and increase the risk of bodily injury The warranty on your vehicle is terminated if any equipment has been added to the vehicle or if any modifications have been...

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 ...

Page 13: ...Department of 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 shield Gloves Wear gloves for comfort and for protection from sun cold weather and other elements Boots Wear sturdy footwear Do not ride a vehicle with bare feet Clothing Wear long sleeves and...

Page 14: ...d for your 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 situations and on different types of terrain Age Restrictions Operation is prohibited for anyone age 16 and under Never operate with a passenger age 12 and under Make sure any passenger is t...

Page 15: ...e vehicle is 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 and maintenance procedures and schedules described in the owner s manual Accessories Installing non approved accessories may seriously affect vehicle handling and stability which could resul...

Page 16: ...ring the seat 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 or accident Always make sure the seat belts are secured for both the operator and passenger before riding Using Alcohol or Drugs Riding in this vehicle after consuming alcohol or drugs coul...

Page 17: ...faces including sidewalks 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 only not for use on pavement 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 ...

Page 18: ...n abruptly or 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 holds or removing feet from the floor while riding increases the risk of loss of control and accident or overturn The operator should always keep both hands on the steering wheel during oper...

Page 19: ...Always follow 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 Never operate the vehicle on hills steeper than 15 degrees Always check the terrain carefully before driving down a hill Never travel down a hill at high speed Avoid traveling down a hill a...

Page 20: ...ile climbing 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 reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed Crossing Hillsides Driving on a sidehill is not recommended Improper procedur...

Page 21: ...ol or overturn 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 rough slippery or loose terrain could cause loss of traction loss of control accident or overturn Always use extra caution when operating on sand or on rough slippery or loose terrain Do not ...

Page 22: ... overturn Before 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 over obstacles Skidding or Sliding Skidding or sliding can cause loss of control or overturn if tires regain traction unexpectedly Always follow proper procedures for operating on slippery...

Page 23: ...ter as described 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 pads Overloading the Vehicle Overloading the vehicle or carrying towing loads may cause changes in stability and handling which could cause loss of control or an accident Never tow objects or...

Page 24: ...rturn or accident 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 frozen bodies of water can result in the vehicle and or riders falling through the ice Never operate this vehicle on a frozen body of water ...

Page 25: ...or near the 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 wash it off with soap and water and change clothing Turn the fuel valve off whenever the vehicle is stored or parked Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss ...

Page 26: ...omptly remove 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 Always remove the ignition key when the vehicle is not in use Safety Labels and Locations Warning labels have been placed on the vehicle for your protection Read and follow the instructio...

Page 27: ...vement may seriously affect handling and control 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 to Wear seat belts grab hand holds passenger and plant feet firmly on the floor Keep hands and feet inside vehicle Avoid quick turns of the steering wheel and ...

Page 28: ...icle WARNING 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 27 Front 14 0 5 96 5 3 5 Rear 14 0 5 96 5 3 5 26 OPTIONAL Front 12 0 5 82 5 3 5 Rear 12 0 5 82 5 3 5 MAXIMUM WEIGHT CAPACITY 990 lbs 450 Kg INCLUDES WEIGHT OF OPERATOR PASSENGER AND ACCESSORIES LOCATE AND READ OWNER S MANUAL FOLLOW ALL I...

Page 29: ...21 FEATURES AND CONTROLS Component Locations ...

Page 30: ...22 FEATURES AND CONTROLS Component Locations ...

Page 31: ...Temperature 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 Gear indicator 12 Oil pressure low warming light 13 Parking indicator light ...

Page 32: ...Driver model 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 switch optional 12 Auxiliary DC jack 12V 120W 10A ...

Page 33: ...erator and passenger Always make sure the seat belts are secured for both the operator and passenger before riding To wear the seat belt properly follow this procedure 1 Take up the seat belts which are located on the edges of seat and across your shoulders just like wear a coat The buckle is in front of your abdomen Make sure the belt is not twisted Tip The position of the shoulder strap can be a...

