BRISTERS TRAIL WAGON, CHUCK WAGON Operator's Manual

Download

Page 1

Brister’s Utility Vehicles

2 Wheel & 4 Wheel Drive Models

Operator’s Manual

January 1, 2007

Page 2

DIN EX

Section 1 Introduction pages 3-4 Serial Number Plate Location page 4

2 10 Section Safety pages 5-

Pre-Delivery Steps page 9

Dealer Inspection Checklist page 10

ection 3 Assembly Instructions pages 11-13 S

Seat Back, Brush guard, Bumper page 12

Steering wheel page 12 Cargo Bed page 13

Seat Base page 13 Section 4 Operating Instructions page 14 Section 5 Maintenance pages 15-22

Fuel Valve Lever page 15 Air Cleaner Page 16 Engine Oil page 17

Transaxle Oil page 18

Drive Belt page 19 Section Troubleshooting pages 20-28 6

Troubleshooting Chart page 26

ection 7 Parts Diagrams pages 29-64 S

Wiring Diagram page 30

11hp 2 wheel drive pages 31-42

265cc 2 wheel drive pages 43-53

13hp 4-wheel drive pages 54-64

arranty Policy page 65 W

Contact Information

page 66

Warrant ate

y Registration Certific page 67

Page 3

Section 1 Introduction

Brister’s welcomes you to its growing family of new product owners. This Brister Utility Vehicle UTV is a light utility vehicle that has been designed with care and built by skilled workers using quality materials. Proper set-up, maintenance and safe operating practices will help you get years of satisfactory use from this vehicle.

Safety First

Brister’s is fully aware of the need for safe operating procedures around all of our equipment. We hope yo will make a sincere effort to put safety above au ll other

riorities. The Brister Utility Vehicle was designed and

p built for work, recreation, and enjoyment; however, improper and irresponsible operation could result in serious injury or death. Since this is an off-road vehicle, operators will seldom see the road safety and warning signs they are accustomed to seeing on highways and public streets. This places additional responsibility on the driver to operate this vehicle well within the safe operational limits and capabilities of the unit.

This manual has been pre safe and responsible operation of your Brister Utility Vehicle. Read and abide by all safety alert information about this vehicle. If you do not understand any part of this manual, contact your local dealer for additional information and clarification. As the operator of this

iece of equipment, you are in complete control. Only p

you can prevent an accident from happening.

pared to instruct you in the

Using This Manual

* Prior to any vehicle operation it is absolutely essenti that you read and compreh

anual to develop an understanding of your vehicle and

m for your safety. After reviewing this manual, store it in dry and easily accessible place for future reference.

The Operator’s Section is designed to help familiarize

* you with safety, assembly, operation, adjustments, troubleshooting, and ma and follow and efficient operation.

* The information contained within this manual was current at the time of printing. Some parts may change slightly to assure you of the best performance.

* To order a new Operator’s or Parts Manual contact y our au

the recommendations to help ensure safe

thorized dealer.

end each section in this

intenance. Read this manual

Brister’s Design & Manufacturing Co. LLC

Toll Free PH: 1-866-646-5278

Fax: 1-866-329-5278

www.bristers.com

Terminology

Right-hand and left-hand as used in this manual are determined by facing the direction the vehicle will travel while in use unless otherwise stated.

Getting Acquainted with your Utility Vehicle

This off-road utility vehicle is a very unique vehicle designed exclusively for off-road use. It is not designe properly equipped, or licensed to be safely operated on public streets and highways. This vehicle is designed to carry two people and a limited amount of gear or cargo comfortably and safely over rough terrain that was onl accessible by ATV’s in the past.

Unlike ATV’s that have handlebar steering, Brister Utilit Vehicle’s have a steering wheel with easy handling rack-and pinion steering. The steering’s tight turning radius makes this vehicle more maneuverable than most ATV’s. Its four wheeled independent suspensio large diameter hi-flotation tires and high center-frame ground clearance adds up to excellent stability and a smooth ride over rough terrain. Outstanding two wheeled rear traction drive is achieved by using premium off-road ATV type tires in tandem with the engine mounted directly in front of the

lso unlike an ATV’s one person “straddle saddle” seat,

e Brister Utility Vehicle sports dual headrest

ushioned seats with seat belts mounted in a highly

c styled and protective full length body. Two passen can ride comfortably in this vehicle protected from

shing water and mud. The Brush Guard Bar

spla mounted to the vehicle’s frame provides protection against low hanging limbs and briars.

rear differential.

gers

Page 4

Section 1 Introduction

The Brush Guard Bar also provides a mounting system for Brister’s optional windshields, canopy tops and weather enclosures. It also serves as a mounting base for many other optional cargo racks, gun and bow racks The cargo bed is for transporting accessories such as camping equipment, tree stands, hunting gear, and fishing gear. A standard hitch moun

uick installation of a rear hitch for pulling small trailers

q full of supplies, tools, gear, and game.

The Brister Utility Vehicle has some similarities to ATV. Like an ATV the Brister Utility Vehicle has a short wheelbase, narrow stance, and high center clearance a which provide for narrow and difficult trail access. This combination of short wheelbase

nables this vehicle to be loaded in the back of most full

e to mid-sized pickups for t

The Brister Utility Vehicle’s ground compaction and is very gentle on the ground and surrounding vegetation. The highly energized four wheeled independent suspension system provides an incredibly soft ride and outstanding stability over difficult terrain. The engine EPA certified and meets California Air Resources Board

ARB) certification (C stand

ransport.

ards.

ting plate enables

and narrow stance also

Owner Assistance

The safety information should be view

nd the Warranty Registration card should be filled out

a by the dealer at the time of purchase. The owner, upon purchasing the vehicle, should have participated in a short drivers training course with the dealer. This information is neces customer service.

he parts on your B le Utility Vehicle rister Utility Vehic have been spec replaced with g

If customer service or repair parts are required contact a Brister’s dealer. They have trained personnel, genuine repair parts and equipment specially designed to repair Brister’s products.

sary to provide you with quality

designed and sho

ially uld only be

enuine Brister’s parts.

ed by the owner

Product Support

Brister’s Design & Manufacturing Co. LLC

P.O. Box 649

Roseland, LA 70456

Toll Free PH: 1-866-646-5278

Fax: 1-866-329-5278

[email protected]

Always use the serial and model number when ord

arts r your Brister Utility Vehicle. The serial-num

fo ber

p plate is located under the cargo bed on the driver’s side just above the engine, on the frame as shown in figure 1 below.

Record your Brister Utility Vehicle serial number here for quick reference:

Model Number:___________________________ Serial Number:___________ Your Brister’s dealer ur

new vehicle. If y manual o please ak fo

Discuss the matter with your dealership service manager. Make sure they are aware of any problems so they can assist you.

If you are still unsatisfied, seek out the owner or general manager of the dealership.

Serial Number Plate Location

Figure 1

wants you to be satisfied with yo

ou do not understand any part o

r you’re not satisfied with the service received,

t e the llowing actions.

For further assistance write to

_________________

ering

f this

Page 5

Read These Important Rules for Safe Operation

Note: The Operator, Passenger, Parent or Guardian must read, study and understand all the items contained within this owners/operators manual before operating utility vehicle. Failure to follow these instructions could endanger the personal safety of the Operator, Passenger and any Bystanders.

When transporting any Brister Utility Vehicle with an installed windshield or

Close adult supervision is required at all times!

Pay close attention to all Caution and Warning labels

Located on the Utility Vehicle

*IMPORTANT*

Color matched top DO NOT reach high speeds!

Assumption Of Risk

The owner or operator assumes all the risks incident to or arising out of the operation of

this Utility Vehicle

Failure to follow and comply with all warnings may

cause serious injury or death

Page 6

Section 2 Safety

It is very important to read, understand, and follow all instructions and warnings located on the decals on your

rister Utility Vehicle. B

Page 7

Section 2 Safety

Safe Operating Procedures

The safe operation of any machinery is a big c

ll consumers. Your Brister Utility Vehicle has been

a designed with many built-in safety features. However, no one sho

ading this Operator’s Manual. Also read all

re instructions noted on the safety decals.

* Be familiar with all functions of this vehicle.

Keep all bystanders away from this vehicle during

* operation.

* Do not allow anyone to operate t

ot fully read and comprehended this manual and who

n has not been properly trained in the safe operation of this vehicle.

* Do not operate a vehicle with damaged or defective parts. R

utting vehicle back in to service.

p * Do not allow any

is vehicle.

Operator must always use both hands on the steering

* wheel.

No riders allowed except in factory designed and

* supplied seating.

Operate this vehicle from the driver’s seat only.

* * Do not leave this vehicle unattended

nning.

ru * Do not dismount a moving

eath could occur.

d * Always operate vehicle with belt guard installed. Do

not leave pulleys * Do not touch engine, engine exhaust pipe and/or

muffler while th * Keep hands, feet, long hair, clothing, and jewelry away

from moving parts and obvious pinch points to avoid getting caught.

* Wear snug-fitting clothing to avoid entanglement with moving parts.

uld operate this vehicle before carefully

his vehicle who has

epair all damages and defective parts before

one under 16 years of age to operate

with engine

vehicle as serious injury or

and belts exposed.

ey are hot.

oncern to

* Some conditions may warrant extra safety gear to be

orn such as safety helmets and/or goggles. w

Keep hands, arms, feet and all bodily a* ppendages

safely inside the confines of the vehicle.

Always be aware of and avoi* that have a potential of hitting and/or poking individuals riding the vehicle. Serious body harm could result.

* Avoid sudden stops, starts, and turns. * Always operate your vehicle at a safe speed that w

allow you to maintain control. * Operator and passenger are responsible for deciding i

their situation warrants using seat belts. * Do not exceed total payload capacity of this vehicle * Do not pull a trailer or implement exceeding 1100

ound towing capacity or lossp

Do not attach an implement, trailer or other d* the hitch that will produce negative tongue weight.

* Follow all towing instructions in this manual when towing the UTV behind another vehicle. Do not tow vehicle faster than 25 MPH.

Do not use the vehicle as an anchor devic* * Beware, tow ropes, cables and chains can break when

ulling another vehicle or op or death to anyone in line with the whipping action created when they break. Never jerk when pulling,

lways ease into a pa tow line. Never be in line with the tow line.

* Reduce speed when loaded with cargo. Heavy car load takes longer to stop.

* Reduce speed and payload on hilly, rough, wet, slick

r unstable grouo * Always make turns at a speed that will maintain control

f vehicle. No

peed when turning empty and reduce speed even

ever make turns at full speed. Reduce

ull gently. Always stay clear of the

nd.

d tree limbs and brush

of control may result.

bject causing serious injury

ill

evice to

Page 8

more when turning loaded with cargo or when pulling a cargo load. The heaver the cargo load, the slower the

rn should be.

tu * Make sure

ed down.

ti * Do not exceed 400 lbs. in cargo bed area, or 900 lb

tal on this vehicle.

to * Do not mount a receiver hitch type carrier p

e vehicle.

th * Do not load the Brush Guard Bar with heavy

quipment. Rollover could result from such loading.

e * The Brush Guard Bar is not ce

rotection System). Always avoid rollovers.

P * Do not operate this vehicle on highways, public roads,

or where it may be a hazard to faster moving * Do not operate this vehicle while drinking or under

influence of alcohol and drugs. * Never attempt wheelies, jumps, or other stunts

drive recklessly. Always operate your vehicle at a s speed that will allow you to maintain control.

Never use vehicle for racing and never modify the

* engine to exceed 25 MPH vehicle speed.

* Never modify any parts on the vehicle without authorization. Unauthorized modifications will void warranty to all parts di

e modification.

th * Always make sure the vehicle pathway is clear o

objects when backing up. Know location of

round vehicle and especially location of small children.

a Take extra precautions when rear view is hindered by cargo.

