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OWNER’S/OPERATOR’S

MANUAL

17. TROUBLESHOOTING

17-6

FAULTY CLUTCH

WHEN ENGINE RUN, UTV DOES NOT RUN

V-belt POOR SPEED PERFORMANCE



Worn/bent/slipping

V-belt



Worn

Cam, slider



Oil V-belt



Worn/damaged

Compression spring Roller weight



Damaged



Worn/improper operation

primary/secondary/sheave

Gears



Worn



Damaged

CLUTCH SLIPPING CVT SYSTEM

Clutch weight spring

Incorrect Primary Clutch Position



Worn/loose



Incorrect engine mount

Clutch shoe

(see 13. CVT system)



Worn/ damaged

Primary sliding sheave



Seized

POOR STARTING FAULTY BRAKE POOR BRAKING

PERFORMANCE 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



Damaged



Leaking brake fluid

compressing spring



Faulty master cylinder kit



Worn/loose



Faulty caliper seal kit

Secondary sliding sheave



Loose union bolt



Improper operation



Broken brake hose



Worn guide pin grove



Oil or greasy brake pad



Worn guide pin



Oil or greasy brake disc

Clutch shoe



Worn/ bent

Содержание XY200U-B

Страница 1: ...G Read this Manual and any Supplements Carefully Before Operating Vehicle Assembly Operation Maintenance THIS VEHICLE IS NOT DESIGNED FOR USE ON RENTAL TRACKS OR RACING BEFORE OPERATING THIS VEHICLE T...

Страница 2: ...5 1 6 V I N NUMBER 6 1 7 CONTROL AND FUNCTIONS 7 1 8 STARTING THE ENGINE 8 1 9 BREAK IN 9 1 10 RIDING GEAR 10 1 11 CARRYING LOADS 11 1 12 DRIVING 12 1 13 CVT SYSTEM 13 1 14 BATTERY 14 1 15 EXHAUST SYS...

Страница 3: ...iliar with the operating characteristic and the many features offered on the UTV The manual also covers information on the care and maintenance of your UTV Please read this manual carefully The inform...

Страница 4: ...intended to increase the speed or power of your UTV Failure to follow these warnings increases the possibility of accidents leading to DEATH or SERIOUS INJURY Additionally failure to follow these req...

Страница 5: ...kets and long pants As with any off road capable vehicle there is a risk of tip over or rollover under certain conditions Uneven terrain or slopes which pitch the vehicle sideways turning too fast or...

Страница 6: ...ng larger hills Always follow proper procedures for climbing hills as described in this manual Check the terrain carefully before you start up any hill Never climb hills with excessively slippery or l...

Страница 7: ...imes to let friction dry out the pads Always be sure there are no obstacles or people behind you when you operate in reverse When it is safe to proceed in reverse go slowly Avoid turning at sharp angl...

Страница 8: ...YOUR VEHICLE BEFORE YOU BEGING RIDING Read this manual thoroughly referring to the various areas which are being discussed on your machine Operating this vehicle carries with it responsibilities for y...

Страница 9: ...t this manual to convey the following messages This is the safety alert symbol When you see this symbol on your machine or in this manual be alert to the potential for personal injury Your safety is i...

Страница 10: ...ARNING 3 1 NOTE Warning decals have been placed on the vehicle for your protection Read and follow the instructions on each decal carefully In the event any decal becomes illegible or comes off contac...

Страница 11: ...OWNER S OPERATOR S MANUAL 3 SAFETY WARNING 3 2 1 2 3 4...

Страница 12: ...OWNER S OPERATOR S MANUAL 3 SAFETY WARNING 3 3 5 6 7...

Страница 13: ...OWNER S OPERATOR S MANUAL 3 SAFETY WARNING 3 4 8 9...

Страница 14: ...ld be a firm feeling when the brakes are applied If not have the vehicle inspected by your dealer Brake fluid leakage Check to see if any brake fluid is leaking out of the pipe joints or the brake flu...

Страница 15: ...gh feeling Have an authorized dealer repair as necessary for proper operation 9 Loose parts visually inspect vehicle for any damaged components or loose nuts bolts or fasteners Always check the tightn...

Страница 16: ...hts of water heaters and clothes dryers WARNING POTENTIAL HAZARD Check the fuel system while smoking or near an open flame WHAT CAN HAPPEN Fuel can ignite or explode causing severe injury or property...

Страница 17: ...not work smoothly check for the cause Correct the problem before operating the vehicle Consult an authorized dealer if you can t find or solve the problem yourself WARNING POTENTIAL HAZARD Take a loo...

Страница 18: ...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 try to stop tipping with your arm or leg You could be severely injured Yo...

