TrailMaster CHALLENGER150 Owner'S/Operator'S Manual Download Page 36 | Manualshive

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35

T

ROUBLESHOOTING

Although vehicles receive a rigid inspection before shipment from the factory, trouble may occur during
operation. Any problem in the fuel, compression, or ignition system can cause poor starting and loss of
power. The troubleshooting chart describes quick, easy procedures for making checks. If your vehicle
requires any repair, take it to a dealer.

Your skilled technician at a dealership has the tools, experience and know‐how to properly service your
vehicle. Use only genuine parts on your vehicle.

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Summary of Contents for CHALLENGER150

Page 1: ...GER4200E XCHALLENGER200 E CHALLENGER200E X CHALLENGER4150 CHALLENGER4150X CHALLENGER300 CHALLENGER300X CHALLENGER4300 E CHALLENGER4300X E CHALLENGER300 E CHALLENGER300X E CHALLENGER4300 CHALLENGER4300X Provincial Municipalgovernmentshavedifferentregulations pertainingto owningandoperatinganoff roadvehicle learnthe regulations in your area READ THIS MANUAL CAREFULLY OWNER S OPERATOR S MANUAL UTV ...

Page 2: ...ingscontainedin thismanualcanresultinseriousinjuriesinjuriesordeath Besuretofollowtherecommendedmaintenance scheduleandserviceyourvehicleaccordingly Preventive maintenance is extremely important to the longevity of your vehicle We hope you will have a pleasant experience with our product and thank you again for choosingour Products Forquestionsregardingoperationand maintenance of this vehicle Plea...

Page 3: ...MATION 5 LOCATION OFWARNINGDECALS 6 SAFETYINFORMATION 8 DESCRIPTION ANDVEHICLE IDENTIFICATION 10 CONTROLFUNCTIONS 13 PRE OPERATINGCHECKS 18 OPERATION 22 DRIVING YOURVEHICLE 25 PERIODIC MAINTENANCE ANDADJUSTMENT 27 Troubleshooting 35 Cleaning andStorage 36 Specifications 38 ...

Page 4: ...his vehicle on public roads orhighways Do not allow your child to ride without supervision Donotrideundertheinfluenceofdrugsoralcohol Theycanaffectyourjudgment and slow your reactiontime Always maintain a safe distance between your vehicle and vehicles aroundyou Never ride this vehicle unless it has been properly adjusted andmaintained Never run the engine in closed areas The exhaust gas contains ...

Page 5: ...that the warranty will not be voided is obtained from authorized dealer Whentransportingthemachineinanothervehicle besurethatitiskeptuprightand that the fuel cock is in the off position Otherwise fuel may leak out of the carburetor or the fueltank Alwaysfollowthebreak in periodasdescribedintheowner smanual Notfollowing the break in period will void the enginewarranty Always clean the air filter as...

Page 6: ...cle NOTE A NOTE provides key information to make procedures easier IMPORTANT MANUAL INFORMATION Note The operator passenger parents or guardian must read study and understand all the items contained within this owners operators manual before operating this vehicle Failure to follow these instructions could endanger the personal safety of the operator passenger and any Bystanders FAILURE TO FOLLOW ...

Page 7: ... all of the labels on your vehicle They contain important information for safe and proper 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 yourdealer 6 ...

Page 8: ...7 ...

Page 9: ...ugs before or while operating thisvehicle Never operate at speeds too fast for your skills or the conditions Always go at a speed that is proper for the terrain visibility operating conditions and your experience Never attempt jumps or otherstunts Always inspect your vehicle each time you use it is in safe operating condition Always follow the inspection and maintenance procedures and schedules de...

Page 10: ...ear Use engine braking to help you go slowly If necessary use the brakes gradually to help you go slowly Always check terrain carefully before going down hills Go as slowly as possible Never go down a hill at highspeed Always check for obstacles before operating in a newarea Never operate the vehicle in fast flowing water or water deeper than the floorboards on this model Remember that wet brakes ...

Page 11: ...ION AND VEHICLE IDENTIFICATION 1 Head lights 2 Front Bumper 3 Front Tire 4 Brush Guards 5 Side Mirrors 6 Top 7 Transmission Shifter 8 Steering Wheel 9 Side Guards 10 Seat 11 Seatbelts 12 Dump 13 Rear Shock adjustable 14 Rear Tires 15 Engine ...

Page 12: ... 16 Parking Brake Lever 17 Shifter Lever D N R 18 Hazard Warning Lights Switch 19 Horn Switch 20 Brake pedal 21 Key Ignition 22 Throttle pedal 23 Engine Stop Switch 24 Auxiliary 12V Plug 25 Head Lights Switch 26 Turn Lights Switch 18 ...

Page 13: ...12 28 27 27 Vehicle Identification Plate 28 Dome Light 29 30 31 32 33 34 35 36 29 Tail Lights 30 Rear Tire 31 Link Chain 32 Sprocket 33 Rear Axle 34 Muffler 35 Electronic fuel pump 36 Gas Tank Cap ...

