Massimo T-BOSS 410 Page 83 Owner'S/Operator'S Manual Download

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T-Boss410

OWNER’S/OPERATOR’S MANUAL 18.0

15. EXHAUST SYSTEM

15-2

WARNING

The engine exhaust from this product contains chemicals known, in

certain quantities, to cause cancer, birth defects or other reproductive

harm.

Summary of Contents for T-BOSS 410

Page 1: ...NTAL TRACKS OR RACING OWNER S OPERATOR S MANUAL US 18 0 T BOSS 410 Independent Rear Suspension 2X4 4X4 BEFORE OPERATING THIS VEHICLE THE OWNER AND EACH OPERATOR MUST HAVE READ AND HAVE AN UNDERSTANDIN...

Page 2: ...ner and 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 Plea...

Page 3: ...UTV 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 NOT...

Page 4: ...s that fits properly The driver and 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 t...

Page 5: ...TV Never operate on excessively rough slippery or loose terrain Always follow proper procedures for turning as described in this manual Practice turning at low speeds before attempting to turn at fast...

Page 6: ...mmended maximum depth Go slowly carefully avoiding sudden 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 h...

Page 7: ...N KNOW 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 responsibilitie...

Page 8: ...roughout 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 safe...

Page 9: ...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 NOTE No 2 ONLY FOR 4WD Attention There is a risk o...

Page 10: ...T Boss410 OWNER S OPERATOR S MANUAL 18 0 3 SAFETY WARNING 3 2 1...

Page 11: ...T Boss410 OWNER S OPERATOR S MANUAL 18 0 3 SAFETY WARNING 3 3 2 3 4 5...

Page 12: ...T Boss410 OWNER S OPERATOR S MANUAL 18 0 3 SAFETY WARNING 3 4 6 7 8 9...

Page 13: ...T Boss410 OWNER S OPERATOR S MANUAL 18 0 3 SAFETY WARNING 3 5 10 11 12 13...

Page 14: ...T Boss410 OWNER S OPERATOR S MANUAL 18 0 3 SAFETY WARNING 3 6 14...

Page 15: ...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...

Page 16: ...ght and left Check for excessive free play abnormal noises or a rough feeling Have an authorized dealer repair as necessary for proper operation 10 Loose parts visually inspect vehicle for any damaged...

Page 17: ...ngine 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 clothe...

Page 18: ...get some gasoline in your eyes see your doctor immediately If gasoline spills on your skin wash with soap and water If gasoline spills on your clothing change your clothes WARNING POTENTIAL HAZARD Cha...

Page 19: ...ng the vehicle Consult an authorized dealer if you can t find or solve the problem yourself WARNING POTENTIAL HAZARD A loose seat WHAT CAN HAPPEN The operator could lose control or the operator or pas...

Page 20: ...ng too fast or sharp or a combination of conditions increase the risk of tip over If you are in a situation where the vehicle is tipping over do not put your arm or and leg outside the vehicle do not...

Page 21: ...r distance 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 T...

Page 22: ...en 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 th...

Page 23: ...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...

Page 24: ...are not familiar with vehicle service WARNING POTENTIAL HAZARD Operating this vehicle with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle m...

Page 25: ...Use parts cleaning solvent to clean the sponge material WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester Hot exhaust system WHAT CAN HAPPEN Could injure the eyes Could cause burns Cou...

Page 26: ...rect Make sure the brakes do not drag All air must be bled from the brake system Replacement of brake components requires professional knowledge These procedures should be performed by an authorized d...

Page 27: ...en 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 1...

Page 28: ...rt 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 HA...

Page 29: ...cident 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...

Page 30: ...Attempting 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 POTE...

Page 31: ...ID THE 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 unf...

Page 32: ...ntrol 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 ove...

Page 33: ...nual 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...

Page 34: ...down 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...

Page 35: ...ing backwards Keep weight 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...

Page 36: ...r fast flowing water 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 ex...

Page 37: ...res 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 th...

Page 38: ...er modify 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 shoul...

Page 39: ...brakes 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 ope...

Page 40: ...RATOR S MANUAL 18 0 6 V I N ENGINE SERIAL NUMBER AND KEY 6 1 Record these numbers from your UTV in the spaces provided 1 Frame VIN found on the front of the frame tube 2 Engine Serial Number Left side...

Page 41: ...a key blank and having it cut by mating it with your existing key Record Key Number The vehicle frame and engine serial numbers are important for model identification when registering your vehicle ob...

Page 42: ...th power 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...

Page 43: ...is on and the headlights are turned off before using the accessory socket otherwise you may drain the battery The accessory socket is rated capacity is DC 12V 120 Watts 10A or less If you exceed this...