Страница 19: ...designed to carry cargo only WARNING POTENTIAL HAZARD Improper shock absorber adjustment WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability which could lead to an accident...

Страница 20: ...losed securely WARNING POTENTIAL HAZARD Operate vehicle without being familiar with all controls WHAT CAN HAPPEN Loss of control which could cause an accident or injury HOW TO AVOID THE HAZARD Read th...

Страница 21: ...en performing maintenance unless otherwise specified Have an authorized dealer perform service if you are not familiar with vehicle service WARNING POTENTIAL HAZARD Operate this vehicle with improper...

Страница 22: ...the spark arrester Always let the exhaust system cool prior to touching exhaust components Do not start the engine when cleaning the exhaust system WARNING POTENTIAL HAZARD Operate with improperly ser...

Страница 23: ...uld be poisoned You could be severely burned by the sulfuric acid in battery electrolyte Batteries produce explosive gases HOW TO AVOID THE HAZARD Avoid contact with skin eyes or clothing Always shiel...

Страница 24: ...lb to cool before touching or removing it WARNING POTENTIAL HAZARD Operate with wet brakes after washing WHAT CAN HAPPEN Wet brakes may have reduced stopping ability increasing the chance of an accide...

Страница 25: ...ould affect your balance and perception Could result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this UTV WARNING POTENTIAL HAZARD Operate this UTV at...

Страница 26: ...from footrests during operation WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the UTV or could cause you to lose your balance and fall off the UTV HOW TO AVOID THE...

Страница 27: ...arp drop or another vehicle or person could be on the other side of the hill WARNING POTENTIAL HAZARD Turn improperly WHAT CAN HAPPEN UTV could go out of control causing a collision or overturn HOW TO...

Страница 28: ...he vehicle to lean sharply to one side Go straight down the hill where possible WARNING POTENTIAL HAZARD Improperly cross hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause...

Страница 29: ...e or to either side if pointed straight uphill WARNING POTENTIAL HAZARD Improperly operate over obstacles WHAT CAN HAPPEN Could cause loss of control or a collision Could cause the UTV to overturn HOW...

Страница 30: ...annot avoid water go slowly balance your weight carefully avoiding sudden movement maintain a slow and steady forward motion do not make sudden turns or stops and do not make sudden throttle changes R...

Страница 31: ...flation could cause the tire to burst WARNING POTENTIAL HAZARD Ride on frozen lakes and rivers WHAT CAN HAPPEN Severe injury or death can result if the UTV and or the operator break through the ice HO...

Страница 32: ...TV in the spaces provided 1 Frame VIN found on the rear right of the frame seat tube 2 Engine Serial Number Left side of engine crankcase Remove the spare key and store it in a safe place Your key can...

Страница 33: ...he vehicle frame and engine serial numbers are important for model identification when registering your vehicle obtaining insurance or whenever replacement parts are required In the event your vehicle...

Страница 34: ...ART The electric starter is engaged by turning and holding the key in this position Release the key when the engine starts CAUTION Do not operate the electric starter continuously for more than 5 seco...

Страница 35: ...cator 14 Speed 5 N A 15 Odometer 6 Neutral indicator 16 N A 7 Reverse indicator 17 N A 8 N A 18 N A 9 High beam headlight indicator 19 Transmission position indicator 10 EFI fault indicator 20 Functio...

Страница 36: ...p Sensor Short GND P0118 Oil Temp Sensor Short V Open P0122 TPS Open GND P0123 TPS Short V P0131 O2 Short GND P0132 O2 Short V P0038 O2 heater V P0037 O2 heater Open GND P0201 Injector1 malfunction P0...

Страница 37: ...cessory socket otherwise you may drain the battery The accessory socket rated capacity is DC 12V 120 Watt 10A or less If you exceed this limit you may blow a fuse When you are done using an accessory...

Страница 38: ...solve the problem yourself BRAKE PEDAL 1 Brake pedal Press the brake pedal to slow or stop the vehicle WARNING Never operate the UTV with a spongy feeling brake pedal Operating the UTV with a spongy...

Страница 39: ...ansmission selector lever has four positions H drive L drive Neutral Reverse CAUTION To change gears stop the vehicle and with the engine idling move the lever to the desired gear Shifting gears with...

Страница 40: ...e the fuel tank cap by turning it counterclockwise SEATS Driver seat Passenger seat To remove the seat lift the front of the seat and then slide the seat up and forward To install the seat insert the...

Страница 41: ...ng operation HOW TO AVOID THE HAZARD Make sure the seat is securely latched SEAT BELTS This vehicle is equipped with three point seat belts for both the operator and passenger Always wear the seat bel...