Always park on level ground, stop engine, set parking

* brake and remove ignition key before leaving the vehicle. Choc

* Use extreme caution when cresting hills or when visibility is limited. Proceed slowly until yo conditions immediately ahead are safe.

* Keep front wheels straight when c

ver bumps.

o * Do not s

oss of control and rollover could result.

all gear or cargo is properly secured and

latform to

rtified ROPS (Roll Over

traffic.

the

. Never

afe

rectly and indirectly affected by

f all

personnel

k tires if condition warrants.

u are sure trail

resting hills or going

top, start suddenly or over accelerate on hills.

* Use extreme caution when descending hills or runn on loose slippery surfaces. Towing, braking, a

apabilities are greatly diminished.

c * Do not operate vehicle on 15 degree slopes or

teeper.

s * Avoid changing direction or making sharp steering

corrections on slopes or rollover m * If this vehicle begins to tip when crossing a slope, turn

the front wheels downhill to regain stability and

When crossing a slope on soft terrain, turn the front

* wheels slightly uphill and maintain a constant speed to maintain a straight line of tr

* When descending hills or slopes apply steady pressure to the foot brake to avoid potential of freewheeling or runaway.

* Never allow vehicle to coast or

ss of control may result.

lo * If your vehicle loses power and stops on a hill,

immediately

own the hill maintaining a straight downhill line of

d travel. Do not attempt to turn the vehicle sideways on the hill or a rollover could result.

* When traveling at night always use your headligh and reduce speed according to visibility, trail, and terra conditions.

Avoid water crossings when possible and never cross

* a body of water where depth is unknown. Loss of powe will occur if the drive belt becomes submerged or wet. Unnecessary crossing of streams an

rodes shore line and damages water-born habitat. If

e you must cross, do it at a point where banks are not steep and proceed at a slow and steady speed.

* Front bumper and brush guards are not

usher bars. Do not attempt to push other vehicles or

p implements or damage may result.

When refueling use an (UL) approved non-metallic

* container that has no screen or filter. Se

n the ground before fueling to eliminate static

o discharge and do not use Methanol fuel.

* Do not smoke or use e

hones while refueling.

p * Always maintain proper tire inflation.

engage the foot brake and back slowly

avel.

lectrical devices including cell

ay occur.

free wheel in neutral or

d waterways

nd tractive

designed as

t the container

ing

control.

Page 9

* Always disconnect the negative battery terminal befo making a

elding on this vehicle.

w * Battery fumes are explosive. A spark will ignite battery

fumes. Wear a face shield when charging or jump battery. Follow all battery safety rules outline

anual.

m * Avoid battery acid spills. Do not get battery acid on

eyes, face, or other body parts. Flush eyes and other body parts immediately with water for

inutes if battery acid has gotten on them.

m * Always check wheel lug nut torque values two hours

fter initial operation and two hours after each tire repair

a and/or replacement. Routinely check lug nut torqu valves every 100 hours of operation.

* Support this vehicle securely before working beneath. Chock the wheels to prevent the vehicle from rolli

* Do not shift transaxle unless this vehicle is fully stopped and the engine is at idle or damage may occur.

Each vehi

y the Dealer. Listed below is an example of the

b checklist that is included w that is to be submitted to Brister’s upon Retail Sale. The Pre-Delivery Certificate and Warranty Registration mu be submitted to Brister’s in order to activate the vehicle warranty.

djustments to the vehicle electrical system or

d in this

at least 15

cle must undergo a Pre-Delivery Inspection

ith the Warranty Registration

ing a

ng.

Pre-Delivery Steps

The dealer is required to complet

efore customer may take possession of the vehicle.

b This information must be filled in and check list checke off or initialed by individuals p

ealership’s name, signatures of individuals filling in the

D form, seller’s signature, custome signing dates are also required.

Below is a list of the information that q

ompleted and checked off. c

ehicle Information

Model No. _______ __ Date ___________

al No. ___________ Seri

Engine Serial No.

e “Pre-Delivery” steps

erforming the checks.

r’s signature, and

is re uired to be

ealer Service and Inspection List

D __

Fully charge battery. Check battery voltage to verify

hat it is fullyt

__ Check fuel valve lever to make sure it is in the correct position.

__ Check tire pressure to make sure front and rear tires have 6 psi.

_ Make sure wheel lug bol_ Newton meters (65ft.lbs).

__ Check engine oil leve 10W30 oil if oil is below the full m *this should be done with seat (a Tray if equipped) removed

_ Che_ specification if needed.

__ Check tie rods for tigh __ Check Choke Control. It should move and return

reely. f

_d_ Step on foot brake to make sure the peda

oes not go to the floor. __ Make sure seats and

to the frame.

_ Make sure all safety decals are in pla_ __ Check headlights to make sure they are working

are properly mounted. __ Inspect air cleaner element. Make certain it is clean

and in place. __ Inspect the fuel tank to make sure it is properly

installed and that there are no leaks. __ Check fuel level to make sure there is at least 1/8 of

a tank of gas prior to performing initial starting operations.

__ Inspect fuel lines to make sure they are properly installed and that there are no leaks.

_ Check steering by exe_ each direction.

__ Check parking brake to ma

old and release.

charged.

ts/nuts are tightened to 90

l at the dipstick. Add SAE

ark on the dipstick.

nd under seat storage

ck engine for correct RPM. Set to factory

tness.

l is firm and

seat belts are properly fastened

ce.

and

cuting a full lock to lock turn in

ke sure it will engage,

Page 10

__ Check throttle control to make sure it moves and returns freely.

__ Check differential oil level at the differential oil plug. Add 30 weight oil if oil is low.

_ Check overall appearance for

_ body and molding damage.

ealer Test Ride List

__ Check engine for starting, accelerating, runni smooth, and idling smoothly.

__ Check steering response. There should be no free play.

__ Check forward, neutral, and reverse shifting

sponse. Also check neutral start response.

re __ Chec

nd disengages.

_ Make sure throttle is responsive and returns freely.

_ __ Make sure the suspen

table.

s __ Make su __Make sure the foot brake has a firm enga

that stopping is straight. __ Make sure there are no abnormal rattles or

vibrations.

k parking brake to make sure it engages, holds,

sion ride is satisfactorily and

re there are no fuel or petroleum leaks.

cleanliness and for

gement and

Dealer Delivery to Customer List

__ Warranty regis __ Owner’s Manual has been delivered to and reviewe

by the customer. __ Engine Manual has been delivered to and reviewed

by the custo __Warranty Policy limits and requirements have been

explained to the c __ Location and functions of vehicle controls have been

explained.

_ Fuel transportation and storage procedures have

_ been explained.

__ Transportation of utility vehicle is limited to 55mph,

hen equipped with top and windshield w

tration form is complete.

mer.

ustomer.

__ Fluid fill and lubrication points have been located and explained to the customer.

__ Information on the safety decals have been reviewed with the customer.

Customer Acceptance List

Customer initials required where accepted as successfully completed.

__ Customer has reviewed and understood warranty policy (ies).

__ Customer has inspected the vehicle and it meets customer satisfaction.

__ Customer understands the importance of following the owner’s manual instructions.

* IMPORTANT NOTICE *

WHEN TRANSPORTING ANY

BRISTER UTILITY VEHICLE

WITH A WINDSHEILD OR COLOR MATCHED

TOP DO NOT EXCEED 55MPH

Brister’s Design & Manufacturing Co. LLC

Toll Free PH: 1-866-646-5278

Fax: 1-866-329-5278

www.bristers.com

Page 11

Section 3 Assembly Instructions

Brister Utility Vehicle Utility Vehicle

Assembly Instructions

Your new Brister Utility Vehicle Utility vehicle should include the f Qty Item

1 #8 black screw (steering cap) 3 ¼” x 1 ¾” Hex head bolts 7 ¼” nylock nuts 4 ¼” x ¾” carriage bolts 4 ¼” flat washers 8 5/16” x 2” socket head bolts 12 5/16” curved washers 10 5/16” nylock nuts 4 5/16” x 2” hex head bolts 2 5/16” center lock nuts

ollowing items to be assembled:

Qty Item

2 5/8” x 4” Hex bolt 2 5/8” nylock nuts 1 set of keys

1 Steering wheel (with cap) 1 Bumper 2 Rear fenders 2 Rear frame stubs 1 Seat back 1 Cage 1 Cargo Bed with tailgate

Page 12

Section 3 Assembly Instructions

Pre-Assembly Instructions

1) wner’s Manual.

Read O

2) Unpack all vehicle a have everything list

3) If y u

Seat / Brushguard Assembly

o have any questions or problems with your Brister's Design & Manufacturing Co. LLC product please call us, 66-646-5278.

1) Place seat back frame on vehicle frame tubes. Insert a 5/16” x 2” socket head bolt through both bottom joints. The head of the bolt should be on the outside of the vehicle. Put a curved washer on the threaded end of the bolt. Place a 5/16” nylock nut on the bolts but do not tighten.

2) Place the cage on front vehicle frame tubes and seat back. Insert a 5/16” x 2” socket head bolt through all four joints. The head of the bolt should be on the outside of the vehicle. Put a curved washer on the threaded end of the bolt. Place a 5/16” nylock nut on the bolts. Tighten all 6 nuts (including step 3).

nd assembly parts. Make sure you

ed on the previous page.

toll free 1-8

Bumper Installation

Steering Wheel Installation

1) Align the holes in the front bumper with the mounting holes in the front frame tubes. Insert the four 5/16” x 2” bolts through the bumper bracket and then into the frame tubes. Put a curved washer on the threaded end of the bolt. Place a 5/16” nylock nut on the bolts and tighten.

1) Remove the plastic steering column cover by removing the 3 screws on the bottom with a 5/16” socket. If equipped with top and bottom steering column covers

2) Turn vehicle steering so that it is pointed straight forward. Line up holes in steering wheel with mounting holes so that the center spoke is pointing down. Install ¼” x 1 ¾” hex head bolts from the back. Tighten with ¼” nylock nuts.

3) Install steering cap with #8 black screw.

4) Re-install steering column cover.

Page 13

Cargo Bed Installation

1) Locate rear frame stubs at the rear of frame. The bed pivot tube on the stub should be at the top. Insert 5/16” x 2” socket head bolt. Loosely install 5/16” center lock nut (do not tighten until after cargo bed is installed)

2) Place the cargo bed on the vehicle and insert a 5/8” x 4” hex head bolt through each pivot bracket and frame stub tube.

3) Tighten both 5/16” frame stub bolts and nuts.

4) Install the 5/8” nylock nuts on the pivot bolts. Tighten the pivots and then loosen ¼ turn.

5) Loosen the bed latch pin bolt on the frame just enough for it to slide in the adjustment slot. (shown in upper right photo)

6) Close the bed and position the latch pin bolt so that it is at the bottom of the latch slot prevent rattles. Tighten the latch pin.

7) Fenders installation (if Equipped, no fenders on TW265) Tilt the cargo bed up. Line up the holes in the rear fenders with the square holes in the bed. The raised rectangular surface on the fender should be completely hidden under the bed. If not, turn the fender around. Insert a ¼” x ¾” carriage bolt through the bed and into the fender. Fasten with a ¼” flat washer and a ¼” nylock.

Sea a

t B se Installation

1) Pl ed to seat base under front seat

ace tabs attach frame bar (if equipped into slots in plastic tray), fold seat base into position. (if equipped The rear tabs sh

ould fall into the slots in the rear of the plastic

tray)

Page 14

Sec oti n 4 Operating Instructions

General Operation

Start your Brister Utility Vehicle by following the starting procedures as noted below.