Page 14: ...t switch ison Ignition The electric starter is engaged by turning and holding the key in this position Release the key when the engine starts CAUTION Donotoperatetheelectricstartercontinuouslyformorethan5seconds orstarterdamagecould occur Wait at least 5 seconds between each operation of the electric starter to let itcool Donotturn thekeytothe START positionwiththeenginerunning ordamagetotheelectr...

Page 15: ...indicating 9 Mileage odometer miles Control Panel 1 Hazard LightsSwitch 2 Horn 3 MainSwitch 4 Engine StopSwitch 5 Auxiliary Power Plug 12Volts 6 Headlight switch High LowBeam 7 Turning Lightswitch Caution Do not use the headlights with the engineturnedoffforanextendedperiodoftime The battery may discharge to the point that the starter motor will not operate properly If this shouldhappen removetheb...

Page 16: ...ke pedal will apply pressure on each brakedisc 1 Parking Brake Lever Parking Brake Lever Theparkingbrakeleverislocatedinbetweenthe driver seat and passenger seat It will help hold the vehicle from moving whileparked Tosettheparkingbrake pressthereleasebutton and pull up on the lever To release the parking brake press the release button and release the lever Spring pressure helps return the lever t...

Page 17: ...l tank cap The Fuel tank is locatedright sidethe vehicle Remove the fuel tank cap by turning it counterclockwise Warning Only use unleaded grade gasoline 1 2 Buckle Latch Plate Seat Belts This vehicle is equipped with three point seat belts for both the operator and passenger Always wear the seat belt while riding the vehicle 1 Hold the latch plate as you pull the belt acrossyourlapandchest Makesu...

Page 18: ...eased 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 latchedsecurely 1 Spring preloaded adjustingring 2 Positionindicator Rear shock absorber adjustment The spring preload can be adjusted to suit the operating conditions You can reduce pre...

Page 19: ...ll with coolant if necessary Final Gear Oil Check for leakage Accelerator Pedal Check for proper accelerator pedal operation Seat belts Check for proper operation and belt wear Steering Check for proper operations Fitting and fasteners Check all fittings and fasteners Lights and switches Check for proper operation Wheels and tires Check tire pressure wear and damage Axle Boots Check for damage WAR...

Page 20: ... vehicle inspected by a dealer Brake Fluid Level Check the brake fluid level Add fluid if necessary Brake Fluid Leakage Check to see if any brake fluid is leaking out of the pipe joints or the brake fluid reservoir Apply the brakes firmly for one minute IF there is any leakage have the vehicle inspected by a dealer Brake Operation Test the brakes at slow speed after starting out to make sure they ...

Page 21: ...h octane number of 91 or higher If knocking or pinging occurs use a different brand of gasoline or premium unleaded fuel Unleaded fuel will give you longer spark plug life and reduced maintenancecost Engine Oil Make sure the engine oil is at the specified level Add oil as necessary CAUTION Make sure that no foreign material entersthecrankcase Accelerator Pedal Check to see that the accelerator ped...

Page 22: ... a dealer repair as necessary for proper operations Steering Pack on level ground Turn the steering wheel right and left Check for excessive free play abnormal noise or a rough feeling 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 a vehicle to a dealer or refer to the service manual for ...

Page 23: ...mmended toshift into neutral before starting theengine 3 Withyourfootofftheacceleratorpedal starttheenginebyturningthekeyto START position NOTE If the engine fails to start release the key and then try starting again Wait a few seconds before the next attempt Each cranking could be as short as possible to preserve battery Do not crank the engine more than 5 seconds on each attempt 4 Seethe EngineB...

Page 24: ... to Low 1 Stop the vehicle Keep your foot off the acceleratorpedal 2 Apply the brakes then shift by moving the driveselectleveralongtheshiftguide 3 Releasethebrakesandpresstheaccelerator pedalgradually NOTE Make sure the drive select lever is completely in the shifted position Shifting Neutral to Reverse 1 Stop the vehicle Keep your foot off the acceleratorpedal 2 Apply the brakepedal 3 Shift from...

Page 25: ...ft into reverse make sure there are no obstacles or people behind you When it is safe to proceed go slowly Parking Whenparking stoptheengineandshiftthedriveselectleverintotheneutralposition Applytheparking brake to help prevent the vehicle fromrolling Parking on a slope 1 Bring the vehicle to stop by applyingthebrakes 2 Stop theengine 3 Withthebrakeapplies set parkingbrakebypullinguptheparkingbrak...

Page 26: ...kg 1100 lb Carrying a passenger and cargo can affect vehicle handling 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 along sleeved shirt or jacket and long pants Keep hands and feet inside the vehicle at all times Going Uphill Do not attempt to climb hills until you have ...

Page 27: ... faster than you will able to react to obstacles that may appear Riding over Rough Terrain Operating over rough terrain should be done with caution Look for obstacles that could cause damage to the vehicle or could lead to a rollover or accident Avoid jumping the vehicle as injury loss of control and damage to the vehicle could occur Tip over warnings and recovery This vehicle CAN be rolled over i...

