Massimo MSU 600 Owner'S Manual Download

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MASSIMO MSU 600

Owner’s Manual

Summary of Contents for MSU 600

Page 1: ...MASSIMO MSU 600 Owner s Manual...

Page 2: ...so includes basic maintenance and inspection procedures If you have any questions regarding the operation or maintenance of your vehicle please consult you dealer AN IMPORTANT SAFETY MESSAGE READ THIS...

Page 3: ...notations NOTE A NOTE provides key information to make procedures easier or clearer The Safety Alert Symbol means ATTENTION BECOME ALERT Failure to follow WARNING instructions could result in severe...

Page 4: ...and unsafe to operate this vehicle on any public street road or highway This vehicle complies with all applicable OFF ROAD noise level and spark arrester laws and regulations in effect at the time of...

Page 5: ...2 Indicator and warning lights 12 Main switch of lights 13 Dump pump and winch 15 4 2 4 4WD and differential locking exchangeable 16 Ignition switch 17 Gear Selector 18 Throttle pedal 19 Parking brake...

Page 6: ...ING YOUR VEHICLE 35 RIDNG DOWNHILL 37 CLIMBING UPHILL 38 PARKING ON A SLOPE 41 PERIODIC MAINTENANCE AND ADJUSTMENT 42 PERIODIC MAINTENANCE LUBRICATION 43 Periodic Maintenance Chart 44 Engine oil and o...

Page 7: ...ke fluid level 61 Steering Wheel Inspection 62 Tires 63 Battery 65 Fuse replacement 67 CVT System 69 CLEANING AND STORAGE 71 Malfunction analysis and elimination 73 WARRANTY 86 SPECIFICATIONS 89 TROUB...

Page 8: ...1 LOCATION OF THE WARNING AND SPECIFICATION LABELS...

Page 9: ...on your machine 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 replacem...

Page 10: ...3...

Page 11: ...size greater than 90cc Never allow a child under age 16 to operate a vehicle without adult supervision and never allow continued use of a vehicle by a child if he or she does not have the abilities to...

Page 12: ...ls too steep for the vehicle or for your abilities Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills as described in this manual Check the ter...

Page 13: ...slippery surfaces such as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control Never operate an vehicle in fast flowing water or in water deeper than...

Page 14: ...refuel while smoking or in the vicinity of sparks open flames or other sources of ignition such as the pilot lights of water heaters and clothes dryers Otherwise fuel may leak out of the carburetor o...

Page 15: ...8...

Page 16: ...9 DESCRIPTION AND MACHINE IDENTIFICATION...

Page 17: ...10...

Page 18: ...ntification number and engine number in the spaces provided for assistance when ordering spare parts from your dealer or for reference in case the vehicle is stolen 500 600UEJ 800UEJ NOTE The vehicle...

Page 19: ...8 2 and 4 wheel drive 9 Brake liquid warning light 10 Reverse over speed alarm light 11 Parking brake light 12 engine oil warning light 13 Engine trouble light 14 Battery conditional warming light 15...

Page 20: ...display X in the middle it means the both front and rear axles are in driving Meanwhile the front differential will be locked up i Alarm light of brake fluid level 9 The alarm light is on when brake...

Page 21: ...headlight low beam meter light and tail light is on c When ignition switch is at ON ACC or ON position press down alarm light blinks d When ignition switch is at ACC or ON position press down or The l...

Page 22: ...when release the press When vehicle stuck in the mud the self rescue could be done by utilizing the front fix stuff or peg Press SWITCH to ON position and then press WINCH to OUT or IN the winch cable...

Page 23: ...e use two wheel drive on the normal road In case to prolong the usage of the vehicle four wheel drive could only be used on muddy slippery snow or up slope road Warning 1 Engine is matched with steple...

Page 24: ...open position All circuits except engine are connected and they could start at any moment or make engine keep running status ST start position Connect engine and ignition circuit and start engine Han...

Page 25: ...ure proper transmission function See your dealer if you experience any shifting problems NOTICE Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission could...

Page 26: ...tion of throttle WHAT CAN HAPPEN The throttle cable 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 th...

Page 27: ...engaged could cause an accident resulting in serious injury or death It could also result in driveline or engine damage Always be sure to disengage the parking brake before operating the vehicle Brake...

Page 28: ...assenger Always make sure the seat belts are secured for both the operator and passenger before riding To wear the seat belt properly follow this procedure 1 Take up the seat belts which are located o...