1. Depress brake pedal with your foot and hold. Pull firmly up on the park brake lever with your hand until the lever is tight.

2. Place gearshift in neutral

3. Apply choke fully when engine is cold.

Turn ignition key fully clockwise and hold to stop engine.

5. Release ignition key to run position and chok

engine starts.

Driving is as transmission. A simple forward and reverse shifter provides direction control.

Just turn the key and the 12 volt electric starter provides safe and easy starting. There is a manual choke control below the seat for quick cold weather starting. A back-up pull-rope s

the battery down. The drive system means there i into either forward or reverse when the stopped and press the throttle pedal to while the vehicle is moving.

pedal that is located on the floorboard left of the accelerator. A lever action parking brake control is mounted o operator and passenger seats. Depress the button on the park brake control lever to release the park brake.

to normal operating position immediately after

6 Turn ignition key counterclockwise to stop

engine.

easy as driving a car with an automatic

tarter mechanism is provided on the engine

st in case y ju

ing is accomplished by simply depressing the brake

rakB

ou accidentally leave the key on and run

n the center console located between the

infinitely variable torque converter

s no clutching. You just shift

vehicle is

go. Never shift

Pre-Start Check List __

Check tire pressure as indicated.

__ Make sure wheel lug bolts/nuts are tightened to 65ft.

_ All nuts, bolts, screws, and fasteners should be

cked.

che

_ Turn on headlights to make sure battery has a charge

nd electrical lighting circuit is working.

_ Check tail lights and brake lights. (if applicable)

_ Check park brake to make sure it will engage, hold

nd release.

_ Check steering by executing a full lock to lock turn in

_ each direction.

__ Check engine oil level at the dipstick. Add oil as indicated.

_ Check differential oil level at the differential oil plug._

Add gear lube as indicated. __ Check fuel valve lever position. Valve lever

ff except when running the engine. o

__ Check fuel level to make sure there is at least 1/8 of a tank of gas prior to performing initial starting operations.

should be

Page 15

Section 5 Maintenance

Fuel Type

The fuel tank is located under seat. TW11, TW 413, CW11, CW413 Fuel Capacity

W-265 & TW265 Fuel capacity is 6.1 Liters

hen filling the fuel tank, place the gear shift in forward

W or reverse, set the park b

move ignition key. Clean dirt from around the fuel tank

re cap, remove cap, and begin filling. When f

e cap back on securely and wipe up any spilled

th gasoline. Use regular unle

ting of 87 or higher.

IMPORTANT:

containing methanol, or gasohol containing more than 10% ethanol because the damaged. Do NOT mix oil with gasoline.

Using a fuel stabilizer/conditioner in the vehicle can provide benefits such as:

* Keeps gasoline fresh during storage of 90 days or less. For longer storage, drain the fuel tank. * Cleans the engine during operation. * Eliminates gum-like

dd the correct amount of gas stabilizer/conditioner to

A the gas. Follow the gas stabilizer/conditioner manufacturer’ st results.

See engine o ual for the following: * Draining the

Checkin* Engine fuel valve lever.

g fuel line for cracks and leaks.

Never use metha

s directions for be

perator’s man

fuel tank.

rake, turn off the engine, and

aded gasoline with an octane

nol, gasoline

fuel system could be

varnish build-up in the fuel system.

is 5 Gal.

inished, screw

Engine Maintenance

General Information

Detailed instructions and recommendations for break-in and regular maintenance are specified in the engine operator’s manual. Engine warranty is backed by the engine manufacturer. Please refer to engine manufacturer’s manual for engine servicing, lubricating oil levels, oil quality and viscosity recommendations, bolt

orques, etc. Specialt

pplicable data that is not duplicated here.

attention should be paid to

Engine Fuel Valve Lever

fer to Figure 5-1

Re The engine fuel valve opens and

tween the fuel tank and carburetor. Leave fuel valve

be lever in the OFF position when the engine is not i to prevent carburetor flooding and reduce possibility of fuel leakage into the cylinder cavity and engine oil reservoir. Turn fuel valve lever to the ON position when running the engine.

closes the passage

n use

FUEL VALVE

Figure 5-1

Page 16

Section 5 Maintenance

Foam element –

detergent in warm water or in a nonflammable solvent. Do not wring element. Squeeze excess cleaning fluids out. Allow time for the element to dry and then soak it

ith clean engine oil. Squeeze excess oil out. Excess oil

ft in the filter will cause engine to smoke briefly when

rst started.

efore installing the filter elements to make sure they

B have not be engine without the filters installed.

Figure 5-2

en damaged during cleaning. Never run an

Clean foam element with

Spark Plugs HONDA

NGK BPR6ES CHAMPION RN9YC

UTOLITE 4263 / 63

A DENSO W20EPR-U

UBARU

NGK BR6HS

HAMPION C

RLH6C

Air Filter Elements Replacement Parts

Description Part No. Honda

Paper Filter Element 17210-ZE3-000

Honda

Foam Filter Element 17210-ZE3 Refer to Figure 5-2

Subaru Paper & Foam Element (265cc) 279-32607-07

Fuel Hose –

leaks or other dama

amage is suspected.

Inspect fuel hos

ge. Replace immediately if any

e monthly for cracks,

-010

Page 17

Section 5 Maintenance

Engine Oil

A general description for engine oil maintenance, recommendations, and capacities is provided below See Eng. ine Operator’s Manual for a detailed description.

Note:

eng

Running engine low on oil can cause

ine damage and void engine warranty.

Note:

Overf

power, engine damage and void engine warranty.

Engin

Ref

REMOV EAS

* Filler c * Drain plug location: At rear end of engine

S * * Subaru Engine Oil Capacity: 1.1 US qts. / 1.0 liters * Quantity: Fill oil to outer edge of oil fill hole.

e Oil Fill and Drain Locations

er to Figure 5-4

Y ACCESS

Type of Lubrication: SAE 30, with API classification*

J, SL or Equivalent Honda Engine Oil Capacity: 1.16 US qts. /1.1 liters

illing of oil level can cause loss of

E SEAT (and plastic tray if equipped) FOR

ap/dipstick location: At front end of engine

Engine Oil Maintenance Schedule

* Check oil level after each use. * Make first oil change after the first month of operation

or at 20 hours of operation (whichever comes first). * Make all subsequent oil changes every 6 months or every 100 hours of operation (whichever comes first).

Engine Oil Level Check

Refer to Figure 5-4 Check engine oil daily with filler cap/dipstick located at

the engine rear end as follows:

1. Park Vehicle on a level surface, set park brake, turn off ignition switch, and remove switch key.

2. Remove filler cap/dipstick and wipe it clean.

3. Insert and remove dipstick without screwing it into the fill neck. Check oil level shown on dipstick.

4. Fill to edge of oil fill hole with recommended oil when oil levels are low.

5. Replace filler cap/dipstick and tighten secure

ly.

Engine Oil Change

Warms oil drains quickly and completely. T

rain used engine oil while engine is still warm as

llows:

1. Park vehicle turn off ignition switch, and remove switch key.

2. Place a suitable container below engine to ca used oil. Remove filler cap/dipstick and drain plug.

3. Allow used oil to drain completely reinstall and tighten drain plug securely.

4. Dispose of used motor oil in a manner th compatible with the environment. Do not throw used oil in the trash. Do not pour it on the ground, or down a drain.

5. Fill oil to the outer edge of the oil fill hole with recommended oil. Engine must be level when filling.

6. Replace filler cap/dipstick and tighten securely.

NOTE: TO DRAIN OIL REMOVE REAR OIL DRAIN PLUG

herefore,

on a level surface, set park brake,

and then

at is

Engine Oil Drain, Fill & Check Locations

Figure 5-4

tch

Page 18

Section 5 Maintenance

Transaxle Oil

A general description for transaxle oil maintenance, recomm

NOTE:

damage transaxle a

Transaxle

Ref * Fil p

* Dr * Ty o * Transa

Transa

* Ch leakage

* Check l every 6 months or every 200 hou w

This ccomplished by Parking vehicle on a level surf ce, set park brake, turn off ignition switch, and remove switch key, using a clean long bladed screw driv r hole until it touch e the screw driver.

il visibo

* (w

endations, and capacities is provided below.

Running vehicle low on transa

nd void warranty.

xle oil can

Oil Type, Fill, and Drain

er to Figure 5-5

l ca location: At rear left hand side (See arrow) ain plug location: At bottom center of transaxle. pe f Lubrication: SAE 30W oil.

xle Lubrication Capacity: 20 oz.

xle Oil Maintenance Schedule

eck transaxle housing for damage and possible oil

after each use. transaxle oil leve

rs ( hichever comes first).

can be a

er (or similar object) insert into fille

es the bottom of gear case. Remov

There should be approximately 2.1/4” to 2.1/2” of

le on screw driver. Refer to Figure 5-5A

Change transaxle oil once a year or every 600 hours

hichever comes first).

Figure 5-5A

Transaxle Oil Change

Refer to Figure 5-5B Warm oil drains quickly and completely. Therefore, drain used transaxle oil while transaxle housing is still warm as follows:

. Park vehicle on a level surface, set park brake,

turn off ignition switch, and remove switch key.

. Place a suitable container below the transfer

case to catch used oil. Remove fill cap and drain plug.

. Allow used oil to drain completely and then

reinstall drain plug and tighten it securely.

4. Dispose of used that is compatible with the environ throw used oil in the trash, pour it on the ground, or down a drain.

5. Fill transaxle housing with 20 oz. SAE 30W oil.

6. Replace fill cap and tighten securely.

Figure 5-5B

transaxle case oil in a manner

ment. Do not

Page 19

Section 5 Maintenance

Drive Belt

The dive belt is considered a wearable item. Replacement intervals depend on vehicle use and environment. If your belt is slipping you may need to replace it.

1. P brake,

ark vehicle on a level surface, set park place shifter in Neutral, turn off ignition switch, and remove switch key.

2. Remove the upper belt covers. (It is not necessary to remove the bot

3. “Walk” the belt off of the rear pulley as sh Figure 5-6.

tom cover.

own in

4. Install the new belt on the front pulley first and “walk” it onto the rear pulley.

5. Reinstall the belt guards. Figure 5-7.

Attention: Failure to reinstall the belt gua void your warranty.

rds may

Figure 5-6

Figure 5-7

Page 20

Section 6 Troubleshooting

Fuel in the Cylinder Cavity

In the event that the fuel valve is left open while tran o ter Utility Vehicle it is

sp rting or towing this Bris

pos e cylinder

sible that fuel has leaked down into th

cav l not start. With

I lity. f this has occurred the engine wi the in will feel like it has “l per steps to follow if

ocked pro up”. Below are the your Brister ine seems to have fuel in the cylinde

Utility Vehicle eng

r cavity.

gine cyl der cavity full of fuel the en

Use EXTREME CAUTION when performing the activity below.

Gasoline is EXTREMELY FLAMABLE!

1. Move the vehicle to a well ventilated area, awa from sparks or flame.

2. Pa

3. Next, remove the wire connected to the spar

4. WARNING: Stand away from the spark plug

6. epeat step 3 until only air escapes out of the

7. roperly replace the spark plug back into the

8. Connect the plug wire. Your Brister Utility

rk Vehicle on a level surface, set park brake,

turn off ignition switch, and remove switch key.

k plug. And remove the spark plug from the engine. (See Figure 6-1) (Spark Plug Wren supplied with Operator’s Manual)

hole when performing step 5. Fuel can sp several feet. Wearing eye protection, slowly pull the recoil start grip handle (See Figure 6-2) in an upward motion. This should force the fuel out of the cylinder cavity through the spark plug hole.

aution: This gasoline spraying out of the

ylinder cavity is very flammable, use extreme

aution and make sure there are no sparks or

ames nearby.

fl R

park plug hole.

s P cylinde s allow for it to evaporate before continuing.

