Massimo ALLIGATOR 500 Owner'S Manual Download

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Periodic Maintenance and Adjustment 8-42

by lifting it up and pulling it out.

1. Battery compartment cover

2. Turn the key to “OFF” and turn off the

electrical circuit in question.

CAUTION:

To prevent accidental short-circuiting, turn off
the main switch when checking or replacing
a fuse.

3. Remove the blown fuse, and then install

a new fuse of the specified amperage.

1.    Main fuse                            2. Spare main fuse
3.  Headlight fuse          4. Ignition fuse
5.    Auxiliary DC jack fuse
6. Four-wheel-drive motor fuse
7.    Signaling system fuse
8.  Backup fuse

（

for odometer and clock

）

9. Fuel system warmer fuse 10. Spare fuse

（

×3

）

Summary of Contents for ALLIGATOR 500

Page 1: ...MASSIMO ALLIGATOR 500 MSU 500 Owner s Manual ...

Page 2: ...cle It also includes basic maintenance and inspection pro cedures If you have any questions regarding the operation or maintenance of your vehicle please consult you dealer AN IMPORTANT SAFETY MESSAGE READ THIS MANUAL FOR THE VEHICLE RIDER CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR VEHICLE MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE VE...

Page 3: ......

Page 4: ...e following notations The Safety Alert Symbol means ATTENTION YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the machine operator bystander or a person inspecting or repairing the machine A CAUTION indicates special precautions that must be taken to avoid damage to the machine A NOTE provides key information to make procedures easier or cle...

Page 5: ...s below 4 F 20 C park the UTV in a place where the temperature is higher than 4 F 20 C Start the UTV after the UTV has warmed up Please see page 6 3 on the warming up process Follow the proper parking procedures when the temperature is higher than 100 F 38 C turn off the engine make sure the radiator fan is on for 3 minutes before turning off the power switch Starting the UTV for the first time wi...

Page 6: ...Odometer and Trip Meter Modes 4 6 Clock time adjustment 4 7 Fault code indicator 4 8 Fuel level indicator 4 9 Switches 4 9 Accelerator Pedal 4 14 Brake Pedal 4 15 Parking Brake Lever 4 15 Drive Select Lever 4 16 Fuel Tank Cap 4 17 Seats 4 17 Seat Belts 4 18 Glove Compartment 4 21 Cargo Bed 4 21 Opening and Closing the Tailgate 4 22 Lifting and Lowering the Cargo Bed 4 22 Front and Rear Shock Absor...

Page 7: ...g Wheel Inspection 5 10 Seat Belts 5 10 Fittings and Fasteners 5 10 Lights 5 10 Switches 5 11 Tires 5 11 How to Measure Tire Pressure 5 12 Tire Wear Limit 5 13 Operation 6 1 Starting the Engine in Low Temperatures 6 1 Starting the Engine 6 2 Warming Up 6 3 Drive Select Lever Operation and Driving In Reverse 6 4 Parking 6 8 Parking on a Slope 6 8 Vehicle Break in Period 6 9 Engine Break In 6 10 Acc...

Page 8: ...rication Chart 8 4 Hood 8 7 Console 8 8 Engine Oil and Oil Filter Cartridge 8 9 To Check the Engine Oil Level 8 9 To Change the Engine Oil 8 10 Final Gear Oil 8 13 Changing the Final Gear Oil 8 15 Differential Gear Oil 8 16 Changing The Differential Gear Oil 8 17 Coolant 8 18 Axle Boots 8 19 Spark Plug Inspection 8 20 Inspection 8 21 Installation 8 21 Cleaning the Air Filter Elements 8 22 V belt C...

Page 9: ...ication 8 37 Steering Shaft Lubrication 8 37 Wheel Removal 8 37 Wheel Installation 8 38 Battery 8 39 Battery Maintenance 8 41 Fuse Replacement 8 41 Replacing Headlight Bulb 8 43 Headlight Beam Adjustment 8 46 Tail brake Light Bulb Replacement 8 47 Troubleshooting 8 49 Solution to Common Problems in the Vehicle 8 50 Cleaning and Storage 9 1 Cleaning 9 1 Storage 9 3 Specifications 10 1 Faultcode of ...

Page 10: ...Location of the Warning and Safety Labels 1 1 ...

Page 11: ...all of the labels on your vehicle They contain important information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or comes off a replacement label is available by contacting your dealer 2 ...

Page 12: ...Location of the Warning and Safety Labels 1 3 ...

Page 13: ...1 4 Location of the Warning and Safety Labels ...

Page 14: ...Location of the Warning and Safety Labels 1 5 ...

Page 15: ...1 6 Location of the Warning and Safety Labels 9 10 ...

Page 16: ...Location of the Warning and Safety Labels 1 7 11 14 12 13 ...

Page 17: ... handgrip fixed before the seat Always avoid operating the vehicle on any paved surfaces including sidewalks driveways parking lots and streets Never operate this vehicle on any public street road or highway even dirt or gravel streets Never operate this vehicle without wearing an approved motorcycle helmet that fits properly You should also wear eye protection goggles or a face shield gloves over...

Page 18: ...e right and left as they respond to the terrain and this movement will be felt in the steering wheel A sudden jolt could wrench the steering wheel around and your thumbs or fingers could be injured if they are in the way of the steering wheel spokes Always go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when driving the vehicle Nev...

Page 19: ...per than the floorboards on this model Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply the brake several times to let friction dry out the linings Always be sure there are no obstacles or people behind you when you operate in reverse When it is safe to proceed in reverse go slowly Do not brake abruptly when carrying loads in the ca...

Page 20: ...n the vicinity of sparks open flames or other sources of ignition such as the pilot light of water heaters and clothes dryers When transporting the vehicle in another vehicle be sure it is kept in an upright position Otherwise fuel may leak out of the engine or fuel tank WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries HOW TO AVOID THE HAZARD If you should swallow some gasoline or inha...

Page 21: ...D Starting or running the engine in a closed area WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time HOW TO AVOID THE HAZARD Always operate your vehicle in an area with adequate ventilation ...

Page 22: ...ir intake duct 5 V belt case 6 Driver seat 7 Driver seat belt 8 Spark plug 9 Cargo bed 10 Tail brake lights 11 Rear shock absorber assembly adjusting ring 12 Cargo bed release levers 13 Spark arrester 14 Passenger seat belt 15 Passenger seat 16 Oil filter cartridge 17 Engine oil dipstick 18 Battery 19 Fuses 20 Coolant reservoir 21 Radiator cap 22 Fuel tank cap ...

Page 23: ...ain switch 27 On Command four wheel drive and differential lock switches 28 Multi function meter unit 29 Auxiliary DC jack 30 Drive select lever 31 Parking brake lever 32 Accelerator pedal 33 Brake pedal NOTE The vehicle you have purchased may differ slightly from those in the figures of this manual ...

Page 24: ... assistance when ordering spare parts from a service center or for reference in case the vehicle is stolen 1 VEHICLE IDENTIFICATION NUMBER 2 MODEL LABEL INFORMATION Vehicle Identification Number The Vehicle Identification Number VIN is stamped into the frame 1 Vehicle identification number NOTE The vehicle identification number VIN is used to identify your vehicle ...