Страница 42: ...e 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 way and t...

Страница 43: ...they must be stored wrap them in an appropriate cushioned material CARGO BED Cargo bed Tailgate Lifting And Lowering The Cargo Bed Cargo bed release lever To lift Push down the cargo bed release lever...

Страница 44: ...ENTIAL HAZARD Overload the cargo bed WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated maximum load limit for this...

Страница 45: ...the tank Do not fill the tank neck If you get gasoline on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area...

Страница 46: ...il 1 Set machine on a level surface 2 Start the engine and let it idle for 20 30 seconds 3 Stop the engine remove the dipstick and wipe it dry with a clean cloth 4 Put the dipstick into the oil filler...

Страница 47: ...g CAUTION You must allow your vehicle adequate warm up time before operating or engine damage could result 1 Apply the brake 2 Shift the drive select lever into the neutral position NOTE When the driv...

Страница 48: ...2 Open the hood 3 Using a charged 12 V battery connect the positive lead of the jumper cable to the positive terminal of the battery in the vehicle and the other end of the positive lead to the posit...

Страница 49: ...ive lead of the jumper cable from the charged battery and the battery in the vehicle 8 Close the hood WARNING If the hood latches are hooked improperly or the latches and their attachments cannot work...

Страница 50: ...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 at firs...

Страница 51: ...tive gear for safe riding A helmet can prevent a severe head injury Select an approved off road motorcycle type helmets that fit properly 2 Eye Protection A pair of goggles or helmet face should offer...

Страница 52: ...rcycle helmet increases your chances of a severe head injury or death in the event of an accident Operating without eye protection can result in an accident and increases your chances of a severe inju...

Страница 53: ...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...

Страница 54: ...er 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 braking...

Страница 55: ...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...

Страница 56: ...miliar with the operation of your vehicle 4 When slowing down or stopping take your foot off the accelerator pedal and smoothly press the brake pedal Improper use of the brakes can cause the tires to...

Страница 57: ...o climb Choose carefully which hills you attempt to climb Avoid hills with slippery surfaces or ones where you will not be able to see far enough ahead of you WARNING POTENTIAL HAZARD Operate on exces...

Страница 58: ...nation of conditions increase the risk of tipping 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 try to stop tipping with yo...

Страница 59: ...mage to the vehicle could occur WARNING POTENTIAL HAZARD Fail to use extra care when operating this vehicle on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without...

Страница 60: ...ath WARNING POTENTIAL HAZARD Improperly 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...

Страница 61: ...e at a low speed for an extended period of time it is best to use the Low range in the transmission In Low range the vehicle will be limited to 7 10 mph You should not try to exceed this speed in Low...

Страница 62: ...be out of balance The CVT housing must be securely in place during operation Failure to comply with this warning can result in severe injury or death CVT SYSTEM On UTV the approximate gear ratio diffe...

Страница 63: ...Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILD...

Страница 64: ...ld down straps 5 Verify that cables are properly routed NOTE When your UTV is placed in storage for one month or more the battery should be removed charged to proper level and stored in a cool dry pla...

Страница 65: ...exhaust pipe must be periodically purged of accumulated carbon as follows 1 Remove the arrestor screw located on the bottom of the muffler pull out the arrestor the mesh 2 Clean the arrestor or replac...

Страница 66: ...in the exhaust and ignited by the catalyst in the muffler MAY RESULT IN THE MUFFLERS OVERHEATING AND FIRE RISK Always reduce throttle when the engine reach top rpm avoid the engine popping WARNING Th...

Страница 67: ...000 6000 9000 12000 15000 Everyday check before riding Re seating Valve I I I I I Spark Plug I R I R I Fuel System I I I I I Engine Oil R R R R R R I Valve Gap A A A A A Idle Speed A A A A A Engine Bo...

Страница 68: ...UE SPECIFICATIONS Bolt Size Specification M12X1 25 50Ft Lbs 69N m NOTE All nuts that have a cotter pin installed must be serviced by an authorized Dealer Rear Tapered nuts install with tapered side ag...

Страница 69: ...VICE 1 Lift the cargo bed See 7 CONTROL AND PARTS FUNCTIONS in this manual for bed lifting and lowering 2 Remove the screws and remove Cover 3 Loosen clamp and remove Filter 4 Remove fabric type pre f...

Страница 70: ...ve your dealer repair them before riding your vehicle The steering assembly should be also checked periodically for free operation steering should move freely through entire range of travel without bi...

Страница 71: ...e these adjustment The recommended toe alignment is 1 8 to 1 4 3to6mm toe out 1 Set the steering wheel in a straight ahead position and hold them in this position 2 Measure A and B A minus B should be...

