MASSIMO ALLIGATOR 500 & MSU 500 Owner’s Manual
INTRODUCTION Congratulations on your purchase of the Massimo Alligator 500 or MSU 500 UTV. With the purchase of this vehicle, you can now appreciate the high degree of craftsmanship. This manual will provide you with a good basic understanding of the features and operation of this vehicle. This manual includes important safety information. It provides information about special techniques and skills necessary to ride your vehicle. It also includes basic maintenance and inspection procedures.
Owner Manual IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the machine operator, bystander or a person inspecting or repairing the machine.
Owner Manual IMPORTANT NOTICE This UTV is designed and manufactured for OFF - ROAD use only. It is illegal and unsafe to operate this UTV on any public street, road or highway. This UTV complies with all applicable OFF - ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture. Please check your local riding laws and regulations before operating this UTV.
Owner Manual 1 Location of the Warning and Specification Labels 1-1 2 Safety Information 2-1 Description and Vehicle Identification Identification Number Records Vehicle Identification Number 3-1 3-3 3-3 Control Functions Main Switch Indicator and Warning Lights Use of EPS system Speedometer Unit Odometer and Trip Meter Modes Clock time adjustment Fault code indicator Fuel level indicator 4-1 4-1 4-2 4-4 4-6 4-6 4-7 4-8 4-9 3 4 Switches Accelerator Pedal Brake Pedal Parking Brake Lever Drive Sel
Owner Manual Brake Fluid Level Brake Fluid Leakage Brake Operation Fuel Gasohol Engine Oil Coolant Final Gear Oil Differential Gear Oil Throttle Pedal Throttle Freeplay Throttle Freeplay Inspection Throttle Freeplay Adjustment Steering Wheel Inspection Seat Belts Fittings and Fasteners Lights Switches Tires How to Measure Tire Pressure Tire Wear Limit 5-2 5-3 5-3 5-4 5-4 5-5 5-6 5-7 5-7 5-8 5-9 5-9 5-9 5-10 5-10 5-10 5-10 5-11 5-11 6 7 5-12 5-13 Operation Starting the Engine in Low Temperatures Starti
Owner Manual Learning to Operate Your Vehicle Turning your Vehicle Braking Going Uphill Going Downhill Crossing Through Shallow Water Riding Over Rough Terrain Riding in Brush or Wooded Areas Encountering Obstacles on the Trail 8 Periodic Maintenance and Adjustment Periodic Maintenance Chart for the Emission Control System General Maintenance and Lubrication Chart Hood Console Engine Oil and Oil Filter Cartridge 7-5 7-6 7-8 7-8 7-10 7-12 7-15 7-17 7-17 8-1 8-3 8-4 8-7 8-8 8-9 To Check the Engine Oil Lev
Owner Manual Brake Fluid Replacement Checking the Brake Pedal Parking Brake Lever Free Play Adjustment Brake Light Switch Adjustment Cable Inspection and Lubrication Brake Pedal and Accelerator Pedal Lubrication Rear Knuckle Upper and Lower Pivot Lubrication Steering Shaft Lubrication Wheel Removal Wheel Installation Battery Battery Maintenance Fuse Replacement Replacing Headlight Bulb Headlight Beam Adjustment Tail/brake Light Bulb Replacement Troubleshooting Solution to Common Problems in the Vehicle 8-
Location of the Warning and Safety Labels ` ⑭ ⑬ 1-1
1-2 Location of the Warning and Safety Labels Read and understand all of the labels 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 by contacting your dealer.
Location of the Warning and Safety Labels 1-3
1-4 Location of the Warning and Safety Labels
Location of the Warning and Safety Labels 1-5
1-6 Location of the Warning and Safety Labels 9 10
11 Location of the Warning and Safety Labels 12 13 14 1-7
2-1 Safety Information SAFETY INFORMATION This off-highway utility vehicle handles differently from other vehicles including cars and UTVs. SEVERE INJURY OR DEATH can result if you do not follow these instructions: ● Read this manual and all labels carefully and follow the operating procedures described. ● This vehicle is designed to carry the driver and one passenger. NEVER CARRY PASSENGERS IN THE CARGO BED. ● Always be sure the driver and passenger are wearing seat belts.
Safety Information ● ● ● ● ● ● ● ● ● 2-2 Never attempt jumps or other stunts. Always inspect your vehicle each time you use it to be sure it is in safe operating condition, Always follow the inspection and maintenance procedures and schedules described in this manual. Always keep hands, arms, feet, and legs inside the vehicle at all times during operation. Keep your feet on the floorboard. Never hold onto the enclosure.
2-3 ● ● ● ● ● ● ● ● ● ● Safety Information Never operate on hills that are slippery or ones where you will not be able to see far enough ahead of you. Never go over the top of a hill at speed if you cannot see what is on other side. Always follow proper procedures for going uphill. If you lose control and cannot continue up a hill, back down the hill with the engine in reverse gear. Use engine braking to help you go slowly. If necessary, use the brakes gradually to help you go slowly.
Safety Information 2-4 WARNING POTENTIAL HAZARD Improper handling of gasoline. WHAT CAN HAPPEN Gasoline can catch fire and you could be burned. HOW TO AVOID THE HAZARD Always turn off the engine when refueling. Do not refuel right after the engine has been running and is still very hot. Do not spill gasoline on the engine or exhaust pipe（or muffler）when refueling.
2-5 Safety Information WARNING POTENTIAL HAZARD Starting 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.
Description and Vehicle Identification 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Headlights Front shock absorber assembly adjusting ring Brake fluid reservoir Air filter element(engine and air intake duct) V-belt case Driver seat Driver seat belt Spark plug Cargo bed Tail/brake lights Rear shock absorber assembly adjusting ring Cargo bed release levers 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
3-2 Description and Vehicle Identification 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. NOTE: The vehicle you have purchased may differ slightly from those in the figures of this manual.
Description and Vehicle Identification Identification Number Records Record the Vehicle Identification Number and model label information in spaces provided for assistance when ordering spare parts from a service center or for reference in case the vehicle is stolen. 3-3 Vehicle Identification Number The Vehicle Identification Number (VIN) is stamped into the frame. 1. VEHICLE IDENTIFICATION NUMBER: 2. MODEL LABEL INFORMATION 1.
4-1 Control Functions CONTROL FUNCTIONS Main switch Functions of the respective switch positions are as follows: ON: All electrical circuits are supplied with power, and the headlights and taillights illuminate when the light switch is on. OFF: All electrical circuits are switched off. The key can be removed in this position. 1. Main switch START: The electric starter is engaged by turning and holding the key in this position. Release the key when the engine starts.
Control Functions Indicator and Warning Lights CAUTION: ● ● ● Do not operate the electric starter continuously for more than 5 seconds at a time or starter damage could occur. Wait at least 5 seconds between each start attempt. 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.) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
4-3 Control Functions Low-Range Indicator Light “L” This indicator light comes on when the drive select lever is in the “L” position. Mechanical Parking Brake Indicator Light “ ” This indicator light comes on when the mechanical parking brake is applied. High-Range Indicator Light “H” This indicator light comes on when the drive select lever is in the “H” position. This indicator light comes on when the drive select lever is in the “R” reverse position.
Control Functions is out. Continuous use while the light is on may cause damage to the engine. 4-4 monitors working condition of EPS system. Fault can be displayed by fault indicator light High beam indicator The light being on means headlight is at high beam mode. and fault indicator of EPS system, so the Position light indicator The light being on means that the position light fixed in the front headlight has been turned on. himself/herself safe.