Page 29: ...2 Push the red release latch in the middle of the buckle to make sure it releases freely 3 Inspect the full length for any damage including cuts wear fraying or stiffness If any damage is found or if...

Page 30: ...ad as follows To increase the spring preload turn the adjusting ring in direction a To decrease the spring preload turn the adjusting ring in direction b 1 Spring preload adjusting ring 2 Position ind...

Page 31: ...24 RIDING YOUR VEHICLE Riding Your vehicle...

Page 32: ...enjoy riding safely Before you begin to ride be sure you have read this Owner s Manual completely and understand the operation of the controls Please also read all caution and warning labels on you v...

Page 33: ...26...

Page 34: ...a certified instructor Become familiar with this vehicle at slow speeds first even if you are an experienced operator Do not attempt to operate at maximum performance until you are totally familiar w...

Page 35: ...an be struck by passing objects or crushed during vehicle rollover Do not put your hands or feet outside of the vehicle for any reason Do not hold onto the door cage frame or hip restraint bar Wear yo...

Page 36: ...en one hand or foot can reduce your ability to control the vehicle or could cause you to lose your balance and fall off of the vehicle If you remove a foot from a footboard your foot or leg may come i...

Page 37: ...f the vehicle or overturn POTENTIAL HAZARD 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 st...

Page 38: ...in some situations could lead to an accident HOW TO AVOID THE HAZARD Never modify this vehicle through improper installation or use of accessories All parts and accessories added to this vehicle shou...

Page 39: ...N HAPPEN ATVs are designed for off road use only Paved surfaces may seriously affect handling and control of the vehicle and may cause the vehicle to go out of control HOW TO AVOID THE HAZARD Always a...

Page 40: ...D 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 ove...

Page 41: ...se loss of traction or vehicle control which could result in an accident including an overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you have lear...

Page 42: ...eel in the desired direction As you do so put your weight on the footboard to the outside of the turn opposite your desired direction and lean your upper body into the turn Use the throttle to maintai...

Page 43: ...ce you have learned this technique you should be able to perform it at higher speeds or in tighter curves Improper riding procedures such as abrupt throttle changes excessive braking incorrect body mo...

Page 44: ...check the terrain carefully before driving down a hill 4 Always drive down a hill with the transmission in forward gear Never coast or drive down a hill with the transmission in neutral 5 Avoid drivi...

Page 45: ...Own er s Manual Always check the terrain carefully be fore you start up any hill Never climb hills with excessively slip pery or loose surfaces Shift your weight forward Never open the throttle sudde...

Page 46: ...after leaving the water Do not continue to ride your vehicle without verifying that you have regained proper braking ability POTENTIAL HAZARD Operating this vehicle through deep or fast flowing water...

Page 47: ...le in water be sure to check the trapped water at the air filter V belt cooling duct the storage compartment If necessary drain any water that may have accumulated Also if it has been operated in salt...

Page 48: ...ou must park on an incline place the machine transversely across the 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 h...

Page 49: ...h clothing or parts of the body causing injury Electrical components can cause shocks or can start fires HOW TO AVOID THE HAZARD Turn off the engine when performing maintenance unless otherwise specif...

Page 50: ...ed dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately ten 10 miles per hour Vehicles su...

Page 51: ...rake pedal travel Daily Wheels fasteners Daily Frame fasteners Daily Engine oil level Daily Check each day before driving the vehicle Make adjustments as needed Engine oil change break in 25 1 M Perfo...

Page 52: ...250 400 Check terminals clean test Toe adjustment Inspect periodically adjust when parts are replaced Headlight aim Adjust as needed Choke 10 Monthly 100 160 Check for proper operation see dealer for...

Page 53: ...ake fluid replacement When disassembling the master cylinder or caliper replace the brake fluid Normally check the brake fluid level and add fluid as required On the inner parts of the master cylinder...

Page 54: ...up for several minutes and then turn it off 3 Wait a few minutes until the oil settles 4 Remove the engine oil filler cap and wipe off the dipstick with a clean rag 5 Insert the dipstick in the oil fi...

Page 55: ...for two to three minutes Stop the engine 3 Clean the area around the drain plug CAUTION Hot oil can cause burns to skin Do not allow hot oil to contact skin 4 Place a drain pan under the engine crankc...

Page 56: ...e to two minutes 14 Stop the engine Inspect for leaks 15 Re check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick 16 Dispose of used filter...

