Massimo BUCK 250 Owner'S/Operator'S Manual Download | Manualshive

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OWNER’S/OPERATOR’S MANUAL

20.0

16. MAINTENANCE

16- 12

STEERING

Steering Inspection

The steering assembly of the machine should be checked periodically
for loose nuts and bolts, worn tie rod ends, worn boots, and damage.
Checking routing of all cables, hoses, and wiring to be sure the steering
mechanism is not restricted or limited. If any found, have your dealer
repair them before riding your vehicle.

The steering assembly should be also checked periodically for free
operation, steering should move freely through entire range of travel
without binding. Park on level ground. Turn the steering wheel right and
left. Check for excessive free play, abnormal noises, or a rough feeling.
Have an authorized dealer repair as necessary for proper operation.

Lubricate the pivoting parts.

Recommended lubricant:

Lithium-soap-based grease

CAMBER AND CASTER

The camber and caster are non-adjustable.

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Summary of Contents for BUCK 250

Page 1: ...SIGENED FOR USE ON RENTAL TRACKS OR RACING OWNER S OPERATOR S MANUAL US 20 0 BUCK 250 BEFORE OPERATING THIS VEHICLE THE OWNER AND EACH OPERATOR MUST HAVE READ AND HAVE AN UNDERSTANDING OF ALL THE INSTRUCTIONS FOR PROPER ASSEMBLY AND SAFE OPERATION AS WELL AS THE INSTRUCTIONS CONCERNING THE ENGINE AND ALL OTHER PORTIONS OF THE VEHICLE ...

Page 2: ...antities to cause cancer birth defects or other reproductive harm NOTE A storage area toolbox has been provided on the UTV for storage of this manual and addendums Please keep this manual and addendums in the glove compartment so that it can be found easily and referenced when needed ...

Page 3: ...L NUMBER 6 1 7 CONTROL AND FUNCTIONS 7 1 8 STARTING THE ENGINE 8 1 9 VEHICLE BREAK IN PERIOD 9 1 10 RIDING GEAR 10 1 11 CARRYING LOADS 11 1 12 RIDING 12 1 13 CVT SYSTEM 13 1 14 BATTERY 14 1 15 EXHAUST SYSTEM 15 1 16 MAINTENANCE 16 1 17 TROUBLE SHOOTING 17 1 18 TOOLS 18 1 19 SPECIFICATION 19 1 20 WIRING DIAGRAM 20 1 21 Emissions Control System Warranty 21 1 ...

Page 4: ... operators of this UTV become familiar with the operating characteristic and the many features offered on the UTV The manual also covers information on the care and maintenance of your UTV Please read this manual carefully The information contained in this Owner s Manual the Warning Labels supplied with this product will help you to understand the safe use and maintenance of your UTV Make sure tha...

Page 5: ... Failure to follow these warnings increases the possibility of accidents leading to DEATH or SERIOUS INJURY Additionally failure to follow these requirements will void the Warranty on your UTV NOTE The addition and use of certain accessories including but not limited to mowers blades sprayers winches and windshields will change the handling characteristics and the performance of your UTV Practice ...

Page 6: ...nd passenger should also wear eye protections goggles or face shields gloves boots long sleeved shirts or jackets and long pants As with any off road capable vehicle there is a risk of tip over or rollover under certain conditions Uneven terrain or slopes which pitch the vehicle sideways turning too fast or sharp or a combination of conditions increase the risk of tip over If you are in a situatio...

Page 7: ...res for turning as described in this manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speed Always have the UTV checked by an authorized dealer if it has been involved in an accident Never operate UTV on hills too steep for the UTV or for your abilities Practice on smaller hills before attempting larger hills Always follow proper procedures ...

Page 8: ...udden movements maintain a slow and steady forward motion do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them lightly several times to let friction dry out the pads Always be sure there are no obstacles or people behind you when you operate in reverse When it is safe to p...

Page 9: ...OW YOUR VEHICLE BEFORE YOU BEGING RIDING Read this manual thoroughly referring to the various areas which are being discussed on your machine Operating this vehicle carries with it responsibilities for your personal safety the safety of others and the protection of our environment NOTE Illustrations used in this manual are for general representation only Your model may differ ...

Page 10: ...ghout this manual to convey the following messages This is the safety alert symbol When you see this symbol on your machine or in this manual be alert to the potential for personal injury Your safety is involved WARNING Indicates a potential hazard which could result in severe injury or death CAUTION Indicates a potential hazard which may result in minor personal injury or damage to the UTV CAUTIO...