Page 34: ...rely latched 2 Push the red release latch in the middle of the buckle to make sure it releases freely 3 Inspect the full length for any damage including cuts wear fraying or stiffness If any damage is found or if the seat belt does not operate properly have the seat belt system checked and or replaced by an authorized dealer 4 To clean dirt or debris from the seat belts sponge the straps with mild...

Page 35: ... CONTROLS Fuel 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 gasoline ...

Page 36: ...switch to ON 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 socket also can be used for phone charging and external power supply Note The voltage of the socket is 12V DC Please check the electrical power so as to avoid damage ...

Page 37: ...ning shift linkage adjustment is important 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 transmission could result Always shift when the vehicle is stationary and the engine is at idle Parking Brake 1 Apply the brakes 2 When the vehicle is fully stopped pull...

Page 38: ... the brake pedal 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 released Always check that the throttle pedal returns normally before starting the engine Make sure there s adequate throttle pedal freeplay See page 60 for throttle pedal adjustment procedure...

Page 39: ...of gasoline 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 components Perform the following procedures carefully NOTICE Excessive heat build up during the first three hours of operation will damage close fitted engine parts and drive components Do no...

Page 40: ... not operate 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 System Break in Apply only moderate braking force for the first 50 stops Aggressive or overly forceful braking when the brake system is new could damage brake pads and rotors CVT Break in Clu...

Page 41: ...rating condition Item Remarks Page Brake Ensure proper operation 73 Steering Ensure free operation 75 Engine oil Ensure proper levels 51 52 53 54 Air filter Inspect clean 66 67 Seat Belts Check length of belt for damage check latches for proper operation 25 Brake fluid Ensure proper level 74 Tires Inspect condition 76 Throttle system Ensure proper operation 69 70 Gearcase fluid Ensure proper level...

Page 42: ...d gravel roads 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 the steering wheel at all times 8 Never consume alcohol or drugs before or while operating this vehicle 9 Always use the size and type of tires specified for your vehicle Always maintain p...

Page 43: ...6 If the engine 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 it does not readily start intermittent use of the choke pulled half way out may be necessary If the engine is over choked when warm depress the throttle lever fully while cranking to aid ...

Page 44: ...ne braking 2 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 parking inside a garage or other structure be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks including any appliance with pilot li...

Page 45: ...the pre ride 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 fasten the seat belt 7 Do not operate or ride in this vehicle if the clearance between the top of your helmet and the overhead cab frame is less than 2 inches 5 cm 8 Do not carry a passeng...

Page 46: ...e starting stopping 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 maneuvers at a slow speed 18 After you become skilled at making turns and begin to operate at faster speeds follow these precautions Avoid sharp turns Make turns gradually Never turn while app...

Page 47: ...riving experience 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 feet on the floor and grasp the hand holds 5 Make sure the passenger has at least 2 inches 5 cm of clearance between his helmet and the top of the cab frame 6 Never carry more than one pa...

Page 48: ... conditions 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 Slippery Surfaces When driving on slippery surfaces such as wet trails loose gravel sand or ice be alert for the possibility of skidding and sliding Skidding or sliding can cause loss of contro...

Page 49: ...n slippery conditions 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 skid Never apply the brakes during a skid ...

Page 50: ...Drive at a steady 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 or person could be on the other side of the hill 8 If the vehicle stalls while climbing a hill apply the brakes Place the transmission in reverse and slowly allow the vehicle to roll strai...

Page 51: ...e or cause the 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 maximum 2 Slow down Never travel down a hill at high speed 3 Always check the terrain carefully before driving down a hill 4 Always drive down a hill with the transmission in forward gear ...

Page 52: ...on will help 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 special attention to engine oil transmission oil and all grease fittings If your vehicle is operated in water deeper than the floor level take it to your dealer for service before starting ...

Page 53: ...s such as logs 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 fallen trees If it s unavoidable use extreme caution and drive slowly 5 Always have a passenger dismount and move away from the vehicle before driving over an obsta cle that could cause a...

Page 54: ...w these precautions 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 stopping 5 Avoid making sharp ...