Vehicle is now ready to start.

r head, move the vehicle away from any

pilled fuel. If there is fuel on the vehicle itself,

ray

www.bristers.com

Figure 6-1

Figure 6-2

Page 21

Supp

lement:

Brister 4x4 Utility Vehicle

CW-413, T

This tional features,

supplement covers the addi

ope e Brister Utility Vehicle

ration and maintenance of th

4x4

atures

• 13 hp, 390cc Honda engin e

• Electric 4x4 selection

• Auto-Locking front differential

• Manual locking rear differential

• 4 wheel hydraulic brakes

o Front disk o Rear drum

• Long travel strut front suspension

peration of Four Wheel Drive

eatures

he rear axle is equipped with a manually operated

T differential lo

ifferential lever to the left and down. Locking the

ifferential sends equal power to both rear wheels for

etter traction. It may be used in both 2WD and 4WD

odes.

ote: Locking the differential on paved or hard

urfaces may increase steering effort and tire wear.

s To switch to four wheel drive, the front wheels are

engaged simply by flipping the dashboard switch to 4WD. In 4WD mode power is automatically sent to the front wheels when the rear wheels lose traction.

Because the power transfer is automatic, you may operate the vehicle in 4WD mode continuously without affecting steering effort or tire wear.

ck. It is engaged (locked) by moving the

Warning: Bring engine to an idle before selecting 4WD mode. Sudden engagement of 4X4 switch under power may damage drive train. Failure to do so may void warranty.

W-413

Maint

Hyd

pressur Bef d

level in the reservoir. The reservoir is located under the hood behi the MAX line with DO

If you notice that the brake pedal feels spongy or the vehicle is not stopping well, take the vehicle to a qualified service center.

Front Differential Gear Box – It is recommended that the oil be changed once every 2000 miles (about 150 to 200 hours). To change the oil, follow each step on the procedure listed below.

enance

raulic Brakes – Hydraulic Brakes use fluid

e to transfer the braking force to the wheels.

ore riving the vehicle each day, check the fluid

nd the front differential gear box. Fill to

T 3 brake fluid.

Gear Box Oil fill

1. Remove the oil drain pl bottom of the gear case using a 7/16” socket.

2. Let all the oil drain out of the unit. Catch and discard the oil properly.

3. Be sure to clean off any debris on the drain plug and reinst

all using a new nylon washer

ug located on the

Page 22

(part #20843). Torque the oil drain plug to 9 ft*lbs. Remove

4. wrench.

5. Add 150 ml. (5 oz.) of Mobil fluid 424 Brister’s part # 20848 (note: do not use any

other type of oil in this system or the 4WD will not

6. Reasse and torque to 10 ft*lbs.

Gear Spacing adjustment

1. Locate set screw on front gear box.

the oil fill plug using a 5/16” hex key

operate properly!)

mble the oil fill plug into the gearcase

1. Remove the oil drain plug located on the bottom of the gearcase using a ¼” hex key

nch.

wre

2. Let all the oil drain o discard the oil properly.

3. Be sure to clean off any debris on the dr plug and reinstall. Torque oil drain plug to 10 ft*lbs.

4. Remove the oil fill plug using a ¼” hex key wrench.

5. Add 200 ml. (7 oz.) of 80W90 gear oil.

6. Reassemble the and torque to 10

ut of the unit. Catch and

ain

oil fill plug into the gearcase

ft*lbs.

2. Turn clockwise until you feel re

3. Turn back counter clockwise ¼ turn.

Rear Tr

the oil b page 18

ansaxle Gear Box – It is recommended that e changed once a year or after 600 hours. See of owner’s manual.

Gear Spacing Adjusting Screw

sistance.

Transfer Gear Box Oil fill

Strut ball joint lube – It is recommended that the

lower strut ball joint be lubricated every 3 months or after driving in water, mud or dusty conditions. The

t. grease fitting is located on the back side of the stru

(see photo)

Grease fitting

90˚

Transfer Gear Box – It is recommended that the

oil be ch

anged once a year or after 600 hours.

Page 23

Brister’s Utility Vehicle

Shifter Trouble Shooting

Notice: Always check transmission oil level. Dip a clean screwdriver straight down in the fill hole

to t

he bottom of the gear case. There should be about 2 ½ inches of oil on the screw diver. If oil

nee

ds to be added, use SAE 30 motor oil. See Page 19 for Instructions

• Engine will not turn over when key is turned to start. – This vehicle is equipped with a safe switch that only allows starting in neutral.

Go to Neutral switch diagnostic procedure.

Gears grind when going into a gear or vehicle stays in gear when shifted to neutral. –

•

Cables need to be lubricated or adjusted.

Go to Cable adjustment procedure.

Neutral switch diagnostic procedure

If starter does not engage when shift lever is in neutral:

1. Apply the parking brake.

2. Turn and hold the key to start. – “Jiggle” the shift lever in the neutral slot. If the starter engages, release the key and call Brandon at Brister’s Customer service to order a neutral switch shim kit.

3. If the starter did not engage in step 2, turn and hold the key to start – slowly move the shift lever from neutral to reverse – if the starter engages, release the key. Repeat, moving the shift lever from neutral to forward.

• If the starter did engage, go to Cable adjustment procedure section.

• If the starter did not engage call Customer Service at 1-866-646-5278.

Cable adjustment procedure

tiff or sticking cables can cause the vehicle to not shift properly and it may affect starting since the

ehicle must go to neutral to start. Before attempting to adjust the cables there are several steps

at can be taken to insure the cables are operating properly.

• Lubricate the cables. Behind the dash board there are two cables attached to the gear selector lever. Slide the rubber dust caps up the cable. Drip or spray a penetrating oil into the cable housing while working the lever. Do housing. Test the vehicle. If this did not help move t

• Remove the center console (with cup holders). Find the shifter cables and cut the plastic ties that fasten them to the fr Replace cable ties but leave them loose so that the cable can move vehicle. If it is still not performing correctly, move to the adjustmen

ame tube. Over tight cable ties can cause the cable to bind.

this several times as the oil soaks into the

o the next step.

in them. Test the

t procedures that follow.

Page 24

Veh

icles with serial number less than 17063.

(See brass tag near top of left rear shock absorber)

1. n the cable adjusters behind the dash board. (photo on left)

Loose

2. Place the selector lever on the dashboard in forward.

3. Make sure the transmission is fully engaged in forward. The top of the shift lever on the transmission should be toward the passenger side. You may have to roll the rear wheels a little until it clicks in.

. Pull the slack out of the forward most cable under the dash (but do not stretch the spring)

and tighten the adjuster nuts.

5. Place the selector lever on the dashboard in reverse.

6. Make sure the transmission is fully engaged in reverse. The top of the shift lever on the transmission should be toward the passenger side. You may have to roll the rear wheels a little until it clicks in.

7. Pull the slack out of the rear most cable under the dash (but do not stretch the spring) and tighten the adjuster nuts.

If you have tried all of this and it is still not operating correctly, you may need new cables and a shifter update kit. Please call Brister’s Customer Service at 1-866-646-5278. Have your serial number handy when you call.

Page 25

Vehicles with serial number greater than 17063.

(See brass tag near top of left rear shock absor eb r)

1. Put the vehicle in neutral.

2. Loosen the cable adjusters behind the dash board. (photo on left)

3. Make sure the selector lever on the dashboard is in neutral.

4. Make sure the transmission is in neutral. You can check by turning the key to Start. The engine will only turn over if the transmission is in neutral.

5. Pull the slack out of both cables (but do not stretch the springs) and tighten the adjuster nuts.

If you have tried all of this and it is still not operating correctly, you may need new cables. Please call Brister’s Customer Service at 1-866-646-5278. Have your serial number handy when you call.

Page 26

Section 6 Troubleshooting

Page 27

Tro b

u le Shooting

Steerin y/pulling to one side/hard to steer (Call normally for 4wd)

Eng

Engine will not start and does not turn over with electric starter. Probable Cause

g feels funn

Pro b

ba le Cause:

•

One side may still be engaged in 4wd with the switch off.

Possible Remedy:

• Put unit in reverse and back up

• If this does not work take

ine Shuts down when turning or on inclines or uneven terrain-

Pro b

ba le Cause:

• Oil is low or Honda oil sensor is bad

Possible Remedy

• Check oil le

to not alert the low

• Honda Low oil alert sensor may be bad and

ngine will not start but does turn over with electric starter.

Probable Cause

• Fuel valve may be off, spark plug may be fouled (excessive idling or running unit with choke engaged can

cause plugs to foul), or engine oil may be low.

Possible Remedy

• Make sure fuel valve is on.

• Replace spark plug and try to restart.

• Check oil level with unit on level ground-Adding more oil or making sure the oil is completely full can help

to not alert the low oil sensor.

• Shifter is not in neutral, battery may be low or smission may be unplugged or

bad, key switch or its connections connectors m e unplugged or bad, electric starter may be bad.

Possible Solutions

Shifter must be in neutral

•

• Turn key to on position and use recoil start

• If this works recharge or replace the battery

• Check neutral switch on transmission to make s ged in.

• Check all connectio ns to key switch (switch may be unplugged behind fire wall).

• Key switch may be bad-switch must be changed out with new one

• Have authorized Honda Service Center check the electric starter

vel with unit on level ground-Adding more oil or making sure the oil is completely full can help

oil sensor.

straight

the unit to a service center.

a few feet to get the axle to release.

must be replaced by authorized Honda service center.

bad, neutral switch on tran

ay b

ure it is plug

Page 28

Gas in oil

Probable Cause

• Unit may have been transported with fuel valve on. Every time a unit is transported on a trailer or in a truck

the fuel must be shut off using the shut off valv e side of the engine. Leaving this valve open during transport could allow fuel to be deposited into the crank case locking the engine up.

Possible Solution

• Oil in engine must be drained completely and ch nged with fresh oil

• Run unit and check oil again –if no gas is found in oil-unit is ready.

Brakes don’t work well / Hard to push / no travel in pedal Probable Cause

• The brake rotors are dirty.

Possible Solution

4x4 units

• Clean the rotors with brake cleaner and test.

• A stiff pedal is normal for our 4x4 unit-

• A stiff pedal means good pressure in the brake lines

• Check brake pads and front calipers

2wd units

• The 2wd units have an automatic brake adjuste Put the unit in reverse, back up at low speed, and step

If you continue to have problems, discontinue use and take it directly to an authorized service center

Belt slipping/will not pull up hill

Probable Cause

• Too much weight (h

• The belt is wet

• The torque converter pulleys are dirty.

• Belt may have stretched or have a low spot causing slipping-replace belt

Possible Solution

• Lighten the load.