Page 11: ...tection Read and follow the instructions on each decal carefully In the event any decal becomes illegible or comes off contact your dealer for a replacement Attention There is a risk of fire from driving the vehicle on the ground where grass has dried up or parking the vehicle on such surface while the engine is hot ...

Page 12: ...OWNER S OPERATOR S MANUAL 20 0 3 SAFETY WARNING 3 2 1 2 NOTE Maximum tire pressure Front 10psi 68 9kPa Rear 10psi 68 9kPa 3 ...

Page 13: ...OWNER S OPERATOR S MANUAL 20 0 3 SAFETY WARNING 3 3 4 5 6 7 ...

Page 14: ...OWNER S OPERATOR S MANUAL 20 0 3 SAFETY WARNING 3 4 8 9 10 11 ...

Page 15: ...OWNER S OPERATOR S MANUAL 20 0 3 SAFETY WARNING 3 5 12 13 14 15 ...

Page 16: ...OWNER S OPERATOR S MANUAL 20 0 3 SAFETY WARNING 3 6 16 17 18 ...

Page 17: ...t it 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 inspected by your dealer Brake fluid leakage Check to see if any brake fluid is leaking out of the pipe joints or the brake fluid reservoir Apply the brakes firmly for one minute If there is any leakage have the vehicle inspected by an authorize...

Page 18: ... wheel right and left Check for excessive free play abnormal noises or a rough feeling Have an authorized dealer repair as necessary for proper operation 9 Loose parts visually inspect vehicle for any damaged components or loose nuts bolts or fasteners Always check the tightness of chassis fittings and fasteners before a ride Take the vehicle to your dealer for correct tightening torque 10 Operato...

Page 19: ...e or exhaust pipe muffler when refueling Never refuel while smoking or while in the vicinity of sparks open flames or other sources of ignition such as the pilot lights of water heaters and clothes dryers WARNING POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame WHAT CAN HAPPEN Fuel can ignite or explode causing severe injury or property damage HOW TO AVOID THE HAZARD D...

Page 20: ...ing change your clothes WARNING POTENTIAL HAZARD Malfunction of the accelerator pedal WHAT CAN HAPPEN The accelerator pedal could be hard to operate making it difficult to speed up or slow down when you need to This could cause an accident HOW TO AVOID THE HAZARD Check the operation of the accelerator pedal before you start the engine If it does not work smoothly check for the cause Correct the pr...

Page 21: ... severely injured You could suffer a crushed hand arm leg or foot HOW TO AVOID THE HAZARD You must keep your arms and legs inside the vehicle until it has stopped moving As with any off road capable vehicle there is a risk of tip over or rollover under certain conditions Uneven terrain or slopes which pitch the vehicle sideways turning too fast or sharp or a combination of conditions increase the ...

Page 22: ...stance for braking WARNING POTENTIAL HAZARD Carrying a passenger passengers in the cargo bed WHAT CAN HAPPEN The passenger s could fall be thrown out or be struck by objects in the cargo bed HOW TO AVOID THE HAZARD Never carry a passenger passengers in the cargo bed This cargo bed is designed to carry cargo only WARNING POTENTIAL HAZARD Improper shock absorber adjustment WHAT CAN HAPPEN Uneven adj...

Page 23: ... care when refueling WHAT CAN HAPPEN Fuel can spill which can cause a fire and severe injury Fuel expands when it heats up If the fuel tank is overfilled fuel could spill out due to heat from the engine or the sun HOW TO AVOID THE HAZARD Do not overfill the fuel tank Be careful not to spill fuel especially on the engine or exhaust pipe Wipe up any spilled fuel immediately Be sure the fuel tank cap...

Page 24: ...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 Allow greater distance for braking WARNING POTENTIAL HAZARD Servicing an engine while it is running WHAT CAN HAPPEN Moving parts can catch clothing or parts of the...

Page 25: ... through improper installation or use of accessories All parts and accessories added to this vehicle should be genuine parts or equivalent components designed for use on this vehicle and should be installed and used according to instructions If you have questions consult an authorized dealer WARNING POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the sponge material WHAT CAN H...

Page 26: ...rior to touching exhaust components Do not start the engine when cleaning the exhaust system WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the brake pedal position is correct Make sure the brakes do no...