Page 25: ...All electrical circuits are supplied with power and the headlights and taillights illuminate when the light switch is on OFF All electrical circuits are switched off The key can be removed in this position START The electric starter is engaged by turning and holding the key in this position Release the key when the engine starts ...

Page 26: ... starting instructions prior to starting the engine See pages 6 1 6 3 for details Indicator and Warning Lights 1 Four wheel locked showing light 2 Fault indicator light of EPS system 3 differential gear lock indicator 4 Coolant temperature warning light 5 Emergency indicator 6 Reverse indicator light R 7 Neutral indicator light N 8 High range indicator light H 9 Low range indicator light L 10 Mech...

Page 27: ...en the drive select lever is in the N position Reverse Indicator Light R This indicator light comes on when the drive select lever is in the R reverse position Coolant Temperature Warning Light When the coolant temperature reaches a specified level this light comes on to warn that the coolant temperature is too hot If the light comes on during operation stop the engine as soon as it is safe to do ...

Page 28: ...Use of EPS system Meter is an important part of UTV Meter works together with EPS system and monitors working condition of EPS system Fault can be displayed by fault indicator light and fault indicator of EPS system so the driver can acknowledge fault of EPS in time and take some measures to keep himself herself safe When fault occurs on EPS system fault indicator light will be lit up At the same ...

Page 29: ...m is lit that means EPS system find out some fault during ECU self checking process then you should consult your local dealer for maintenance in time Speedometer Unit 1 Speed indicator 2 Clock Hour fault code meter 3 RPM indicator 4 Metric mile button 5 TRIP ODO button 6 Right turn indicator light 7 Left turn indicator light 8 Clock Hour fault code reset button ...

Page 30: ...y pressing the button on the left side toggles the display from the odometer to the tripometer and then to the hours meter then it starts the cycle over The odometer displays the total distance traveled by the UTV The tripometer records distances for a specific trip and can record distances from 0 through 999 9 miles To reset a trip meter select it by pressing the left button Press left button to ...

Page 31: ... panel The left 4WD indicator has a blinking circle on the front axle when the grey and yellow 4WD selector buttons are pressed in indicating the 4WD function has been activated This position also indicates that the 4WD is NOT locked This allows the wheels on the left and right sides to rotate at different speeds to accommodate turning Differential gear lock indicator The right 4WD symbol will sho...

Page 32: ...w and the gray buttons to the 2WD unlocked position There should be no symbols showing in either the left or right 4WD indicators CAUTION If the display indicators flash or the speedometer does not show the speed while the UTV is in motion Ask a dealer to check the speed sensor and circuits Fault code indicator When the EFI encounters faults the ECU will send the fault code to the instrument displ...

Page 33: ...l display will indicate the fuel volume When the fuel is getting low the fuel pump symbol will flash 1 Fuel level indicator 2 Fuel level warning indicator Switches 1 Light switch OFF Light switch OFF Set the switch to to turn on the low beam and the taillights Set the switch to to turn on the high beam and the taillights Set the switch to OFF to turn off all the lights ...

Page 34: ...te properly If this happens remove the battery and recharge it On Command Four Wheel Drive and Differential Gear Lock Switches 1 On Command four wheel drive switch 2WD 4 WD 2 Differential gear lock switch LOCK 4WD This vehicle is equipped with an On Command four wheel drive switch 2WD 4WD and a differential gear lock switch 4WD LOCK Select the appropriate drive according to terrain and the ...

Page 35: ...G POTENTIAL HAZARD Changing from 2WD to 4WD or from 2WD to 2WD Differential UNLOCK or vice versa while the vehicle is moving WHAT CAN HAPPEN The vehicle handles differently in 4WD than in 2WD and in 2WD Differential UNLOCK in some circumstances Changing from 2WD to 4WD or from 2WD to 2WD Differential UNLOCK or vice versa while moving may cause the vehicle to unexpectedly handle differently This co...

Page 36: ...ll come on in the multi function meter unit display To change from 4WD to 2WD stop the vehicle be sure the select lever is set to positionⓐ and then set the switch to 2WD On Command Differential Gear Lock Switch 4WD LOCK 1 On Command differential gear lock switch 4WD LOCK 2 Select lever To lock the differential gear in 4WD stop the vehicle make sure the On Command four wheel drive switch is set to...

Page 37: ...The amount of effort required is greater the faster you go You may lose control and have an accident if you cannot make a sharp enough turn for the speed you are traveling HOW TO AVOID THE HAZARD Always ride at a slow speed when the vehicle is in 4WD LOCK and allow extra time and distance for maneuvers NOTE z When the switch is set to LOCK the differential gear lock indicator and indicator light w...

Page 38: ...e speed Spring pressure returns the pedal to the rest position when released Always check that the accelerator pedal returns normally before staring the engine 1 Accelerator pedal Before starting the engine check the accelerator pedal to be sure it is operating smoothly Make sure the accelerator pedal fully returns to the idle position as soon as it is released ...

Page 39: ...eration of the accelerator pedal before you start the engine If it does not work smoothly check for the cause Correct the problem before operating the vehicle Consult a service center if you cannot find or solve the problem yourself 1 Brake pedal Parking brake lever The parking brake lever is located at the right side of the driver s seat It will help keep the vehicle from moving while parked To s...

Page 40: ...ease the parking brake before starting out Failure to do so may result in poor performance and premature wearing of the rear brake and V belt 1 Parking brake lever 2 Release button Drive select lever The drive select lever is used to shift you vehicle into the low high neutral and reverse positions Refer to pages 6 4 6 6 for the drive select lever operation 1 Drive select lever ...

Page 41: ...move the fuel tank cap by turning it counterclockwise 1 Fuel tank cap Seats To remove a seat pull its seat lock lever upward lift the front of the seat and then slide the seat forward and up 1 Driver seat 2 Passenger seat 3 Seat lock lever 2 ...

Page 42: ...AL HAZARD A loose seat WHAT CAN HAPPEN The operator could lose control or the operator or passenger could fall if the seat is loose during operation HOW TO AVOID THE HAZARD Make sure the seat is securely latched Seat belts This vehicle is equipped with three point seat belts for both the operator and passenger Always wear the seat belt while riding in the vehicle ...

Page 43: ...y portion of the vehicle your clothing or any equipment you are carrying 2 Push the latch plate into the buckle until it clicks Pull up on the latch plate to make sure it is secure 1 Buckle 2 Latch plate 3 Put the lap portion of the belt low on your hips Push down on the buckle end of the belt as you pull up on the shoulder part so the belt is snug across your hips 4 Position the shoulder belt ove...

Page 44: ...ase button 1 Buckle 2 Release button WARNING POTENTIAL HAZARD Not wearing the seat belt or wearing the seat belt improperly WHAT CAN HAPPEN There is increased risk of being killed or seriously injured in an accident HOW TO AVOID THE HAZARD Always wear your seat belt when riding in the vehicle Be sure the seat belt is close fitting across your hips and chest and is latched securely ...