• Clean the torque converter and dry the belt

• Replace the belt

hard on the brakes. This should give enough br e adjustment.

auling/towing excessive weight can cause belt to slip).

e on th

Page 29

Wiring Diagram

All Mod

els

Page 30

Terminal Block Wiring

Page 31

Section 7 Parts

Brister’s

2-wheel drive

Utility Vehicle

Parts

Breakdown

Page 32

Page 33

Page 34

Page 35

Reference

Number

1 45419 Frame, CW11 1 2 45401 Rear frame stub, CW - black 2

50168 5/16 x 2-1/4" USS Socket Head bolt 2

50007 nut, 5/16 nylock 2

50702 bent washer 5/16 2

3 45413 bumper, CW - black 1

45432 Bumper, Trail Wagon – Black 1 50167 bolt, 5/16 x 2 4 50007 nut, 5/16 nylock 4 50702 bent washer 5/16 4 70208 Vinyl Caps 1 3/4 x 1 1/2 2

4 45412 Brush Guard roof, CW – black 1

50168 5/16 x 2-1/4” USS Socket Head bolt 4 50007 nut, 5/16 nylock 4 50702 bent washer 5/16 4

5 45411 brshgrd seat back, CW – black 1

50168 5/16 x 2-1/4” USS Socket Head bolt 2 50007 nut, 5/16 nylock 2 50702 bent washer 5/16 2

6 45404 A-arm upper, CW – black (left or right) 2

51100 suspension bu shings 4 ea 50262 bolt, 5/8 x 9” 1 ea 50254 Bolt, 5/8 x 3.5 bolt 1 ea 50015 Nut, 5/8 nylock 2 ea

7 45405 A-arm Lower, CW – black (left or right) 2

51100 suspension bu shings 4 ea 50262 bolt, 5/8 x 9” 1 ea 50254 Bolt, 5/8 x 3.5 bolt 1 ea 50015 Nut, 5/8 nylock 2 ea

8 45408 spindle mount, CW – black 2 9a 45406 Spindle, cw left – black 1 9b 45407 Spindle, cw right – black 1

51100 suspension bu shings 2 ea 50262 bolt, 5/8 x 9” 1 ea 50015 Nut, 5/8 nylock 1 ea

10 ete with Bearings & Seals 30604 Hub, 4 bolt high speed 1” Compl 2

11205 bearing, 1” tapered 30620 seal 30622 castle nut, 1” 30621 cotter pin 30623 ust cap d

Part

Number

Part Description - 2WD Models

Quantity

Required

Page 36

Reference

Number

50060 Lug nuts, ½”

11 70301 Shock, Heavy duty #1 6

50400 Bolt, 10 mm x 40mm 12

50065 Nut, 10mm nylock 12 15L 30122 Rim/Tire Assembly, UTV 22/9-10” Left 1 15R 2/9-10” Right 30123 Rim/Tire Assembly, UTV 2 1

30480 Wheel rim, 10” x 6”

30195 Tire, Pathfinder 22/9-10” 17L TV 22/11-10” Left 30124 Rim/Tire Assembly, U 1 17R 10” Right 30125 Rim/Tire Assembly, UTV 22/11- 1

30480 Wheel rim, 10” x 6”

30194 Tire, Pathfinder 22/11-10”

20 10521 Rack & pinion with rod ends 1

10593 Rack & Pinion Boots 2

10590 Rack & Pinion Rod 2 50171 Bolt, 5/16 x 3 ¾” USS 4 50005 Nut, 5/16 keps 4 50063 Nut, ½” SAE nylock 2

2 1 10524 Rod end 2

50078 Nut, ½” SAE jam 2

22 10522 Steering Shaft w/u-joints 1

50402 Bolt, 10mm x 30mm 1 50066 Nut, 10mm Tri Lock Jam 1 50403 Bolt, 8mm x 30mm 1 50780 Lock washer, 8mm 1

23 ck 45422 Steering Stub Shaft Assembly, CW – Bla 1 24 45400 Steering support, CW – black 1

51100 suspension bu shings 2 ea 50152 bolt, 5/16 x 1 4 50005 Nut, 5/16 keps 4

25 10502 Steering Wheel 13” 1

Center cap screw, black center cap 50081 bolt, ¼ x 1 ¾ 3 50001 nut, ¼ nylock 3

30 ck 45402 Pedal assembly, CW – bla 1

50152 bolt, 5/16 x 1 6 50081 bolt, ¼ x 1 ¾” 1 50159 olt, 5/16 x 1 ½ b 1 50005 Nut, 5/16 keps 8 50701 asher, 5/16 flat W 2

Part

Number

Part Description – 2WD Models

Quantity

Required

Page 37

Reference

Number

31 11180 Brake Rod, with clevis 1

50215 bolt, 3/8 x 1 ¼ 1 50010 nut, 3/8” nylock 1 50801 cotter pin 1/8” x 1 1

32 r, CW – black 45417 parking brake ba 1

50806 Clevis, 5/16 rod end 1 50170 Bolt, 5/16”-24 X 4” SAE 1 50077 Nut, 5/16” Hex SAE 1 50087 olt, ¼” x 1 b 1 50001 nut, ¼” nylock 1

3 3 11127 Parking Brake 1

50086 Bolt, ¼ x 1 ¼ 1 50001 nut, ¼” nylock 1 50163 bolt, 5/16 x ¾” NC 4 50005 Nut, 5/16 keps 4 50701 Washer, 5/16 flat 4

36 45415 Brake equalizer, CW (2 ½”) – black 1

50215 bolt, 3/8 x 1 ¼ 2 50010 nut, 3/8” ny-lock 2

37 embly, black (built after 2-1-05) 11085 Shifter control ass 1

11083 Knob 1 11082 Cable, shifter (built after 2-1-05) 2 11080 Shifter Cable and Shifter Control (built before 2-1-05) 1 50053 nut, #10-24 Keps nut 2 50616 screw, #10-24 X ¾” Pan Head Phillips 2 50770 Washer, #10 flat 2

38 l assembly with cable and knob 11086 Differential Contro 1

11083 Knob

11090 Differential Control Handle – 1 11091 cable, diff lock 50053 nut, #10-24 Keps nut 2 50616 screw, #10-24 X ¾” Pan Head phillips 2 50770 Washer, #10 flat 2

4 0 70012 Wire Harness 1 41 -UTV 12Volt, 240 CCA 70000 Battery, U1L-8250 1

70002 Battery Cable, Red – 17” 1 70010 Battery Cable, Black (24”) 1 70009 Battery Terminal Cover 2 50087 bolt, ¼” x 1 2 50000 nut, ¼” keps 2

Part

Number

Part Description – 2WD Models

Quantity

Required

Page 38

Reference Part

Number umbe

42 45414 Battery strap, CW (8 ¾”) – black 1

50083 bolt, ¼ x 7 ½ 2 50002 nut, ¼” wing 2

4 3 70055 Light Switch 1 4 4 70052 Key Switch 1

70060 Key, 1 pair

4 5 70080 Accessory Plug 1

70081 Accessory Plug cap 1

46 tic 18500 Terminal Block Cover – plas 1

50625 screw, #10-24 X 1” Pan Head Phillips 2 50053 nut, #10-24 Keps nut 2

4 7 70129 Headlights 2 50 18311 Hood, plastic Green 1

18302 Hood, plastic Red

18350 Hood, plastic Camo 50620 ¼” X 1 ¼” Pan Head Phillips Machine screw 2 50621 ¼” X 2” Pan Head Phillips Machine screw 2 50717 ¼” SAE Flat washer 8 50001 nut, ¼” nylock 4 50846 Clamp-Tube-vinyl coated 1-1/4” 2

51 18309 Glove Box 1

50624 Screw, #10 x ¾ hex – black 5

52 18308 Steering Cover 1

18317 Steering Cover Bottom 1 50624 Screw, #10 x ¾ hex – black 1

53 18306 Center Console 1

50624 Screw, #10 x ¾ hex – black 14

54 18316 Access Cover, Center Console 1

50624 Screw, #10 x ¾ hex – black 4

55 18305 Plastic, Seat Bottom wrap 1

50624 Screw, #10 x ¾ hex – black 5

56 18304 Under seat storage box 1 57 18303 Rear Fender 1

50001 nut, ¼ nylock 4 50091 ¼”-20 X ¾” Carriage bolt 4 50717 ¼” SAE Flat washer 4 70150 Reflectors 2

N r

Part Description – 2WD Models

Quantity

Required

Page 39

Reference

Number

58 55060 Fuel Tank 1

55063 Elbow Fuel Inlet w/ #200 Mesh Screen 1

55062 Fuel Fitting Grommet 1

55061 Cap Fuel Tank 1

50163 bolt, 5/16 x 3/4" NC 3

50706 Washer, 5/16 fender 3

50703 Washer, 5/16 lock 3

60 10754 Seatback 43 ½ x 17 ½ 1

50619 #14 X 1-3/4” Pan head-Tapping screw 6

61 10803 Headrest – UTV 9 x 6 ½ 2

50085 bolt, ¼ x 1 ½” 4

62 10755 Seat bottom 43 ½ x 17 ½ 1 63 45416 seat bar, CW (17 ½”) – black 2

50609 #14 x ¾ Pan Head Screw 6

65 10705 Seat Belt, 2pt 2

50025 7/16 Nylock 4

70 45426 Cargo Bed, Green 1

45420 Cargo Bed, Red 1

45424 Cargo Bed, Black 1

18352 Camo Bed Panel Left 1

18353 Camo Bed Panel Right 1

18354 Camo Bed Panel Tail Gate 1 50255 5/8 x 4” bolt Zinc plate 2 50015 5/8 nylock 2

18402 Bed Rubber Plug 2

73 50208 Bed latch bolt, 3/8 x 2 1/2" 1

50013 nut, 3/8 keps 2 50740 washer, 3/8 flat 2

75 45427 Tail gate, green 1

45421 Tail gate, Red 1

45425 Tail gate, Black 1 50152 bolt, 5/16 x 1 2 50701 washer, 5/16 sae 4 50007 nut, 5/16 nylock 2 70230 rubber bump stops 4

78 50815 1/4" Lynch Pin - tailgate latch 2

Part

Number

Part Description – 2WD Models

Quantity

Required

Page 40

Reference

Number

80 18312 Roof, green 1

18301 Roof, Red 1

18351 Roof, Camo 1

18391 Roof, Top Vinyl Trim 1 18390 Roof, Hardware bolt kit

50847 Clamp-Tube-vinyl coated 1-3/4" 4 50087 bolt, 1/4" x 1 4 50718 Washer, ¼” rubber domed 4

50001 nut, 1/4" nylock 4

85 18400 Windshield - clear

18401 Windshield - tinted 18403 astener kit, windshield F

88 40723 Front receiver hitch kit

101 20010 Engine, Honda 11hp 1

- 50202 3/8-16 x 1 3/4" Hex Hd Bolt 4

- 50740 3/8" Flat washer, USS 4

102 20833 ana Transaxle D 1

70057 Neutral Safety Switch 1

51500 Shims – Neutral Safety Switch

103 45423 Swing arm, CW - Black 1 104 45430 Motor Plate, CW - Black 1 105 18023 Throttle Guard Laser 1

- 50086 1/4-20 x 1 1/4" Hex Hd Bolt 3

- 50082 1/4-20 x 2 1/4" Hex Hd Bolt 1

- 50000 /4" Keps Nut 1 5

- 50715 1/4" Flatwasher, USS 8

107 20648 TC, Driver Comet 500 – used before Serial Number # 25658 1

20665 TC, Driver CVTECH – used fter Serial Number # 25658 1 a

108 20649 TC, Driven Comet 500 – us efore Serial Number # 25658 1 ed b

20666 TC, Driven CVTECH – used fter Serial Number # 25658 1 a

109 11166 Brake Shoes - Rear UTV – Dana 2 110 50745 1" I.D. Spacer Washer – Comet only (not used with CVTech pulley) 4 111 - 1/4" Key stock 1 112 - 3/8" I.D. Fender Washer – Comet only (not used with CVTech pulley) 1 113 50741 3/8" Lock Washer – Comet only (not used with CVTech pulley) 1 114 50219 3/8x 3" Bolt Hex Hd NF – Comet only (not used with CVTech pulley) 1 115 20693 Belt, Comet 300668 - used before Serial Number # 25658 1

20694 Belt, CV TECH – used after Serial Number # 25658 1

116 50239 1/2 x 2" SAE 1

Part

Number

Part Description - 2WD Models

Quantity

Required

Page 41

Reference

Number

117 50722 1/2" Lock Washer 1

50721 1/2" Uss Flat Washer 1

118 - Key stock – Special Key – 3/16” X 1/4” X 31/2” 1 119 45431 Tension Mount Engine, CW - Black 1