Page 27: ...te carefully WHAT CAN HAPPEN You could be poisoned You could be severely burned by the sulfuric acid in battery electrolyte Batteries produce explosive gases HOW TO AVOID THE HAZARD 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...

Page 28: ...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 WARNING POTENTIAL HAZARD Operation with wet brakes after washing WHAT CAN HAPPEN Wet brakes may have reduced stopping ability increasing the chance ...

Page 29: ...nt and increases your chances of a severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved helmet which fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants WARNING POTENTIAL HAZARD Operating this UTV after consuming alcohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Co...

Page 30: ...mpting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps WARNING POTENTIAL HAZARD Failure to inspect the UTV before operating Failure to properly maintain the UTV WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always in...

Page 31: ...HE HAZARD Always keep both hands on the steering wheel and both feet on the footrests of your UTV during operation WARNING POTENTIAL HAZARD Failure to use extra care when operating this UTV on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the UTV overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and...

Page 32: ...l the UTV on such terrain Always be especially cautious on these kinds of terrain WARNING POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Could cause loss of control or cause UTV to overturn HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the Owner s Manual Always check the terrain carefully before you start up any hill Never climb hills with e...

Page 33: ... Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speed WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level surfaces or small hills HOW TO AVOID THE HAZARD Never operate the UTV on hills too steep for the UTV or for your abilities Practice on small...

Page 34: ...n a hill at an angle which would cause the vehicle to lean sharply to one side Go straight down the hill where possible WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause UTV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the UTV around on any hill until you have mastered the turning technique as described in the O...

Page 35: ...eight uphill never apply engine power Apply the brake gradually When fully stopped apply rear brake as well and then lock parking brake Dismount on uphill side or to either side if pointed straight uphill WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or a collision Could cause the UTV to overturn HOW TO AVOID THE HAZARD Before operating in...

Page 36: ... WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident HOW TO AVOID THE HAZARD Never operating the UTV through water which exceeds the recommended maximum depth in this manual Avoid operating the UTV through deep or fast flowing water If you cannot avoid water go slowly balance your weight carefully avoiding sudden movement maintain a slow and...

Page 37: ...or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires on this UTV or operation of this UTV with improper or uneven tier pressure may cause loss of control and increases the risk of an accident HOW TO AVOID THE HAZARD Always use the size and type ties specified in the Owner s Manual for this vehicle Always maintain proper tire pressure a described in the Owner s Manual Use ...

Page 38: ...odify this UTV through improper installation or use of accessories All parts and accessories added to this vehicle should be genuine or equivalent components designed for use on this UTV and should be installed and used according to instructions If you have questions consult our authorized dealer WARNING POTENTIAL HAZARD Riding on frozen lakes and rivers WHAT CAN HAPPEN Severe injury or death can ...

Page 39: ...kes throttle and steering for possible damage WARNING Safe operation of this rider active vehicle requires good judgment and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturns and loss of control which could result in severe injury or death CAUTION Keep combustible materials away from exhaust system Fire may result ...

Page 40: ...OWNER S OPERATOR S MANUAL 20 0 6 V I N AND ENGINE SERIAL NUMBER 6 1 ...

Page 41: ...he right side under seat 2 Engine Serial Number Left side of engine crankcase The vehicle frame and engine serial numbers are important for model identification when registering your vehicle obtaining insurance or whenever replacement parts are required In the event your vehicle were stolen these numbers are essential to the recovery and identification of your UTV ...

Page 42: ...Optional 7 USB Charger Optional 4 Hi Lo Beam Switch 1 Turn Signal Lamp Switch 2 Main Switch Functions of the respective switch positions are as follows All electrical circuits are switched off The key can be removed in this position All electrical circuits are supplied with power The electric starter is engaged by turning and holding the key in this position Release the key when the engine starts ...

Page 43: ... Do not turn the key to the START position with the engine running or damage to the electric starter can result 3 Horn Switch Optional 4 Hi Lo Beam Switch When turn on the high beam headlight the low beam headlight will also be on Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness 5 Emergency Switch Optional 6 USB Charger USB output 5 0 1V 600...

Page 44: ... Working Hour Counter 5 Safety Belt Lamp 13 MIL Indicator 6 Turn Right Indicator Light A ODO TRIP HOUR Selector 7 Engine RPM Meter B km h mph and km mile Selector 8 Fuel Gauge Indicator When turn on the key but not start the engine the MIL Indicator will on After the engine starting the MIL Indicator will turn off If the MIL Indicator lighting or flashing while the engine working please consult an...

