Cub Cadet Challenger 500, Challenger 700 Operator's Manual

Download

perator’s

anual

Challenger 500\700

CUB CADET LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019

Form No. HS-01231401C

(December 4, 2017)

WARNING

READ AND FOLLOW ALL SAFETY RULES AND INSTRUCTIONS IN THIS MANUAL BEFORE ATTEMPTING TO OPER-

ATE THIS MACHINE. FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.

Owner’s Manual

WARNING: This symbol points out important safety instructions, which, if not followed, could

endanger the personal safety and/or property of yourself and others. Read and follow all instructions in this manual before attempting to operate this machine. Failure to comply with these instructions may result in personal injury When you see this symbol, HEED ITS WARNING!

WARNING: Engine Exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to State of California to cause cancer and birth defects or other reproductive harm. WARNING: Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling DANGER: T his machine was built to be operated according to the rules for safe operation in this manual. As with any type of power equipment, carelessness or error on the part of the operator can result in serious injury. Failure to observe the following safety instructions could result in serious injury

or death

Owner’s Manual

INTRODUCTION

Congratulations on your purchase of the Cub Cadet Challenger U TV . Th i s Owner’s / Operator’s manual will provide you with information regarding safe operation, operational inst ructions, maintenance and care. Fully understanding this manual and following all of the instructions herein will provide the knowledge needed to have safe and enjoyable UTV operation.

If you have any ques tion s re gar din g the operation or maintenance of your UTV, please consult

your Cub Cadet dealer.

IMPORTANT SAFETY MESSAGES

●

READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR UTV. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS.

●

PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE UTV.

●

NEVER OPERATE THE UTV WITHOUT PROPER TRAINING OR INSTRUCTION.

●

THIS UTV SHOULD NOT BE OPERATED BY ANYONE UNDER 16 YEARS OF AGE.

Owner’s 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, passengers, bystanders, or any person inspecting or

repairing the machine.

A CAUTION indicates special precautions that must be taken to avoid damage to the machine.

NOTE:

A NOTE

provides key information to make procedures easier or clearer

Owner’s 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 U TV 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. When the temperature is below -4°F (-20°C), park the UTV in a place where the temperature is higher

than -4°F (-20°C). Start the UTV after the UTV has warmed up. Please see page 6-3 on the warming up process.

Follow the proper parking procedures when the temperature is higher than 100°F (38°C): turn off the engine; make sure the radiator fan is on for 3 minutes before turning off the power switch.

Starting the UTV for the first time will take longer because the fuel will need reach the fuel injectors. To start the UTV the first time, hold the ignition key on at 5-second intervals. Allow the starter to rest 15 seconds between each start attempt.

