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Massimo MSU 800, Owner'S Manual

The Massimo MSU 800 Owner's/Operator's Manual is a comprehensive guide providing important instructions and insights on safely operating and maintaining the MSU 800 model. Easily downloadable for free, find this essential manual at manualshive.com, ensuring a seamless user experience from the start.

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8-43

Replacing a Headlight Bulb 
If  a  headlight  bulb  burns  out,  replace  it  as 
follows. 

1.  Lift  the  hood  up.  (See  pages  8-7-8-8  for 

hood opening and closing procedures.) 

2.  Remove  the  cover  at  the  rear  of  the 

headlight by pulling it off. 

   

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  counter 
clockwise. 

5.  Remove  the  defective  bulb  by  pulling  it 

out. 

6.  Insert a new headlight bulb into the bulb 

holder by pushing it in. 

 

Summary of Contents for MSU 800

Page 1: ...MASSIMO MSU 800 Owner s Manual ...

Page 2: ...mation It provides information about special techniques and skills necessary to ride your UTV It also includes basic maintenance and inspec tion procedures If you have any questions regarding the operation or maintenance of your UTV please consult the dealer AN IMPORTANT SAFETY MESSAGE READ THIS MANUAL TOGETHER WITH TIPS FOR THE UTV RIDER CARE FULLY AND COMPLETELY BEFORE OPERATING YOUR UTV MAKE SU...

Page 3: ...wing notations The SafetyAlert Symbol means ATTENTION YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the machine operator a bystander or a person inspecting or repairing the machine A CAUTION indicates special precautions that must be taken to avoid damage to the machine A NOTE provides key information to make procedures easier or clearer N...

Page 4: ...ng up process When the temperature is higher than 38 100 F and when you park the UTV after it run at high speed please keep engine running for 3 minutes at idle mode and make sure that the radiator fan still work for 3 minutes to prevent cooling water from boiling Then turn off the power switch to save the battery When you park the UTV and cut off the engine please turn off the ignition switch to ...

Page 5: ...ion Display Gauge 4 6 Odometer And Trip Meter Modes 4 7 Clock Mode 4 8 Fuel Gauge 4 9 Switches 4 10 On Command Four Wheel Drive And Differential Gear Lock Switches 4 11 Accelerator Pedal 4 15 Brake Pedal 4 16 Drive Select Lever 4 16 Fuel Tank Cap 4 17 Seats 4 17 Seat Moving ForwardAnd Backward 4 19 Seat Belt 4 19 Cargo Bed 4 21 Front And Rear Shock Absorber Adjustment 4 23 Trailer Hitch Bracket 4 ...

Page 6: ...ture 6 1 Starting The Engine 6 2 Warming Up 6 3 Drive Select Lever Operation And Reverse Driving 6 4 Parking 6 6 Parking On A Slope 6 7 Vehicle Break in Period 6 8 Engine Break In 6 9 Accessories And Loading 6 10 7 DRIVING YOUR VEHICLE 7 1 Getting To Know Your Vehicle 7 1 Learning To Operate Your Vehicle 7 5 Turning Your Vehicle 7 6 Operating Improperly in Reverse 7 7 Cab Nets And Shoulder Protect...

Page 7: ...1 Cleaning The Spark Arrester 8 25 Valve Clearance 8 27 Front Brake Pad Check 8 27 Rear Brake Pad Check 8 28 Checking The Brake Fluid Level 8 28 Brake Fluid Replacement 8 30 Checking The Brake Pedal 8 30 Checking The Brake Pedal 8 30 Parking brake lever free play adjustment 8 31 Brake Light Switch Adjustment 8 33 Cable Inspection And Lubrication 8 34 Brake Pedal And Accelerator Pedal Lubrication 8...

Page 8: ...ear Turning Light Bulb 8 48 Troubleshooting 8 50 Check and solution to Common Problems in Vehicle 8 51 CLEANING AND STORAGE 9 1 A Cleaning 9 1 B Storage 9 3 SPECIFICATIONS 10 1 FAULT CODE OF ELECLRONIC INJECTION SYSTEM 11 1 9 10 11 ...

Page 9: ...1 1 LOCATION OF THE WARNING AND SPECIFICATION LABELS ...

Page 10: ...ls 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 from your dealer ...

Page 11: ...1 3 ...

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Page 13: ...1 5 ...

Page 14: ...ehicle on any paved surfaces including sidewalks driveways parking lots and streets Driving in the slimy ground and sands is prohibited 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 the ankle boots long sleeved shirt or jacket and long pants Never consume alcohol or drugs before o...

Page 15: ...r 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 Never operate on excessively rough slippery or loose terrain until you have learned and practiced the skills necessary to control the vehicle on such terrain Always...

Page 16: ...ity 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 cargo bed Always use the size and type of tires specified in this manual Always maintain proper ...

Page 17: ...ty 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 carburetor 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 inhale a lot...

Page 18: ... 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 19: ...late 9 Driver seat belt 10 Air filter element 11 Cargo bed 12 Tail brake lights rear turning light 13 Rear reflector 14 License light 15 Rear shock absorber assembly 16 Spark arrester 17 CVT belt case 18 Passenger seat belt 19 Right shoulder protection plate 20 Spark plug 21 Oil filter cartridge 22 Fuel tank cap 23 Switch lock assy 24 Passenger seat 25 Coolant reservoir 26 Radiator cap ...

Page 20: ...DC jack 31 Passenger handrail 32 Drive select lever 33 Accelerator pedal 34 Brake pedal 35 Cab nets 36 Front turning light NOTE The vehicle you have purchased may differ slightly from those in the figures of this manual WARNING To protect drivers and passengers arm leg and feet make sure the cab nets is in function before driving ...

Page 21: ...when ordering spare parts from a dealer or for reference in case the vehicle is stolen 1 VEHICLE IDENTIFICATION NUMBER 2 MODEL LABEL INFORMATION Vehicle Identification Number The Vehicle Identification Number is stamped into the frame 1 Vehicle identification number NOTE The vehicle identification number is used to identify your vehicle ...

Page 22: ...ower and the headlights and taillights come on 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 KEY Turning the steering wheel can lock the direction while unplugging the key ...

Page 23: ...e electric starter to let it cool Do not turn the key to the START position with the engine running or damage to the electric starter can result See starting instructions prior to starting the engine See pages 6 1 6 3 for details Switch Lock Assy 1 Horn switch 2 Main switch 1 Position light switch 2 Headlight switch 3 Right turn signal 4 Left turn signal 5 Head light ...

Page 24: ...olant temperature warning light Low Range Indicator Light L This indicator light comes on when the drive select lever is in the L position Parking Brake Indicator Light P This indicator light comes on when the parking brake is applied High Range Indicator Light H This indicator light comes on when the drive select lever is in the H position On Command Differential Gear Lock Indicator Light DIFF LO...

Page 25: ...he drive mode as 2WD first then turn the handle to the right side then press UNLOCK button to unlock the rear differential and the light will turn off Neutral Indicator Light N This indicator light comes on when 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 NOTE If the indicator light fla...