Page 45: ...st position when released Always check that the accelerator pedal returns normally before starting the engine WARNING POTENTIAL HAZARD Malfunction of the accelerator pedal WHAT CAN HAPPEN The accelerator pedal could be hard to operate making it difficult to speed up or slow down when you need to This could cause an accident HOW TO AVOID THE HAZARD Check the operation of the accelerator pedal befor...

Page 46: ...e lever is located at the left side of the steering wheel It will help hold the vehicle from moving while parked To set the parking brake pull the lever back completely The parking indicator light will come on if the main switch is on To release the parking brake pull back on the lever press the release button and then push the lever all the way front Be sure to fully release the parking brake bef...

Page 47: ...ehicle and with the engine idling move the lever to the desired gear Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage Always place the transmission in gear with the parking brake locked whenever the vehicle is left unattended Maintaining shift cable adjustment is important to assure proper transmission function Should you experience any...

Page 48: ...n the rear of the seat into the seat holders WARNING POTENTIAL 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 1 Seat belt 2 2 Latch plate 2 3 Buckle 2 This vehicle is equipped with three point seat belts for both the operator a...

Page 49: ...quipment 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 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 over your shoulder and across your chest The shoulder belt should fit aga...

Page 50: ...curely CAUTION 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 Load Limit CARGO BED Maximum load limit 50 kg 110 lb WARNING POTENTIAL HAZARD Overloading the cargo bed WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident HOW TO A...

Page 51: ... carry a passenger passengers in the cargo bed This cargo bed is designed to carry cargo only HOOD 1 latch 2 To Open Unhook the hood latches pull down the hood and then take it out To Close Put the hood in place push up it and then lock the latch WARNING If the hood latches are hooked improperly or the latches and their attachments can not work properly the front hood can come off during operation...

Page 52: ...kin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time WARNING The engine exhaust from this product contains chemicals known in certain quantities to cause cancer birth defects or other reproductive harm ...

Page 53: ...s 3 Stop the engine remove dipstick 1 and wipe dry with a clean cloth 4 Put dipstick into the oil tank don t screw in it remove it and read the oil level 5 Remove dipstick and check to see that the oil level is between the full and add marks 2 Add oil as indicated by the level on the dipstick Do not overfill CAUTION Use only SAE 10W 40 SF OIL Never substitute or mix oil brands Serious engine damag...

Page 54: ...her always make sure all control cables work smoothly before you begin riding CAUTION You must allow your vehicle adequate warm up time before operating or engine damage could result 1 Apply the brake 2 Shift the drive select lever into the neutral position NOTE When the drive select lever is in the neutral position the Gear Position Indicator display N If the Gear Position Indicator does not disp...

Page 55: ... battery should be removed and charged instead However if the vehicle must be jumpstarted proceed as follows 1 Turn the key to 2 Open the seat 3 Using a charged 12 V battery connect the positive lead of the jumper cable to the positive terminal of the battery in the vehicle and the other end of the positive lead to the positive terminal of the charged battery 1 Jumper cable positive lead 2 Jumper ...

Page 56: ...INE 8 3 6 After the engine starts disconnect the negative lead of the jumper cable from the vehicle and charged battery and then disconnect the positive lead of the jumper cable from the charged battery and the battery in the vehicle 7 Close the seat ...

Page 57: ...se fitted engine parts and drive components Do not operate at full throttle or high speeds during the first 3 hours of use 1 Fill fuel tank 2 Check oil reservoir level indicated on dipstick Add oil if necessary 3 Drive slowly at first Select an area which is open and will give you room to familiarize yourself with vehicle operation and handling 4 Do not operate at sustained idle 5 Perform regular ...

Page 58: ...prevent a severe head injury Select an approved off road motorcycle type helmets that fits properly 2 Eye Protection A pair of goggles or helmet face shield offer the best protection for your eyes 3 Gloves off road style Wear gloves for comfort and for protection from sun cold weather and other elements 4 Boots A pair of strong over the calf type boots with heels such as motocross boots 5 Clothing...

Page 59: ...motorcycle helmet 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 sle...

Page 60: ... the cargo bed as close to the center of the vehicle as possible and tie it down using the cargo hooks equipped on the cargo bed Make sure the load does not interfere with controls or your ability to see where you are going Drive more slowly than you would without a load The more weight you carry the slower you should go Allow more braking distance A heavier vehicle takes longer to stop Avoid maki...