4-5 z Control Functions Check the meter. If fault indicator light of Speedometer Unit EPS system does not be lit, ECU can be for regular use. z If fault indicator light of EPS system is lit, that means EPS system find out some fault during ECU self-checking process, then you should consult your local dealer for maintenance in time. 1. 2. 3. 4. 5. 6. 7. 8.
Speedometer unit functions: z a speedometer (which shows the speed) z an odometer (which shows the total distance covered) z a tripometer (which can be cleared and then show any new distances traveled) z an RPM indicator (which shows the revolutions per minute of the engine) z a clock z an EFI fault code indicator (which shows the fault code for problems with the EFI ) Odometer and trip meter modes On the display panel there are two large buttons, one located on the left side and one on the right side.
4-7 Control Functions button on the display. This will also change the displayed mileage from miles to kilometers. Clock time adjustment Press the left button and hold for three seconds and the clock goes into the hour ‘set’ mode. 1. Press the right button to set the hour. 2. Press the left button again and the clock goes into the minute ‘set’ mode. 3. Press the right button to set the minutes. 4. Press the left button again and the clock will exit the ‘set’ mode.
Control Functions When riding on a flat road at a comparatively high speed, adjust the settings to “2WD/UNLOCK” and there are no symbols in either of the 4WD indicators. Riding an UTV while the differential is functioning and is NOT locked, may improve the stability and safety of the UTV operation. CAUTION: When the selector is set to 4WD, the right 4WD symbol front axle will have an ‘X’ in the middle .
4-9 Control Functions fixed, will the time show automatically. The description for the fault codes are shown in Chapter 11 of this manual. Switches Fuel level indicator The fuel level display will indicate the fuel volume. When the fuel is getting low the fuel pump symbol will flash. 1. Light switch “OFF/ / ” Light switch “OFF/ / ” Set the switch to “ ”to turn on the low beam and the taillights. 1. Fuel level indicator 2.
CAUTION: 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 happens, remove the battery and recharge it. Control Functions 4-10 On-Command Four-Wheel–Drive and Differential Gear Lock Switches 1. On-Command four-wheel –drive switch “2WD”/ “4 WD” 2.
4-11 Control Functions conditions. z Two-wheel drive (”2WD”): Power is supplied to the rear wheels only. z Four-wheel drive (“4WD’): Power is supplied to the rear and front wheels. z Four–wheel drive with the differential gear locked (“4WD-LOCK”): Power is supplied to the rear and front wheels when the differential gear is locked.Unlike the 4WD mode, all wheels turn at the same speed regardless of traction.
On-Command four-wheel-drive switch “2WD/4WD” Control Functions 4-12 the select lever is set to positionⓐ, and then set the switch to “2WD”. On-Command Differential Gear Lock Switch “4WD”/”LOCK” 1. 2. Select lever On-Command four –wheel-drive switch “2WD/4WD” To change from 2WD to 4WD ,stop the vehicle, and then set the switch to “4WD”.When the vehicle is in 4WD, the 4WD indicator will come on in the multi-function meter unit display .To change from 4WD to 2WD .stop the vehicle ,be sure 1.
4-13 Control Functions set the switch to “LOCK”. When the differential gear is locked, the differential gear lock indicator light will come on along with the differential gear lock indicatorin the multifunction meter unit display .To release the differential gear lock , stop the vehicle and set the switch to “4WD”. WARNING POTENTIAL HAZARD Riding too fast while the vehicle is in 4WD-LOCK.
Control Functions 4-14 will cause the engine speed to be limited until engagement is complete. Accelerator pedal Press the accelerator pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check that the accelerator pedal returns normally before staring the engine. 1. Accelerator pedal Before starting the engine, check the accelerator pedal to be sure it is operating smoothly.
4-15 Control Functions Brake pedal Press the brake pedal to slow or stop the vehicle. WARNING POTENTIAL HAZARD Malfunction of the accelerator pedal. WHAT CAN HAPPEN A faulty pedal that makes it difficult to speed up or slow down could cause loss of control. HOW TO AVOID THE HAZARD Check the operation of the accelerator pedal before you start the engine .If it does not work smoothly, check for the cause. Correct the problem before operating the vehicle.
lever, press the release button, and then push the lever all the way down. Spring pressure helps return the lever to the released position. Be sure to fully release the parking brake before starting out, Failure to do so may result in poor performance and premature wearing of the rear brake and V-belt. Control Functions 4-16 Drive select lever The drive select lever is used to shift you vehicle into the low, high, neutral and reverse positions. (Refer to pages 6-4—6-6 for the drive select lever operation.
4-17 Control Functions Fuel tank cap Remove the fuel tank cap by turning it counterclockwise. 1. Seats To remove a seat, pull its seat lock lever upward, lift the front of the seat, and then slide the seat forward and up. Fuel tank cap 1. Driver seat 3. Seat lock lever (×2) 2.
Control Functions 4-18 To install a seat, insert the projection on the rear of the seat into the seat holders and push down on the seat at the front. 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 securely latched. Seat belts This vehicle is equipped with three-point seat belts for both the operator and passenger.
4-19 Control Functions 2. Push the latch plate into the buckle until it clicks. Pull up on the latch plate to make sure it is secure. 1. Seat belt (×2) 3. Buckle (×2) 2. Latch plate (×2) To wear the seat belt properly, do the following: 1. Hold the latch plate as you pull the belt across your lap and chest. Make sure the belt is not twisted and is not caught on any portion of the vehicle, your clothing, or any equipment you are carrying. 1. Buckle 2. Latch plate 3.
Control Functions shoulder belt should fit against your chest. If it is loose, pull the belt out all the way and then let it retract. 5. To release the buckle, firmly press the release button. 4-20 WARNING POTENTIAL HAZARD Not wearing the seat belt or 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 Always wear your seat belt when riding in the vehicle. Be sure the seat belt is close fitting 1.
4-21 Control Functions Glove compartment Cargo bed CAUTION: To protect from damage, do not put metal products, like tools or sharply edged products directly in the glove compartment. If they must be stored, wrap them in appropriate cushion material. a. Unlock b. Open. 1. Cargo bed 3. Cargo hook(×4) 2.
Opening and closing the tailgate Control Functions Lifting and lowering the cargo bed 1. 1. Tailgate 2. Latch (×2) To open Unhook the latches, and then lower the tailgate. To close Place the tailgate in the original position, and then hook the latches. 4-22 Cargo bed release lever To lift Push down cargo bed release lever on left or right side of the vehicle; slowly lift up cargo bed until it stops. To lower Lower cargo bed slowly to its original position and be sure it locks into place.
4-23 Control Functions WARNING POTENTIAL HAZARD Pinch points. WHAT CAN HAPPEN You or someone else could be pinched between the cargo bed and the frame when the bed is being lowered. HOW TO AVOID THE HAZARD Before closing the bed, be sure others are standing away from the vehicle. Keep hands and fingers away from the pinch points between the bed and the frame. WARNING POTENTIAL HAZARD Overloading the cargo bed WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident.
The passenger could fall, be thrown out, Control Functions 4-24 Front and rear shock absorber adjustment The spring preload can be adjusted to suit the operating conditions. You can reduce preload for a softer ride, or increase preload if frequent bottoming out of the UTV occurs. or be struck by objects in the cargo bed. CAUTION: WARNING POTENTIAL HAZARD Carrying a passenger in the cargo bed WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Never carry a passenger in the cargo bed.