Page 26: ...n stop the engine as soon as it is safe to do so and allow the engine to cool down for about 15 minutes 1CAUTION The engine may overheat if the vehicle is overloaded If this happens reduce the load to specification After restarting make sure that the light is out Continuous use while the light is on may cause damage to the engine High beam indicator The light being on means headlight is at high be...

Page 27: ...lock Hour fault code reset button The multi function meter unit is equipped with the following Speedometer which shows the riding speed Odometer which shows the total distance traveled Two trip meters which show the distance traveled since they were last set to zero Clock Hour meter which shows the total time the key has been turned to ON Fault code meter To display the faults of Electronic Fuel I...

Page 28: ...p meter select it by pushing the TRIP ODO button and then push the TRIP ODO button for at least three seconds The trip meters can be used to estimate the distance that can be traveled with a full tank of fuel This information will enable you to plan future fuel stops NOTE Holding in the TRIP ODO button and then turning the key to ON switches the display between mph and km h 1 Front R horn 2 Front ...

Page 29: ...E button to set the hours 4 Press the TRIP ODO button to set the minutes 5 Press the watch button for 3 5 seconds and then release it the clock will begin to work Fault Codes Display Of Electronic Injection System When the faults come out meter will display the fault codes to guide the repair See attachment for faults code page 11 1 When the fault code is confirmed and has been repaired you just n...

Page 30: ...uge The fuel gauge will indicate the fuel volume As the fuel is running out the indicator will turn green into red Vice versa 1 Fuel level warning indicator 2 Fuel meter 1 Rear license bracket 2 Rear license light ...

Page 31: ...e switch to to turn on the high beam and the taillights Set the switch to OFF to turn off all lights 1CAUTION Do not use the headlights with the engine turned off for an extended period of time The battery may discharge to the point that the starter motor will not operate properly If this should happen remove the battery and recharge it ...

Page 32: ...Only rear wheels have differential lock mechanism Two wheel drive 2WD DIFF LOCK Power is sup plied to the rear wheels only With the rear wheels differential gear locked red light DIFF LOCK is on the two rear wheels turn at the same speed regardless of traction Four wheel drive 4WD DIFF LOCK Power is supplied to the rear and front wheels With the rear wheels differential gear locked red light DIFF ...

Page 33: ...AT 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 could distract the operator and increase the risk of losing control and an accident HOW TO AVOID THE HAZARD Always stop the vehic...

Page 34: ...t to position and then set the switch to 4WD When the vehicle is in 4WD the 4WD indicator will come on in the multi function display To change from 4WD to 2WD stop the vehicle and then set the switch to 2WD the 4WD indicator will go out in the multi function display On Command Differential Gear Lock Switch 2WD UNLOCK 1 On Command differential lock switch 2WD UNLOCK 2 Select lever ...

Page 35: ...e unlocked the rear differential starts to work WARNING POTENTIAL HAZARD Riding too fast while the vehicle is in 4WD LOCK WHAT CAN HAPPEN All wheels turn at the same speed when the differential is locked so it takes more effort to turn the vehicle 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 spee...

Page 36: ...he accelerator pedal fully returns to the idle position as soon as it is released 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...

Page 37: ...l to slow or stop the vehicle 1 Brake pedal Drive Select Lever The drive select lever is used to shift the vehicle into low high neutral and reverse positions Refer to pages 6 4 6 5 for the drive select lever operation 1 Drive select lever ...

Page 38: ...move the fuel tank cap by turning it counter clockwise 1 Fuel tank cap Seats To remove a seat Remove bolts M6 with socket wrench and then remove the seat Installation is the reverse of removal 1 Driver seat 2 Passenger seat ...

Page 39: ...d normally Improper installation can result in seat rail blocked and failure to move the seat back and forth 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 mounted firmly ...

Page 40: ...ht of different drivers Pull up the handle then you can move the seat forward and backward 1 Seat handle Seat Belt 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 1 Seat belt 2 2 Latch plate 2 3 Buckle 2 ...

Page 41: ... 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 over your shoulder and across your chest The shoulder belt should fit against your chest If it is loose pull the belt out all the ...

Page 42: ...PPEN 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 Cargo Bed 1 Cargo bed Maximum load limit 100kg 220lb ...

Page 43: ...r this cargo bed 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 be thrown out or be struck by objects in the cargo bed HOW TO AVOID THE HAZARD Never carry a passenger in the cargo bed This cargo bed is designed to ca...

Page 44: ... severe bottoming can cause increased wear or damage to the vehicle Adjust the spring preload as follows To increase the spring preload turn the adjusting ring in direction To decrease the spring preload turn the adjusting ring in direction 1 Spring preload adjusting ring 2 Position indicator NOTE A special wrench can be obtained at a dealer to make this adjustment Standard position B A Minimum so...

Page 45: ...mproper shock absorber adjustment WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability which 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 ...

Page 46: ...ailer hitch bracket Auxiliary DC Jack The auxiliary DC jack is located at the right side of the front panel The auxiliary DC jack can be used for suitable 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...

Page 47: ...ssories requiring more than the above maximum capacity This may overload the circuit and cause the fuse to blow 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 Do not use an automotive cigarette lighter or other accessories with a plug that gets hot because the jack can be damaged ...

Page 48: ...r Check coolant level Fill with coolant if necessary 5 6 8 15 8 16 Final gear oil Differential gear oil Check for leakage 5 7 Accelerator pedal Check for proper accelerator pedal operation 5 8 5 10 Seat belts Check for proper operation and belt wear 5 10 Steering Check for proper operation 5 8 5 10 Fittings and fasteners Check all fittings and fasteners 5 11 Lights and switches Check for proper op...

Page 49: ...ibed in the Owner s Manual Brakes Always check brake pedal travel and the brake fluid reservoir level before each use of the vehicle When applied the brake pedal should feel firm Any sponginess would indicate a possible fluid leak or low brake fluid level which must be corrected before riding If you discover any irregularities in brake system operation including excessive pedal travel contact your...

Page 50: ...oints or the brake fluid reservoir Apply the brakes firmly for one minute If there is any leakage have the vehicle inspected by a dealer Brake Operation Test the brakes at slow speed after starting out to make sure they are working properly If the brakes do not provide proper braking performance inspect the brake system See pages 8 26 8 29 Emergency Braking When the braking system is out of order ...

Page 51: ...ke system 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 brakes If a problem cannot be corrected by the adjustment procedures provided in this manual have the vehicle ...

Page 52: ...h a pump octane number R M 2 of 86 or higher or research octane number of 93 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 requirements of relevant rule of the United States ...

Page 53: ...ately Be sure the fuel tank cap is closed securely Engine Reduction Gear box Oil Make sure the engine reduction gear box oil is at the specified level Add oil as necessary See pages 8 7 8 10 1CAUTION 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...

Page 54: ...he coolant every two years See pages 8 15 8 17 for details 1CAUTION Hard water or salt water is harmful to the engine You may use soft water if you cannot get distilled water Coolant reservoir capacity up to the maximum level mark 0 627L 0 555lmp qt 0 663US qt WARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot WHAT CAN HAPPEN You could be burned by hot fl...