Page 61: ...ZARD Never exceed the stated load capacity for this vehicle Cargo should be properly distributed and securely attached Reduce speed when carrying cargo Allow greater distance for braking WARNING POTENTIAL HAZARD Carrying a passenger in the cargo bed WHAT CAN HAPPEN The passenger 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...

Page 62: ...NING 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 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 WARNING The engine rpm limiter works at 8000 rpm this may c...

Page 63: ...rt to accelerate Avoid higher speeds until you are thoroughly familiar with the operation of your vehicle 4 When slowing down or stopping take your foot off the accelerator pedal and smoothly press the brake pedal Improper use of the brakes can cause the tires to lose traction reducing control and increasing the possibility of an accident MAKING TURNS It is possible for the vehicle to roll over or...

Page 64: ...d 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 before attempting any hill Use common sense and remember that some hills are too steep for you to climb Choose carefully which hills you attempt to climb Avoid hills w...

Page 65: ...you cannot clearly see what is on the other side there could be another person an obstacle or a sharp drop off If you start to lose traction or momentum 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 Release the brake and begin to coast down the ...

Page 66: ...an obstacle do so slowly and carefully If the vehicle starts to tip gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance gradually steer again in the direction you want to go WARNING POTENTIAL HAZARD Try to stop the tipping vehicle with your arm or leg WHAT CAN HAPPEN You could be severely injured You could suffer a crushed hand arm leg or f...

Page 67: ... serviced as outlined in the maintenance chart see 16 maintenance The following areas need special attention engine oil transmission oil 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 in fast flowing...

Page 68: ...river or passenger Never hold onto the enclosure so your hand is outside the vehicle Hold only onto the handgrip inside the enclosure ENCOUNTERING OBSTACLES ON THE TRAIL If you cannot go around an obstacle 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 your approach side and the exit side ...

Page 69: ...king brake to help prevent the vehicle from rolling 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 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 inc...

Page 70: ...iod as recommended Pull only light loads Avoid aggressive acceleration and high speed operation during the break in period If a belt fails always clean any debris from the CVT intake and outlet duct and from the clutch and engine compartments when replacing the belt CVT DRYING NOTE After operating in water the vehicle s CVT system should be checked immediately Use the following instructions to dry...

Page 71: ... process or remove the outer clutch cover to inspect the CVT system NOTE If the vehicle has ingested a large amount of water into the CVT system and has not been operated for a period of time be sure to check the CVT system components for water damage ...

Page 72: ...cal attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Battery Removal 1 Open the Cushion and remove the pressure rod on the battery 2 Disconnect the black negative battery cable first 3 Disconnect the red positive battery cable next 4 Li...

Page 73: ...e properly routed 5 Reinstall the pressure rod on the battery 6 Put back the cushion NOTE When you UTV is placed in storage for one months or more the battery should be removed charged to proper level and stored in a cool dry place Before reusing take the battery to your dealer for testing and recharging Power plug leads may need to be bent down so that battery cover may be installed When installi...

Page 74: ...ing through tall grass The potential for fire exists SPARK ARRESTER The exhaust pipe must be periodically purged of accumulated carbon as follows 1 Remove the 3 bolts and remove the arrester from the end of the muffler 2 Use a non synthetic brush to clean the arrester screen A synthetic brush may melt if components are warm If necessary blow debris from the screen with compressed air 3 Inspect the...

Page 75: ...er run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas Catalyst There is catalyst inside the muffler on all U S models WARNING The engine rpm limiter will work at 8000rpm this may cause excessive fuel to build in the exhaust and ignited by the catalyst in the muffler MAY RESULT IN THE MUFFLERS OVERHEATING AND FIRE RISK Always reduce throttle when the engine reach top ...

Page 76: ...e periodic maintenance chart Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts genuine parts are available from your dealer Equivalent parts may be used for emissions related service Service and adjustments are important for proper vehicle operation If you re not familiar with safe service and adjustment procedures a qualified deal...

Page 77: ...Oil I R R R R R R I I Valve Gap A A A A A A A Idle Speed I I I I I I I I I Gear Oil I I I R I I I I GL 4 85W 140 Oil Filter C R R R R R R I Clean when replace oil Fuel Filter C C C C C C R Air Cleaner C C C C C C C R Cooling System I I I I I I I Engine Mount I I I I I I I Fuel Line I I I I I I I Throttle Operation I I I I I I I Brake Shoes Pad Wear I I I I I I I Brake System I I I I I I I Brake Li...