Location of the Warning and Specification Labels

Owner’s Manual

1-1

Accelerator Pedal

4-14

Brake Pedal

4-15

Parking Brake Lever

4-16

Safety Information 2-1

Description and Vehicle

3-1

Identification

Drive Select Lever

4-17

Fuel Tank Cap

4-17

Seats

4-18

On-Command Four-Wheel-Drive and

Identification Number Records 3-3

Seat Belts

4-19

Vehicle Identification Number

3-3

Glove Compartment

4-21

Cargo Bed

4-22

Control Functions

4-1

Opening and Closing the Tailgate

4-22

Main Switch

4-1

Lifting and Lowering the Cargo Bed

4-23

Indicator and Warning Lights

4-2

Front and Rear Shock Adjustment

4-25

Use of EPS system

4-4

Spring Preload

4-28

Speedometer Unit

4-5

Rebound Damping Force

4-29

Odometer and Trip Meter Modes

4-6

Compression Damping Force

4-30

Fault code indicator

4-8

Trailer Hitch Bracket

4-31

Fuel level indicator

4-9

Auxiliary DC Jack

4-31

Switches

4-10

Pre Operation Checks

5-1

Differential Gear Lock Switches

4-11

Brakes

5-2

Owner’s Manual

Brake Fluid Level

5-2

Tire Wear Limit

5-1

Brake Fluid Leakage

5-3

Brake Operation

5-3

6 Operation 6-1

Fuel

5-4

Starting the Engine in Low

6-1

Gasohol

5-4

Temperatures

Engine Oil

5-5

Starting the Engine

6-2

Coolant

5-6

Warming Up

6-3

Final Gear Oil

5-7

Drive Select Lever Operation and

Differential Gear Oil

5-7

Driving In Reverse

Throttle Pedal

5-8

Parking

6-8

Throttle Freeplay

5-9

Parking on a Slope 6-8

Throttle Freeplay Inspection

5-9

Vehicle Break-in Period

6-9

Throttle Freeplay Adjustment

5-9

Engine Break-In 6-1

Steering Wheel Inspection

5-10

Accessories 6-11

Seat Belts

5-10

6-1

Fittings and Fasteners

5-10

Lights

5-10

Driving Your Vehicle 7-1

Switches

5-11

Getting to Know Your Vehicle

7-1

Tires

5-11

Learning to Operate Your Vehicle

7-5

How to Measure Tire Pressure

5-12

Turning your Vehicle

7-6

Owner’s Manual

Engine Oil and Oil Filter Cartridge 8-12

Braking

7-8

To Check the Engine Oil Level

8-13

Going Uphill

7-8

To Change the Engine Oil

8-14

Going Downhill

7-10

Final Gear Oil

8-17

Crossing Through Shallow Water

7-12

Checking the Final Gear Oil Level

8-17

Riding Over Rough Terrain

7-15

Changing the Final Gear Oil

8-18

Riding in Brush or Wooded Areas

7-17

Differential Gear Oil

8-19

Encountering Obstacles on the Trail

7-17

Checking the Differential Gear Oil

Level

8-19

Changing The Differential Gear Oil

8-20

Periodic Maintenance and

8-1

Coolant

8-21

Adjustment

Axle Boots

8-23

Periodic Maintenance Chart for the

Spark Plug Inspection

8-23

Emission Control System

Removal

8-23

General Maintenance and Lubrication

Inspection

8-24

Chart

Installation

8-25

Hood

8-7

Cleaning the Air Filter Ele ments

8-26

Console

8-8

V-belt Cooling Duct Check Hose

8-30

EFI System

8-9

V-belt Case Drain Plug

8-30

ECU

8-12

Cleaning the Spark Arrester

8-31

EFI System Inspection

8-12

Valve Clearance

8-33

Owner’s Manual

Front Brake Pad Check 8-33 Rear Brake Pad Check 8-34 Checking the Brake Fluid Level 8-34 Brake Fluid Replacement 8-35 Checking the Brake Pedal

8-35

Parking Brake Lever Free Play

8-37

Adjustment Brake Light Switch Adjustment

8-38

Cable Inspection and Lubrication

8-39

Headlight Beam Adjustment

8-50 Tail/Brake Light Bulb Replacement 8-51 Troubleshooting 8-53 Solution to Common Problems in the Vehicle 8-54

Cleaning and Storage 9-1

Cleaning 9-1 Storage

9-3

Brake Pedal and Accelerator Pedal Lubrication Rear Knuckle Upper and Lower Pivot

8-40 8-40

Specifications 10-1

Lubrication Steering Shaft Lubrication

8-41

Wheel Removal

8-41

Fault code of Electronic Injection

System

USA EPA Emissions Limited

11-1

Wheel Installation

8-42

Battery

8-43

Battery Maintenance

8-45

Fuse Replacement

8-45

Replacing Headlight Bulb

8-47

Warranty and Standard Warranty

12-1

1-1 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 W ar ni ng and Safety Labels

1-2

' Chongqi ng H uansong Science And Te chnol ogy I ndust r i al Co.,Ltd:

2 '

This structureme e ts ROPSr e q u ir emen ts

for

earth-moving machinery under ISO 3471 .

CAUTION

•Use only 91 Octane or higher gasoline (E-10 max).

•Use Non-Ethanol gasoline when possible for better engine performance.

•NEVER USE E-85 gasoline, it will damage the engine and void the warranty.