Page 55: ...e 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 56: ...lified 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 Definition Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed operation E...

Page 57: ...avel Daily Wheels fasteners Daily Frame fasteners Daily Ⅰ Engine oil level Daily Check each day before driving the vehicle Make adjustments as needed See the Pre Ride Checklist on page33 Ⅰ Engine oil change break in 25 1 M Perform a break in oil change at one month Engine oil change 100 6 M Perform a break in oil change at one month Ⅰ Air filter main element Weekly Inspect replace as needed Ⅰ Ⅱ Br...

Page 58: ...nthly 250 400 Check terminals clean test Ⅱ Toe adjustment Inspect periodically adjust when parts are replaced Headlight aim Adjust as needed Ⅱ Choke 10 Monthly 100 160 Check for proper operation see dealer for adjustments Ⅰ Main gearcase oil 25 Monthly 250 400 Inspect level change yearly Ⅰ Perform these procedures more often for vehicles subjected to severe use Ⅱ Have an authorized dealer perform ...

Page 59: ...il Always check 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 Recommendations NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands Engine oil classification of ...

Page 60: ...pe it dry with a clean cloth 3 Reinstall the dipstick completely 4 Remove the dipstick and check the oil level 800cc Tip A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase If the oil level is over the full safe mark change the oil immediately 5 Add the recommended oil as needed 6 Reinstall the dipstick ...

Page 61: ...e engine 3 Clean 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 drain completely 800cc NOTE The sealing surfaces on drain plug and crankcase should be clean and free of burrs or scratches 6 Using a cap style oil filter wrench turn the oil filter cartr...

Page 62: ...f 14ft lbf 10 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 one to two minutes 14 Stop the engine Inspect for leaks 15 Re check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick 16 Dispose o...

Page 63: ...ommended oil 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 drain plug Allow the oil to drain completely 4 Clean the drain plug 5 Reinstall the drain plug with a new o ring 6 Add SAE 80W 90 GL 5 of the recommended oil to the fill hole Maintain the oil ...

Page 64: ...e spark plug firing end condition 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 protective gloves when removing a spark plug for inspection Specified spark plug K6RTG 1100cc DCPR8E 800cc Spark Plug Removal and Replacement 1 Remove the spark plug cap 2 Us...

Page 65: ...ghtening torque No 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 21102 T02 0000 Locking nut M32x1 5 40 1 Combination of fixed disk driving wheel 4 GB T6184 2000 Locking nut M5 6 1 Swing block shaft 5 21001 T02 0000 Driving chain connection bolt M12...

Page 66: ... serious effect 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 distance between driving plate and driven plate is 39 8 0 15 checked by exclusive check tool for CVT assembly refer to picture3 1 1 Picture 3 1 1 ...

Page 67: ...E CVT System 1100cc 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: ...he 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 ...

Page 69: ...erating life of 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 is serious abrasion or the loose edge verticality of belt is more than 15mm WARNING The driving driven parts have been checked by dynamic balance combine gain weight with remove weight...

Page 70: ...List Please maintenance 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 1500 Check change if needs Countermark position ...

Page 71: ...63 MAINTENANCE CVT System 1100cc Appearance installation dimension map ...

Page 72: ... to be out of 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 conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe This CVT system is intended for use on our...

Page 73: ...art the engine 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 speed 5 Test for belt slippage If the belt slips repeat the process 6 Take the vehicle to your dealer for service as soon as possible NOTICE Exposure to salt water will cause corrosion to...

Page 74: ...ng on page 49 1 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 If the filter element is damaged install a new filter 1 JOINT AIR CLEANER 2 CIRCLIP 3 PRIMARY COVER 4 FILTER ELEMENT 5 TAIL COVER ...

Page 75: ...r sediments in 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 severe damage to the engine 7 Reinstall rear decorative board ...

Page 76: ... reservoir cap 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 under pressure Wait for the engine to cool before removing the radiator cap Always use a thick rag over the cap Allow any remaining pressure to escape before completely removing the cap NOTE...