Page 44: ...amage When switch on 4WD the button will stay in 4WD position but 4WD mechanics maybe still disengaged Always apply throttle gently and let the wheels move slightly to allow the 4WD mechanics finally...

Page 45: ...lector B km mile selector 9 front differentia lock indicator ACCELERATOR PEDAL WARNING Before starting the engine check the accelerator pedal to be sure it is operating smoothly Make sure the accelera...

Page 46: ...or stop the vehicle WARNING Never operate the UTV with a spongy feeling brake pedal Operating the UTV with a spongy brake pedal can result in loss of braking Loss of braking could cause an accident P...

Page 47: ...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 ge...

Page 48: ...of the seat and then slide the seat up and forward To install a seat insert the projections on the rear of the seat into the seat holders and push down on the seat at the front WARNING POTENTIAL HAZA...

Page 49: ...S FUNCTIONS 7 8 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 and passenger Always wear the seat belt while riding in t...

Page 50: ...n 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...

Page 51: ...ARTS FUNCTIONS 7 10 CARGO BED 1 Cargo bed 2 Tailgate 3 Cargo hook 4 Opening And Closing The Tailgate 1 Tailgate 2 Latch 2 To open Unhook the latches and then lower the tailgate To close Place the tail...

Page 52: ...o bed until it stops To lower Lower the cargo bed slowly to its original position and be sure that it is locked into place WARNING POTENTIAL HAZARD Pinch points WHAT CAN HAPPEN You or someone else cou...

Page 53: ...Cargo should be properly distributed and securely attached Reduce speed when carrying cargo Allow greater distance for braking WARNING POTENTIAL HAZARD Carrying a passenger passengers in the cargo bed...

Page 54: ...latch 2 To Close Lower the hood slowly to its original position and then hook the hood latches and be sure that they are locked into place WARNING If the hood latches are hooked improperly or the lat...

Page 55: ...e tank past the pressure cap and into the radiator NOTE Some coolant level drop on new machines is normal as the system is purging itself of trapped air Observe coolant levels and maintain as recommen...

Page 56: ...lways exercise extreme caution whenever handling gasoline Always refuel with the engine stopped and outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the are...

Page 57: ...ilter Oil System 1 Dipstick The oil tank is located on the right side of the engine To check the oil 1 Set machine on a level surface 2 Start the engine and let it idle for 20 30 seconds 3 Stop the en...

Page 58: ...in 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...

Page 59: ...1 Turn the key to OFF 2 Open the hood 3 Remove the battery compartment cover 4 Using a charged 12 V battery connect the positive lead of the jumper cable to the positive terminal of the battery in th...

Page 60: ...n disconnect the positive lead of the jumper cable from the charged battery and the battery in the vehicle 8 Install the battery compartment cover 9 Close the hood WARNING If the hood latches are hook...

Page 61: ...ng the break in period Excessive heat can build up and cause damage to close fitted engine parts 1 Fill fuel tank 2 Check oil reservoir level indicated on dipstick Add oil if necessary 3 Drive slowly...

Page 62: ...protective gear for safe riding A helmet can 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 shie...

Page 63: ...ved 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 sev...

Page 64: ...l weight on trailer hitch point 11 kgf 25 lbf Choose a trailer hitch drawbar designed for use with a 5 cm 2 in receiver Do not exceed the maximum tongue weight You can measure tongue weight with a bat...

Page 65: ...ng a trailer Allow more braking distance A heavier vehicle takes longer to stop Avoid making sharp turns unless at very slow speeds Avoid hills and rough terrain Choose terrain carefully Added weight...

Page 66: ...RD Never exceed the stated load capacity for this vehicle Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for br...

Page 67: ...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 AVOID THE HAZARD...

Page 68: ...l slowly and smoothly The centrifugal clutch will engage and you will start to accelerate Avoid higher speeds until you are thoroughly familiar with the operation of your vehicle 4 When slowing down o...

Page 69: ...avoid overturns on hills and slopes Drive straight up hills and avoid crossing the side of a hill which increases your chance of rollover Practice first on gentle slopes before attempting steeper hill...

Page 70: ...fast enough to keep your momentum going but not so fast that you cannot react to changes in the terrain as you climb Slow down when you reach the crest of the hill if you cannot clearly see what is o...

Page 71: ...than you will be able to react to obstacles that may appear WARNING POTENTIAL HAZARD Going down a hill improperly WHAT CAN HAPPEN Could cause loss of control or cause the vehicle to overturn HOW TO A...

Page 72: ...teer 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 a...

Page 73: ...TE After running the vehicle in water it is critical your machine is serviced as outlined in the maintenance chart see 16 maintenance The following areas need special attention engine oil transmission...