Page 55: ... Differential Gear Oil Make sure the differential gear oil is at the specified level Add oil as necessary See pages 8 16 8 17 for details Recommended oil SAE 80 API GL 5 Hypoid gear oil Adjustment of steering wheel You can adjust the height of the steering board according to the driver s height and driving habits 1 Releasing the locking nut 2 Adjusting the steering wheel to the proper location by ...

Page 56: ...ation 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 dealer for service if throttle problems arise Always check the pedal for free movement a...

Page 57: ...y 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 Ajustment 1 Remove both seats Remove the middle cover of the engine see PAGE 8 6 2 Loose the nut of throttle rope on ...

Page 58: ...n 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 dealer repair as necessary for proper operation Fittings and Fasteners Always check the tightness of chassis fittings and fasteners before a ride Take the vehicle to a dealer or refe...

Page 59: ... 1 The tires listed below have been approved by Motor Manufacturing corporation of America for this model Other tire combinations are not recommended 2 The tires should be set to the recommended pressure Recommended tire pressure Front 140kpa 0 7 kgf cm2 20psi Rear 140kpa 0 7 kgf cm2 20psi Check and adjust tire pressures when the tires are cold Tire pressures must be equal on both sides 3 Tire pre...

Page 60: ... Rear 126kpa 0 64kgf cm2 18psi 4 Use no more than the following Pressures when seating the tire beads Front 250kpa 2 5kgf cm2 36psi Rear 250kpa 2 5kgf cm2 36psi Higher pressures may cause the tire to burst Inflate the tires very slowly and carefully Fast inflation could cause the tire to burst ...

Page 61: ...d reading Dust or dirt in the gauge could cause the first reading to be incorrect Set pressure with tires cold Set tire pressures to the following specifications Recommended pressure Minimum Maximum Front 140kpa 0 70kgf cm 2 20psi 126kpa 0 64kgf cm 2 18psi 154kpa 0 77kgf cm 2 22psi Rear 140kpa 0 70kgf cm 2 20psi 126kpa 0 64kgf cm 2 18psi 154kpa 0 77kgf cm 2 22psi 1 Tire pressure gauge ...

Page 62: ...5 15 Tire Wear Limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire a Tire wear limit ...

Page 63: ...k your dealer Starting The Engine In Low Temperatures WARNING POTENTIAL HAZARD Freezing control cables in cold weather WHAT CAN HAPPEN You could be unable to control the vehicle 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 re...

Page 64: ...hould come on If the neutral indicator light does not come on ask a dealer 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 fails to start release the key and then try sta...

Page 65: ...s over 12V the idle speed will be normal If the idle speed is still high please contact your dealer 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 warm check if it responds to the throttle normally 1 Release the brakes and press the accelerator pedal gradually 2 If the rotation rate of the ...

Page 66: ...gh and High to Low 1 Bring the UTV to a complete stop and return the throttle lever to the closed position 2 Apply the brakes then shift by moving the drive select lever along the shift guide NOTE Make sure that the drive select lever is completely shifted into position 1 Drive select lever Shifting Neutral to Reverse NOTE The drive select lever cannot be shifted into or from reverse without apply...

Page 67: ... 1 Drive select lever NOTE When in reverse the reverse indicator light should be on If the light does not come on ask a dealer to inspect the electrical circuit Due to the synchronizing mechanism in the engine the light may not come on until the UTV starts moving 4 Check behind for people or obstacles and then release the brake pedal 5 Open the throttle lever gradually and continue to watch to the...

Page 68: ...y HOW TO AVOID THE HAZARD When you shift into reverse make sure there are no obstacles or people behind you When it is safe to proceed go slowly Parking 1 When parking stop the engine and shift the drive select lever into the neutral position 2 Push the brake pedal down and pull the parking brake to top position to park the vehicle 1 Parking handbar ...

Page 69: ...l 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 Do not park the vehicle at all on hills that are so steep you could not walk up them easily ...

Page 70: ...me it 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 Excessive heat build up during the first three hours of operation will damage close fitted ...

Page 71: ...rolonged 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 the temporary build up o...

Page 72: ... 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 and Loading Accessories Accessories can affect the handing and control of your vehicle Keep the following in mind when considering an accessory or operating a vehicle which has accessories Choose only accessories designed for y...

Page 73: ...hen driving a vehicle with accessories The vehicle may handle differently than it does without accessories Loading Carrying cargo or towing 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 following points in mind Never exceed the weight limits shown An overloaded vehicle can be unstable MAXIMU...

Page 74: ...carrying cargo and towing a trailer include the tongue weight in the maximum vehicle load limit Load cargo in 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 Tie down cargo securely in the trailer Make sure cargo in the trailer cannot move around A shifting load can cause an accident Make sure the load does not interfe...

Page 75: ...ing of the vehicle WARNING POTENTIAL HAZARD Overloading this vehicle or carrying or towing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle hand ling 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 great...

Page 76: ...ase also read all 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 passenger 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 HOW TO AVO...

Page 77: ...he 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 829Kg 1825lb See Loading on page 6 11 Carrying a passenger and cargo can affect vehicle handling ...

Page 78: ...istributed 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 and an approved motorcycle helmet Also wear eye protection and protective clothing including over the ankle boots gloves a long sl...

Page 79: ...ases 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 Jacket Lo...

Page 80: ...before attempting more difficult maneuvers Perform the Pre Operation Checks on pages 5 1 5 15 Set the parking brake shift to neutral and follow the instructions on page 6 1 to start the engine Once it has warmed up and you have turned the choke off 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 t...

Page 81: ...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 res...

Page 82: ...hrottle suddenly 3 Back 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 s safe to proceed back slowly Cab Nets And Shoulder Protection Plate Your vehicle is equipped with cab nets and shoulder protection plates on both sides of the vehicle Cab nets and shoulder protection pla...

Page 83: ...avel Always allow for greater braking distance on rough 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 attemptin...

Page 84: ...T 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 attempting large hills Maximum slope angle 15 w...

Page 85: ... 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 gently applying the brakes when...

Page 86: ...s 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 start going too fast gently apply the brakes 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 regain control If you must turn on the ...

Page 87: ...er 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 deepe...

Page 88: ...onditions 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 dealer before starting the engine If it s impossible to take your vehicle to a dealer before starting it follow the steps outlined below 1 Move the vehicle to dry land 2 Check the air box If water is present dry the air box and repl...

Page 89: ... or not 8 If water has been ingested into the CVT make sure inspect the hole without water left inside If it is muddy water open the CVT cap and wash the parts before reassemble 9 check the gearshift release the water inside Wash it if it is necessary CAUTION Make sure all motion parts coated with grease after wash and reassemble 1 Air filter case check hose 1 Drive select lever box check hose ...

Page 90: ... skid process has destroyed the soil structure Even if you lock the differential the rear wheels may continue to slip and will not drive the vehicle ahead WARNING POTENTIAL HAZARD The rear axle differential is in a locking state while driving on the standard road WHAT CAN HAPPEN The vehicle will be difficult to drive especially in the corners which may cause steering difficulties HOW TO AVOID THE ...