- 50157 5/16x 3/4" Bolt Hex Hd NF 2

- 50703 5/16" Lock Washer 2

- 50704 5/16" Flatwasher 2

120 70250 Rubber Feet (Isolators) 5

- 50010 3/8 Nylock Nut 10

- 50740 3/8 Flatwasher USS 5

121 10581 Rod End Sphcl-UTV (4681-MPM-12) 3 122 50021 3/4 Jam n 3 ut SAE 123 45403 Panhard b 1 ar, CW - black

124 50206 bolt, 3/8 x 4 1

- 50010 3/8" Nyloc 4 k Nut

- 50740 3/8" Flatwas 4 her, USS

125 50730 3/4' Spacer W 6 asher 126 50280 3/4 x 2.5 SA 3 E bolt 127 500 3 20 3/4 SAE nylock 128 180 1 12 shifter lever, CW - black - used before Serial Number #15244

- 500 1 84 1/4-20 x 3/4" Hex Hd Bolt

- 2 50000 1/4" Keps Nut

129 1 18011 shifter cable mount, CW - black - used after Serial Number #15245

- 1 50084 1/4-20 x 3/4" Hex Hd Bolt

- 1 50000 1/4" Keps Nut

- 2 50715 1/4" Flatwasher, USS

130 11103 Brake Cables 2

- 50150 5/16-18 x 1" Hex Hd Bolt 2

- 50007 5/16" Nylock Nut 2

131 11010 Throttle Cable, UTV 1

- 50087 1/4-20 x 1" Hex Hd Bolt 1

- 50000 1/4" Keps Nut 2

- 11804 Spring #80704 Black painted 1

132 11084 Differential Cable All 2WD models before serial #22187 1

- 50087 1/4-20 x 1" Hex Hd Bolt 1

- 50000 1/4" Keps Nut 2

- 50159 5/16-18 x 1 1/2" Hex Hd Bolt 1

- 50005 5/16" Keps Nut 2

Part

Number

Part Description - 2WD Models

Quantity

Required

Page 42

Reference

Number

132 11086 Differential Control Assembly w/ cable all models after serial # 22187 1

- 11083 Knob 1

- 11091 Differential Control Cable Only used on all models after serial # 22187 1

- 50053 nut, #10-24 Keps nut 2

- 50616 screw, #10-24 X 3/4" Pan Head phillips 2

- 50770 Washer, #10 flat 2

- 50087 1/4-20 x 1" Hex Hd Bolt 1

- 50000 1/4" Keps Nut 2

- 50159 5/16-18 x 1 1/2" Hex Hd Bolt 1

- 50005 5/16" Keps Nut 2

133 11804 Spring #80704 Black painted 1

135 11080 Shifter Cable and Shifter Control - used before Serial Number #15244 1

11082 Cable, shifter - used after Serial Number #15245 2

136 65500 fuel hose 3/16" dia - 24" 1 137 50849 hose clamps - small 3

138 18313 Belt Guard Plastic UTV - Front 1 139 18314 Belt Guard Plastic UTV - Rear 1 140 18315 Belt Guard Plastic UTV - Bottom 1

- 50624 #10 x 3/4" Blunt Point Black 7

- 50050 #10 Speed Nut - for Plastic 7

- 50770 #10 Flat washer 7

141 20011 Choke Bracket Honda Engine 1

Part

Number

Part Description - 2WD Models

Quantity

Required

Page 43

Brister

265cc

Utility Vehicle

Parts Breakdown

Page 44

Page 45

Page 46

Page 47

Reference

Num er N

1 45419 Frame, CW11 1 2 45401 Rear frame stub, CW - black 2

50168 5/16 x 2-1/4" USS Socket Head bolt 2

50007 nut, 5/16 nylock 2 50702 bent washer 5/16 2

3 45413 bumper, CW - black 1

45432 Bumper, Trail Wagon – Black 1 50167 bolt, 5/16 x 2 4 50007 nut, 5/16 nylock 4 50702 bent washer 5/16 4 70208 Vinyl Caps 1 3/4 x 1 1/2 2

4a f, CW265 – black 45412 Brush Guard roo 1 4b TW265 – black 42300 Brush Guard roof,

50168 5/16 x 2-1/4” USS Socket Head bolt 4 50007 nut, 5/16 nylock 4 50702 bent washer 5/16 4

5 45411 brshgrd seat back, CW – black 1

50168 5/16 x 2-1/4” USS Socket Head bolt 2 50007 nut, 5/16 nylock 2 50702 bent washer 5/16 2

6 42045 A-arm upper, 265 – black (left or right) 2

51100 suspension bushings 4 ea 50262 bolt, 5/8 x 9” 1 ea 50254 Bolt, 5/8 x 3.5 bolt 1 ea 50015 Nut, 5/8 nylock 2 ea

7 42046 A-arm Lower, 265 – black (left or right) 2

51100 suspension bushings 4 ea 50262 bolt, 5/8 x 9” 1 ea 50254 Bolt, 5/8 x 3.5 bolt 1 ea 50015 Nut, 5/8 nylock 2 ea

8 45408 pindle mount, CW – black s 2 9a 45406 Spindle, left – black 1 9b 45407 Spindle, right – black 1

51100 suspension bushings 2 ea 50262 bolt, 5/8 x 9” 1 ea 50015 Nut, 5/8 nylock 1 ea

10 30604 Hub, 4 bolt high speed 1” Complete with Bearings & Seals 2

11205 bearing, 1” tapered 30620 seal

Part

umber

Part Description – 265cc 2WD Models

Required b

antity

Page 48

Reference Part

Number umbe

30623 dust cap 30622 castle nut, 1” 30621 cotter pin

50060 Lug nuts, ½”

11 70301 Shock, Heavy duty #1 6

50400 Bolt, 10 mm x 40mm 12

50065 Nut, 10mm nylock 12 15L 30142 Rim/Tire Assembly, UTV 22/11-8” Front Left 1 15R TV 22/11-8” Front Right 30143 Rim/Tire Assembly, U 1 17L 30144 Rim/Tire Assembly, UTV 22/11-8” Rear Left 1 17R r Right 30145 Rim/Tire Assembly, UTV 22/11-8” Rea 1

20 ends 265 10596 Rack & pinion with rod 1

10593 Rack & Pinion Boots 2

Rack & Pinion Rod - 265 2 50171 Bolt, 5/16 x 3 ¾” USS 4 50005 Nut, 5/16 keps 4 50063 Nut, ½” SAE nylock 2

2 1 10524 Rod end 2

50078 Nut, ½” SAE jam 2

22 10522 Steering Shaft w/u-joints 1

50402 Bolt, 10mm x 30mm 1 50066 Nut, 10mm Tri Lock Jam 1 50403 Bolt, 8mm x 30mm 1 50780 Lock washer, 8mm 1

23 45422 Steering Stub Shaft Assembly, CW – Black 1 24 45400 Steering support, CW – black 1

51100 suspension bushings 2 ea 50152 bolt, 5/16 x 1 4 50005 Nut, 5/16 keps 4

25 10502 Steering Wheel 13” 1

Center cap screw, black center cap 50081 bolt, ¼ x 1 ¾ 3 50001 nut, ¼ nylock 3

30 45402 Pedal assembly, CW – black 1

50152 bolt, 5/16 x 1 6 50081 bolt, ¼ x 1 ¾” 1 50159 bolt, 5/16 x 1 ½ 1 50005 Nut, 5/16 keps 8 50701 Washer, 5/16 flat 2

N r

Part Description – 265cc 2WD Models

Quantity

Required

Page 49

Reference

Number

31 11180 Brake Rod, with clevis 1

50215 bolt, 3/8 x 1 ¼ 1 50010 nut, 3/8” nylock 1 50801 cotter pin 1/8” x 1 1

32 45417 parking brake bar, CW – black 1

50806 Clevis, 5/16 rod end 1 50170 Bolt, 5/16”-24 X 4” SAE 1 50077 Nut, 5/16” Hex SAE 1 50087 bolt, ¼” x 1 1 50001 nut, ¼” nylock 1

33 11127 Parking Brake 1

50086 Bolt, ¼ x 1 ¼ 1 50001 nut, ¼” nylock 1 50163 bolt, 5/16 x ¾” NC 4 50005 Nut, 5/16 keps 4 50701 Washer, 5/16 flat 4

36 CW (2 ½”) – black 45415 Brake equalizer, 1

50215 bolt, 3/8 x 1 ¼ 2 50010 nut, 3/8” ny-lock 2

37 mbly, black (built after 2-1-05) 11085 Shifter control asse 1

11083 Knob 1 11082 Cable, shifter (built after 2-1-05) 2 11080 Shifter Cable and Shifter Control (built before 2-1-05) 1 50053 ut, #10-24 Keps nut n 2 50616 crew, #10-24 X ¾” Pan Head Phillips s 2 50770 Washer, #10 flat 2

40 70053 Wire Harness – 265 1 41 70000 Battery, U1L-8250-UTV 12Volt, 240 CCA 1

70002 Battery Cable, Red – 17” 1 70010 Battery Cable, Black (24”) 1 70009 Battery Terminal Cover 2 50087 bolt, ¼” x 1 2 50000 nut, ¼” keps 2

Part

Number

Part Description – 265cc 2WD Models

Quantity

Required

Page 50

Reference

Number

42 45414 Battery strap, CW (8 ¾”) – black 1

50083 bolt, ¼ x 7 ½ 2 50002 nut, ¼” wing 2

43 70055 Light Switch 1 4 4 70052 Key Switch 1

70060 Key, 1 pair

45 70080 Accessory Plug 1

70081 Accessory Plug cap 1

46 18500 Terminal Block Cover – plastic 1

50625 screw, #10-24 X 1” Pan Head Phillips 2 50053 nut, #10-24 Keps nut 2

47a 70129 Headlights CW265 – oval 2 47b 70133 Headlights TW265 – rectangular 2 50a 18302 Hood, plastic Red CW265 1 50b 18350 Hood, plastic Yellow TW265 1

18387 TW265 grill 1

18389 TW265 headlight bucket - left 1

18388 TW265 headlight bucket - right 1 50620 ¼” X 1 ¼” Pan Head Phillips Machine screw 2 50621 ¼” X 2” Pan Head Phillips Machine screw 2 50717 ¼” SAE Flat washer 8 50001 nut, ¼” nylock 4 50846 Clamp-Tube-vinyl coated 1-1/4” 2

51 18309 Glove Box 1

50624 Screw, #10 x ¾ hex – black 5

52 18308 Steering Cover 1

18317 Steering Cover Bottom 1 50624 Screw, #10 x ¾ hex – black 1

53 18306 Center Console 1

50624 Screw, #10 x ¾ hex – black 14

54 18316 Access Cover, Center Console 1

50624 Screw, #10 x ¾ hex – black 4

55 18305 Plastic, Seat Bottom wrap 1

50624 Screw, #10 x ¾ hex – black 5

57 18303 Rear Fender CW only 1

50001 nut, ¼ nylock 4 50091 ¼”-20 X ¾” Carriage bolt 4 50717 ¼” SAE Flat washer 4 70150 eflectors R 2