Page 78: ...her qualified person perform these services MAINTENANCE INTERVALS NOTE The maintenance interval charts outline required maintenance and inspection based on estimated vehicle engine hours miles Each table states the number of hours miles that service is required on the vehicle Some items or components may need to be serviced more often due to severe use such as operation in water or under severe lo...

Page 79: ...gs for leaks and abrasion Battery Check terminals clean test XU Main Gearcase Oil Inspect level change yearly XU Engine Oil Change D Valve Clearance Valve lash adjustment Every 40 hours after first 10 hour adjustment XU General Lubrication Lubricate all fittings pivots cables etc Shift Cable Inspect lubricate adjust XU Steering Lubricate XU Front Suspension Lubricate XU Rear Suspension Lubricate T...

Page 80: ...rize fuel pump check for leaks at fill cap fuel lines rail and fuel pump replace lines every two years XU Spark Plug Inspect replace as needed XU Engine Mounts Inspect Exhaust Muffler Pipe Inspect XU Wiring Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc D Clutches Drive and Driven Inspect clean replace worn parts Drive belt Inspect replace as nee...

Page 81: ...Every 40 hours after first 10 hour adjustment XU General Lubrication Lubricate all fittings pivots cables etc Shift Cable Inspect lubricate adjust XU Steering Lubricate XU Front Suspension Lubricate XU Rear Suspension Lubricate Throttle Body Intake Duct Inspect duct for proper sealing air leaks 175 HOUR 1750 MILE 2800 KM SERVICE ITEM REMARKS Fuel System Inspect cycle key to pressurize fuel pump ch...

Page 82: ...ize fuel pump check for leaks at fill cap fuel lines rail and fuel pump replace lines every two years XU Spark Plug Inspect replace as needed XU Engine Mounts Inspect Exhaust Muffler Pipe Inspect XU Wiring Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc D Clutches Drive and Driven Inspect clean replace worn parts Drive belt Inspect replace as need...

Page 83: ...Rear Suspension Lubricate Throttle Body Intake Duct Inspect duct for proper sealing air leaks LUBRICATION RECOMMENDATIONS Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning or more often under severe use such as wet or dusty conditions Items not listed in the chart should be lubricated at the general lubrication interval ITEM LUBE Engine Oil 10...

Page 84: ...ANCE 16 9 PERIODIC MAINTENANCE RECORD Use the following chart to record periodic maintenance work Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks First 5 Hrs 10 Hrs 25 Hrs 50 Hrs 75 Hrs 100 Hrs 125 Hrs 150 Hrs ...

Page 85: ...t Size Specification Front M10X1 25 30Ft Lbs 41N m Rear M10X1 25 30Ft Lbs 41N m Wheel Hub Tightening Wheel bearing tightness and spindle nut retention are critical component operations Service work must be performed by an authorized dealer SPRING ADJUSTMENT The shock absorber spring is adjusted by rotating the adjuster in the direction required to increase or decrease spring tension Rear Spring Ad...

Page 86: ...lly remove it from the air box 3 Remove the filter 2 4 Inspect the air box for oil or water deposits Wipe away any deposits with a clean shop towel Note If the filter has been soaked with fuel or oil it must be replaced 5 Inspect the air filter and replace if necessary Note DO NOT attempt to clean the air filter with compressed air 6 Place the air filter into the air box and reinstall the air box ...

Page 87: ...d have your dealer repair them before riding your vehicle The steering assembly should be also checked periodically for free operation steering should move freely through entire range of travel without binding Park on level ground Turn the steering wheel right and left Check for excessive free play abnormal noises or a rough feeling Have an authorized dealer repair as necessary for proper operatio...

Page 88: ...Make these adjustment The recommended toe alignment is 1 8 to 1 4 3to6mm toe out 1 Set the steering wheel in a straight ahead position and hold them in this position 2 Measure A and B A minus B should be 1 16 to 1 8 1 5 to 3mm 3 If this measurement needs to be adjusted contact your dealer for service WARNING If the tie rod is positioned incorrectly or adjusted incorrectly it will not pivot may bre...

Page 89: ...der reservoirs Normal functioning of the diaphragm is to extend into the reservoir as fluid lever drops If the fluid lever is low and the diaphragm is not extended a leak is indicated and the diaphragm should be replaced Always fill the reservoir as indicated whenever the cover is loosened or removed to insure proper diaphragm operation Use DOT 3 brake fluid Check brake system for fluid leaks Chec...