4-25 Control Functions Standard position: B A-Minimum(soft) E-Maximum(hard) 1. Spring preload adjusting ring 2. Position indicator NOTE: A special wrench can be obtained at a service center to make this adjustment. 1.
WARNING POTENTIAL HAZARD Improper shock absorber adjustment. WHAT CAN HAPPEN Uneven adjustment can cause poor Control Functions 4-26 Trailer hitch bracket This vehicle is equipped with a 1 ¼ in receiver bracket for a standard trailer hitch. Trailer towing equipment can be obtained at a service center. (See pages 6-12 - 6-14 for precaution information.) handling and loss of stability, which could lead to an accident.
4-27 Control Functions 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. jack. 1. 1. Auxiliary DC jack cap 1. Set the light switch to “OFF”. 2. Start the engine. (See pages 6-1 - 6-3.) 3.
Control Functions 4. When the auxiliary DC jack is not being used, cover it with the cap. CAUTION: z Do not use accessories requiring more than the above maximum capacity. This may overload the circuit and cause the fuse to blow. z 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. z Do not use an automotive cigarette lighter or other access with a plug that gets hot because the jack can be damaged.
5-1 Pre Operation Checks Before using this vehicle, check the following items: ITEM ROUTINE Brakes ● Parking brake ● Fuel ● Engine/Gear box oil ● Coolant reservoir ● ● Check operation, free play, fluid level and fluid leakage Fill with DOT 4 brake fluid if necessary Check for proper operation, condition and free play PAGE 5-2 - 5-3， 8-32 6-8 - 6-9 ● Check fuel level Fill with fuel if necessary Check oil level Fill with oil if necessary Check coolant level Fill with coolant if necessary ●
Pre Operation Checks WARNING POTENTIAL HAZARD Failure to inspect the vehicle before operating. Failure to properly maintain the vehicle. 5-2 Brakes Check for correct brake pedal free play. If the brake pedal free play is incorrect, have a service center adjust it. (See pages 8-34 8-35.) WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your vehicle each time you Check the operation of the brake pedal.
5-3 Pre Operation Checks 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 service center. WARNING POTENTIAL HAZARD Driving with improperly operating brakes. WHAT CAN HAPPEN You could lose braking ability which could lead to an accident. Brake operation Test the brakes at slow speed after starting out to make sure they are working properly.
Fuel Make sure there is sufficient gasoline in the tank. Recommended fuel: Unleaded gasoline only Fuel tank capacity: 7.7 gal (29L) Pre Operation Checks 5-4 Your engine has been designed to use regular unleaded gasoline with a pump octane number ([R+M] /2) of 91 or higher, or research 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 maintenance cost.
5-5 Pre Operation Checks POTENTIAL HAZARD Engine oil Make sure the engine oil is at the specified level. Add oil as necessary. (See pages 8-10) Improper care when refueling. CAUTION: WARNING 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 the sun. HOW TO AVOID THE HAZARD Do not overfill the fuel tank.
Pre Operation Checks Recommended engine oil type and quantity: See page 10-2 Coolant Check the coolant level in the coolant reservoir when the engine is cold. (The coolant level will vary with engine temperature.) The coolant level is satisfactory if it is between the minimum and maximum level marks on the coolant reservoir. If the coolant level is at or below the minimum level mark, add additional coolant to bring the level up to maximum level mark. If coolant is not available, add distilled water.
5-7 Pre Operation Checks WARNING 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. Final gear oil Make sure the final gear oil is at the specified level. Add oil as necessary.
Pre Operation Checks 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 service center for service if throttle problems arise. Always check the pedal for free movement and return before starting the engine and occasionally during operation.
5-9 Pre Operation Checks Throttle Freeplay If the throttle pedal has excessive play due to cable stretch or mis-adjustment, it will cause a delay in throttle response, especially at low engine speed. The throttle may also not open fully. If the throttle pedal has no freeplay, the throttle may be hard to control, and the idle speed may be erratic. Check the throttle pedal freeplay. Adjust the freeplay if necessary. Throttle Freeplay Inspection 1. Lift the parking brake to the top to park the car. 2.
4. Resume the center cover and seat to their position Steering Wheel Inspection Check the steering wheel for specified freeplay and smooth operation. 1. Position the vehicle on level ground. 2. Lightly turn the steering wheel left and right. 3. There should be 0.8″-1.0″ (20-25 mm) of freeplay.
5-11 Pre Operation Checks as necessary for proper operation. Tires WARNING Switches Check the operation of all switches. Have a service center repair as necessary for proper operation. POTENTIAL HAZARD Operating this vehicle with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this vehicle, or operation of this vehicle with improper or uneven tire pressure, may cause loss of control, increasing your risk of accident. HOW TO AVOID THE HAZARD 1.
Pre Operation Checks 3. The tires should be set to the 5-12 5. Use no more than the following pressures recommended pressure: when seating the tire beads. 2 Front 10psi (70kpa, 0.7 kgf/cm ) Front 36psi (250kpa, 2.5kgf/cm2) Rear 10psi (70kpa, 0.7 kgf/cm2) Rear 36psi (250kpa, 2.5kgf/cm2) Check and adjust tire pressures when the Higher pressures may cause the tire to burst. tires are cold. Tire pressures must be Inflate the tires very slowly and carefully. Fast equal on both sides.
5-13 Pre Operation Checks Set pressure with tires cold. Set tire pressures to the following specifications: Recommended Pressure 10psi (70kpa Front (0.70kgf/ cm2) 10psi (70kpa Rear (0.70kgf/ cm2) Minimum 9 psi (63kpa, 0.64kgf/ cm2) 9 psi (63kpa, 0.64kgf/ cm2) Maximum Tire wear limit When the tire groove decreases to 0.12 in (3 mm) due to wear, replace the tire. 11 psi, (77kpa, 0.77kgf/ cm2) 11 psi, (77kpa, 0.77kgf/ cm2) a. Tire wear limit 1.
Operation WARNING WARNING POTENTIAL HAZARD POTENTIAL HAZARD Operating vehicle without being familiar Freezing control cables due to cold with all controls. weather conditions. WHAT CAN HAPPEN WHAT CAN HAPPEN Loss of control, which could cause an Loss of vehicle control, which could accident or injury. lead to an accident or collision. HOW TO AVOID THE HAZARD HOW TO AVOID THE HAZARD Read the Owner’s Manual carefully.
6-2 Operation Starting the Engine CAUTION: See the “Engine Break-In”section prior to operating the engine for the first time. 1. Turning the key to “ON”, the light in the display will turn on, and electronic injection system’s fuel pump will start to work; wait for 10 second before the following operation. 2. Apply the brake. 3. Shift the drive select lever into the neutral position. NOTE: When the drive select lever is in the neutral position“N”, the neutral indicator light should come on.
Operation 5. Continue warming up the engine until it idles smoothly before riding. WARNING POTENTIAL HAZARD Engine idle speed exceeds the regulated speed. WHAT CAN HAPPEN Will make it difficult to select the proper gear, which could lead to loss of control, causing serious injury or even death. HOW TO AVOID THE HAZARD Because of electronic injection system, the idle speed will be speed up when the voltage of battery is low.