Page 57: ...d oil as needed 5 Reinstall the fill plug Oil change The drain plug is located on the bottom of the gearcase 1 Remove the fill plug 2 Place a drain pan under the drain plug 800cc Front gearcase 3 Remo...

Page 58: ...he coolant cap remove the cap add coolant to the maximum level mark install the reservoir cap Don t removing the radiator cap when the engine and radiator are still hot or you could be burned by hot f...

Page 59: ...ipe 2 Add more coolant If only a little coolant needed fill up from the intake of radiator till it is full and then cap the radiator 3 Method of release the air If the engine is still overheat when th...

Page 60: ...out coolant pipe by hand make sure do not burn your hand if the temperature is close to the engine s and also the temperature of coolant in pipe is higher than coolant out pipe this means the circulat...

Page 61: ...plug to slowly break down and erode If electrode erosion becomes excessive or if carbon and other deposits are excessive you should replace the spark plug with the specified plug NOTICE Using non rec...

Page 62: ...ighten it to the specified torque 500 600cc 17 5 Nm 12 5 ft lbf 800cc 20 Nm 14 3 ft lbf 4 Install the spark plug cap a Spark plug gap 0 6 0 7mm 500 600cc a Spark plug gap 0 7 0 8mm 800cc NOTE If a tor...

Page 63: ...2 Remove the filter element of the air filter 4 from the air box 3 Wash the filter element in warm soapy water then rinse and let dry If the filter element is damaged install a new filter 4 Wash the...

Page 64: ...gs for an airtight seal Tighten all fittings securely to avoid the possibility of unfiltered air entering the engine Never operate the engine with the air filter element removed This will allow unfilt...

Page 65: ...ugh the accelerator back guy reduces expenses to enter engine cylinder s gas flow amount the damper opening transmits from the damper position transducer to engine control unit ECU Flows through the b...

Page 66: ...flow amount the damper opening transmits from the damper position transducer to engine control unit ECU Flows through the by pass canal the gas flow amount by the unit motor control meets the system...

Page 67: ...ny irregularities in brake system operation including excessive pedal travel contact your dealer for proper diagnosis and repairs Check the brake pads for damage and wear If a brake pad thickness is l...

Page 68: ...ds for wear and the brake system for leakage Observe these precautions z When checking the fluid level make sure the top of the master cylinder reservoirs are level z Use only the designated quality b...

Page 69: ...er check the cause if the brake fluid level goes down Complete fluid replacement should be done only by trained service personnel Have your dealer replace the following components during periodic main...

Page 70: ...ire pressure below the minimum specified could also cause the tire to dislodge from the rim under severe riding conditions TIRE PRESSURE IN PSI KPa Front 21 1 145 6 9 Rear 28 1 193 6 9 LOADING CAPACIT...

Page 71: ...on are critical component operations All service must be performed by your authorized dealer Wheel Removal 1 Position the vehicle on a level surface 2 Place the transmission in neutral Set the parking...

Page 72: ...battery cells You may damage the battery POTENTIAL HAZARD Failure to handle batteries or battery electrolyte carefully WHAT CAN HAPPEN You could be poisoned You could be severely burned by the sulfuri...

Page 73: ...other sources of ignition Ventilate when charging or using in a closed space 1 When the machine is not used for a month or longer remove the battery and store it in a cool dark place Completely recha...

Page 74: ...witch If the fuse immediately blows again consult your dealer POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a f...

Page 75: ...68 Fuse replacement...

Page 76: ...out of balance creating vibration and additional loads on components The CVT syst em rotates at high speeds creating large amounts of force on clutch components Extensive enginee ring and testing has...

Page 77: ...engine Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds 4 Allow the engine RPM to settle to...

Page 78: ...e the dirt and degreaser off with a garden hose Use only enough pressure to do the job Once the majority of the di rt has been hosed off wash all surfaces with warm water and mild detergent type soap...

Page 79: ...n the engine over several times to coat the cylinder wall with oil 3 Lubricate all control cables 4 Block up the frame to raise all wheels off the ground 5 Tie a plastic bag over the exhaust pipe outl...

Page 80: ...ur dealer dealership have the tools experience and know how to properly service your machine Use only genuine parts on your machine Imitation parts may look like parts but they are often inferior Cons...

Page 81: ...seat of valve is not suitable plug is loose Starting motor is too slow Air circulation is not right Gap of valve is not suitable change change change Repair or change Tighten Check electric system Adj...

Page 82: ...d not start 4 Miscellaneous Gear is not in neutral Put gear on neutral 1 Mechanic problem Valve gap is not suitable Valve base is not suitable Problem on air pipe Broken on bush of swing arms IAC valv...