Page 90: ...r is level Use only the recommended quality brake fluid Otherwise the rubber seals may deteriorate causing leakage and poor braking performance Recommended brake fluid DOT 3 Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance Be careful that water does not enter the brake fluid reservoir when refilling Water will sig...

Page 91: ... the adjustor on the lever 2 Loosen the jam nut of the adjuster on the caliper 3 Turn the adjuster bolt CW clockwise by hand till the pad touch the brake disc turn the adjuster bolt CCW counterclockwise by 1 4 to one turn for 10 to 20mm free play at the end of the parking lever 4 Tighten the jam nuts securely against the adjusters 5 Make sure the rear wheels turns freely without dragging 6 Turn th...

Page 92: ...brake cable on the parking lever side by turn the adjuster nut directly But the adjust range is limited Always do the procedure 1 to 8 when necessary Throttle Free Play Inspection 1 Apply the parking brake 2 Put gear in Neutral position 3 Start the engine and warm it up thoroughly 4 Measure the distance the throttle pedal moves before the engine begins to pick up seep Free play should be 1 16 to 1...

Page 93: ...ner or wire brush Measure Spark plug gap Out of specification Adjust gap Spark Plug Removal and Replacement WARNING Never attempt to remove a spark plug while the engine is warm The exhaust system or engine could burn you causing severe injury 1 Remove the spark plug by rotating counterclockwise 2 Reverse the procedure for spark plug installation Torque to 17ft Ibs 23N m Standard spark plug CR7HSA...

Page 94: ...nstall the dipstick completely 4 Remove the dipstick and check if oil level is within safe range 2 5 Add the recommended oil as needed 6 Reinstall the dipstick OIL CHANGE 1 Position the vehicle on a level surface Set the parking brake 2 Clean the area around the pre filter plug 3 Start the engine Allow it to idle for two to three minutes 4 Stop the engine CAUTION Oil may be hot Do not allow hot oi...

Page 95: ... should be clean and free of burrs nicks or scratches 9 Reassemble the pre filter screen and spring to the pre filter plug 10 Reinstall the pre filter drain plug Torque to 11 ft lbs 15 Nm 11 Remove the dipstick Add 37 oz 1 1 liters of the recommended oil Do not overfill See the specifications section for capacities 12 Reinstall the dipstick 13 Start the engine Allow it to idle for one to two minut...

Page 96: ...located on the bottom of the transmission gearcase Access the drain plug from the bottom of the vehicle To change the transmission fluid do the following 1 Remove the fill plug 2 Place a drain pan under the transmission drain plug 3 Remove drain plug 2 and allow lubricant to drain completely 4 Clean the drain plug magnetic surface 5 Reinstall the drain plug and torque to 14 ft lbs 19 N m 6 Add the...

Page 97: ...sult in severe damage to the transmission and drive components Always make sure the chain adjusted within the stated specifications 1 Loosen upper nut on the chain tensioner bracket 2 Turn lower nut clockwise in 1 2 turn increments then turn upper nut until tight Follow this procedure until chain is at proper tension To check for proper tension press the down on the middle of the chain with thumb ...

Page 98: ...heels are installed properly If wheels are improperly installed it could affect vehicle handling and tire wear Tire Pressure front rear see detail on the mark of sidewall see detail on the mark of sidewall Wheel Removal Procedure 1 Stop the engine place the transmission in gear and lock the parking brake 2 Loosen the wheel nuts slightly 3 Elevate the side of the vehicle by placing a suitable stand...

Page 99: ...er s Manual for tire specifications LIGHTS Keep your headlights and taillights clean Poor light while riding can result in an accident causing severe injury or death Do not service while headlight is hot Serious burns may result Do not touch a halogen lamp with bare fingers Oil from your skin leaves a residue causing a hot spot which will shorten the life of the lamp Headlight Lamp Replacement and...

Page 100: ...t Brake light Lamp Replacement If the Taillight Brake light does not work the lamp may need to be replaced 1 Remove the Side cover 2 Take off the Taillight Brake Light 3 Loosen bulb base 4 Remove bulb and replace it with recommended bulb 5 Test the Taillight Brake Light to see that it s working 6 Re install the Light CLEANING YOUR UTV Keeping your UTV clean will extend the life of various componen...