Page 74: ...g terrain conditions when operating the vehicle RIDING IN BRUSH OR WOODED AREAS When operating in areas with brush or trees watch carefully on both sides and above the vehicle for obstacles such as br...

Page 75: ...perly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or a collision Could cause the vehicle to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles...

Page 76: ...e 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 blo...

Page 77: ...ly at speeds less than 7 MPH due to the system s dependence on engine speed By switching to low range while operating at low ground speeds the air temperature in the clutch will be reduced Reducing th...

Page 78: ...lists provide a guideline for when to use low range rather than high Low Range Basic operation at speeds less than 7 MPH 11km h Heavy pulling Riding through rough terrain swamps mountains etc at low...

Page 79: ...hysician immediately Eyes Flush with water for 15minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an...

Page 80: ...to allow cleaning solution or tap water into the battery 1 Set the battery in its holder 2 First connect and tighten the red positive cable 3 Second connect and tighten the black negative cable 4 Rei...

Page 81: ...BATTERY 14 3 CAUTION Your UTV is equipped with a 14Ah Battery This may no be sufficient to provide power for optional equipment When installing optional equipment please upgrade your battery as neces...

Page 82: ...result Be especially careful when traveling through tall grass The potential for fire exists Catalyst There is catalyst inside the muffler on all Europe models and some U S models WARNING The engine...

Page 83: ...410 OWNER S OPERATOR S MANUAL 18 0 15 EXHAUST SYSTEM 15 2 WARNING The engine exhaust from this product contains chemicals known in certain quantities to cause cancer birth defects or other reproductiv...

Page 84: ...ained in the following chart on the following pages NOTE Maintenance intervals are based upon average riding conditions and an average vehicle speed of approximately 16 km 10 miles per hour However ke...

Page 85: ...ide inspection item Air Filter Pre Cleaner Daily Daily Inspect Clean Coolant Level Inspection Daily Daily Replace engine coolant every one year Air Box Sediment Tube Daily Daily Drain deposits wheneve...

Page 86: ...h seasonally Shift linkage 50 hrs 6 months Inspect adjust Drive belt 50 hrs 6 months Inspect replace if necessary D Steering system 50 hrs 6 months Check operation and for looseness worn damage bindin...

Page 87: ...l surface Cooling System hoses 50 hrs 6 months Inspect replace if necessary Spark arrestor 10 hrs monthly Clean out replace if necessary Clutches drive and driven 25 hrs 3 months Inspect clean D Engin...

Page 88: ...GL 4 85W 90 Add to proper level on dipstick Change annually or at 100 hours 4 Rear Gear case oil SAE GL 4 85W 90 See 16 MAI NTENANCE Rear Gear Case Lubrication Change annually or at 100 hours 5 Front...

Page 89: ...e Joint Grease Locate fitting and Grease Semi annually 12 Front Rear A arm pivot Shaft Grease Locate fitting on pivot shaft and grease with grease gun Every3monthsor 50hours 13 Throttle Cable Grease M...

Page 90: ...T Boss410 OWNER S OPERATOR S MANUAL 18 0 16 MAINTENANCE 16 7...

Page 91: ...INTENANCE 16 8 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 H...

Page 92: ...alled must be serviced by an authorized Dealer Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations Service work must be performed by an...

Page 93: ...cargo bed See 7 CONTROL AND PARTS FUNCTIONS in this manual for bed lifting and lowering 2 Release clips and remove Cover 3 Loosen clamp and remove Filter 4 Remove fabric type pre filter from main filt...

Page 94: ...ree 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...

Page 95: ...ght 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...

Page 96: ...ystem in good operating condition How often they need checking depends upon the type of driving that has been done Keep fluid level in the master cylinder reservoirs as described see 7 Control and par...

Page 97: ...brake system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage The brake fluid reservoir is located under the hood When checking the fl...

Page 98: ...then lock the lock nut Brake pedal and accelerator pedal lubrication Lubricate the pivoting parts Recommended lubricant Lithium soap based grease all purpose grease PARKING BRAKE Checking Although the...

Page 99: ...he adjustor the one on the lever and apply the lever While adjusting it is important you apply the lever back and forth for operation free play and the locking of the parking position 7 Make sure the...

Page 100: ...roperly then lock the lock nut all purpose grease 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 dist...

Page 101: ...move a spark plug while the engine is warm The exhaust system or engine could burn you causing severe injury Remove the spark plug by rotating counterclockwise Reverse the procedure for spark plug ins...

Page 102: ...ing NOTE Severe use cold weather riding is all riding below 10 F 12 and riding between 10 F 12 and 30 F 0 when most trips are slow speed and less than 5 mph 8km h Be sure to change the oil filter when...