Page 91: ...rollover accident Avoid jumping the vehicle as injury loss of control and damage to the vehicle could occur WARNING POTENTIAL HAZARD Failure to use extra care when operating this vehicle on unfamiliar 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 an...

Page 92: ...ides and above the vehicle for obstacles such as branches that the vehicle might hit causing an accident or for brush that might enter the vehicle as you pass and strike the driver or passenger Never hold onto the enclosure so your hand is outside the vehicle Hold only onto the handgrip inside the enclosure ...

Page 93: ...ping Go only fast enough to maintain your momentum but still give yourself plenty of time to react to changes in conditions If there is any question about your ability to maneuver safely over the obstacle you should turn around if the ground is flat and you have the room or back up until you find a less difficult path WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Cou...

Page 94: ...ges The service information included in this manual is intended to provide you the owner with the necessary information for completing your own preventive maintena nce 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...

Page 95: ... 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 accesso ries All parts and accessories added to this vehicle should...

Page 96: ...special tools data and technical skills ITEM ROUTINE Whichever Comes first INITIAL EVERY Month 1 3 6 6 12 Km mi 320 200 1 200 750 2 400 1 500 2 400 1 500 4 800 3 000 hours 20 75 150 150 300 Fuel Line Check fuel hose for cracks or damage Replace if necessary Valves Check valve clearance Adjust if necessary Spark Plug Check condition Adjust gap and clean Replace if necessary Carburetor Check idle sp...

Page 97: ...idge Replace Final Gear Oil Check oil level Check oil leakage Replace Differential Gear Oil Front Brake Check operation brake pad wear fluid leakage see NOTE page 8 6 Correct if necessary Replace pads if worn to the limit Rear Brake Check operation brake pad wear fluid leakage see NOTE page 8 6 Correct if necessary Replace pads if worn to the limit Accelerator Pedal Check operation and free play C...

Page 98: ...Mount Check for cracks or damage Check bolt tightness Front and Rear Axle Boots Check operation Replace if damaged Anti Roll Bar Bushings Check for cracks or damage Fittings and Fasteners Check all chassis fittings and fasteners Check if necessary NOTE Recommended brake fluid DOT4 Brake fluid replacement When disassembling the master cylinder or caliper replace the brake fluid Normally check the b...

Page 99: ... back to closed position and fasten the latches 1 Sundry box cover Engine Cover To Open Close 1 Remove two seats see page 4 16 2 Unscrew all the screws on the engine cover 3 Pull the engine cover upward to open it 1 Engine cover 2 Screw M6 12 1CAUTION When installing the engine cover be sure not to pinch the cables or wires ...

Page 100: ... be sure to warm up the engine sufficiently and then wait at least ten minutes until the oil settles for an accurate reading 4 Remove the engine oil filler cap and wipe off the dipstick with a clean rag 5 Insert the dipstick in the oil filler hole without screwing it in and then remove it again to check the oil level NOTE The engine oil should be between the minimum and maximum level marks 1 Maxim...

Page 101: ...gine to collect the used oil and then remove the engine oil filler cap 3 Remove the engine oil drain bolt to drain the oil from the crankcase 1 Engine oil drain bolt NOTE Skip steps 4 6 if the oil filter cartridge is not being replaced 4 Remove the oil filter cartridge with an oil filter wrench 1 Oil filter cartridge 2 Oil filter bolt NOTE An oil filter wrench is available at a nearby dealer ...

Page 102: ...w oil filter cartridge with an oil filter wrench and then tighten it to the specified torque with a torque wrench Tightening torque Oil filter cartridge 17Nm 1 7m kgf 12 ft lbs 1 Oil filler cartridge 2 Torque bolt 7 Install the engine oil drain bolt and then tighten it to the specified torque Tightening torque Engine oil drain bolt 24Nm 2 4m kgf 17 ft lbs ...

Page 103: ...lso 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 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 ...

Page 104: ...sufficient engine oil 4 Screw up oil inlet bolt 1 Oil inlet bolt Tighlening torgue Oil inlet bolt 24N m 2 4m kgf 17 ft lbs Oil outlet bolt 24N m 2 4m kgf 17 ft lbs 1 Oil outlet bolt Recommended engine oil See page 10 2 Oil quantity Without oil filter cartridge replacement 1 05L 1 67 lmp qt 2 01 US qt With oil filter cartridge replacement 2 0 L 1 76 lmp qt 2 11 US qt ...

Page 105: ...orrect oil level NOTE The oil level should be at the brim of the filler hole 3 If the oil is below the brim of the filler hole add sufficient oil of the recommended type to raise it to the correct level 1CAUTION Be sure no foreign material enters the final gear case 4 Install the oil filler bolt and then tighten it to the specified torque Tightening torque Final gear oil filler bolt 23 Nm 2 3 m kg...

Page 106: ... the oil 1 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 20 Nm 2 0 m kgf 14 ft lbs 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 4 L 0 35 lmp qt 0 42 US qt 1CAUTION Be sure no foreign material enters the final gear case ...

Page 107: ... Gear Oil Level 1 Place the vehicle on a level surface 2 Remove the differential 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 1 Speed sensor 2 Correct oil level 3 Differential gear oil 4 oil level sensor 1CAUTION 1 Be sure no foreign material enters the d...

Page 108: ... Place the vehicle on a level surface 2 Place a container under the differential gear case to collect the used oil 3 Remove the differential gear oil filler bolt and differential gear oil drain bolt to drain the oil 1 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 23Nm 2 3m kg...

Page 109: ...orque Differential gear oil filler bolt 23Nm 2 3m kgf 16 3 ft lbs 7 Check for oil leakage If oil leakage is found check for the cause Coolant The coolant level should be checked before each ride Checking the Coolant Level 1 Place the vehicle on a level surface 2 Open the hood See pages 8 7 8 8 for hood opening and closing procedures 3 Check the coolant level in the coolant reservoir when the engin...

Page 110: ...anti freeze with distilled water only However if distilled water is not available soft water may be used for refilling Changing the Coolant The coolant must be changed by a dealer at the intervals specified in the periodic maintenance and lubrication chart Recommended antifreeze High quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Antifreeze and water mixing...

Page 111: ...nt of the coolant as soon as possible The radiator fan is automatically switched on or off according to the coolant temperature in the radiator If your vehicle overheats see page 8 45 for details Axle Boots Check the protective boots for holes or tears If any damage is found have them replaced by a dealer 1 Front axle boot 2 each side 1 Rear axle boot 2 each side ...

Page 112: ... Spark plug cap 1 Spark plug wrench Inspection The spark plug is an important engine component and is easy to inspect The condition of the spark plug can indicate the condition of the engine The ideal color of the porcelain insulator around the center electrode is a medium to light tan for a vehicle that is being ridden normally Do not attempt to diagnose such problems ...

Page 113: ...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 DPR8EA 9 NGK Installation 1 Measure the electrode gap with a wire thickness gauge and if necessary adjust the gap to specification a Spark plug gap Spark plug gap 0 8 0 9mm 0 031 0 035 in ...

Page 114: ...t 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 or water collects in this hose empty t...