6-4 Operation Otherwise, go on with the third step. 3. Continue warming up the engine until it idles smoothly. CAUTION: See the “Engine break-in” section prior to operating the engine for the first time. Drive Select Lever Operation and Driving In Reverse CAUTION: Before shifting, you must stop the UTV and return the throttle lever to the closed position; otherwise the transmission may be damaged. Shifting: Neutral to High and High to Low 1. Stop the vehicle. Keep your foot off the accelerator pedal. 2.
Operation 6-5 the shift guide. NOTE: Please kick the brake pedal first, before place gearshifts lever to“reverse”position. ● In the brake pedal, there is a cable, which is connected to a position pin located on the gearshift assembly. Only when the brake pedal is depressed, the position pin will be retracked, and gearshifts can be removed to “reverse” position. ● 1. Drive select lever 3. Release the brakes and press the accelerator pedal gradually. Shifting: Neutral to Reverse 1. Stop the vehicle.
6-6 Operation until the vehicle starts moving. 4. Check behind for people or obstacles, and then release the brake pedal. 5. Press the accelerator pedal gradually and continue to watch to the rear while backing up. 1. Drive select lever NOTE: ● When in reverse, the reverse indicator light should be on. If the light does not come on, ask a service center to inspect the reverse indicator light electrical circuit.
Operation WARNING POTENTIAL HAZARD Parking on a hill 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. Never park the vehicle on hills that are too steep. WARNING POTENTIAL HAZARD Improperly operating in reverse.
6-8 Operation Parking Parking on a Slope a) When parking, stop the engine and shift the drive select lever into the neutral position. b) Push the brake pedal down, and pull the parking brake to top position to park the vehicle 1. Bring the vehicle to a stop by applying the brakes. 2. Stop the engine. 3. With the brakes applied, set the parking brake.
Operation 1．parking handbar NOTE: Like many other vehicles, the parking brake acts on the rear wheels. For the parking brake to operate all four wheels, shift to 4WD before stopping the engine. 6-9 Vehicle Break-in Period The break-in period for your new UTV vehicle is the first 25 hours of operation, or the time 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.
6-10 Operation of use. ● Use of any engine oil not mentioned in this manual will cause severe damage to the engine. Engine Break-In There is never a more important period in the life of your vehicle than the period between 0 and 25 hours. For this reason, we ask that you carefully read the following material. Because the engine is brand new, you must not put an excessive load on it for the first several hours of running.
10-25 Hours: Avoid prolonged operation above 3/4 throttle. Rev the vehicle freely but do not use full throttle at any time. After break-in: The vehicle can now be operated normally. Brake System Break-in Apply only moderate braking force for the first 50 stops. Aggressive or overly forceful braking when the brake system is new could damage brake pads and rotors. CVT Break-in (Clutches/Belt) A proper break-in of the clutches and drive belt will ensure a longer life and better Operation 6-11 performance.
6-12 Operation test all nonstandard accessories, nor have any control over the quality or suitability of them. Choose a genuine accessory, or one that is equivalent in design and quality. ● Accessories should be rigidly and securely mounted. An accessory that can shift position or come off while you are operating could affect your ability to control the vehicle. ● Do not mount an accessory where it could interfere with your ability to control the vehicle.
Operation the loaded trailer on the scale with the tongue at hitch height. Adjust the load in the trailer, if necessary, to reduce the weight on hitch. If you are carrying cargo and towing a trailer, include the tongue weight in the maximum vehicle load limit.
6-14 Operation Make sure cargo in the trailer cannot move around. A shifting load can cause an accident. ● Make sure the load does not interfere with controls or your ability to see where you are going. ● Drive more slowly than you would without a load. The more weight you carry, the slower you should go. Although conditions vary, it is good practice not to exceed low range whenever you are carrying heavier loads or when towing a trailer. ● Allow more braking distance.
Operation WARNING POTENTIAL HAZARD Overloading this vehicle or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling 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 greater distance for braking.
7-1 Your Vehicle DRIVING YOUR VEHICLE GETTING TO KNOW YOUR VEHICLE This off-highway utility vehicle will handle and maneuver differently form an ordinary passenger car or other vehicle. Before you begin to use your vehicle, be sure you have read this Owners Manual completely and understand all the features. Pay particular attention to the safety information on pages 2-1 - 2-5. Please read all the caution and warning labels on your vehicle. This vehicle is designed for the operator and one passenger.
Your Vehicle WARNING POTENTIAL HAZARD Carrying a passenger in the cargo bed. WHAT CAN HAPPEN The passenger could fall or be struck by objects in the cargo bed. HOW TO AVOID THE HAZARD Never carry a passenger in the cargo bed. The cargo bed is designed to carry cargo only. 7-2 The total weight of operator, passenger, accessories, cargo, trailer tongue weight, and the vehicle itself must not exceed 1,880 lbs (853Kg).
7-3 Your Vehicle WARNING POTENTIAL HAZARD Overloading this vehicle or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling 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 greater distance for braking.
Your Vehicle WARNING POTENTIAL HAZARD Operating this vehicle without wearing an approved motorcycle helmet, eye protection, and protective clothing. WHAT CAN HAPPEN Operating without an approved 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 severe injury in the event of an accident.
7-5 Your Vehicle LEARNING TO OPERATE YOUR VEHICLE You should become familiar with the performance characteristics of the vehicle in a large, flat area that is free of obstacles and other vehicles. Practice control of the accelerator pedal, brakes, steering, and drive select lever. Drive at a slow speed and become comfortable at that speed before gradually increasing your speed.
Your Vehicle CAUTION: Do not shift from low to high or vice versa without coming to a complete stop and waiting for the engine to return to normal idle speed. Damage to the engine or drive train may occur. TURNING YOUR VEHICLE The vehicle is easier to steer in two-wheel drive (2WD) than four-wheel drive (4WD). Steering takes the most effort in 4WD with the differential locked. It is possible for the vehicle to roll over or go out of control if you attempt sharp, high-speed turns.
7-7 Your Vehicle Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Apply the throttle lightly. Never open the throttle suddenly. 3. Back up slowly. 4. Apply the brakes lightly for stopping. 5. Avoid making sharp turns. Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures.
Your Vehicle 7-8 BRAKING Braking ability is affected by the type of terrain. In most cases, gradual application of the brakes is more effective than abrupt braking, particularly on loose surfaces like gravel. 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.
7-9 Your Vehicle some hills are too steep for you to climb. Maximum slope angle:15° WARNING POTENTIAL HAZARD Operating on excessively steep hills. WHAT 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 Choose carefully which hills you attempt to climb.
Your Vehicle 7-10 Before climbing the hill, first be sure you are around. With your foot on the brake, look operating in low range 4WD or, if necessary, behind you and plan your descent. Shift the with 4WD. To climb a hill, you need traction, drive select lever in reverse so you can use momentum, and steady throttle. Travel fast the engine brake if necessary to slow your enough to keep your momentum going, but descent.
7-11 Your Vehicle 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 AVOID THE HAZARD Always check the terrain carefully before you start down any hill. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side. Go straight down the hill where possible.
Your Vehicle 7-12 CROSSING THROUGH SHALLOW WATER If you must cross shallow, slow moving water up to the depth of the vehicle’s floorboards, choose your path carefully to avoid sharp drop-offs, large rocks, or slippery surfaces that could cause the vehicle to overturn. Never operate through water deeper than 13 in (33 cm) or fast flowing water. Wet brakes may have reduced effectiveness. After leaving the water, test your brakes.