Page 28: ...iodic inspection adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible Safety is an obligation of the vehicle owner The most important points of vehicle inspection adjustment and lubrication are explained on the following pages ...

Page 29: ...km 750 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 Everyday check before riding Engine Oil R R R R R Oil Filter C C C C Ail Filter Clean filter every 3000Km Change it when necessary Cam Chain A A A Fuel System A A A BrakeSystem I I I I I I I I I I I I I Driving Chain I L I L I L I L I L I Fasteners I I I I I I Coolant I I I I I Gearbox Oil I I I I Wheel Tires I R I R I R I R Whe...

Page 30: ...s if worn to the limit YES YES YES YES YES Rear Brake Check operation brake pad wear fluid leakage Correct if necessary Replace pads if worn to the limit YES YES YES YES YES Accelerator Pedal Check operation and free play YES YES YES YES YES V Belt Check operation Repair for wear cracks of damage YES YES YES Wheels Check balance damage run out YES YES YES YES Wheels bearing Check bearing assemblie...

Page 31: ...ap drain plug located forward of the engine oil fill plug on the bottom right side of the engine Upon removal of the plug a filter screen will be visible Elevating the front of the vehicle slightly will help drain all of the oilout 2 Emptyalloftheoilintoasuitablecontainer 3 Remove and clean the oilscreen 4 With the oil completely drained replace the screenanddrainplug thentightensecurely 5 Replace...

Page 32: ...od engine performance Chain Lubrication To increase the chain life it should be lubricated with a spray on type chain lubricant Chain Adjustment Check the chain adjustment after the first two hours of use Readjust if it has more than 1 2 flex 1 Loose Nut 1 2 Adjust Nut 2 Turn Nut 2 clockwise in 1 2 turn increments then turn Nut 1 until tight Follow this procedure until chain is at propertension Re...

Page 33: ... cables due to physical stretch found during normal operation of the vehicle To make shift adjustments follow the below instructions 1 Pushtheshifterlevertoforwardor D position 2 Check the shifter control disc found just behind the oil level dipstick to ensure that it has rotated forward all the way Look for any slack in control cable1 3 Loosen adjustment nuts 1 and 2 pulling the housing to draw t...

Page 34: ...hub assembly It is only necessarytoremovethefourlugnutstoremovethe wheels byitself Front Wheel Alignment Thefrontwheelsshouldbesetwitha toe in from 1 4 to 3 8 At the center line of the tires measure the Distance A and the Distance B For propertoeadjustment DimensionAshouldbe1 4 3 8 greater than Dimension B 1 LoosenthelocknutsonbothsidesofFrontTie Rods Ensure the steering wheel is centered and adju...

Page 35: ... if the brake fluid level goesdown Brake fluid replacement Complete fluid replacement should be done by trained service personnel Have a dealer replace the following components during periodic maintenance or when they are damaged or leaking 5 Replace the oil seals everytwoyears 6 Replace the brake hoses every fouryears Battery The vehicle is equipped with a sealed type battery Therefore it is not ...

Page 36: ...l compression or ignition system can cause poor starting and loss of power The troubleshooting chart describes quick easy procedures for making checks If your vehicle requires any repair take it to a dealer Your skilled technician at a dealership has the tools experience and know how to properly service your vehicle Use only genuine parts on your vehicle ...

Page 37: ...se water seepage and deterioration of wheel bearings brakes transmission seals and electrical devices Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin operated car washers 4 Once the majority of the dirt has been hosed off wash all surfaces with warm water and mild detergent type soap An old toothbrush or bottle brush is h...

Page 38: ...iminates the need to drain the fuel system Consult a dealer if the fuel system needs to be drainedinstead 3 Remove the spark plug pour about one tablespoon of SAE 10W30 or 20W40 motor oil in the spark plug Ground the spark plug wire and turn the engine over several times to coat the cylinder wall withoil 4 Lubricate all controlcables 5 Block up the frame to raise all wheels off theground 6 Tie a p...

Page 39: ...600mm 1600mm Wheel base 1830mm 1830mm 2580mm 2580mm Ground clearance 160mm 160mm 160mm 160mm Basic weight 300kg 300kg 350kg 350kg Total Vehicle Weight Capacity including passenger 450kg 450kg 650kg 650kg Engine 300cc Type Single cylinder water cooled 4 stroke Engine Displacement 275 6cc Bore x Stroke 72 5 66 8 Carburetor ECU Y28V1L HZE C 15 Output Power 18 HP 6500 rpm 22Nm 5000 rpm Starting Keyed ...

Page 40: ...AE 10W 40 Transmission CVT automatic with Neutral and Reverse Spark Plug Gap C7HSA CR7HSA NGK 0 6 0 7 mm Fuel Type Only use mid grade unleaded 89 93Octane Chassis Front Tire 22 x 7 10 15 psi Rear Tire 22 x 10 10 15 psi Front Brakes Hydraulic Disc Brake Rear Brake Hydraulic Disc Brake Front Suspension Dual A Arm Rear Suspension Spring over shock with 2 0 of travel Dry Weight 700 Lbs Capacities Maxi...

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