Part

Number

Part Description – 265cc 2WD Models

Quantity

Required

Page 51

Reference

Number

60 10754 Seatback 43 ½ x 17 ½ 1

50619 #14 X 1-3/4” Pan head-Tapping screw 6

61 10803 Headrest – UTV 9 x 6 ½ 2

50085 bolt, ¼ x 1 ½” 4

62 10755 Seat bottom 43 ½ x 17 ½ 1 63 45416 seat bar, CW (17 ½”) – black 2

50609 #14 x ¾ Pan Head Screw 6

65 10705 Seat Belt, 2pt 2

50025 7/16 Nylock 4

70a 45420 Cargo Bed, Red CW265 1 70b 45434 Flat Cargo Bed, Black - TW265 1

50255 5/8 x 4” bolt Zinc plate 2 50015 5/8 nylock 2

18402 Bed Rubber Plug 2

73 50208 Bed latch bolt, 3/8 x 2 1/2" 1

50013 ut, 3/8 keps n 2 50740 asher, 3/8 flat w 2

75 45421 Tail gate, Red 1

50152 bolt, 5/16 x 1 2 50701 washer, 5/16 sae 4 50007 nut, 5/16 nylock 2 70230 rubber bump stops 4

78 50815 1/4" Lynch Pin - tailgate latch 2

Part

Number

Part Description – 265cc 2WD Models

Quantity

Required

Page 52

Reference

Number

101 20016 Engine, Subaru 265cc 1

- 50202 3/8-16 x 1 3/4" Hex Hd Bolt 4

- 50740 3/8" Flat washer, USS 4

102 20869 Dana Transaxle – 265 mode 1 ls

70057 Neutral Safety Switch 1

51500 Shims – Neutral Safety Swi tch

103 45423 Swing arm, CW - Black 1 104 45430 Motor Plate, CW - Black 1 107 20667 TC, Driver Comet 40 1 108 20668 TC, Driven Comet 40 1 109 11166 Brake Shoes - Rear UTV – Dana 2 110 50745 1" I.D. Spacer Washer 4

112 50795 7/16" I.D. Fender Washer 1 113 50793 7/16” Lock Washer 1 114 50302 7/16 x 2 ½ SAE Bolt 1

115 20693 Belt, Com 1 et 300668 116 50239 1/2 x 2" SA 1 E

Part

Number

Part Descri n - 265cc 2WD Models

ptio

Quantity

Required

117 50722 1/2" Lock 1 Washer

50721 1/2" Uss F 1 lat Washer

118 1019 1 1 Key stock – 3/16” 119 1806 1 1 Tension Mount Engine, 265 - Black

- 5015 2 7 5/16x 3/4" Bolt Hex Hd NF

- 507 2 03 5/16" Lock Washer

- 507 2 04 5/16" Flatwasher

120 702 5 50 Rubber Feet (Isolators)

- 500 10 10 3/8 Nylock Nut

- 5 50740 3/8 Flatwasher USS

121 3 10581 Rod End Sphcl-UTV (4681-MPM-12) 122 3 50021 3/4 Jam nut SAE 123 1 45403 Panhard bar, CW - black

124 50206 bolt, 3/8 x 1 4

- 50010 3/8" Nylock Nut 4

- 50740 3/8" Flatwasher, USS 4

125 50730 3/4' Spacer Washer 6 126 50280 3/4 x 2.5 SAE bolt 3 127 50020 3/4 SAE nylock 3 128 18011 Shifter cable mount

Page 53

Reference

Number

129 18012 shifter cable lever, 1

- 50084 1/4-20 x 3/4" Hex Hd Bolt 1

- 50000 1/4" Keps Nut 1

- 50715 1/4" Flatwasher, USS 2

130 11103 Brake Cables 2

- 50150 5/16-18 x 1" Hex Hd Bolt 2

- 50007 5/16" Nylock Nut 2

131 11013 Throttle Cable, 265 1

135 11082 Cable, shifter 2

138 18313 Belt Guard Plastic UTV - Fr 1 ont 139 18314 Belt Guard Plastic UTV - Re 1 ar 140 18315 Belt Guard Plastic UTV - Bottom 1

- 50624 #10 x 3/4" Blunt Point Black 7

- 50050 #10 Speed Nut - for Plastic 7

- 50770 #10 Flat washer 7

Part

Number

Part Descri - 265cc 2WD Models

ption

Quantity

Required

Page 54

Brister

4-wheel drive

Utility Vehicle

Parts Breakdown

Page 55

Page 56

Page 57

Page 58

Referenc Num Nu

/16 50702 bent washer 5 2

Part

ber

1 45501 Frame, CW413 - 4x4 1 2 45401 Rear frame stub, CW - black 2

50168 5/16 x 2-1/4" USS Socket Head bolt 2 50007 nut, 5/16 nylock 2

3 45413 Bumper, CW - black 1

45433 Bumper, Trail Wagon – with grill guard - Black 50167 bolt, 5/16 x 2 4 50007 nut, 5/16 nylock 4 50702 bent washer 5/16 4 70208 Vinyl Caps 1 3/4 x 1 1/2 2

4 45412 Brush guard roof, CW - black 1

50168 5/16 x 2-1/4" USS Socket Head bolt 4 50007 nut, 5/16 nylock 4 50702 bent washer 5/16 4

5 45411 Brush guard seat back, CW - black 1

50168 5/16 x 2-1/4" USS Socket Head bolt 2 50007 nut, 5/16 nylock 2 50702 bent washer 5/16 2

6 43007 A-arm 4x4, CW – black (left or right) 2

51100 suspension bushings 2 ea 50266 bolt, 5/8 x 9 1/2" 1 ea 50015 Nut, 5/8 nylock 1 ea

45150 Spacer/CW A-arm bushing-4x4

7 25001 Strut assembly, left 1

25009 Strut assembly, right 1 50028 Nut, 7/16 NF jam 2 50041 Nut, 3/8 NF slotted 2 50801 cotter pin 1/8" x 1 2

7a 25020 Lower ball joint 2

8 25003 strut bearing 2

50163 bolt, 5/16 x 3/4" NC 8 50005 Nut, 5/16 keps 8

9 25002 Hub / rotor 4x4 2

50040 Nut, 5/8 NF slotted 2 30621 cotter pin 2 30623 dust cap 2 50060 Lug nuts, 1/2" 16

11 70301 Shock, Heavy duty #1 4

50400 Bolt, 10 mm x 40mm 6 50404 10 mm x 70mm bolt 2 50065 Nut, 10mm nylock 8 spacer, shock 2

12L bly, UTV 22/9-10" Left 30122 Rim/Tire Assem 1

12R 30123 im/Tire Assembly, UTV 22/9-10" Right R 1

30480 Wheel rim, 10" x 6" 30195 Tire, Pathfinder 22/9-10"

mber

Part Description – 4x4mo

dels

Quantity Requir

Page 59

Reference Part Number Numb

13L 30124 Rim/Tire Assembly, UTV 22/11-10" Left 1

13R " Right 30125 Rim/Tire Assembly, UTV 22/11-10 1

30480 Wheel rim, 10" x 6" 30194 Tire, Pathfinder 22/11-10"

14 20851 CV half shaft (axle) – (Left or Right) 2

20868 Boot CV

15 tial – 4x4 20839 front differen 1

20848 Hilliard Front Differential Replacement Oil 50206 Bolt, 3/8 x 1 4 50740 washer, 3/8 flat 4 50741 washer, 3/8 lock 4

16 25006 drive shaft, front 1

50092 bolt, ¼ x 2” 2 50003 nut, ¼ keps 2

17 25008 bearing, shaft support 1

50163 bolt, 5/16 x ¾” NC 2 50005 Nut, 5/16 keps 2

18 25007 drive shaft, rear telescoping 1

50631 Screw, 3/8” – 16 x ½” square head set 2 10184 key, 3/16 x 1 3

19 g 17 inch 20804 convoluted tubin 20 10591 Rack & pinion with rod ends 4x4 1

10593 Rack & Pinion Boots 2 50171 Bolt, 5/16 x 3 3/4" USS 4 50005 Nut, 5/16 keps 4

21 10594 Rod end 4x4 2

10595 Tie rod 4x4 2 10593 Rack boot 2

22 10592 Steering Shaft w/u-joints 4x4 1

50402 Bolt, 10mm x 30mm 1 50066 Nut, 10mm Tri Lock Jam 1 50403 Bolt, 8mm x 30mm 1 50780 Lock washer, 8mm 1

23 45422 Steering Stub Shaft Assembly, CW - Black 1 24 pport, CW - black 45400 Steering su 1

51100 suspension bushings 2 ea 50152 bolt, 5/16 x 1 4 50005 Nut, 5/16 keps 4

2 5 10502 Steering Wheel 13" 1

10506 Center cap screw, black center cap 50081 bolt, 1/4 x 1 3/4 3 50001 nut, 1/4 nylock 3

30 - black 45402 Pedal assembly, CW 1

50152 olt, 5/16 x 1 b 6 50081 olt, 1/4 x 1 3/4" b 1 50159 bolt, 5/16 x 1 1/2 1 50005 Nut, 5/16 keps 8 50701 Washer, 5/16 flat 2

Part Description – 4x4models

Quantity Required

Page 60

Reference Number

31 11123 master cylinder 1

50167 bolt, 5/16 x 2 2 50005 Nut, 5/16 keps 2 50806 Clevis, 5/16 rod end 1 50077 Nut, 5/16" Hex SAE 1

32 11124 brake caliper 2

11167 brake pads (2 pads required per wheel) 4 11168 brake pins 4 11169 brake clips 4 50826 Spacer Lock collar, 3/8 4 50217 bolt, 3/8 x 1 1/2 4 50013 nut, 3/8 keps 4 18030 caliper bracket 2

3 3 11127 Parking Brake 1

50086 Bolt, 1/4 x 1 1/4 1 50001 nut, 1/4" nylock 1 50163 bolt, 5/16 x 3/4" NC 4 50005 Nut, 5/16 keps 4 50701 Washer, 5/16 flat 4

3 r 4 18038 Brake spreade 2

50152 bolt, 5/16 x 1 4 50007 nut, 5/16 nylock 1

35 nt 11135 Brake hose, fro 1 36 11136 Brake hose, rear 1 37 11085 Shifter control assembly, black 1

11083 Knob 1 11082 Cable, shifter 2 50053 nut, #10-24 Keps nut 2 50616 screw, #10-24 X 3/4" Pan Head phillips 2 50770 Washer, #10 flat 2

3 Control Assy - 4x4 Diff Control w/ cable 8 11086 Differential 1

11083 Knob 1 11091 cable, diff lock 1 50053 nut, #10-24 Keps nut 2 50616 screw, #10-24 X 3/4" Pan Head phillips 2 50770 Washer, #10 flat 2 50087 1/4-20 x 1" Hex Hd Bolt 1 50000 1/4" Keps Nut 2 50159 5/16-18 x 1 1/2" Hex Hd Bolt 1 50005 5/16" Keps Nut 2

4 0 70012 Wire Harness 1 41 12 Volt – 240 CCA 70000 Battery, U1L-8250-UTV – 1

70002 Battery Cable, Red - 17" 1 70010 Battery Cable, Black (24") 1 70009 Battery Terminal Cover 2 50087 bolt, 1/4" x 1 2 50000 nut, 1/4" keps 2 50000 nut, 1/4" keps 2

Part Number

Part Description – 4x4models

Quantity Required

Page 61

Reference Number

42 45414 Battery strap, CW (8 3/4") - black 1

50083 bolt, 1/4 x 7 1/2 2 50002 nut, 1/4" wing 2

43 70055 Light Switch / 4x4 switch 2 4 4 70052 Key Switch 1

70060 Key, 1 pair

4 5 70080 Accessory Plug 1

70081 Accessory Plug cap 1

46 18500 Terminal Block Cover - plastic 1

50625 screw, #10-24 X 1" Pan Head phillips 2 50053 nut, #10-24 Keps nut 2

47 70129 Headlights 2 48 70019 Relay w/harness, 4x4 1 50 18380 ) Hood, plastic - 4x4 (green 1