7-13 Your Vehicle CAUTION: Vehicle Immersion After riding your vehicle in water, be sure to CAUTION: drain the trapped water by removing the If your vehicle becomes immersed, major check hose at the bottom of the air filter case, engine damage can result if the machine is the V-belt cooling duct check hose, the drive not thoroughly inspected. Take the vehicle to select lever box check hose and the V-belt your service center before starting the case drain plug.
Your Vehicle 5. Dry the spark plugs and reinstall them, or install new plugs. 6. Attempt to start the engine. If necessary, repeat the drying procedure. 7. Take the vehicle to your service center for service as soon as possible, whether you succeed in starting it or not. 8. If water has been ingested into the CVT, make sure to inspect the hole without water left inside. If it is muddy water, open the CVT cap and wash the parts before you reassemble. 9. Check the gearshift, release the water inside.
7-15 Your Vehicle 1. Drive select lever box check hose 1．V-belt cooling duct check hose 1．V-belt case drain plug 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 accident.
Your Vehicle 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 and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the vehicle.
7-17 Your 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 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 the handgrip inside the enclosure.
Your Vehicle 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 in a new area, check for obstacles. Use extreme caution when operating over large obstacles, such as large rocks or fallen trees.
8-1 Periodic Maintenance and Adjustment NOTE: If you do not have a torque wrench available Periodic Maintenance and Adjustment Periodic inspection, adjustment and during a service operation requirin lubrication will keep your vehicle in the safest g one, take your vehicle to service center to and most efficient condition possible. Safety check the torque settings and adjust them as is an obligation of the vehicle owner. The necessary.
Periodic Maintenance and Adjustment WARNING POTENTIAL HAZARD Servicing an engine while it is running. WHAT CAN HAPPEN Moving parts can catch 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 specified. Have a service center perform service if you are not familiar with vehicle service.
8-3 Periodic Maintenance and Adjustment Periodic Maintenance Chart for the Emission Control System ● For vehicles not equipped with an odometer or hour meter, follow the month maintenance intervals. ● For vehicles equipped with an odometer or an hour meter, follow the mile (km) or hours maintenance intervals. However, keep in mind that if the vehicle is not used for a long period, the month maintenance intervals should be followed.
Periodic Maintenance and Adjustment General maintenance and lubrication chart ITEM ROUTINE Cooling system ● ● ● Air filter element ● ● Engine oil Engine oil filter cartridge ● Whichever Comes first Month Miles (Km) hours Check coolant leakage. Repair if necessary. Replace coolant every 24 months. Clean. Replace if necessary. 1 200 (320) 20 ○ Replace (warm engine before draining.) Replace ○ ○ ● ● Check oil lever oil leakage. Replace.
8-5 Periodic Maintenance and Adjustment ITEM ROUTINE Whichever Comes first Month Miles (Km) hours Wheel bearings* ● ● Check bearing assemblies for looseness/damaged. Stabilizer bushings* ● Check for cracks or damage. ● Check all chassis fittings and fasteners. Check if necessary. Fittings and fasteners* Rear upper and lower knuckle pivots* Drive shaft universal joint* ● ● ● ● Steering system* ● Engine mount* Front and rear axle boots* ● ● ● ● Repair if damaged.
Periodic Maintenance and Adjustment 8-6 NOTE: ● ● Recommended brake fluld:DOT4 Brake fluid replacement. ● When disassembling the master cylinder or caliper, replace the brake fluid. Check the brake fluid level and add fluid as required. ● On the inner parts of the master cylinder and caliper, replace the oil seals every two years. ● Replace the brake hoses every four years, or if cracked or damaged.
8-7 Periodic Maintenance and Adjustment Hood To open Unhook the hood latches, and then slowly tilt the hood up until it stops. 1. 1. Latch (×2) Hood To close Lower the hood slowly to its original position, and then hook the hood latches. Secure projections ① on the underside of the hood into slots ② on the back of the instrument panel. Secure slots ③ on the side of the hood around projections ④ on the frame.
Periodic Maintenance and Adjustment 8-8 Console To remove 1. Remove the seats. (See pages 4-17─ 4-18 for seat removal and installation procedures.) 2. Remove the parking brake lever boot. 3. Pull the console upward (the drive select lever boot will come loose.) 1. Projection (×2) 2. Slot (×2) 3. Slot (×2) 4. Projection (×2) CAUTION: z Make sure that all cables and wires are in place when closing the hood. z Do not drive the vehicle with the hood open, unlatched, or removed. 1.
8-9 Periodic Maintenance and Adjustment procedures.) 2. Install the parking brake lever boot. 3. Check the engine oil level on a cold 3. Install the seats. engine. CAUTION: NOTE: z When installing the console, be sure not If the engine was started before checking the to pinch the cables or wires.
Periodic Maintenance and Adjustment 8. Install the console. 1. Maximum level mark 2. 3. Dipstick 4. Engine oil filler cap Minimum level mark 6. If the engine oil is at or below the minimum level mark, add sufficient oil of the recommended type to raise it to the correct level. 7. Insert the dipstick into the oil filler hole, and then tighten the oil filler cap. 8-10 To change the engine oil (with or without oil filter cartridge replacement) 1. Remove the console.
8-11 1. Periodic Maintenance and Adjustment 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 wrench NOTE: An oil filter wrench is available at a nearby service center. 5. Apply a light coat of engine oil to the O-ring of the new oil filter cartridge. NOTE: Make sure the O-ring is seated properly.
Periodic Maintenance and Adjustment 1. O-ring 6. Install the new 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: 12 ft·lbf (17Nm, 1.7m·kgf) 1. Oil filler cartridge 2. 8-12 Torque wrench 7. Install the engine oil drain bolt, and then tighten it to the specified torque. Tightening torque: Engine oil drain bolt: 22 ft·lbf (30Nm, 3.0m·kgf) 8.
8-13 Periodic Maintenance and Adjustment Recommended engine oil: See page 10-2. Oil quantity: Without oil filter cartridge replacement 2.01 qt (1.9L) With oil filter cartridge replacement: 2.22 qt (2.1L) several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause. 10. Turn the engine off, wait at least ten minutes, and then check the oil level and correct it if necessary. 11. Install the console.
Periodic Maintenance and Adjustment 8-14 CAUTION: 1. Be sure no foreign material enters the final gear case. 2. Please clean the sensor every 320 mile period. 3. Install the oil filler bolt, and then tighten it to the specified torque. 1. Speedometer sensor 3. Correct oil level 2. final gear oil 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.
8-15 Periodic Maintenance and Adjustment Changing the final gear oil Tightening torque: 1. Place the vehicle on a level surface. Final gear oil drain bolt: 2. Place a container under the final gear 14 ft·lbf (20 Nm, 2.0 m·kgf ) case to collect the used oil. 5. Add the recommended final gear oil up to 3. Remove the oil filler bolt and the drain the brim of the filler hole. bolt to drain the oil. Recommended oil: SAE 80 API GL-4Hypoid gear oil Oil quantity: 0.26 qt (0.
Periodic Maintenance and Adjustment 8-16 Tightening torque: Final gear oil filler bolt: 17 ft·lbf (23 Nm, 2.3 m·kgf) 7. Check for oil leakage. If oil leakage is found, check for the cause. Differential gear oil Checking the differential 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.