Page 101: ...and chemicals will damage plastic surfaces Care must be taken when using these products plastic surfaces STORAGE TIPS CAUTION Do not start the engine during the storage period This will disturb the protective film created by fogging Cleaning Clean the UTV thoroughly Fuel To avoid possible fire drain the fuel tank for long term storage However when starting the UTV again ensure that there is enough...

Page 102: ...entilated Cover the machine with a UTV cover NOTE Do not use plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation TRANSPORTING Whenever the UTV is to be transported the following measures should be taken 1 Turn off the engine and remove the key 2 Be certain the fuel cap oil cap and seat are installed correctly 3 Always tie...

Page 103: ...application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large objects from a stopped position Carefully use fast brief aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Low Battery Possible Cause Solutions Starting a faulty engine for long time See 8 STARTING THE EN...

Page 104: ...ect Throttle body The connect not good Air cleaner Clogged air cleaner element Improper air cleaner setting COMPRESSION SYSTEM Cylinder and cylinder head Loose spark plug Loose cylinder head Broken cylinder head gasket Broken cylinder gasket Worn damaged or seized cylinder Valve system Improperly adjusted valve clearance Improperly sealed valve Improperly contacted valve and vale seat Improper val...

Page 105: ... coil body Wiring Loose battery terminal Loose coupler connection Improperly grounded Broken wire harness POOR IDLE SPEED PERFORMANCE EFI the fuel pressure not correct fuel filter clogging fuel injector clogging Air cleaner Clogged air cleaner element Valve system Improperly adjusted valve clearance Ignition system Faulty spark plug Faulty high tension cord Faulty ignitor unit Faulty pick up coil ...

Page 106: ...e seat Faulty valve timing Fuel system Clogged fuel tank breather hole Clogged air cleaner element fuel filter clogging the fuel pressure not correct Clutch Refer to CLUTCH SLIPPING DRAGGING section Engine oil Improper oil level low or over Oil level Ignition system Faulty spark plug Faulty high tension cord Faulty ignitor unit Faulty pick up coil Faulty ignition coil Valve system Improperly adjus...

Page 107: ...ne oil level Improper engine oil quality High viscosity Low engine oil quality Brakes Dragging brake FAULTY CLUTCH WHEN ENGINE RUN UTV DOES NOT RUN V belt Worn bent slipping POOR SPEED PERFORMANCE V belt Worn Oil V belt Cam slider Worm damaged Compression spring Damage Roller weight Worn improper operation primary secondary sheave Worm Gears Damage ...

Page 108: ...n front hub bearing Slipping oily V belt Worn brake pad Worn brake disc Air in brake fluid Leaking brake fluid Primary sliding sheave Improper operation Damage Faulty master cylinder kit Faulty caliper seal kit Loose union bolt Broken brake hose Compressing spring Worm loose Oily or greasy brake pad Oily or greasy brake disc Secondary sliding sheave Improper operation Worn guide pin grove Worn gui...

Page 109: ...OWNER S OPERATOR S MANUAL 20 0 18 TOOL 18 1 ...

Page 110: ...ed Rider Payload 300 kg 661 lb Gross Vehicle Weight Maximum Technically Permissible Mass 650kg 1433 lb Drive System Front Tire AT22 x 7 10 Rear Tire AT22 x 10 10 Tire Pressure front See detail on the mark of sidewall Tire Pressure rear See detail on the mark of sidewall Brake System Brake Front Brake Dual Hydraulic Disc Front and rear unified Rear Brake Operation Foot Parking Brake Mechanical Disc...

Page 111: ...al Drive CVT F N R Chain Chain ration 13 41 Chain number 54 Maximum Net power Kw r min 9 0KW 7000 7500RPM Maximum Net Torque Nm r min 13N m 6000 6500RPM Maximum Vehicle Speed km h 48km h Electrical Equipment Battery 12V 9Ah High beam headlamp LED X2 Dipped beam headlamp LED X2 Front position lamp LED X2 Front turn signal LED X2 Brake Tail Light 21W X2 Rear turn signal 10W X2 Specified fuses USB ou...

Page 112: ...OWNER S OPERATOR S MANUAL20 0 20 WIRNING DIAGRAM 20 1 ...

Page 113: ...OWNER S OPERATOR S MANUAL 20 0 21 Emissions Control System Warranty 21 1 ...

Page 114: ...OWNER S OPERATOR S MANUAL 20 0 21 Emissions Control System Warranty 21 2 ...

Page 115: ...OWNER S OPERATOR S MANUAL US 20 0 ...

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