Page 103: ...rain pan beneath engine crankcase 6 Remove Oil filler plug Drain plug Compression spring Oil strainer O ring 7 Allow oil to drain completely 8 Install O ring New Compression spring Oil strainer New if...

Page 104: ...ct transmission lubricant to use is SEA GL 4 85W 90 Lubricant And see 16 Maintenance lubrication recommendations for the correct fluid level Transmission Oil Changing Procedure 1 Remove the screws on...

Page 105: ...fill hole NOTE Do not add lubricant to the bottom of the fill plug threads The correct gear case lubricant to use is SAE GL 4 85W 90 Weight Gear Lube Oil Changing Procedure 1 Remove the drain plug Ca...

Page 106: ...e With the ATV on a level surface remove fill plug and visually inspect the lubricant level through the fill hole Lubricant should be kept even with the center of the drill point approximately below t...

Page 107: ...with worn tires improperly inflated tires non standard tires or improperly installed tire will affect vehicle handling which could cause an accident resulting in serious injury or death Follow the sa...

Page 108: ...l hub Be sure the valve stem is toward the outside and totation arrows on the tire point toward forward rotation 2 Attach the wheel nuts and finger tighten them 3 Lower the vehicle to the ground 4 Sec...

Page 109: ...the taillight brakelight to see that it s working 5 Reinstall the lens and screws CLEANING YOUR UTV Keeping your UTV clean will extend the life of various components Washing Never use a high pressure...

Page 110: ...nspect All Fluid Levels Inspect the following fluid levels and change if necessary transmission brake fluid change every two years or as required if fluid looks dark or contaminated Fog the Engine Spr...

Page 111: ...llowing 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 the frame of the UTV to the transporting until...

Page 112: ...onger component life Insufficient warm up of CUV s exposed to low ambient temperatures Warm engine at least 5 min they with transmission in neutral advance throttle to approx 1 8throttle in short burs...

Page 113: ...key off at once WARNING This CUV equipped with an electric start system If the battery is under charging the CUV will not run This UTV is equipped with EFI system If the battery is under 12 Volt the e...

Page 114: ...foreign material the fuel pressure not correct Throttle body The connect not good Air cleaner Clogged air cleaner element Improper air cleaner setting COMPRESSION SYSTEM Cylinder and cylinder head Va...

Page 115: ...plug gap Faulty main switch Worn electrodes Faulty brake switch Wire between terminals broken Improper heat range Faulty spark plug cap Wiring Ignition coil Loose battery terminal Broken or shorted pr...

Page 116: ...l pressure not correct Clogged air cleaner fuel filter clogging fuel injector clogging POOR SPEED PERFORMANCE Ignition system Compression system Dirty spark plug Worn cylinder Improper heat range Worn...

Page 117: ...n system Faulty spark plug Faulty high tension cord Faulty ignitor unit Faulty pick up coil Faulty ignition coil Valve system Improperly adjusted valve clearance OVER HEATING OVER COOLING Ignition sys...

Page 118: ...tor Faulty thermostat Faulty thermo switch Incorrect coolant level low coolant level Faulty radiator Clogged damage Faulty radiator cap Impeller shaft gear malfunction bent dowel pin gear Damaged impe...

Page 119: ...RAKE PERFORMANCE POOR BRAKING EFFECT V belt Worn front hub bearing Slipping oily V belt Worn brake pad Primary sliding sheave Worn brake disc Improper operation Air in brake fluid Damage Leaking brake...

Page 120: ...T Boss410 OWNER S OPERATOR S MANUAL 18 0 18 TOOL 18 1...

Page 121: ...L 1 48 US qt Dry Weight 493 kg 1087lb Cargo Bed Maximum load limit 150 kg 330 lb Load Capacity Combined Rider Payload 300 kg 660 lb Gross Vehicle Weight Maximum Technically Permissible Mass 804 kg 177...

Page 122: ...id Cooled Lubrication System Wet Sump Ignitions EFI Spark Plug Type DR8EA NGK Electrical Equipment Battery 12V 30AH Head light 35W 35W x2 Brake Tail Light 21W 5W x2 High Beam Indicator Light 12V 1W Ne...

Page 123: ...T Boss410 OWNER S OPERATOR S MANUAL 18 0 19 SPECIFICATION 19 3 ECU 2 10A Backup Fuse 1 5A Backup Fuse 2 10A Backup Fuse 3 15 A...

Page 124: ...T Boss410 OWNER S OPERATOR S MANUAL 18 0 20 WIRNING DIAGRAM 20 1...

Page 125: ...OWNER S OPERATOR S MANUAL US 18 0 T Boss410 18 0...

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Massimo T-BOSS 410, Owner'S/Operator'S Manual

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