Page 45: ... To protect from damage do not put metal products like tools or sharply edged products directly in the glove compartment If they must be stored wrap them in appropriate cushion material a Unlock b Open Cargo bed 1 Cargo bed 2 Tailgate 3 Cargo hook 4 ...

Page 46: ...lgate in the original position and then hook the latches Lifting and lowering the cargo bed 1 Cargo bed release lever To lift Push down cargo bed release lever on left or right side of the vehicle slowly lift up cargo bed until it stops To lower Lower cargo bed slowly to its original position and be sure it locks into place Maximum load limit 350lb 159kg ...

Page 47: ...g away from the vehicle Keep hands and fingers away from the pinch points between the bed and the frame WARNING POTENTIAL HAZARD Overloading the cargo bed WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated maximum load limit for this cargo bed Cargo should be properly distributed and securely attached Reduce speed...

Page 48: ...nly Front and rear shock absorber adjustment The spring preload can be adjusted to suit the operating conditions You can reduce preload for a softer ride or increase preload if frequent bottoming out of the UTV occurs CAUTION Frequent or severe bottoming out of the UTV can cause increased wear or damage to the vehicle Adjust the spring preload as follows To increase the spring preload turn the adj...

Page 49: ...l Functions 1 Spring preload adjusting ring 2 Position indicator NOTE A special wrench can be obtained at a service center to make this adjustment Standard position B A Minimum soft E Maximum hard 1 Special wrench ...

Page 50: ...h could lead to an accident HOW TO AVOID THE HAZARD Always adjust the shock absorbers on the left and right side to the same setting Trailer hitch bracket This vehicle is equipped with a 1 in receiver bracket for a standard trailer hitch Trailer towing equipment can be obtained at a service center See pages 6 12 6 14 for precaution information 1 Trailer hitch bracket ...

Page 51: ...e work lights radios etc The auxiliary DC jack should only be used when the engine is running 1 Auxiliary DC jack cap 1 Set the light switch to OFF 2 Start the engine See pages 6 1 6 3 3 Open the auxiliary DC jack cap and then insert the accessory power plug into the jack 1 Auxiliary DC jack Maximum rated capacity for the auxiliary DC jack DC 12V 120W 10 A ...

Page 52: ...e maximum capacity This may overload the circuit and cause the fuse to blow z If accessories are used without the engine running or with the headlights turned on the battery will lose its charge and engine starting may become difficult z Do not use an automotive cigarette lighter or other access with a plug that gets hot because the jack can be damaged ...

Page 53: ...r Check coolant level Fill with coolant if necessary 5 6 8 19 8 20 Final gear oil Differential gear oil Check for leakage 5 7 Accelerator pedal Check for proper accelerator pedal operation 5 8 Seat belts Check for proper operation and belt wear 5 10 Steering Check for proper operation 5 10 Fittings and fasteners Check all fittings and fasteners 5 11 Lights and switches Check for proper operation 5...

Page 54: ...tion Always follow the inspection and maintenance procedures and schedules described in the Owner s Manual Brakes Check for correct brake pedal free play If the brake pedal free play is incorrect have a service center adjust it See pages 8 34 8 35 Check the operation of the brake pedal It should move smoothly and there should be a firm feeling when the brakes are applied If not have the vehicle in...

Page 55: ... working properly If the brakes do not provide proper braking performance inspect the brake system See pages 8 30 8 35 WARNING POTENTIAL HAZARD Driving with improperly operating brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride Do not operate the vehicle if you find any problem with the b...

Page 56: ...esigned to use regular unleaded gasoline with a pump octane number R M 2 of 91 or higher or research octane number of 91 or higher If knocking or pinging occurs use a different brand of gasoline or premium unleaded fuel Unleaded fuel will give you longer spark plug life and reduced maintenance cost Gasohol The UTV uses an electric fuel injection system and its emissions completely meet the require...

Page 57: ...cially on the engine or exhaust pipe Wipe up any spilled fuel immediately Be sure the fuel tank cap is closed securely Engine oil Make sure the engine oil is at the specified level Add oil as necessary See pages 8 10 CAUTION z In order to prevent clutch slippage since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specification of CD or oi...

Page 58: ...m and maximum level marks on the coolant reservoir If the coolant level is at or below the minimum level mark add additional coolant to bring the level up to maximum level mark If coolant is not available add distilled water Change the coolant every two years See pages 8 19 8 20 for details CAUTION Hard water or salt water is harmful to the engine You may use soft water if you cannot get distilled...

Page 59: ...emaining pressure to escape before completely removing the cap Final gear oil Make sure the final gear oil is at the specified level Add oil as necessary See pages 8 14 8 15 for details Recommended oil SAE 80 API GL 4 Hypoid gear oil If desired an SAE 80W90 hypoid gear oil may be used for all conditions NOTE GL 4 is a quality and additive rating GL 5 or GL 6 rated hypoid gear oils may also be used...

Page 60: ... operation WARNING Failure to check or maintain proper operation of the throttle system can result in an accident and 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 service center for service if throttle problems arise Always check the pedal for fr...

Page 61: ...y if necessary Throttle Freeplay Inspection 1 Lift the parking brake to the top to park the car 2 Apply the brakes 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 1 16 to 1 8 inches 1 5 3mm Throttle Freeplay Adjustment 1 Remove both seats Remove the middle cover of the engine see PAGE 8 9 2 Lo...

Page 62: ...elts Make sure that both seat belts are not frayed or damaged The seat belt must move smoothly when pulled out and retract on its own when released The latch plate should click securely into the buckle and release when the release button is pushed firmly Wash off any dirt or mud which could affect operation Have a service center repair as necessary for proper operation Fittings and fasteners Alway...

Page 63: ... improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires on this vehicle or operation of this vehicle with improper or uneven tire pressure may cause loss of control increasing your risk of accident HOW TO AVOID THE HAZARD 1 The tires listed below have been approved by Manufacturer for this model Other tire combinations are not recommended 2 Type Size Front 25...

Page 64: ...s Front 9psi 63 kpa 0 64kgf cm2 Rear 9psi 63 kpa 0 64kgf cm2 5 Use no more than the following pressures when seating the tire beads Front 36psi 250kpa 2 5kgf cm2 Rear 36psi 250kpa 2 5kgf cm2 Higher pressures may cause the tire to burst Inflate the tires very slowly and carefully Fast inflation could cause the tire to burst How to measure tire pressure Use the tire pressure gauge NOTE The tire pres...

Page 65: ... Pressure Minimum Maximum Front 10psi 70kpa 0 70kgf cm2 9 psi 63kpa 0 64kgf cm 2 11 psi 77kpa 0 77kgf cm 2 Rear 10psi 70kpa 0 70kgf cm2 9 psi 63kpa 0 64kgf cm 2 11 psi 77kpa 0 77kgf cm 2 1 Tire pressure gauge Tire wear limit When the tire groove decreases to 0 12 in 3 mm due to wear replace the tire a Tire wear limit ...