8-17 Periodic Maintenance and Adjustment Changing the differential gear oil 1. Place the vehicle on a level surface. Tightening torque: 2. Place a container under the differential Differential gear oil drain bolt: gear case to collect the used oil. 7.1 ft·lbf (9.8Nm, 0.98 m·kgf) 3. Remove the differential gear oil filler bolt 5. Fill the differential gear case with the and differential gear oil drain bolt to drain recommended oil. the oil. Recommended oil: SAE 80 API GL-5 Hypoid gear oil Oil quantity: 0.
Tightening torque: Differential gear oil filler bolt: 17 ft·lbf (23Nm, 2.3m·kgf) Periodic Maintenance and Adjustment 8-18 temperature. NOTE: The coolant should be between the minimum and maximum level marks. 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 8-8－8-9 for hood opening and closing procedures.) 3.
8-19 Periodic Maintenance and Adjustment content of the coolant as soon as the hood. possible. Coolant reservoir capacity ● The radiator fan is automatically (up to the maximum level mark): switched on or off according to the 0.37 qt (0.35L) coolant temperature in the radiator. CAUTION: Mix anti freeze with distilled water only. However, if distilled water is not available, soft water may be used for refilling.
Periodic Maintenance and Adjustment 8-20 Spark plug inspection Removal 1. Lift the cargo bed up. (See pages 4-21 4-22 for cargo bed lifting and lowering procedures.) 2. Remove the spark plug cap. 1.Front axle boot (×2 each side) 1. 1. Spark plug cap 3. Use the spark plug wrench in the tool kit to remove the spark plug as shown. 1.
8-21 1. Periodic Maintenance and Adjustment Do not attempt to diagnose such problems yourself. Instead, take the vehicle to a service center. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark 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.
Periodic Maintenance and Adjustment 8-22 Tightening torque: Spark plug: 12.7 ft·lbf (17.5 Nm, 1.75 m·kgf) a. Spark plug gap 2. Clean the surface of the spark plug gasket and its mating surface, and then wipe off any grime from the spark plug threads. 3. Install the spark plug and tighten it to the specified torque. NOTE: If a torque wrench is not 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.
8-23 1. Periodic Maintenance and Adjustment Air filter check hose 1. Remove the seats. (See pages 4-17 4-18 for seat removal and installation procedures.) 2. Remove the console. (See page 8-9 for console removal and installation procedures.) 3. Remove the air filter case cover by unhooking the holders. 1. Holder (×4) 2. Air filter case cover 4. Remove the air filter element. 5. Remove the sponge material from its frame.
Periodic Maintenance and Adjustment 1. 3. Air filter frame 2. Element retaining plate 8-24 Sponge material 6. Wash the sponge material gently but thoroughly in solvent. WARNING 1. Air filter element POTENTIAL HAZARD Using low flash point solvents 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.
8-25 Periodic Maintenance and Adjustment CAUTION: Do not twist the sponge material when squeezing it. 8. Inspect the sponge material and replace it if damaged. 9. Thoroughly apply foam air filter oil or other quality liquid foam air filter oil (not spray type) to the sponge material. 1. NOTE: The sponge material should be wet but not dripping. 10. Pull the sponge material over its frame. 11. Install the air filter element. 12.
Periodic Maintenance and Adjustment 8-26 V-belt cooling duct check hose element rubber joint to the fuel system and The V-belt cooling duct check hose is located manifold fittings securely to avoid the under the driver seat. (See pages 4-17 - 4-18 possibility of unfiltered air entering the for seat removal and installation procedures.) engine. If dust or water collects in the V-belt cooling duct check hose, remove the hose and clean it. CAUTION: Never operate the engine with the air filter element removed.
8-27 Periodic Maintenance and Adjustment V-belt case drain plug The V-belt case drain plug is located under the driver seat. (See pages 4-17 - 4-18 for seat removal and installation procedures.) After riding in water deep enough to allow water to enter the V-belt case, remove the drain plug to drain any water from the case. NOTE: If water drains from the V-belt case after removing the drain plug, have a service center inspect the vehicle as the water may affect other engine parts. 1.
Periodic Maintenance and Adjustment 1. Bolt(×3) 2. Remove the tailpipe by pulling it out of the muffler. 3. Tap the tailpipe lightly, and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing. 1. Tailpipe 2. 8-28 Spark arrester 4. Insert the tailpipe into the muffler and align the bolt holes. 5. Install the tailpipe by installing the bolts, and then tighten the bolts to the specified torque.
8-29 Periodic Maintenance and Adjustment 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 when cleaning the exhaust system.
Periodic Maintenance and Adjustment 8-30 Rear 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. 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 service center replace the brake pads as a set. 1. Brake pad wear indicator groove NOTE: The wheels need to be removed to check the brake pads.
8-31 Periodic Maintenance and Adjustment The brake fluid reservoir is located under the Checking the brake fluid level hood. (See pages 8-8- 8-9 for hood opening Insufficient brake fluid may let air enter the and closing procedures.) brake system, possibly causing the brakes to become ineffective. Before riding, check that Observe these precautions: the brake fluid is above the minimum level z When checking the fluid level, make sure mark and replenish if necessary.
Periodic Maintenance and Adjustment 8-32 should be no free play in the brake pedal. the fluid and may result in vapor lock. The brakes should operate smoothly and z Brake fluid may deteriorate painted there should be no brake drag. If the brakes surfaces or plastic parts. Always clean up feel soft or spongy, this could indicate air in spilled fluid immediately. the brake system. Have a service center z Have a service center inspect the brake check the brake system if necessary.
8-33 Periodic Maintenance and Adjustment WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing: z Make sure the brakes operate smoothly and that the brake pedal position is correct. z Make sure the brakes do not drag. z All air must be bled from the brake system. Replacement of brake components requires professional knowledge.
Periodic Maintenance and Adjustment 1.Parking brake lever free play NOTE: The parking brake lever must be released when checking and adjusting the parking brake lever free play. 5. Loosen the locknut. 1. Locknut 8-34 2. Adjusting nut 6. Turn the adjusting nut in direction increase the free play or in direction to decrease the free play. 7. Tighten the locknut. 8. Install the console. 9. Install the seats.
8-35 Periodic Maintenance and Adjustment Brake light switch adjustment The brake light switch, which is activated by the brake pedal, is properly adjusted when the brake light comes on just before braking takes effect. If necessary, adjust the brake light switch as follows. 1. Open the hood. (See pages 8-8 - 8-9 for hood opening and closing procedures.) 2. Turn the adjusting nut while holding the brake light switch in place. To make the 1. Brake light switch. 2. Adjusting nut brake light switch in place.
Periodic Maintenance and Adjustment WARNING POTENTIAL HAZARD Damaged control cables. WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes 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. Recommended lubricant: Engine oil Brake pedal and accelerator pedal lubrication Lubricate the pivoting parts.
8-37 Periodic Maintenance and Adjustment Rear knuckle upper and lower pivot Steering shaft lubrication lubrication Lubricate the pivot points. Lubricate the knuckle upper and lower pivots Recommended lubricant: with a grease gun.
Wheel removal Loosen the wheel nuts . Elevate the vehicle and place a suitable stand under the frame. Remove the nuts from the wheel. Remove the wheel. 1. Periodic Maintenance and Adjustment 8-38 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. Nut（×4） 1.