Страница 72: ...see 7 Control and part functions Normal functioning of the diaphragm is to extend into the reservoir as fluid lever drops If the fluid lever is low and the diaphragm is not extended a leak is indicat...

Страница 73: ...level Use only the recommended quality brake fluid Otherwise the rubber seals may deteriorate causing leakage and poor braking performance Recommended brake fluid DOT 3 Refill with the same type of b...

Страница 74: ...c turn the adjuster bolt CCW counterclockwise by 1 4 to one turn for 10 to 20mm free play at the end of the parking lever 4 Tighten the nuts securely against the adjusters 5 Make sure the rear wheels...

Страница 75: ...come on properly then lock the lock nut all purpose grease ENGINE IDLE RPM ADJUSTMENT Throttle Free Play Inspection 1 Apply the parking brake 2 Put gear in Neutral position 3 Start the engine and war...

Страница 76: ...of specification Adjust gap Spark Plug Removal and Replacement WARNING Never attempt to remove a spark plug while the engine is warm The exhaust system or engine could burn you causing severe injury...

Страница 77: ...nuous duty in dusty or wet conditions and cold weather riding 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 l...

Страница 78: ...ase with 1 4L engine oil refer to Recommended Engine Oil 9 Check the oil level refer to Engine Oil Level Inspection 10 Reinstall the Oil filler plug Transmission Lubrication CAUTION Be sure no foreign...

Страница 79: ...If wheels are improperly installed it could affect vehicle handling and tire wear Tire Pressure front rear 48kPa 7SI 48kPa 7PSI Wheel Removal Procedure 1 Stop the engine place the transmission in gea...

Страница 80: ...s a residue causing a hot spot which will shorten the life of the lamp High Beam Headlight Adjustment The headlight beam can be adjusted up and down 1 Place the vehicle on a level surface with the hea...

Страница 81: ...V is with a garden hose and a pail of mild soap water Use a professional type washing mitten cleaning the upper body first and lower parts last Rinse with water frequently and dry with a cloth to prev...

Страница 82: ...y Maintenance Remove the battery and add electrolyte as required to the proper level Do not use tap water which may contain minerals that reduce battery life Apply Dielectric Grease to the terminal bo...

Страница 83: ...the engine turn off the main switch key off at once WARNING This UTV is equipped with an electric start system If the battery is under charging the UTV will not run NOTE The following troubleshooting...

Страница 84: ...ment Nozzle clogging or failure Improper air cleaner setting Throttle position sensor failure EFI relay does not work COMPRESSION SYSTEM Cylinder and cylinder head Valve system Loose spark plug Improp...

Страница 85: ...tion coil Loose battery terminal Broken or shorted primary Loose coupler connection secondary coil Improperly grounded Faulty high tension cord Broken wire harness Broken ignition coil body POOR IDLE...

Страница 86: ...Ignition system Compression system Dirty spark plug Worn cylinder Improper heat range Worn or seized piston ring Faulty ignition unit Cylinder head gasket broken Faulty pick up coil Cylinder gasket b...

Страница 87: ...oling system Improperly spark plug gap Faulty thermostat Improper spark plug heat rang Faulty thermo switch Faulty ignition unit Fuel system Improper EFI setting Improper fuel level adjustment Clogged...

Страница 88: ...Incorrect engine mount Clutch shoe see 13 CVT system Worn damaged Primary sliding sheave Seized POOR STARTING FAULTY BRAKE POOR BRAKING PERFORMANCE EFFECT V belt Worn front hub bearing Slipping oily...

Страница 89: ...OWNER S OPERATOR S MANUAL 18 TOOL 18 1 Tool Bag Spark Plug Wrench Wrench 8 10mm Wrench 12 14mm Screw Driver Hexagon Bar Wrench...

Страница 90: ...11 lbs Cargo Bed Maximum load limit 100 kg 220 lbs Load Capacity Combined Rider Payload 250kg 551 6 lbs Tow Capacity 200 kg 450 lbs Drive System Drive System CVT Front Tire 24X8 12 Rear Tire 24X8 12 T...

Страница 91: ...ctrical Equipment Battery 12V 9AH Head light LED Brake Taillight LED High Beam Indicator Light LED Reverse Indicator Light LED Turn Light Europe Only LED Turn Indicator Light Europe Only LED Front Pos...

Страница 92: ...ter temperature sensor G Accessory Accessory Sock Sock parking parking switch switch Bl R Bl OFF OFF LEFT RIGHT Front Front turn turn left left light light Rear Rear turn turn left left light light Re...

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