Page 66: ...your service center Starting the engine in low temperatures WARNING POTENTIAL HAZARD Freezing control cables due to cold weather conditions WHAT CAN HAPPEN Loss of vehicle control which could lead to an accident or collision HOW TO AVOID THE HAZARD When riding in cold weather always make sure all control cables work smoothly before you begin riding 1 Check the throttle cable parking cable and the ...

Page 67: ...tion N the neutral indicator light should come on If the neutral indicator light does not come on ask a service center to inspect the electric circuit The engine can be started in any gear if the brake is applied However it is recommended to shift into neutral N before starting the engine 4 With your foot off the accelerator pedal start the engine by turning the key to START NOTE If the engine fai...

Page 68: ... N and press the throttle pedal to make the engine run at 2500RPM to charge the battery for 5 10 minutes when the voltage of battery is over 12V the idle speed will be normal If the idle speed is still high please contact your service center Warming Up To get maximum engine life always warm up the engine before driving Never accelerate hard with a cold engine To see whether or not the engine is wa...

Page 69: ... Driving In Reverse CAUTION Before shifting you must stop the UTV and return the throttle lever to the closed position otherwise the transmission may be damaged Shifting Neutral to High and High to Low 1 Stop the vehicle Keep your foot off the accelerator pedal 2 Apply the brakes and then shift by moving the drive select lever along the shift guide NOTE Make sure that the drive select lever is com...

Page 70: ... to reverse or vice versa by moving the drive select lever along the shift guide NOTE Please kick the brake pedal first before place gearshifts lever to reverse position In the brake pedal there is a cable which is connected to a position pin located on the gearshift assembly Only when the brake pedal is depressed the position pin will be retracked and gearshifts can be removed to reverse position...

Page 71: ...ice center to inspect the reverse indicator light electrical circuit Due to the synchronizing mechanism in the engine the light may not come on until the vehicle starts moving 4 Check behind for people or obstacles and then release the brake pedal 5 Press the accelerator pedal gradually and continue to watch to the rear while backing up ...

Page 72: ...es or people behind you When it is safe to proceed go slowly WARNING POTENTIAL HAZARD Parking on a hill or other incline WHAT CAN HAPPEN The vehicle could roll out of control increasing the chance of an accident HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines If you must park on an incline apply the parking brake and block the front and rear wheels with rocks or other objects Neve...

Page 73: ...t lever into the neutral position b Push the brake pedal down and pull the parking brake to top position to park the vehicle 1 Parking handbar Parking on a Slope 1 Bring the vehicle to a stop by applying the brakes 2 Stop the engine 3 With the brakes applied set the parking brake ...

Page 74: ... takes to use the first three tanks full 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 CAUTION Excessive heat build up during the first three hours of operation will damage close fitt...

Page 75: ...es During this period prolonged full throttle operation or any condition which might result in excessive engine heating must be avoided However momentary 2 3 seconds maximum full throttle operation under load does not harm the engine Each full throttle acceleration sequence should be followed with a substantial rest period for the engine by cruising at lower r min so the engine can rid itself of t...

Page 76: ... drive belt will ensure a longer life and better performance Break in the clutches and belt by operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggressive acceleration and high speed operation during the break in period Accessories Accessories can affect the handing and control of your vehicle Keep the following in mind when considering an accessory ...

Page 77: ... limited to an object that limits your ability to turn the steering wheel or one that limits your view Use extra caution when driving a vehicle with accessories The vehicle may handle differently than it does without accessories Loading Cargo or a trailer can change the stability and handling of a vehicle You must use common sense and good judgment when carrying cargo or towing a trailer Keep the ...

Page 78: ...LOADING LIMIT Vehicle loading limit total weight of cargo operator passenger and accessories and tongue weight 882 lb 400Kg Cargo bed 350 lb 159Kg Trailer hitch Pulling load total weight of trailer and cargo 1 212lbf 550Kgf Tongue weight vertical weight on trailer hitch point 110lbf 50Kgf Load cargo in the cargo bed as close to the center of the vehicle as possible and tie it down using the cargo ...

Page 79: ...thout a load The more weight you carry the slower you should go Although conditions vary it is good practice not to exceed low range whenever you are carrying heavier loads or when towing a trailer Allow more braking distance A heavier vehicle takes longer to stop Avoid making sharp turns unless at very slow speeds Avoid hills and rough terrain Choose terrain carefully Added weight affects the sta...

Page 80: ... CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this vehicle Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking ...

Page 81: ...2 1 2 5 Please read all the caution and warning labels on your vehicle This vehicle is designed for the operator and one passenger The driver and passenger must always wear a seat belt Never carry passengers in the cargo bed WARNING POTENTIAL HAZARD Not wearing the seat belt Wearing the seat belt improperly WHAT CAN HAPPEN There is increased risk of being killed or seriously injured in an accident...

Page 82: ...ssenger could fall or be struck by objects in the cargo bed HOW TO AVOID THE HAZARD Never carry a passenger in the cargo bed The cargo bed is designed to carry cargo only The total weight of operator passenger accessories cargo trailer tongue weight and the vehicle itself must not exceed 1 880 lbs 853Kg ...

Page 83: ...be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking Always follow the instructions in your Owner s Manual for carrying cargo or pulling a trailer The driver and passenger must always wear a seat belt an approved motorcycle helmet eye protection and protective clothing including over the ankle boots gloves a long sle...

Page 84: ... increases your chances of a severe head injury or death in the event of an accident Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jac...

Page 85: ...operation before attempting maneuvers that are more difficult Perform the Pre Operation Checks on pages 5 1 5 11 Set the parking brake shift to neutral and follow the instructions on page 6 1 to start the engine Once it has warmed up you are ready to begin driving your vehicle With the engine idling shift the drive select lever into low or high Then release the parking brake Press the accelerator ...

Page 86: ... go out of control if you attempt sharp high speed turns You should also be careful making sharp turns on rough terrain Do not attempt to turn around or make abrupt maneuvers on slope Position your hands on the steering wheel so that your thumbs and fingers do not wrap around the wheel This is particularly important when driving in rough terrain The front wheels will move right and left as they re...

Page 87: ...low these precautions when operating in reverse 1 Always check for obstacles or people behind the vehicle 2 Apply the throttle lightly Never open the throttle suddenly 3 Back up slowly 4 Apply the brakes lightly for stopping 5 Avoid making sharp turns Before shifting into reverse gear always check for obstacles or people behind the vehicle When it is safe to proceed back up slowly ...

Page 88: ... loose or slippery surfaces GOING UPHILL Do not attempt to climb hills until you have mastered basic maneuvers on flat ground Use proper driving techniques to avoid overturns on hills and slopes Drive straight up hills and avoid crossing the side of a hill which increases your chance of rollover Practice first on gentle slopes before attempting steeper hills Always check the terrain carefully befo...

Page 89: ...perating on excessively steep hills WHAT CAN HAPPEN The vehicle can over turn more easily on extremely steep hills than on level surfaces or small hills HOW TO AVOID THE HAZARD Never operate your vehicle on hills too steep for it or your abilities Never operate vehicles on hills steeper than 15 Do not drive across the face of a hill Go straight up the hill Practice on smaller hills before attempti...