8-39 Periodic Maintenance and Adjustment Battery This vehicle is equipped 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 service center. 1. Tapered nut 2. Lower the vehicle so that the wheel is on the ground. 3. Tighten the wheel nuts to the specified torque. Wheel nut torque: Front：40 ft·lbf (55Nm, 5.5 m·kgf） Rear：40 ft·lbf (55Nm, 5.
Periodic Maintenance and Adjustment 8-40 WARNING POTENTIAL HAZARD Failure to handle batteries or battery electrolyte carefully. WHAT CAN HAPPEN You could 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 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.
8-41 Periodic Maintenance and Adjustment Battery maintenance 1. When the vehicle is not used for a month or longer, remove the battery and store it in a cool, dark place. Completely recharge the battery before reinstallation. CAUTION: 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. 2.
Periodic Maintenance and Adjustment by lifting it up and pulling it out. 1. Battery compartment cover 2. Turn the key to “OFF” and turn off the electrical circuit in question. CAUTION: To prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse. 3. Remove the blown fuse, and then install a new fuse of the specified amperage. 1. 3. 5. 6. 7. 8. 9. Main fuse 2. Spare main fuse Headlight fuse 4.
8-43 Periodic Maintenance and Adjustment Specified fuse: Main fuse: Headlight fuse: Auxiliary DC jack fuse: Signaling system fuse: Fuel system warmer fuse: Four-wheel-drive motor Fuse: Backup fuse: 30.0A 15.0A 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 service center check the electrical system. 6. Install the battery compartment cover. 7. Close the hood.
Periodic Maintenance and Adjustment 1. Cover at the rear of the headlight 3. Remove the headlight bulb holder cover by pulling it off. 1. 8-44 Headlight bulb holder cover 4. Remove the headlight bulb holder by pushing it in and turning it counterclockwise.
8-45 Periodic Maintenance and Adjustment WARNING 1. Headlight bulb holder 5. Remove the defective bulb by pulling it out. POTENTIAL HAZARD A headlight bulb is hot when it is on and immediately after it is turned off. WHAT CAN HAPPEN You can be burned, or a fire could start if the bulb touches something flammable. HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it. 6. Insert a new headlight bulb into the bulb holder by pushing it in.
Periodic Maintenance and Adjustment 8-46 turning it clockwise. 8. Install the bulb holder cover and the cover at the rear of the headlight. CAUTION: Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly. 9. Close the hood. 10. Adjust the headlight beam if necessary. 1. Do not touch the glass part of the bulb.
8-47 1. Periodic Maintenance and Adjustment Headlight beam adjusting screw 1. Panel A 1. Panel B 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.
Periodic Maintenance and Adjustment 1. Quick fastener（×8） 3. Panel A 2. Bolt（×2） 2. Remove the bulb holder（together with the bulb）by turning it counterclockwise. 1. 8-48 Tail/brake light bulb holder 3. Push the defective bulb in and turn it counterclockwise to remove it 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. 6.
8-49 Periodic Maintenance and Adjustment Imitation parts may look like genuine parts, Tightening torque: but they are often inferior. Panel bolt: Consequently, they have a shorter service 4.7 ft·lbf (6.5N·m, 0.65 m·kgf） life and can lead to expensive repair bills. Troubleshooting Although vehicles receive a rigid inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems can cause poor starting and loss of power.
Periodic Maintenance and Adjustment 8-50 Solution to Common Problems in Vehicle The below tables show some common problems that may come up when you are driving a UTV, which will help to solve these problems. To repair a UTV requires technical skills, if you cannot repair the UTV yourself, please contact your service center. Table 1: Solution of Common Problems in Appearance Parts and Impact Fittings. S/N Problems Solutions 1. Repair cover at authorized service center. 1 Covers are cracked. 2.
8-51 Periodic Maintenance and Adjustment Table 2：Solution of Common Problems in Brake System. S/N Problems 1 Brake system is locked up. 2 Brake performance is diminished. 3 Front or rear brake system makes unusual noise. Solutions 1. Check if the handle of parking brake return to its position. 2. Check if the brake discs are bent or deformed. 3. Check if the calipers' hydraulic cylinders are stuck or the fasteners are bent. 1. Check if the brake discs are over-worn. 2.
Periodic Maintenance and Adjustment 8-52 fasteners of calipers are deformed. 1. Check if left and right brake force deviation of front brake is with specified limit. 4 Vehicle makes odd turn 2. Check if the brake force of front brake goes down, which causes the rear wheels to lock up before the front wheels. when braked at high speed. 3. Check if spring force deviation of shock absorbers in front left and right suspension are within specified limit. 4.
8-53 Periodic Maintenance and Adjustment Table 3: Solution of Common Problems in Electrical System S/N Problems 1 Lights do not work. 2 Vehicle cannot go into 4 wheel drive mode. 3 Rear differential will not work. 4 Meter display is not normal. 5 Start switch on meter board will not work. Solutions Check if the headlight switch functions properly. Check if the wires are broken. Check if the lamps or bulbs are broken. Check if the control switch on meter board works well.
Periodic Maintenance and Adjustment 8-54 Table 4: Solution of Common Problems in Running System S/N 1 2 3 Problems Solutions 1. Check the fasteners connecting steering rod to steering stem and knuckle to find out if they are loose or broken. Swing clearance of 2. Check the bolts on the ends of steering rod to find out if steering wheel is out of they are broken. specification. 3. Check the clearance between gears of steering machine if it is too big. 1.
8-55 Periodic Maintenance and Adjustment 3 Rear wheels shake during use. 4 Wheels jump during use. 5 Shock absorbers become soft and not comfortable during use. 6 Front bridge makes noise during use. 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 loose or broken. 5.
Periodic Maintenance and Adjustment 8-56 Table 5: Solution of Common Problems in Engine System S/N 1 Problems Idle speed is not stable 3 Power performance is falling. 4 Popping noise in engine. 5 Engine is difficult to start at low temperature. 1. 2. 3. 1. 2. 3. 1. 2. 3. 1. 2. 1. 6 Coolant boils. 2. 3. Solutions Check the battery voltage for Within specified value Check the rectifier output voltage for within specified value Check MEUI for failure Check and clean air filter.
8-57 7 Periodic Maintenance and Adjustment Engine cannot start. 4. 1. 2. 3. 4. 5. 6. 7. 8. 9. Check the coolant drain tube for with air. Check the battery charge. Check the battery connection. Check the starter for damage. Check if the ignition loop is in good condition. Check if the spark plug creating sparks. Check if the ignition signal is in good condition. Check if the air cleaner is blocked. Check to make sure the coolant is not frozen. Check if the exhaust system is blocked.
Periodic Maintenance and Adjustment 8-58 WARNING 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.
9-1 Cleaning and Storage Cleaning Frequent, thorough cleaning of your vehicle will not only enhance its appearance but also will improve its general performance and extend the useful life of many components. 1. Before cleaning the vehicle: a. Block off the end of the exhaust pipe to prevent water entry. A plastic bag and strong rubber band may be used. b. Make sure the spark plug and all filler caps are properly installed. 2. If the engine case is excessively greasy, apply degreaser with a paintbrush.
Cleaning and Storage chamois, clean towel or soft absorbent cloth. 6. Clean the seats with vinyl upholstery cleaner to keep the cover pliable and glossy. 7. Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid combination cleaner waxes as many contain abrasives that may scratch the paint or protective finish. When finished, start the engine and let it idle for several minutes. 9-2 WARNING POTENTIAL HAZARD Operation with wet brakes after washing.