18384 Hood, plastic - 4x4 (camo) 1

18381 Hood, plastic - 4x4 (red) 1 50620 1/4" X 1 1/4" Pan phillips Machine screw 2 50621 1/4" X 2" Pan phillips Machine screw 2 50717 1/4" SAE Flat washer 8 50001 nut, 1/4" nylock 4 50846 Clamp-Tube-vinyl coated 1-1/4" 2

5 1 18309 Glove Box 1

50624 hex - black Screw, #10 x 3/4 5

52 18308 Steering Cover 1

50624 Screw, #10 x 3/4 hex - black 1

53 18383 Center Console 4x4 1

50624 Screw, #10 x 3/4 hex - black 14

54 18316 Access Cover, Center Console 1

50624 Screw, #10 x 3/4 hex - black 4

55 rap 4x4 18382 Plastic, Seat Bottom w 1

50624 Screw, #10 x 3/4 hex - black 5

56 18304 Underseat storage box 1 57 18303 Rear Fender 1

70150 Reflectors 2 50091 1/4"-20 X 3/4" Carriage bolt 4 50717 1/4" SAE Flat washer 4

58 55060 Fuel Tank 1

55063 Elbow Fuel Inlet w/ #200 Mesh Screen 1

55062 Fuel Fitting Grommet 1

55061 Cap Fuel Tank 1

50163 bolt, 5/16 x 3/4" NC 3

50706 Washer, 5/16 fender 3

50703 Washer, 5/16 lock 3

5 9 18033 Shaft guard 1

50163 bolt, 5/16 x 3/4" NC 3 50005 Nut, 5/16 keps 4 50171 Bolt, 5/16 x 3 3/4" USS 1 10001 tube, 1" 14ga 1

Part Number

Part Description – 4x4models

Quantity Required

Page 62

Reference Number

60 10754 Seatback 43 1/2 x 17 1/2 1

50619 #14 X 1-3/4" Pan head-Tapping screw 6

61 10803 Headrest - UTV 9 x 6 1/2 2

50085 bolt, 1/4 x 1 1/2" 4

62 10755 Seat bottom 43 1/2 x 17 1/2 1 63 45416 seat bar, CW (17 1/2") - black 2

50609 #14 x 3/4 pan head tapping 6

65 10705 Seat Belt, 2pt 2

50025 7/16 Nylock 4

70 45426 Cargo Bed, Green 1

45420 Cargo Bed, Red 1

45424 Cargo Bed, Black 1

18352 Camo Bed Panel Left 1

18353 Camo Bed Panel Right 1

18354 Camo Bed Panel Tail Gate 1 50255 5/8 x 4” bolt Zinc plate 2 50015 5/8 nylock 2

18402 Bed Rubber Plug 2

73 50208 Bed latch bolt, 3/8 x 2 1/2" 1

50013 nut, 3/8 keps 2 50740 washer, 3/8 flat 2

75 45427 Tail gate, green 1

45421 Tail gate, Red 1

45425 Tail gate, Black 1 50152 bolt, 5/16 x 1 2 50701 washer, 5/16 sae 4 50007 nut, 5/16 nylock 2 70230 rubber bump stops 4

78 50815 1/4" Lynch Pin - tailgate latch 2 80 18312 Roof, green 1

18301 Roof, Red 1

18351 Roof, Camo 1

18391 Roof, Top Vinyl Trim 1

18390 Roof, Hardware bolt kit

50847 Clamp-Tube-vinyl coated 1-3/4" 4

50087 bolt, 1/4" x 1 4 50717 1/4" SAE Flat washer 4 50001 nut, 1/4" nylock 4

50718 Washer, ¼” Rubber Domed 4

85 18400 Windshield - clear

18401 Windshield - tinted 18403 Fastener kit, windshield

88 40729 Front receiver hitch 4x4 kit 1

50162 Bolt, 5/16 x 1-3/8 - U 4 50704 Washer, 5/16 Flat 8 50007 Nut, 5/16 Nylock 8

101 20012 Engine, Honda 13hp 1

50202 3/8-16 x 1 3/4" Hex Hd Bolt 4 50740 3/8" Flatwasher, USS 4

102 20838 Dana Transaxle 4x4 1

Part Number

Part Description – 4x4models

Quantity Required

Page 63

Reference Number

103 45502 Swing arm, CW - Black 4x4 1 104 45430 Motor Plate, CW - Black 1 105 18023 Throttle Guard Laser 1

50086 1/4-20 x 1 1/4" Hex Hd Bolt 3 50082 1/4-20 x 2 1/4" Hex Hd Bolt 1 50000 1/4" Keps Nut 5 50715 1/4" Flatwasher, USS 8

107 20648 TC, Driver Comet 500 – used before Serial Number #25663 1

20665 TC, Driver CVTECH – used after Serial Number #25663 1

108 20649 TC, Driven Comet 500 – used before Serial Number #25663 1

20666 TC, Driven CVTECH – used after Serial Number #25663 1

109 11166 Brake Shoes - Rear UTV – Dana ( 1 set per wheel) 2 110 50745 1" I.D. Spacer Washer– Comet only (not used with CVTech pulley) 4 111 - 1/4 x 3/16" Keystock 1 112 50742 3/8" I.D. Fender Washer– Comet only (not used with CVTech pulley) 1 113 50741 3/8" Lock Washer– Comet only (not used with CVTech pulley) 1 114 50219 3/8x 3" Bolt Hex Hd NF– Comet only (not used with CVTech pulley) 1 115 20693 Belt, Comet 300668 used before Serial Number # 25663 1

20694 Belt, CV TECH – used after Serial Number # 25663 1

116 50239 1/2 x 2" SAE 1 117 50722 1/2" Lock Washer 1

50721 1/2" Uss Flat Washer 1

118 - 3/16" Key stock 1 119 45431 Tension Mount Engine, CW - Black 1

50157 5/16x 3/4" Bolt Hex Hd NF 2 50703 5/16" Lock Washer 2 50704 5/16" Flatwasher 2

120 70250 Rubber Feet (Isolators) 5

50010 3/8 Nylock Nut 10 50740 3/8 Flatwasher USS 5

121 10581 Rod End Sphcl-UTV (4681-MPM-12) 3 122 50021 3/4 Jam nut SAE 3 123 42093 Panhard bar, CW - black 4x4 1 124 50206 bolt, 3/8 x 1 4

50010 3/8" Nylock Nut 4 50740 3/8" Flatwasher, USS 4

125 50730 3/4' Spacer Washer 6 126 50280 3/4 x 2.5 SAE bolt 3 127 50020 3/4 SAE nylock 3 128 18012 shifter lever, CW - black 1

50084 1/4-20 x 3/4" Hex Hd Bolt 2 50000 1/4" Keps Nut 4

129 18011 shifter cable mount, CW - black 1 130 11104 Parking Brake Cables 4x4 2

50150 5/16-18 x 1" Hex Hd Bolt 2 50007 5/16" Nylock Nut 2

131 11010 Throttle Cable, UTV 1

50087 1/4-20 x 1" Hex Hd Bolt 1 50000 1/4" Keps Nut 2 11804 Spring #80704 Black painted 1

Part Number

Part Description – 4x4models

Quantity Required

Page 64

Reference Number

133 11804 Spring #80704 Black painted 1 136 65500 fuel hose 3/16" dia - 24" 1 137 50849 hose clamps - small 3 138 18313 Belt Guard Plastic UTV - Front 1 139 18314 Belt Guard Plastic UTV - Rear 1 140 18315 Belt Guard Plastic UTV - Bottom 1

50624 #10 x 3/4" Blunt Point Black 7 50050 #10 Speed Nut - for Plastic 7 50770 #10 Flatwasher 7

141 20011 Choke Bracket Honda Engine 1 150 25004 right angle gearbox 1

10184 Key, 3/16 x 1 3

151 20852 gearbox coupling 1 152 18042 Gear box bracket “torque arm” (long) built before 10-06 1

18083 Gear box bracket (short) built after 10-06 1 70232 rubber washer - built before 10-06 2 50163 bolt, 5/16 x 3/4" NC 4 50701 Washer, 5/16 flat 6 50703 Washer, 5/16 lock 2

50005 Nut, 5/16 keps 2 50303 Bolt 7/16 x 1 3/4" - built before 10-06 1 50794 Washer, 7/16 flat - built before 10-06 2 50028 Nut, 7/16 nylock - built before 10-06 1

153 18032 diff lock mount 1

50163 bolt, 5/16 x 3/4" NC 2 50701 Washer, 5/16 flat 2 50703 Washer, 5/16 lock 2

Part Number

Part Description – 4x4models

Quantity Required

Accessories Available call 1-866-646-5278

BRISTER’S DESIGN & MANUFACTURING CO., LLC.

Page 65

ONE (1) – YEAR

LIMITED PRODUCT WARRANTY

This warranty applies to defects in workmanship or materials only.

No other warranty expressed or implied exists.

Brister's Design & Mfg LLC warrants its products with the following conditions: Warranty Coverage: If, within one 1-year of the original date of purchase, any defects in

workmanship or materials appear in the product, Brister's Design & Manufacturing LLC will repair or replace, at its sole option, any defective product. Only an authorized dealer or the manufacturer (BDM) determines the existence of a warranty defect, damage or abuse to the product.

Exclusions: This warranty does not apply to normal wear & tear or minor mechanical adjustment. This limited warranty does not apply to component failure or structural damage

caused by any of the following: collision; neglect; abuse; abnormal strain or stress; improper assembly or improper maintenance. Any repairs or modifications made to the product in question by anyone other than the authorized dealer or authorized service center voids the product warranty.

Engines: This BDM warranty does not apply to the engine, which is covered by its manufacturer’s warranty. Please refer to the engine manufactures warranty policy included with your BDM product.

American Honda Motor Co, Inc. (770)-497-6400 Phone Two-Year Limited Engine Warranty Warranty Service: To obtain warranty service you must return your BDM product to the local

authorized dealer, you must inform them of your warranty problem and provide proof of purchase before any warranty service is provided. The authorized dealer will inspect the product to determine what warranty repairs or parts are needed and if the problem meets the requirements of BDM’s One (1) - year Limited Warranty Policy. To locate the authorized dealer nearest you please call BDM customer service at 1-866-646-5278 or (985)-748-4889, or visit our website at

www.bristers.com for more information. This One (1) - Year Limited Warranty in not transferable and can only be used by the

original owner. Warranty registration and dealer setup forms must be completed and returned to BDM within 10 days of the purchase date to validate factory warranty.

Always read, view and follow the recommended service instructions.

found in your owners’ manual

Brister’s Design & Manufacturing Co, LLC.

P.O. Box 649

Roseland, LA 70456-0649

Effective 11-1-06

Page 66

Service and Warranty

Special Note

Should your Brister’s product require warranty repair, service or if you have any questions concerning assembly, replacement parts or how to care for your product please contact your local Brister’s dealer or Brister’s Design & Manufacturing directly.

Brister’s Dealer:

To locate the authorized dealer nearest you please call Brister’s Design & Mfg. customer service at 1-866-646-5278 or (985)-748-4889, visit our website at

www.bristers.com or contact your place of purchase.

Mail:

Customer Support c/o Brister’s Design & Manufacturing Co., LLC. P.O. Box 649 Roseland, LA 70456-0649

Telephone:

Customer Support Brister’s Design & Manufacturing Co., LLC. 1-866-646-5278 or (985)-748-4889

Fax:

Customer Support Brister’s Design & Manufacturing Co., LLC. 1-866-329-5278 (fax) or

(985)-748-4877 (fax)

e-mail:

Customer Support Brister’s Design & Manufacturing Co., LLC.

[email protected]

Page 67

Page 68