Page 90: ... when climbing and you decide you will be unable to continue use the brakes to come to a stop Do not attempt to turn the vehicle around With your foot on the brake look behind you and plan your descent Shift the drive select lever in reverse so you can use the engine brake if necessary to slow your descent Release the brake and begin to coast down the hill Use engine braking as much as possible ge...

Page 91: ... downhill make sure the vehicle is in low range 4WD On most slopes this will let you use engine braking to help you go downhill slowly Go as slowly as possible If you pick up too much speed apply the brakes gently Avoid sudden application of the brakes which could cause the vehicle to start sliding If you are sliding or skidding try to steer in the direction the vehicle is sliding to help you rega...

Page 92: ...e water test your brakes If necessary apply the brakes several times to let friction dry out the linings WARNING POTENTIAL HAZARD Operating this vehicle through deep or fast flowing water WHAT CAN HAPPEN Loss of control which could result in an accident including overturn which could increase the risk of drowning HOW TO AVOID THE HAZARD Never operate this vehicle in fast flowing water or in water ...

Page 93: ... water or muddy conditions Vehicle Immersion CAUTION If your vehicle becomes immersed major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your service center before starting the engine If it is impossible to take your vehicle to a service center before starting it follow the steps outlined below 1 Move the vehicle to dry land 2 Check the air box If water i...

Page 94: ... possible whether you succeed in starting it or not 8 If water has been ingested into the CVT make sure to inspect the hole without water left inside If it is muddy water open the CVT cap and wash the parts before you reassemble 9 Check the gearshift release the water inside Wash if necessary CAUTION Make sure all components that are washed and assembled are coated lightly with grease 1 Air filter...

Page 95: ...ck hose 1 V belt case drain plug Riding Over Rough Terrain Operating over rough terrain should be done with caution Look for obstacles that could cause damage to the vehicle or could lead to a rollover accident Avoid jumping the vehicle as injury loss of control and damage to the ...

Page 96: ...r terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the vehicle overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the vehicle ...

Page 97: ...acle such as a fallen tree trunk or a ditch stop the vehicle where it is safe to do so Set the parking brake and get out to inspect the area thoroughly Look from both your approach side and the exit side If you believe you can continue safely decide the path that will allow you to get over the obstacle at as close to a right angle as possible to minimize vehicle tipping Go only fast enough to main...

Page 98: ...obstacles WHAT CAN HAPPEN Could cause loss of control or a collision Could cause the vehicle to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Use extreme caution when operating over large obstacles such as large rocks or fallen trees ...

Page 99: ... service information included in this manual is intended to provide you the owner with the necessary information for completing your own preventive maintenance and minor repairs The tools provided in the Owner s tool kit are sufficient for this purpose except that a torque wrench is also necessary to properly tighten nuts and bolts NOTE If you do not have a torque wrench available during a service...

Page 100: ...r with vehicle service WARNING POTENTIAL HAZARD Operating this vehicle with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident HOW TO AVOID THE HAZARD Never modify this vehicle through improper installation or use of accessories All parts and accessories added t...

Page 101: ...th an asterisk should be performed by service center as they require special tools data and technical skills INITIAL EVERY Month 1 3 6 6 12 miles km 200 320 750 1 200 1 500 2 400 1 500 2 400 3 000 4 800 ITEM ROUTINE Whichever Comes first hours 20 75 150 150 300 Valves Check valve clearance Adjust if necessary Fuel line Check fuel hose for cracks or damage Replace if necessary Spark plug Check cond...

Page 102: ... warm engine before draining Engine oil filter cartridge Replace Final gear oil Differential gear oil Check oil lever oil leakage Replace Accelerator pedal Check operation and free play V belt Check operation Check for wear cracks or damage Wheels Check balance damage runout Replace if necessary Front brake Check operation brake pad wear fluid leakage see page 8 6 Correct if necessary Replace pads...

Page 103: ...ushings Check for cracks or damage Fittings and fasteners Check all chassis fittings and fasteners Check if necessary Rear upper and lower knuckle pivots Drive shaft universal joint Lubricate with lithium soap based grease Lubricate with lithium soap based grease Steering system Check operation and for looseness Replace if damaged Check toe in Adjust if necessary Engine mount Check for cracks or d...

Page 104: ...cement When disassembling the master cylinder or caliper replace the brake fluid Check the brake fluid level and add fluid as required On the inner parts of the master cylinder and caliper replace the oil seals every two years Replace the brake hoses every four years or if cracked or damaged ...

Page 105: ...lt the hood up until it stops 1 Latch 2 1 Hood To close Lower the hood slowly to its original position and then hook the hood latches Secure projections on the underside of the hood into slots on the back of the instrument panel Secure slots on the side of the hood around projections on the frame ...

Page 106: ...sing the hood z Do not drive the vehicle with the hood open unlatched or removed Console To remove 1 Remove the seats See pages 4 17 4 18 for seat removal and installation procedures 2 Remove the parking brake lever boot 3 Pull the console upward the drive select lever boot will come loose 1 Console To install 1 Place the console in its original position ...

Page 107: ... intervals specified in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the vehicle on a level surface 2 Remove the console See page 8 9 for console removal and installation procedures 3 Check the engine oil level on a cold engine NOTE If the engine was started before checking the oil level be sure to warm up the engine sufficiently and then wait at least ten m...

Page 108: ...ect level 7 Insert the dipstick into the oil filler hole and then tighten the oil filler cap 8 Install the console To change the engine oil with or without oil filter cartridge replacement 1 Remove the console See page 8 9 for console removal and installation procedures 2 Place an oil pan under the engine to collect the used oil and then remove the engine oil filler cap 3 Remove the engine oil dra...

Page 109: ...s not being replaced 4 Remove the oil filter cartridge with an oil filter wrench 1 Oil filter cartridge 2 Oil filter wrench NOTE An oil filter wrench is available at a nearby service center 5 Apply a light coat of engine oil to the O ring of the new oil filter cartridge NOTE Make sure the O ring is seated properly ...

Page 110: ...a torque wrench Tightening torque Oil filter cartridge 12 ft lbf 17Nm 1 7m kgf 1 Oil filler cartridge 2 Torque wrench 7 Install the engine oil drain bolt and then tighten it to the specified torque Tightening torque Engine oil drain bolt 22 ft lbf 30Nm 3 0m kgf 8 Add the specified amount of recommended engine oil and then install engine oil filler cap and tighten ...

Page 111: ...han specified In addition do not use oils labeled ENERGY CONSERVING II or higher z Make sure that no foreign material enters the crankcase 9 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause 10 Turn the engine off wait at least ten minutes and then check the oil level and correct it ...

Page 112: ...l is below the brim of the filler hole add sufficient oil of the recommended type to raise it to the correct level CAUTION 1 Be sure no foreign material enters the final gear case 2 Please clean the sensor every 320 mile period 3 Install the oil filler bolt and then tighten it to the specified torque Tightening torque Final gear oil filler bolt 17 ft lbf 23 Nm 2 3 m kgf ...