9-3 Cleaning and Storage Storage Long-term storage (60 days or more) of your vehicle will require some preventive procedures to guard against deterioration. After thoroughly cleaning the vehicle, prepare for storage as follows: 1. Fill the fuel tank with fresh fuel and add the specified amount of Fuel Stabilizer and Conditioner or equivalent product. Operate the vehicle for at least 5 minutes to distribute treated fuel through the fuel system. 2.
Cleaning and Storage 6. Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering. 7. If storing in a humid or salty atmosphere, coat all exposed metal surfaces with a light film of oil. Do not apply oil to any rubber parts or the seat covers. 8. Remove the battery and charge. Store it in a dry place and recharge it once a month. Do not store the battery in an excessively warm or cold place (less than 32°F (0°C) or more than 86°F (30°C)).
10-1 Specifications Model HS500UTV Dimensions: Overall length Overall width Overall height Seat height Wheelbase Ground clearance Minimum turning radius Basic weight with oil and full fuel tank 3010mm (118.5 in) 1460m m (57.5 in) 1940mm (76.4 in) 818mm (32.2 in) 1890mm (74.4 in) 280mm (11.
Specifications Model 10-2 HS500UTV Engine oil: Type Recommended engine oil classification API service SG type or higher, JASO standard MA CAUTION: Quantity: Without oil filter cartridge replacement With oil filter cartridge replacement 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.
10-3 Specifications Model HS500UTV Final gear case oil: Type SAE80 API GL-4 Hypoid gear oil Quantity: 0.25L (0.26 qt ) Differential gear case oil: Type SAE80 API GL-5 Hypoid gear oil Quantity: 0.32L (0.34 qt ) Radiator capacity（including all routes）: 2.50L (2.64 qt ) Air filter: Engine Wet element Intake duct Dry element Fuel: Type Unleaded gasoline only Fuel tank capacity 29 L (7.
Specifications Model HS500UTV Spark plug: Type DR8EA Spark plug gap 0.6-0.7 mm (0.023-0.027 in) Clutch type: Wet, centrifugal automatic Transmission: Primary reduction system V-belt Secondary reduction system Shaft drive Secondary reduction ratio Transmission type V-belt automatic Operation Right hand operation Reverse gear 1.471 Sub transmission ratio low 2.059 High 1.238 Chassis: Frame type Steel tube frame Caster angle 5.0° Trail 26.0mm (1.
10-5 Specifications Model HS500UTV Tire: Tubeless Type Size Brakes: Ⅰ: Front brake Rear brake Ⅱ: Front brake Rear brake Suspension: Front / rear suspension Shock absorber: Front shock absorber Rear shock absorber front 25×8-12 rear 25×10-12 Type Operation Type Operation Type Operation Type Operation Dual disc brake Foot operation Single disc brake Foot operation Dual disc brake Foot operation Dual disc brake Foot operation Double wishbone Coil spring/oil damper Coil spring/oil damper
Specifications Model Wheel travel: Front wheel travel Rear wheel travel Electrical: Ignition system Generator system Battery type Battery capacity Bulb voltage, wattage × quantity: Headlight Tail/brake light Indicator lights: Neutral / Reverse indicator light Coolant temperature warning light Parking brake indicator light On-Command four-wheel-drive/differential gear lock indicator On-Command differential gear lock indicator light HS500UTV 130mm (5.12in) 150mm (5.
10-7 Specifications Model HS500UTV High-range/ Low-range indicator light LED Specified fuses: Main fuse Headlight fuse Auxiliary DC jack fuse Four-wheel-drive motor fuse Signaling system fuse Backup fuse 30.0A 15.0A 10.0A 3.0A 10.0A 10.
Fault Code of Electronic Injection System Fault Code of Electronic Injection System DTC DTC Description Number 11-1 Related Calibration HEX DEC P0107 MAP Circuit Low Voltage or Open KsDGDM_MAP_ShortLow 107 263 P0108 MAP Circuit High Voltage KsDGDM_MAP_ShortHigh 108 264 P0112 IAT Circuit Low Voltage KsDGDM_IAT_ShortLow 112 274 P0113 IAT Circuit High Voltage or Open KsDGDM_IAT_ShortHigh 113 275 KsDGDM_CoolantShortLow 117 279 KsDGDM_CoolantShortHigh 118 280 P0117 P0118 Coolant
11-2 Fault Code of Electronic Injection System P0132 O2S 1 Circuit High Voltage KsDGDM_O2_1_ShortHigh 132 306 P0031 O2S Heater Circuit High Voltage KsDGDM_O2_HeaterShortHigh 31 49 P0032 O2S Heater Circuit Low Voltage KsDGDM_O2_HeaterShortLow 32 50 P0201 Injector 1 Circuit Malfunction KsDGDM_INJ_CYL_A_Fault 201 513 P0202 Injector 2 Circuit Malfunction KsDGDM_INJ_CYL_B_Fault 202 514 P0230 FPR Coil Circuit Low Voltage or Open KsDGDM_FPP_CircuitShortLow 230 560 P0232 FPR Coil Ci
Fault Code of Electronic Injection System 11-3 P0563 System Voltage High KsDGDM_SysVoltHigh 563 1379 P0650 MIL Circuit Malfunction KsDGDM_MIL_Circuit 650 1616 P1693 Tachometer Circuit Low Voltage KsDGDM_TAC_Circuit_Low 1693 5779 P1694 Tachometer Circuit High Voltage KsDGDM_TAC_Circuit_High 1694 5780 P0137 O2S 2 Circuit Low Voltage KsDGDM_O2_2_ShortLow 137 311 P0138 O2S 2 Circuit High Voltage KsDGDM_O2_2_ShortHigh 138 312 P0038 O2S Heater 2 Circuit High Voltage KsDGDM_O2_Hea
Hisun Motors Corp., U.S.A. Emission Control System Warranty Statement 12-1 YOUR WARRANTY RIGHTS AND OBLIGATIONS Hisun Motors Corp., U.S.A. (hereinafter “HISUN”) is pleased to explain the emission control system warranty on your 2013 Off-Road ATV or UTV vehicle. New off-road motor vehicles must be designed, built and equipped to meet California’s anti-smog standards.
Hisun Motors Corp., U.S.A. Emission Control System Warranty Statement 12-2 As the vehicle owner, you should be aware that HISUN may deny your warranty coverage if your vehicle or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications. If you use your vehicle in any type of competitive event, this warranty is immediately and completely void. If you have any questions regarding your warranty rights and responsibilities, you should contact Hisun Motors Corp., U.S.A.
Hisun Motors Corp., U.S.A. Emission Control System Warranty Statement 12-3 (2) misuse, (3) repairs improperly performed or replacements improperly installed, unless performed by a HISUN authorized dealer, (4) use of improper replacement parts or accessories not conforming to specifications set forth by HISUN, which adversely affect performance and/or (5) Use in competitive racing or related events. B. Inspections, replacement of parts and other services and adjustments required for required maintenance. C.
Hisun Motors Corp., U.S.A. Emission Control System Warranty Statement 12-4 C. No dealer is authorized to modify this Limited Emission Control System Warranty issued by HISUN. IV. LEGAL RIGHTS. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. V. This warranty is in addition to the limited vehicle warranty. VI. ADDITIONAL INFORMATION.