Page 115: ...for Engine cover removal and installation procedure 3 Remove the connecting rubber tube between air cleaner and throttle valve and the screws fixing the air cleaner and then remove the air cleaner 1 Holder 6 2 Air filter case cover 4 Remove the air filter element 5 Remove the sponge material from its frame 1 Air filter element ...

Page 116: ...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 1CAUTION Do not twist the sponge material when squeezing it 8 Inspect the sponge material and replace it if damaged ...

Page 117: ...e 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 engine cover 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 Each time air filter element maintenance is perform...

Page 118: ...ne damage Additionally operation without the air filter element will affect carburetor jetting with subsequent poor performance and possible engine overhea ting Cleaning the Spark Arrester Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester 1 Remove the bolts 1 muffler 2 Spark Arrester 2 Remove the tailpipe by pulling it out of the muffler 3 Tap the tailpipe lightly an...

Page 119: ...Nm 1 2 m kgf 8 5 ft lbs WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester Hot exhaust system WHAT CAN HAPPEN Could injure the eyes Could cause burns Could cause carbon monoxide poisoning possibly leading to death Could start a fire HOW TO AVOID THE HAZARD When cleaning the spark arrester Always let the exhaust system cool prior to touching exhaust components Do not start the engine ...

Page 120: ...ofessional 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 having to disassemble the brake system 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 dealer replace the brake pads as a set 1 ...

Page 121: ... brake pad has worn to the point that the wear indicator grooves have almost disappeared have a dealer replace the brake pads as a set 1 Brake pad wear indicator groove Checking the Brake Fluid Level Insufficient brake fluid may let air enter the brake system possibly causing the brakes to become ineffective Before riding check that the brake fluid is above the minimum level mark and replenish if ...

Page 122: ...eriorate causing leakage and poor braking performance Recommended brake fluid DOT 4 Refill with the same type of brake fluid Mixing fluids may result 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 significantly lower the boiling point of the fluid and may result in vapor lock Brake fluid may ...

Page 123: ...y two years Replace the brake hoses every four years Checking the Brake Pedal Have a dealer 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 smoothly and there should be no brake drag If the brakes feel soft or spongy this could indicate air in the brake system Have a dealer check...

Page 124: ... components re quires professional knowledge These procedures should be performed by a dealer 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 pages 4 16 4 17 for seat removal and installation procedures 3 Remove the console See page 8 9 for console removal ...

Page 125: ... and adjusting the parking brake lever free play 5 Loosen the locknut 1 Locknut 2 Adjusting ntu 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 126: ... necessary adjust the brake light switch as follows 10 Open the hood See pages 8 7 8 8 for hood opening and closing procedure 11 Turn the adjusting nut while holding 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 ...

Page 127: ...comes 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 Lubricate the inner cables and the cable ends If the cables do not operate smoothly ask a dealer to replace them Recommended lubricant Engine oil see page 10 2 ...

Page 128: ...thium based grease all purpose grease Rear Knuckle Upper and Lower Pivot Lubrication Lubricate the knuckle upper and lower pivots with a grease gun Recommended lubricant Lithium based grease Steering Shaft Lubrication Lubricate the pivot points Recommended lubricant Lithium based grease all purpose grease ...

Page 129: ...8 36 upper universal joint steering transmit ssion shaft lower universal joint steering transmit ssion shaft front balance rod rear balance rod ...

Page 130: ...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 131: ...d 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 dealer 1CAUTION Do not try to remove the sealing caps of the battery cells You may damage the battery Wheel nut torque Front 70Nm 7 0 m kgf 49 7 ft lbs Rear 70Nm 7 0 m kgf 49 7 ft lbs ...

Page 132: ... 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 flames cigarettes or ot...

Page 133: ...ON A special battery charger constant voltage ampere or constant voltage is required for recharging a sealed type battery Using a conventional battery charger may shorten the battery life Fuse Replacement The main fuse and the fuse box are located under the hood See pages 8 7 8 8 for hood opening and closing procedures If a fuse is blown turn off the ignition switch and install a new fuse of the s...

Page 134: ...ion switch when checking or replacing a fuse WARNING OTENTIAL 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 Always use a fuse of the specified rating Never use a material in place of the proper fuse 3 Remove the blown fuse and then install a new fuse of the specified amperage ...

Page 135: ... Fuse Main Fuse Headlight Fuse Ignition Fuse Auxiliary DC Jack Fuse Signaling System Fuse Carburetor Warmer Fuse Four Wheel Drive Motor Fuse Backup Fuse 30 0A 15 0A 10 0A 10 0A 10 0A 10 0A 3 0A 10 0A 4 Turn the key to ON and turn on the electrical circuit in question to check if the device operates 5 If the fuse immediately blows again have a dealer check the electrical system 6 Install the batter...

Page 136: ...over at the rear of the headlight by pulling it off 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 counter clockwise 5 Remove the defective bulb by pulling it out 6 Insert a new headlight bulb into the bulb holder by pushing it in ...

Page 137: ...f the bulb touches something flammable HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it 1CAUTION Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth m...

Page 138: ...lder cover is securely fitted over the bulb holder and seated properly 9 Close the hood 10 Adjust the headlight beam if necessary 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 139: ...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 1 Tail brake light bulb holder 6 Install the panel by installing the quick fasteners and bolts and then tighten the bolts to the specified torque Tightening torque Panel bolt 6 5N m 0 65 m kgf 4 7 ft lbs ...

Page 140: ...the front turning light by pulling it off 1 Cover at the rear of the front turning light 3 Remove the front turning light bulb holder cover by pulling it off 1 Front turning light bulb holder cover 4 Remove the front turning light bulb holder by pushing it in and turning it counter clockwise 5 Remove the defective bulb by pulling it out 6 Insert a new front turning light bulb into the bulb holder ...

Page 141: ... rear turning light bulb burns out replace it as follows 1 Lift the hood up See pages 8 7 8 8 for hood opening and closing procedures 2 Remove the cover at the rear of the rear turning light by pulling it off 1 Cover at the rear of the rear turning light 3 Remove the rear turning light bulb holder cover by pulling it off ...

Page 142: ...ng light bulb holder by pushing it in and turning it counter clockwise 5 Remove the defective bulb by pulling it out 6 Insert a new rear turning light bulb into the bulb holder by pushing it in 1 Rear turning light bulb holder 1 Do not touch the glass part of the bulb ...

Page 143: ...ians at a dealership have the tools experience and know how to properly service your vehicle Imitation parts may look like original parts but they are often inferior Consequently they have a shorter service life and can lead to expensive 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...

Page 144: ...e parts and impact fittings S N Problems Solutions 1 Covers are cracked up when go a crossing the field 1 Covers are cracked up when go a crossing the field 2 Change for new plastic covers 3 Re paste the stickers and re rivet the warning lables 2 Vehicle s bottom protect tion plate is damaged by prominence on ground 1 Check if the reduction gear box and differential in front and rear bridge are da...

Page 145: ...n calipers are over worn or contaminated by stuffs which can reduce friction 3 Check if there is any leakage in brake system s oil lines or conjunctions 4 Check if the post rod in brake master cylinder is deformed 5 Check if there is any air go into the oil lines and drain the air with special equipment 6 Check if the remain oil in master cylinders of front and rear brake is still above the lowest...