Page 113: ...Final gear oil drain bolt 4 Install the drain bolt and then tighten it to the specified torque Tightening torque Final gear oil drain bolt 14 ft lbf 20 Nm 2 0 m kgf 5 Add the recommended final gear oil up to the brim of the filler hole Recommended oil SAE 80 API GL 4Hypoid gear oil Oil quantity 0 26 qt 0 25 L CAUTION Be sure no foreign material enters the final gear case 6 Install the oil filler b...

Page 114: ... gear oil filler bolt and check the oil level It should be up to the brim of the filler hole If the level is low add sufficient oil of the recommended type to raise it to the specified level CAUTION Be sure no foreign material enters the differential gear case 1 Differential gear oil filler bolt 2 Correct oil level 3 Differential gear oil 3 Install the differential gear oil filler bolt and then ti...

Page 115: ... Differential gear oil drain bolt 4 Install the differential gear oil drain bolt and tighten it to the specified torque Tightening torque Differential gear oil drain bolt 7 1 ft lbf 9 8Nm 0 98 m kgf 5 Fill the differential gear case with the recommended oil Recommended oil SAE 80 API GL 5 Hypoid gear oil Oil quantity 0 34 qt 0 32 L CAUTION Be sure no foreign material enters the differential gear c...

Page 116: ... surface 2 Open the hood See pages 8 8 8 9 for hood opening and closing procedures 3 Check the coolant level in the coolant reservoir when the engine is cold as the coolant level varies with engine temperature NOTE The coolant should be between the minimum and maximum level marks 1 Coolant reservoir cap 2 Maximum level mark 3 Minimum level mark 4 If the coolant is at or below the minimum level mar...

Page 117: ... center at the intervals specified in the periodic maintenance and lubrication chart NOTE Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant have a service center check the antifreeze content of the coolant as soon as possible The radiator fan is automatically switched on or off according to the coolant temperature in the radiator Axle ...

Page 118: ...1 1 Rear axle boot 2 each side Spark plug inspection Removal 1 Lift the cargo bed up See pages 4 21 4 22 for cargo bed lifting and lowering procedures 2 Remove the spark plug cap 1 Spark plug cap 3 Use the spark plug wrench in the tool kit to remove the spark plug as shown ...

Page 119: ...t attempt to diagnose such problems yourself Instead take the vehicle to a service center You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode erosion becomes excessive or if carbon and other deposits are excessive you should replace the spark plug with the specified plug Specified spark plug DR8EA...

Page 120: ...75 m kgf NOTE If a torque wrench is not available when you are installing the spark plug a good estimate of the correct torque is 1 4 to 1 2 turn past finger tight Have the spark plug tightened to the specified torque as soon as possible 4 Install the spark plug cap 5 Lower the cargo bed Cleaning the engine air filter element NOTE There is a check hose at the bottom of the air filter case If dust ...

Page 121: ... 18 for seat removal and installation procedures 2 Remove the console See page 8 9 for console removal and installation procedures 3 Remove the air filter case cover by unhooking the holders 1 Holder 4 2 Air filter case cover 4 Remove the air filter element 5 Remove the sponge material from its frame ...

Page 122: ...tly but thoroughly in solvent WARNING POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the sponge material WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the sponge material 7 Squeeze the excess solvent out of the sponge material and let it dry ...

Page 123: ...10 Pull the sponge material over its frame 11 Install the air filter element 12 Install the air filter case cover and be sure the crankcase breather hose is connected 1 Crankcase breather hose 13 Install the console 14 Install the seats NOTE The air filter element should be cleaned every 20 40 hours It should be cleaned and lubricated more often if the vehicle is operated in extremely dusty areas ...

Page 124: ...causing rapid engine wear and possible engine damage Additionally operation without the air filter element will affect performance with subsequent poor performance and possible engine overheating V belt cooling duct check hose The V belt cooling duct check hose is located under the driver seat See pages 4 17 4 18 for seat removal and installation procedures If dust or water collects in the V belt ...

Page 125: ...ep enough to allow water to enter the V belt case remove the drain plug to drain any water from the case NOTE If water drains from the V belt case after removing the drain plug have a service center inspect the vehicle as the water may affect other engine parts 1 V belt case drain plug Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester 1 Re...

Page 126: ... remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing 1 Tailpipe 2 Spark arrester 4 Insert the tailpipe into the muffler and align the bolt holes 5 Install the tailpipe by installing the bolts and then tighten the bolts to the specified torque Tightening torque Tailpipe bolt 6 9 ft lbf 9 5 Nm 0 95 m kgf ...

Page 127: ...exhaust system Valve clearance The correct valve clearance changes with use resulting in improper fuel air supply or engine noise To prevent this the valve clearance must be adjusted regularly This adjustment however should be left to a professional service technician Front brake pad check Each brake pad is provided with wear indicator grooves which allow you to check the brake pad wear without ha...

Page 128: ...Rear brake pad check Each brake pad is provided with wear indicator grooves which allow you to check the brake pad wear without having to disassemble the brake To check the brake pad wear check the wear indicator grooves If a brake pad has worn to the point that the wear indicator grooves have almost disappeared have a service center replace the brake pads as a set 1 Brake pad wear indicator groov...

Page 129: ...system for leakage The brake fluid reservoir is located under the hood See pages 8 8 8 9 for hood opening and closing procedures Observe these precautions z When checking the fluid level make sure the top of the brake fluid reservoir is level z Use only the recommended quality brake fluid Otherwise the rubber seals may deteriorate causing leakage and poor braking performance Recommended brake flui...

Page 130: ...er replace the following components during periodic maintenance or when they are damaged or leaking z Replace the oil seals every two years z Replace the brake hoses every four years Checking the brake pedal Have a service center check the brakes at the intervals specified in the periodic maintenance and lubrication chart There should be no free play in the brake pedal The brakes should operate sm...

Page 131: ...lacement of brake components requires professional knowledge These procedures should be performed by a service center Parking brake lever free play adjustment Periodically check the parking brake lever free play and adjust it if necessary 1 Shift the drive select lever into low gear L 2 Remove the seats See page 4 16 4 17 for seat removal and installation procedures 3 Remove the console See page 8...

Page 132: ...ver must be released when checking and adjusting the parking brake lever free play 5 Loosen the locknut 1 Locknut 2 Adjusting nut 6 Turn the adjusting nut in direction to increase the free play or in direction to decrease the free play 7 Tighten the locknut 8 Install the console 9 Install the seats ...

Page 133: ...or hood opening and closing procedures 2 Turn the adjusting nut while holding the brake light switch in place To make the brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction To make the brake light come on later turn the adjusting nut in direction 1 Brake light switch 2 Adjusting nut 3 Close the hood Cable inspection and lubrication Lubricate the...

Page 134: ...damaged Cables can also become frayed or kinked Operation of controls could be restricted which could cause an accident or injury HOW TO AVOID THE HAZARD Inspect cables frequently Replace damaged cables Recommended lubricant Engine oil Brake pedal and accelerator pedal lubrication Lubricate the pivoting parts Recommended lubricant Lithium soap based grease all purpose grease ...