Page 77: ...problems arise 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 cause a delay in throttle response especially at low engine speed The throttle may also not open fully If the throttle pedal has no freeplay the throttle may be hard to control and the idl...

Page 78: ...spection 1 Place 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 Freeplay should be 1 16 to 1 8 inches 1 5 3 mm ...

Page 79: ... through the accelerator 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 canal the gas flow amount by the unit motor control meets the system requirements the idling regime goal rotational speed NOTE The idle speed limit screw does not allow the adjustment the ...

Page 80: ...r s gas flow amount the damper opening transmits from the damper position transducer to engine control unit ECU Flows through the by pass canal the gas flow amount by the unit motor control meets the system requirements the idling regime goal rotational speed Crankcase Position Sensor Intake air Temperature Pressure Sensor Fuel Injector Water Temperature Sensor Throttle body position sensor Thrott...

Page 81: ...em operation 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 resulting in severe injury or death Never operate the vehicle with a spongy feeling brake pedal Brake Inspection 1 Check the brake system for fluid leaks 2 Check the brake pedal for excessive t...

Page 82: ... of accident 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 unknown Access the brake fluid reservoir through the left front wheel well 1 Position the vehicle on a level surface 2 Place the transmission in neutral Set the parking brake 3 View the brake...

Page 83: ...spected by an 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 make adjustments Always apply the same adjustment setting to all four wheels WARNING Uneven adjustment may cause poor handling of the vehicle which could result in an accident Always adjus...

Page 84: ...tain proper 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 surfa...

Page 85: ...nd 2 Check the 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 the spark plugs and reinstall them or install new plugs 6 Attempt to start the engine If necessary repeat the drying procedure 7 Take the vehicle to your dealer for service as soon as possib...

Page 86: ...n battery electrolyte 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 body take the follow measures EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Get prompt medical attention ...

Page 87: ...g a conventional battery charger may shorten the battery life Fuse replacement 1 The fuses are under the garnish cover of the engine cover 2 If a fuse is blown turn off the main switch 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 ...

Page 88: ...re the connections 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 use a fuse of the specified rating Never use a material in place of the proper fuse CAUTION To prevent accidental short circuiting turn off the main switch when checking or replacing a fu...

Page 89: ...tly toward the CVT 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 including insect repellents and chemicals will damage plastic surfaces Do not allow these types of products to contact the vehicle The best and safest way to clean your vehicle is w...

Page 90: ...g Ground the 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 prevent moisture from entering 5 If storing in a humid or salt air atmosphere coat all exposed metal surfaces with a light film of oil Do not apply oil to any rubber parts or the seat cover...

Page 91: ...valve is not 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 difficultly or could not start 2 No ignition generated from plug Dirt on spark plug Wet on plug or smudge Ignition coil problem Touch loop got open or short circuit Magneto problem ECU proble...

Page 92: ... or could not 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 blocked in inlet exhaust pipe Adjust screw of idle sets wrong Adjust Repair or Change Change Change Adjust or Change Adjust Engine has no idle speed or uneven 2 Electric parts problem Dirt on pl...

Page 93: ...ight pressure 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 Valve pipe worn out Cylinder wall scratched Valve rod worn out Seal of valve rod broken Drain the extra lube Change Change Change Change Change 1 Fuel supply system fault Blocked in muzzle...

Page 94: ...hange Change 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 correct Swing arm or cam shaft worn out Change operation method Check remove or change Adjust Change Change Change or repair Change Engine overheats 1 Fuel system fault Octane number is lower Fu...

Page 95: ...Repair or change 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 temperature unit problem Fault on motor of fan or switch of heat sensor Clear Release air refill coolant Change Change Change Change 5 Miscellaneous Carbon accumulated on top of piston Too ...

Page 96: ... clutch Spline 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 or worn out Roller or main wheel damage Change Change engine Noise from transmission system Gear damaged Input and output shaft damaged Bearing worn out Bush worn out Change Change Change ...