Page 146: ... damper rubber sleeves connecting front suspension rock and frame are damaged Table 3 Check and Solution of Common Problems in Electrical System S N Problems Solutions 1 Lamps don t work 1 check if the headlight switch functions well 2 Check if the wires are broken 3 Check if the lamps or bulbs are broken 2 Vehicle cannot go into 4 drive mode 1 Check if the control switch on meter board works well...

Page 147: ...e switch is broken 2 Check if the wire is broken 3 Check if the ECU in electrical injection system is broken Table 4 Check and Solution of Common Problems in Running System S N Problems Solutions 1 Swing clearance of stee ring wheel is too big 1 Check the fix screws connecting steering rod to steering stem and knuckle to find out if they are loose or broken 2 Check the bulbs on the ends of steerin...

Page 148: ...ke seriously in running 1 Check the bearing in rear bridge bearing seat to find out if they are broken 2 Check the sliding bearing connecting rear bridge and rocks to find out if they are worn or loose 3 Check the inner splines of rear wheel hubs and outer splines of rear wheel axles to find out if they are worn or broken 4 Check the lock screws of rear wheels and axles to find out if they are loo...

Page 149: ...sorbers lose their damping force in their travel 6 Front bridge makes noise in running 1 Check if the spline of intermediate driving shaft is broken 2 Check if the splines in left right drive shafts of front rear bridges are broken 3 Check if the gears in rear bridge reduction gear box and differential are over worn 4 Check the dust cover of constant velocity universal joint in right left drive sh...

Page 150: ...d value 3 Check MEUI for failure 3 Power performance is falling 1 Check if there is one cylinder not working 2 Check gasoline nozzle for block 3 Check and clean core of air cleaner 4 Check muffler for partly block and clean spark arrestor 4 Popping in engine 1 Check air cleaner and admission line for leak 2 Check the connection joint of exhaust pipe with engine or muffler for leak 3 Check the grad...

Page 151: ... with low electricity may cause the motor failure 2 Check the starting motor for damage 3 Check if MEUI can work in good condition 4 Check if the ignition loop can work in good condition 5 Check if the spark plug is foulled or burned 6 Check if the ignition signal is in good condition 7 Check if the air cleaner is blocked 8 Check if the oil circuit is smooth 9 Check if the exhaust system is blocke...

Page 152: ...ARNING 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 153: ...ges The service information included in this manual is intended to provide you the owner with the necessary information for completing your own preventive maintena nce 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...

Page 154: ... 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 accesso ries All parts and accessories added to this vehicle should...

Page 155: ...special tools data and technical skills ITEM ROUTINE Whichever Comes first INITIAL EVERY Month 1 3 6 6 12 Km mi 320 200 1 200 750 2 400 1 500 2 400 1 500 4 800 3 000 hours 20 75 150 150 300 Fuel Line Check fuel hose for cracks or damage Replace if necessary Valves Check valve clearance Adjust if necessary Spark Plug Check condition Adjust gap and clean Replace if necessary Carburetor Check idle sp...

Page 156: ...idge Replace Final Gear Oil Check oil level Check oil leakage Replace Differential Gear Oil Front Brake Check operation brake pad wear fluid leakage see NOTE page 8 6 Correct if necessary Replace pads if worn to the limit Rear Brake Check operation brake pad wear fluid leakage see NOTE page 8 6 Correct if necessary Replace pads if worn to the limit Accelerator Pedal Check operation and free play C...

Page 157: ...Mount Check for cracks or damage Check bolt tightness Front and Rear Axle Boots Check operation Replace if damaged Anti Roll Bar Bushings Check for cracks or damage Fittings and Fasteners Check all chassis fittings and fasteners Check if necessary NOTE Recommended brake fluid DOT4 Brake fluid replacement When disassembling the master cylinder or caliper replace the brake fluid Normally check the b...

Page 158: ... back to closed position and fasten the latches 1 Sundry box cover Engine Cover To Open Close 1 Remove two seats see page 4 16 2 Unscrew all the screws on the engine cover 3 Pull the engine cover upward to open it 1 Engine cover 2 Screw M6 12 1CAUTION When installing the engine cover be sure not to pinch the cables or wires ...

Page 159: ... be sure to warm up the engine sufficiently and then wait at least ten minutes until the oil settles for an accurate reading 4 Remove the engine oil filler cap and wipe off the dipstick with a clean rag 5 Insert the dipstick in the oil filler hole without screwing it in and then remove it again to check the oil level NOTE The engine oil should be between the minimum and maximum level marks 1 Maxim...

Page 160: ...gine to collect the used oil and then remove the engine oil filler cap 3 Remove the engine oil drain bolt to drain the oil from the crankcase 1 Engine oil drain bolt NOTE Skip steps 4 6 if the oil filter cartridge is not being replaced 4 Remove the oil filter cartridge with an oil filter wrench 1 Oil filter cartridge 2 Oil filter bolt NOTE An oil filter wrench is available at a nearby dealer ...

Page 161: ...w oil filter cartridge with an oil filter wrench and then tighten it to the specified torque with a torque wrench Tightening torque Oil filter cartridge 17Nm 1 7m kgf 12 ft lbs 1 Oil filler cartridge 2 Torque bolt 7 Install the engine oil drain bolt and then tighten it to the specified torque Tightening torque Engine oil drain bolt 24Nm 2 4m kgf 17 ft lbs ...

Page 162: ...lso 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 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 ...

Page 163: ...sufficient engine oil 4 Screw up oil inlet bolt 1 Oil inlet bolt Tighlening torgue Oil inlet bolt 24N m 2 4m kgf 17 ft lbs Oil outlet bolt 24N m 2 4m kgf 17 ft lbs 1 Oil outlet bolt Recommended engine oil See page 10 2 Oil quantity Without oil filter cartridge replacement 1 05L 1 67 lmp qt 2 01 US qt With oil filter cartridge replacement 2 0 L 1 76 lmp qt 2 11 US qt ...

Page 164: ...orrect oil level NOTE The oil level should be at the brim of the filler hole 3 If the oil is below the brim of the filler hole add sufficient oil of the recommended type to raise it to the correct level 1CAUTION Be sure no foreign material enters the final gear case 4 Install the oil filler bolt and then tighten it to the specified torque Tightening torque Final gear oil filler bolt 23 Nm 2 3 m kg...

Page 165: ... the oil 1 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 20 Nm 2 0 m kgf 14 ft lbs 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 4 L 0 35 lmp qt 0 42 US qt 1CAUTION Be sure no foreign material enters the final gear case ...

Page 166: ... Gear Oil Level 1 Place the vehicle on a level surface 2 Remove the differential 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 1 Speed sensor 2 Correct oil level 3 Differential gear oil 4 oil level sensor 1CAUTION 1 Be sure no foreign material enters the d...

Page 167: ... Place the vehicle on a level surface 2 Place a container under the differential gear case to collect the used oil 3 Remove the differential gear oil filler bolt and differential gear oil drain bolt to drain the oil 1 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 23Nm 2 3m kg...