Page 83: ...ange Adjust or change Adjust Change Adjust or change Clean or change Exhaust blue smoke Mechanical fault too many lube Piston ring worn out Valve pipe worn out Cylinder wall scratched Valve rod worn o...

Page 84: ...ot suitable Block in exhaust pipe Carbon accumulated on top of piston Tightening or Change Clean Change decrease or add Change Clean Clear Noise on air valve Gap on valve is too big Spring on valve is...

Page 85: ...t Roller or main wheel damage Change Change Noise from transmission system Gear damaged Input and output shaft damaged Bearing worn out Bush worn out Change Change Change Change Gasoline engine lacks...

Page 86: ...n constant temperature meter Change Cover the radiator Change Spark weak Ignition System Fault on starter problem on spark plug Magneto problem Voltage of battery is weak Ignition loop problem Startin...

Page 87: ...e Change Repair or Change Repair or Change Change III Malfunction in running system suspension and steering organization Running is leaning Running system Air pressure in left and right wheel is diffe...

Page 88: ...jump axial radial is too great Air pressure in tyre is too hig or too low Adjust or Change Change Check or adjust Check load Change Adjust or Change Change Adjust air pressure in tyre Front wheel sha...

Page 89: ...cation is wrong Steering pole pipe is blocked Mesh clearance of redirector is too small Charge the tyre to applicable air pressure Change Check and adjust Repair or Change Adjust IV Malfunction in bra...

Page 90: ...le is leaning Thread abrasion of left and right wheel is different Clean or Change Repair or Change Equalize the air pressure Adjust as the stipulation Repair or Adjust Repair or adjust Repair Check r...

Page 91: ...ange adjuster Check Change Change Repair circuit Repair Change Change Only one front headlight does not illuminate Lighting system Bulb has been damaged Lead or grounding happens malfunction Change Re...

Page 92: ...of lamplight is bad or complete lamplights are damaged not including headlight Lamplight circuit Switch has been damaged Bulb has been burned Circuit has been cut off linking parts contact badly Fuse...

Page 93: ...ree operation WARRANTY COVERAGE LIMITATIONS OF WARRANTIES AND REMEDIES The limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cove...

Page 94: ...it to a company Servicing Dealer When requesting warranty service you must present your related proof form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Compa...

Page 95: ...temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Company dealer You must show the related proof Upon verification the servicing dealer wi...

Page 96: ...ground clearance 330mm 13 0in Minimum turning radius 5000mm 196 9in Maximum speed 70 km h 85 km h Basic weight Mass of whole equipments Not include driver 640kg Engine Engine type 500cc CF188 B 600cc...

Page 97: ...ication system Pressure spray Engine oil Type Recommended engine oil classification Quantity Without oil filter cartridge replacement 500cc 600cc 1 9L 2 0 US qt 800cc 2 2L 2 3 US qt With oil filter ca...

Page 98: ...cc 0 25L 0 27US qt Air filter Dry element Fuel Type Unleaded gasoline 93octane or above Fuel tank capacity 35 L 9 3Gal Fuel reserve amount about 4 L 1Gal EFI System Type quantity 500cc 600cc MSE 3 0 8...

Page 99: ...m Shaft drive Transmission type V belt automatic Operation Right hand operation High gear 3 514 2 886 Low gear 5 857 5 29 Reverse gear 3 828 5 087 Chassis Frame type Steel tube frame Caster angle 4 Tr...

Page 100: ...n Rear suspension Double swing arm independent suspension two shock absorbers on each side Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber Coil spring oil damper Electri...

Page 101: ...UIT VOLTAGE TOO LOW 13 P0118 ENIGNE COOLANT TEMPERATURE S ENSOR C IRCUIT VOLTAGE TOO H IGH No Code Instruction 14 P0122 THROTTLE POSITION S ENSOR CIRCUIT VOLTAGE UNDER LIMINAL VALUE 15 P0123 THROTTLE...

Page 102: ...IL PUMP RELAY CONTROL CIRCUIT OPENING 33 P0628 OIL PUMP RELAY CONTROL CIRCUIT SHORTCIRCUIT TO GROUND 34 P0629 OIL PUMP RELAY CONTROL CIRCUIT SHORTCIRCUIT TO POWER 35 P0650 MIL LAMP DRIVING STAGE TROUB...

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Massimo MSU 600, Owner'S Manual

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