Page 135: ... and lower pivot lubrication Lubricate the knuckle upper and lower pivots with a grease gun Recommended lubricant Lithium soap based grease Steering shaft lubrication Lubricate the pivot points Recommended lubricant Lithium soap based grease all purpose grease ...

Page 136: ... the frame Remove the nuts from the wheel Remove the wheel 1 Nut 4 Wheel installation 1 Install the wheel and the nuts NOTE The arrow mark on the tire must point toward the rotating direction of the wheel Tapered nuts are used for both the front and rear wheels Install the nut with its tapered side towards the wheel 1 Arrow mark ...

Page 137: ...ehicle is equipped with a sealed type battery Therefore it is not necessary to check the electrolyte or add distilled water in the battery If the battery seems to have discharged consult a service center CAUTION Do not try to remove the sealing caps of the battery cells You may damage the battery Wheel nut torque Front 40 ft lbf 55Nm 5 5 m kgf Rear 40 ft lbf 55Nm 5 5 m kgf ...

Page 138: ...ZARD Avoid contact with skin eyes or clothing Always shield eyes when working near batteries Keep out of reach of children Antidote 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 EYES Flush with water for 15 minutes and get prompt medical attention Keep batteries away from sparks flame...

Page 139: ...ealed type battery Using a conventional battery charger may shorten the battery life 2 Always make sure the connections are correct when putting the battery back in the vehicle 1 Negative battery lead 2 Positive battery lead Fuse replacement The main fuse and the fuse box are located under the hood See pages 8 8 8 9 for hood opening and closing procedures If a fuse is blown turn off the main switc...

Page 140: ...vent accidental short circuiting turn off the main switch when checking or replacing a fuse 3 Remove the blown fuse and then install a new fuse of the specified amperage 1 Main fuse 2 Spare main fuse 3 Headlight fuse 4 Ignition fuse 5 Auxiliary DC jack fuse 6 Four wheel drive motor fuse 7 Signaling system fuse 8 Backup fuse for odometer and clock 9 Fuel system warmer fuse 10 Spare fuse 3 ...

Page 141: ...ice center check the electrical system 6 Install the battery compartment cover 7 Close the hood WARNING POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire HOW TO AVOID THE HAZARD A ways use a fuse of the specified rating Never use a material in place of the proper fuse Replacing a headlight bulb If a headlig...

Page 142: ... Adjustment 8 44 1 Cover at the rear of the headlight 3 Remove the headlight bulb holder cover by pulling it off 1 Headlight bulb holder cover 4 Remove the headlight bulb holder by pushing it in and turning it counterclockwise ...

Page 143: ... HAZARD A headlight bulb is hot when it is on and immediately after it is turned off WHAT CAN HAPPEN You can be burned or a fire could start if the bulb touches something flammable HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it 6 Insert a new headlight bulb into the bulb holder by pushing it in ...

Page 144: ...loth moistened with alcohol or thinner 7 Install the bulb holder by pushing it is and turning it clockwise 8 Install the bulb holder cover and the cover at the rear of the headlight CAUTION Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly 9 Close the hood 10 Adjust the headlight beam if necessary Headlight beam adjustment CAUTION It is advisable...

Page 145: ...g screw Tail brake light bulb replacement If a tail brake light bulb burns out replace it as follows 1 Remove panel A if replacing the left tail brake bulb or panel B if replacing the right tail brake bulb by removing the quick fasteners and bolts 1 Panel A 1 Panel B ...

Page 146: ... light bulb holder 3 Push the defective bulb in and turn it counterclockwise to remove it from the bulb holder 4 Push a new bulb in and turn it clockwise to install in the bulb holder 5 Install the bulb holder together with the bulb by turning it clockwise 6 Install the panel by installing the quick fasteners and bolts and then tighten the bolts to the specified torque ...

Page 147: ...t to a service center The skilled technicians at a service center ship have the tools experience and know how to properly service your vehicle Imitation parts may look like genuine parts but they are often inferior Consequently they have a shorter service life and can lead to expensive repair bills WARNING POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame WHAT CAN HAPPE...

Page 148: ...Solution of Common Problems in Appearance Parts and Impact Fittings S N Problems Solutions 1 Repair cover at authorized service center 2 Change for new plastic covers 1 Covers are cracked 3 Replace the stickers and re rivet the warning labels 1 Check if the reduction gear box and differential in front and rear bridge are damaged or if there is any oil leakage 2 Check if the bottom of engine is dam...

Page 149: ... in calipers are over worn or contaminated by dirt or debris that can reduce friction 3 Check if there is any leakage in brake system s oil lines or junctions 4 Check if the post rod in brake master cylinder is bent 5 Check if there is any air going into the oil lines and drain the air with special equipment 2 Brake performance is diminished 6 Check if the remaining oil in master cylinders of fron...

Page 150: ...ck if the brake force of front brake goes down which causes the rear wheels to lock up before the front wheels 3 Check if spring force deviation of shock absorbers in front left and right suspension are within specified limit 4 Vehicle makes odd turn when braked at high speed 4 Check if the damper rubber sleeves connecting front suspension mount and frame are damaged ...

Page 151: ... 2 Vehicle cannot go into 4 wheel drive mode 3 Check if the wire is broken 1 Check if the control switch on meter board works well 2 Check if the differential lock control magneto plug in rear bridge reduction gear box is broken 3 Rear differential will not work 3 Check if the wire is broken 1 Check if the sensor is broken 2 Check if the meter is broken 4 Meter display is not normal 3 Check if the...

Page 152: ... bearings in knuckles if they are broken 2 Check the main ball pins to find out if they are broken 3 Check the lock screws of front wheels and axles to find out if they are loose or broken 4 Check the inner splines of front wheel hubs and outer splines of front wheel axles to find out if they are worn or broken 2 Front wheels shake during use 5 Check rubber bushings between the front suspension mo...

Page 153: ...s are bent 4 Wheels jump during use 3 Check if the tires are worn or damaged 1 Check if overloaded 2 Check if the springs are two soft and need replacing 5 Shock absorbers become soft and not comfortable during use 3 Check if the shock absorbers lose their damping force over time 1 Check if the spline of intermediate driving shaft is broken 2 Check if the splines in left right drive shafts of fron...

Page 154: ...er and admission line for leak 2 Check the connection joint of exhaust pipe with engine or muffler for leak 4 Popping noise in engine 3 Check the grade of gasoline to see if it s too low 1 Check to determine if the battery voltage drops during cold weather 5 Engine is difficult to start at low temperature 2 If the temperature is under 18 have the vehicle placed in warmer place for start 1 Check th...

Page 155: ...connection 3 Check the starter for damage 4 Check if the ignition loop is in good condition 5 Check if the spark plug creating sparks 6 Check if the ignition signal is in good condition 7 Check if the air cleaner is blocked 8 Check to make sure the coolant is not frozen 7 Engine cannot start 9 Check if the exhaust system is blocked ...

Page 156: ...soon as possible WARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure HOW TO AVOID THE HAZARD 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 ...