Page 168: ...orque Differential gear oil filler bolt 23Nm 2 3m kgf 16 3 ft lbs 7 Check for oil leakage If oil leakage is found check for the cause Coolant The coolant level should be checked before each ride Checking the Coolant Level 1 Place the vehicle on a level surface 2 Open the hood See pages 8 7 8 8 for hood opening and closing procedures 3 Check the coolant level in the coolant reservoir when the engin...

Page 169: ...anti freeze with distilled water only However if distilled water is not available soft water may be used for refilling Changing the Coolant The coolant must be changed by a dealer at the intervals specified in the periodic maintenance and lubrication chart Recommended antifreeze High quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Antifreeze and water mixing...

Page 170: ...nt of the coolant as soon as possible The radiator fan is automatically switched on or off according to the coolant temperature in the radiator If your vehicle overheats see page 8 45 for details Axle Boots Check the protective boots for holes or tears If any damage is found have them replaced by a dealer 1 Front axle boot 2 each side 1 Rear axle boot 2 each side ...

Page 171: ... Spark plug cap 1 Spark plug wrench Inspection The spark plug is an important engine component and is easy to inspect The condition of the spark plug can indicate the condition of the engine The ideal color of the porcelain insulator around the center electrode is a medium to light tan for a vehicle that is being ridden normally Do not attempt to diagnose such problems ...

Page 172: ...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 DPR8EA 9 NGK Installation 1 Measure the electrode gap with a wire thickness gauge and if necessary adjust the gap to specification a Spark plug gap Spark plug gap 0 8 0 9mm 0 031 0 035 in ...

Page 173: ...t 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 or water collects in this hose empty t...

Page 174: ...for Engine cover removal and installation procedure 3 Remove the connecting rubber tube between air cleaner and throttle valve and the screws fixing the air cleaner and then remove the air cleaner 1 Holder 6 2 Air filter case cover 4 Remove the air filter element 5 Remove the sponge material from its frame 1 Air filter element ...

Page 175: ...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 1CAUTION Do not twist the sponge material when squeezing it 8 Inspect the sponge material and replace it if damaged ...

Page 176: ...e 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 engine cover 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 Each time air filter element maintenance is perform...

Page 177: ...ne damage Additionally operation without the air filter element will affect carburetor jetting with subsequent poor performance and possible engine overhea ting Cleaning the Spark Arrester Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester 1 Remove the bolts 1 muffler 2 Spark Arrester 2 Remove the tailpipe by pulling it out of the muffler 3 Tap the tailpipe lightly an...

Page 178: ...Nm 1 2 m kgf 8 5 ft lbs WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester Hot exhaust system WHAT CAN HAPPEN Could injure the eyes Could cause burns Could cause carbon monoxide poisoning possibly leading to death Could start a fire HOW TO AVOID THE HAZARD When cleaning the spark arrester Always let the exhaust system cool prior to touching exhaust components Do not start the engine ...

Page 179: ...ofessional 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 having to disassemble the brake system 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 dealer replace the brake pads as a set 1 ...

Page 180: ... brake pad has worn to the point that the wear indicator grooves have almost disappeared have a dealer replace the brake pads as a set 1 Brake pad wear indicator groove Checking the Brake Fluid Level Insufficient brake fluid may let air enter the brake system possibly causing the brakes to become ineffective Before riding check that the brake fluid is above the minimum level mark and replenish if ...

Page 181: ...eriorate causing leakage and poor braking performance Recommended brake fluid DOT 4 Refill with the same type of brake fluid Mixing fluids may result 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 significantly lower the boiling point of the fluid and may result in vapor lock Brake fluid may ...

Page 182: ...y two years Replace the brake hoses every four years Checking the Brake Pedal Have a dealer 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 smoothly and there should be no brake drag If the brakes feel soft or spongy this could indicate air in the brake system Have a dealer check...

Page 183: ... components re quires professional knowledge These procedures should be performed by a dealer 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 pages 4 16 4 17 for seat removal and installation procedures 3 Remove the console See page 8 9 for console removal ...

Page 184: ... and adjusting the parking brake lever free play 5 Loosen the locknut 1 Locknut 2 Adjusting ntu 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 185: ... necessary adjust the brake light switch as follows 10 Open the hood See pages 8 7 8 8 for hood opening and closing procedure 11 Turn the adjusting nut while holding 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 ...

Page 186: ...comes 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 Lubricate the inner cables and the cable ends If the cables do not operate smoothly ask a dealer to replace them Recommended lubricant Engine oil see page 10 2 ...

Page 187: ...thium based grease all purpose grease Rear Knuckle Upper and Lower Pivot Lubrication Lubricate the knuckle upper and lower pivots with a grease gun Recommended lubricant Lithium based grease Steering Shaft Lubrication Lubricate the pivot points Recommended lubricant Lithium based grease all purpose grease ...

Page 188: ...8 36 upper universal joint steering transmit ssion shaft lower universal joint steering transmit ssion shaft front balance rod rear balance rod ...

Page 189: ...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 190: ...d 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 dealer 1CAUTION Do not try to remove the sealing caps of the battery cells You may damage the battery Wheel nut torque Front 70Nm 7 0 m kgf 49 7 ft lbs Rear 70Nm 7 0 m kgf 49 7 ft lbs ...

Page 191: ... 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 flames cigarettes or ot...

Page 192: ...ON A special battery charger constant voltage ampere or constant voltage is required for recharging a sealed type battery Using a conventional battery charger may shorten the battery life Fuse Replacement The main fuse and the fuse box are located under the hood See pages 8 7 8 8 for hood opening and closing procedures If a fuse is blown turn off the ignition switch and install a new fuse of the s...

Page 193: ...ion switch when checking or replacing a fuse WARNING OTENTIAL 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 Always use a fuse of the specified rating Never use a material in place of the proper fuse 3 Remove the blown fuse and then install a new fuse of the specified amperage ...

Page 194: ... Fuse Main Fuse Headlight Fuse Ignition Fuse Auxiliary DC Jack Fuse Signaling System Fuse Carburetor Warmer Fuse Four Wheel Drive Motor Fuse Backup Fuse 30 0A 15 0A 10 0A 10 0A 10 0A 10 0A 3 0A 10 0A 4 Turn the key to ON and turn on the electrical circuit in question to check if the device operates 5 If the fuse immediately blows again have a dealer check the electrical system 6 Install the batter...

Page 195: ...over at the rear of the headlight by pulling it off 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 counter clockwise 5 Remove the defective bulb by pulling it out 6 Insert a new headlight bulb into the bulb holder by pushing it in ...

Page 196: ...f the bulb touches something flammable HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it 1CAUTION Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth m...

Page 197: ...lder cover is securely fitted over the bulb holder and seated properly 9 Close the hood 10 Adjust the headlight beam if necessary 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 198: ...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 1 Tail brake light bulb holder 6 Install the panel by installing the quick fasteners and bolts and then tighten the bolts to the specified torque Tightening torque Panel bolt 6 5N m 0 65 m kgf 4 7 ft lbs ...