Page 97: ...ing stick unsuitable 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 or change Adjust Throttle body works not properly Idle and low speed not stable Reducer valve blocked or loose Valve channel Blocked Air inlet channel blocked Air inlet bypass Blocked Star...

Page 98: ... is weak Ignition 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 slips Speed adjusting plate abrasion is too much Speeding adjusting plate slipping is blocked Spring force of adjuster is short Change Change Repair or Change Repair or Change Out of gear ...

Page 99: ...running system 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 absorbing spring Front wheel location is wrong One side wheel is locked or brake could not release Front and rear suspension parts have been loosened bent or damaged Adjust air pressure in ty...

Page 100: ...y jump axial 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 or jump Steering organization running system Tyre and wheel is not balance Wheel hub bearing has been damaged or adjustment is wrong Left and right swing arm ball head has been abraded or l...

Page 101: ...ocked Front 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 Malfunction in brake system Brake is not hard enough Brake system Brake pipeline leaks oil Brake disk and brake hoof contacts badly or dirt on surface Brake drum and brake hoof wear badly Brake main...

Page 102: ...on parts loose 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 Check repair and fasten Verify repair and adjust Change Brake clip block Brake system Brake main pump could not return correctly Brake hoop return spring is too soft Parking brake adjustm...

Page 103: ...hange adjuster 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 circuit Steering light does not illuminate Steering relay has been damaged Individual steering bulb has burned Grounding is bad Fuse burn out Switch damaged Change Change Repair Change Change St...

Page 104: ... of lamplight 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 burned Grounding wire contacts badly Change Change Repair circuit Change Repair Meter works badly Meter and wire Fuse has been burned Route has been cut off tie in contacts badly Instrument ...

Page 105: ...free operation 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 accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any vehicle that has been altered structurally modified neglected improperly maintained used for ...

Page 106: ...t to 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 suggests that you use your original selling dealer however you may use any Company Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your...

Page 107: ...here your vehicle was purchased you should take 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 registered outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for warra...

Page 108: ...ound 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 include driver 800UE 700kg 1100UE 711 kg 800UEL 800 kg 1100UEL 820 kg Engine Engine type 800cc Water cooled 4 stroke 2V91MW 1100cc Water cooled 4 stroke SQR472 Number of cylinder Two cylinder 800cc Four cylinder 1100cc Displacement 800cc 0 8L 1100cc 1 0...

Page 109: ...ed idle 800cc 1250 50rpm 1100cc 850 50rpm Starting system Electric Lubrication system Pressure spray Engine oil Type Recommended engine oil classification Quantity Without oil filter cartridge replacement 800cc 2 2L 2 3 US qt 1100cc 3 6L 3 8 US qt With oil filter cartridge replacement 800cc 2 1L 2 2 US qt 1100cc 3 5L 3 7 US qt ...

Page 110: ...eriodic oil change 0 25L 0 27US qt Air filter dry element Fuel Type UNLEADED GASOLINE 93 OCTANE OR ABOVE Fuel tank capacity 35L 9 3Gal EFI System Type DELPHI MT05 800cc SIMK31 1100cc Manufacturer DELPHI 800cc SIEMENS VDO 1100cc Spark plug Type manufacturer 800cc DCPR7E 1100cc K6RTG Spark plug gap 800cc 0 7 0 8 mm 1100cc 0 9 1 1 mm Clutch type wet hoof centrifugal type ...

Page 111: ...ic Operation Right hand operation High gear 1100cc 2 66 800cc 2 886 Low gear 1100cc 5 527 800cc 5 29 Reverse gear 1100cc 6 80 800cc 5 087 Chassis Frame type Steel tube frame Caster angle 8 Trail Tire Type Tubeless front 27 9 14 26 9 14 optional Size rear 27 11 14 26 11 14 optional Brake type Dual disc brake Front brake operation Left foot operation ...

Page 112: ...on Rear suspension Double 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 Battery type Battery capacity 12V 36Ah Headlight type Bulb voltage wattage quantity Headlight 12 V 35 W 35 W 2 Tail brake light 12 V 21W 5W 2 ...

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