Page 157: ...intbrush Do not apply degreaser to the wheel axles 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job CAUTION Excessive water pressure may cause water seepage and deterioration of wheel bearings brakes transmission seals and electrical devices Many expensive repair bills have resulted from improper high pressure detergent applications such as those availab...

Page 158: ...cleaner waxes as many contain abrasives that may scratch the paint or protective finish When finished start the engine and let it idle for several minutes WARNING POTENTIAL HAZARD Operation with wet brakes after washing WHAT CAN HAPPEN Wet brakes may have reduced stopping ability increasing the chance of an accident HOW TO AVOID THE HAZARD Test the brakes after washing Apply the brakes several tim...

Page 159: ... the fuel from the fuel system as much as possible and pour the drained fuel into the fuel tank Specified amount 1 oz of stabilizer to each gallon of fuel or 7 5 ml of stabilizer to each liter of fuel NOTE Use of fuel stabilizer and conditioner eliminates the need to drain the fuel system Consult a service center if the fuel system needs to be drained instead 3 Remove the spark plug pour about one...

Page 160: ...t all exposed metal surfaces with a light film of oil Do not apply oil to any rubber parts or the seat covers 8 Remove the battery and charge Store it in a dry place and recharge it once a month Do not store the battery in an excessively warm or cold place less than 32 F 0 C or more than 86 F 30 C NOTE Make any necessary repairs before storing the vehicle ...

Page 161: ...m 57 5 in 1940mm 76 4 in 818mm 32 2 in 1890mm 74 4 in 280mm 11 0 in 3900mm 154 in Basic weight with oil and full fuel tank 543 kg 1 197 l b Engine Engine type Cylinder arrangement Displacement Bore stroke Compression ratio Starting system Lubrication system Liquid cooled 4 stroke Water cool Forward inclined single cylinder 471cm 3 84 5 84 0mm 9 4 1 Electric starter Wet sump ...

Page 162: ...placement API service SG type or higher JASO standard MA CAUTION In order to prevent clutch slippage since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERVING Ⅱ or higher 1 90L 2 01 qt 2 10L 2 22 qt ...

Page 163: ... 0 26 qt Differential gear case oil Type Quantity SAE80 API GL 5 Hypoid gear oil 0 32L 0 34 qt Radiator capacity including all routes 2 50L 2 64 qt Air filter Engine Intake duct Wet element Dry element Fuel Type Fuel tank capacity Unleaded gasoline only 29 L 7 6 gal Throttle valve Type quantity DELPHI MT05 ...

Page 164: ...al automatic Transmission Primary reduction system Secondary reduction system Secondary reduction ratio Transmission type Operation Reverse gear Sub transmission ratio low High V belt Shaft drive V belt automatic Right hand operation 1 471 2 059 1 238 Chassis Frame type Caster angle Trail Steel tube frame 5 0 26 0mm 1 02 in ...

Page 165: ...Operation Ⅱ Front brake Type Operation Rear brake Type Operation Dual disc brake Foot operation Single disc brake Foot operation Dual disc brake Foot operation Dual disc brake Foot operation Suspension Front rear suspension Double wishbone Shock absorber Front shock absorber Rear shock absorber Coil spring oil damper Coil spring oil damper ...

Page 166: ...CU AC magneto U1L 11 or GSU1 9 12V32 0Ah or 12V30 0Ah Bulb voltage wattage quantity Headlight Tail brake light 12V30 3W 30 0W 2 12V5 0W 21 0W 2 Indicator lights Neutral Reverse indicator light Coolant temperature warning light Parking brake indicator light On Command four wheel drive differential gear lock indicator On Command differential gear lock indicator light LED LED LED LED LED ...

Page 167: ...ns Model HS500UTV High range Low range indicator light LED Specified fuses Main fuse Headlight fuse Auxiliary DC jack fuse Four wheel drive motor fuse Signaling system fuse Backup fuse 30 0A 15 0A 10 0A 3 0A 10 0A 10 0A ...

Page 168: ...cuit Low Voltage KsDGDM_IAT_ShortLow 112 274 P0113 IAT Circuit High Voltage or Open KsDGDM_IAT_ShortHigh 113 275 P0117 Coolant Oil Temperature Sensor Circuit Low Voltage KsDGDM_CoolantShortLow 117 279 P0118 Coolant Oil Temperature Sensor Circuit High Voltage or Open KsDGDM_CoolantShortHigh 118 280 P0122 TPS Circuit Low Voltage or Open KsDGDM_TPS_ShortLow 122 290 P0123 TPS Circuit High Voltage KsDG...

Page 169: ...on KsDGDM_INJ_CYL_B_Fault 202 514 P0230 FPR Coil Circuit Low Voltage or Open KsDGDM_FPP_CircuitShortLow 230 560 P0232 FPR Coil Circuit High Voltage KsDGDM_FPP_CircuitShortHigh 232 562 P0336 CKP Sensor Noisy Signal KsDGDM_CrankNoisySignal 336 822 P0337 CKP Sensor No Signal KsDGDM_CrankNoSignal 337 823 P0351 Cylinder 1 Ignition Coil Malfunction KsDGDM_EST_A_Fault 351 849 P0352 Cylinder 2 Ignition Co...

Page 170: ...GDM_O2_2_ShortHigh 138 312 P0038 O2S Heater 2 Circuit High Voltage KsDGDM_O2_HeaterShortHigh 38 56 P0037 O2S Heater 2 Circuit Low Voltage KsDGDM_O2_HeaterShortLow 37 55 P0500 VSS No Signal KsDGDM_VSS_NoSignal 500 1280 P0850 Park Neutral Switch Error KsDGDM_ParkNeutralSwitch 850 2128 P0445 CCP short to high KsDGDM_CCP_CircuitShortHigh 445 1093 P0444 CCP short to low open KsDGDM_CCP_CircuitShortLow ...

Page 171: ...ted pollutant Where a warrantable condition exists HISUN will repair your vehicle at no cost to you including diagnosis parts and labor If an emission related part on your vehicle is defective the part will be repaired or replaced by HISUN This is your EMISSION CONTROL SYSTEM WARRANTY NOTICE Use of any HISUN brand vehicle in any type of competitive event completely and absolutely voids this and al...

Page 172: ...each new 2013 HISUN brand off road vehicle A is designed built and equipped so as to conform at the time of initial retail purchase with all applicable regulations of the United States Environmental Protection Agency and the California Air Resources Board and B is free from defects in material and workmanship which cause such vehicle to fail to conform to applicable regulations of the United State...

Page 173: ...e of business during customary business hours This warranty does not cover inconvenience or loss of use of the vehicle or transportation of the vehicle to or from the HISUN dealer HISUN shall not be liable for any other expenses loss or damage whether direct incidental consequential or exemplary arising in connection with the sale or use of or inability to use the HISUN brand vehicle for any purpo...

Page 174: ... by the owner However HISUN is not liable for these parts The owner is responsible for the performance of all required maintenance Such maintenance may be performed at a service establishment or by any individual The warranty period begins when the vehicle is placed into service If you have any questions regarding your warranty rights and responsibilities you should contact Hisun Motors Corp U S A...

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Massimo ALLIGATOR 500, Owner'S Manual

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