Page 199: ...the front turning light by pulling it off 1 Cover at the rear of the front turning light 3 Remove the front turning light bulb holder cover by pulling it off 1 Front turning light bulb holder cover 4 Remove the front turning light bulb holder by pushing it in and turning it counter clockwise 5 Remove the defective bulb by pulling it out 6 Insert a new front turning light bulb into the bulb holder ...

Page 200: ... rear turning light bulb burns out replace it as follows 1 Lift the hood up See pages 8 7 8 8 for hood opening and closing procedures 2 Remove the cover at the rear of the rear turning light by pulling it off 1 Cover at the rear of the rear turning light 3 Remove the rear turning light bulb holder cover by pulling it off ...

Page 201: ...ng light bulb holder by pushing it in and turning it counter clockwise 5 Remove the defective bulb by pulling it out 6 Insert a new rear turning light bulb into the bulb holder by pushing it in 1 Rear turning light bulb holder 1 Do not touch the glass part of the bulb ...

Page 202: ...ians at a dealership have the tools experience and know how to properly service your vehicle Imitation parts may look like original parts but they are often inferior Consequently they have a shorter service life and can lead to expensive 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...

Page 203: ...e parts and impact fittings S N Problems Solutions 1 Covers are cracked up when go a crossing the field 1 Covers are cracked up when go a crossing the field 2 Change for new plastic covers 3 Re paste the stickers and re rivet the warning lables 2 Vehicle s bottom protect tion plate is damaged by prominence on ground 1 Check if the reduction gear box and differential in front and rear bridge are da...

Page 204: ...n calipers are over worn or contaminated by stuffs which can reduce friction 3 Check if there is any leakage in brake system s oil lines or conjunctions 4 Check if the post rod in brake master cylinder is deformed 5 Check if there is any air go into the oil lines and drain the air with special equipment 6 Check if the remain oil in master cylinders of front and rear brake is still above the lowest...

Page 205: ... damper rubber sleeves connecting front suspension rock and frame are damaged Table 3 Check and Solution of Common Problems in Electrical System S N Problems Solutions 1 Lamps don t work 1 check if the headlight switch functions well 2 Check if the wires are broken 3 Check if the lamps or bulbs are broken 2 Vehicle cannot go into 4 drive mode 1 Check if the control switch on meter board works well...

Page 206: ...e switch is broken 2 Check if the wire is broken 3 Check if the ECU in electrical injection system is broken Table 4 Check and Solution of Common Problems in Running System S N Problems Solutions 1 Swing clearance of stee ring wheel is too big 1 Check the fix screws connecting steering rod to steering stem and knuckle to find out if they are loose or broken 2 Check the bulbs on the ends of steerin...

Page 207: ...ke seriously in running 1 Check the bearing in rear bridge bearing seat to find out if they are broken 2 Check the sliding bearing connecting rear bridge and rocks to find out if they are worn or loose 3 Check the inner splines of rear wheel hubs and outer splines of rear wheel axles to find out if they are worn or broken 4 Check the lock screws of rear wheels and axles to find out if they are loo...

Page 208: ...sorbers lose their damping force in their travel 6 Front bridge makes noise in running 1 Check if the spline of intermediate driving shaft is broken 2 Check if the splines in left right drive shafts of front rear bridges are broken 3 Check if the gears in rear bridge reduction gear box and differential are over worn 4 Check the dust cover of constant velocity universal joint in right left drive sh...

Page 209: ...d value 3 Check MEUI for failure 3 Power performance is falling 1 Check if there is one cylinder not working 2 Check gasoline nozzle for block 3 Check and clean core of air cleaner 4 Check muffler for partly block and clean spark arrestor 4 Popping in engine 1 Check air cleaner and admission line for leak 2 Check the connection joint of exhaust pipe with engine or muffler for leak 3 Check the grad...

Page 210: ... with low electricity may cause the motor failure 2 Check the starting motor for damage 3 Check if MEUI can work in good condition 4 Check if the ignition loop can work in good condition 5 Check if the spark plug is foulled or burned 6 Check if the ignition signal is in good condition 7 Check if the air cleaner is blocked 8 Check if the oil circuit is smooth 9 Check if the exhaust system is blocke...

Page 211: ...ARNING 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 212: ... 3 in 1 360mm 53 5in 1 840mm 73 2 in 800mm 31 5 in 1 940mm 76 4 in 260 mm 10 2 in 6 730 mm 265 in Basic weight With oil and full fuel tank 526 0 kg 1 508 lb Engine Engine type Cylinder arrangement Displacement Bore stroke Compression ratio Starting system Lubrication system 4 stroke Water cooled V type twin cylinder 800cm3 91 61 5mm 9 5 1 Electric starter Wet sump ...

Page 213: ...SG type or higher JASO standard MA 1CAUTION 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 1 67lmp qt 2 01 US qt 2 00L 1 76lmp qt 2 11 US qt ...

Page 214: ... SAE80 API GL 5 Hypoid gear oil 0 10L 0 08 lmp qt 0 1 US qt Radiator capacity including all routes 2 50L 2 20 lmp qt 2 64 US qt Air filter Wet element Fuel Type Fuel tank capacity Unleaded gasoline only 29 0L 6 38 lmp gal 7 67 US gal Throttle valve Type quantity Spark plug Type Spark plug gap 0 8 0 9 mm 0 031 0 035 in Clutch type Wet centrifugal automatic ...

Page 215: ...on ratio Transmission type Operation Reverse gear Sub transmission ratio Low High CVT belt Shaft drive 0 68 2 7 CVT belt automatic Right hand operation 5 45 5 29 2 866 Chassis Frame type Caster angle Trail Steel tube frame 1 0 26 0mm 1 02 in Tire Type Size Front Rear Tubeless 25 8 12NHS 25 10 12NHS ...

Page 216: ...n Rear suspension Double wishbone Double wishbone Shock absorber Front shock absorber Rear shock absorber Coil spring oil damper Coil spring oil damper Wheel travel Front wheel travel Rear wheel travel 130mm 5 9 in 150mm 6 8 in Electrical Ignition system Generator system Battery type Battery capacity ECU AC magneto U1L 11 12V32Ah Headlight type Krypton bulb ...

Page 217: ...erse indicator light Coolant temperature warning light Parking brake indicator light Diff lock indicator On Command differential gear lock indicator light High range indicator light Low range indicator light LED LED LED LED LED LED LED LED Specified fuses Main fuse Headlight fuse Ignition fuse Auxiliary DC jack fuse Four wheel drive motor fuse Signaling system fuse Backup fuse 30 0A 15 0A 10 0A 10...

Page 218: ...T 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 KsDGDM_TPS_ShortHigh 123 291 P0131 O2S 1 Circuit Low Volt...

Page 219: ...age 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 Coil Malfunction KsDGDM_EST_B_Fault 352 850 P0505 Idle Speed Control Error KsDGDM_IdleControl 505 1285 P0562 System Voltage Low KsDGDM_SysVoltLow ...

Page 220: ...ter 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 444 1092 P0171 BLM Max Adapt Kohler Special KsFDIAG_BLM_MaxAdapt 171 369 P0172 BLM Min Adapt Kohler Special KsFD...

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