VEHI CLE EM 1S8' 0N CO NTROL INFORM ATION

C UB CADE T L LC

ENGINE DfSPL ACEMENT :

ENGINE FAMILY:

ENGINE EXHAUST CONTROL SYSTEM:

PERM FAMILY:

FIEMD

SFl,TWC, HIX!S

ENGINETUNEUP

SPECIFICATtoNS :

IDLE MIXTURE : NON ADJUSTABLE

THPIESRVEAS.

THIS

VE I

REGUL

F 201 0 L

YEAR NEW

UTVS ANO IS CERTIFIED

TO 1.5 G/KM

HC + NOX, 35 GIKM CO

EXHAUST EMISSION STANDARDS

...

,, ,

: . M

• UST.ABLE

MANUFA C TUR ED IN CHINA

IDLE SPEED: t 500 + 150 RPM

FUEL

: UNLEADED GASOLINE ONLY · 91

(R+M),"1 OCTANE OR

HIGHER

IL: t0W40

SEE OWNER·s MANUA L

CuJ.OuJee .

.,_

A .W....,.A......,R......,N l..,N...,.G

----t

•Keep hands and body safely

away when closing bed..

•NEVER operate the vehicle with the bed up.

WARNING

rne ;w'""" '"

''"'"d" 4w

:;:

:i h:ba l1r•

for

Ba el,t y

'\.,

Exhaustop ennig

Take off1herubber,u ling

capandromovof,llin . plu s

RoplaconibtHircapw,1h

R&mov• rul>btro • p

xhaust 1ub& or<ivlded

Filling elec1roly1e(acid)

Conneot a,hauottu be

Gr av ityof , coo!ortemperateclimale 1.270-1.280

trop 1c a l climate 1.250-1 .260

The electro

lyte temperature when fill ing mus t not be lower than 1s•c

or higher than JO" C

ll batter y to upper level as indicatedon the ba tterycase

Lea ve b a ttery tostand foratleast J Om

i nu tes afle r fi lling

Elect rol yte

l evelm a yf all during th isper iod. refill to upperlevel

before charg ing

Tnebatterycontar1sorerntschemcalsknown1ncertil1nqua1t1\es

to cause cancer b rthdefects o r otherre roduct 1ve harm

Improper tire pressur e or o verloading can cause loss of control .

Loss of control can re sult in sev ere injur y or death.

•

Cold tire pressure:

Fr on t . 10psi (70kPa )

Rear : 10psi (70kPa)

•

Ma xi mu m wei gh t cap acity:880 Ibs.(399kg )

WARNING

1-3

Location of the Warning and Safety Labels

6 8

Cert1f1es tha t this ROV complies with theAmencan National Standard for Recreational Off-Highway Vehicles, ANSI/ROHVA 1-2011 Standard

TYPE OF VEHICLE UTV

AWARNING:

EXHAUST F UMES MA Y CAUSE HARM

Engine exhaust from this product contains chemicals, known in certain quantities to cause cancer, birth defects, or other reproductive harm.

WARNING

Severe INJURY or DEATH can result if you ignore

the following guideline s :

•

Maximum load in cargo bed is 3501b ( 159kg )

• Never carry passengers in cargo bed. Passengers can be thrown off causing serious injury or death.

•

Cargo can affect handling and stability.

•

Read Owner's Manual b ef ore loading or towing _

• When operating with cargo or towing a trailer always reduce speed, allow more room to stop and avoid hills

and rough terrain _

•

sure cargo is secured sinc e a loose load can

change vehi cle handling _

•

Keep weight in the cargo bed centered and as low and

as far for wa rd as possible.

•

Top-heavy l oads increase the risk of rollover.

WARNING

NEVER CARRY PASSEN G ERS

IN CARGO BED.

• Operat ion of this equipmen

may create sparks that can start fires around dry vegetation.

•

A spark arrester may be

required . The operator

should contact local fire agencies for laws or regulati ons relating to fire prevention requirementsdj

- •

•

Max towing weight:544kg(1200Ibs

•

Max tongue weight:50kg( 11Olbs)

Location of the Warning and Safety Labels 1-4

)

• •

•

_j -- .. ...

Improper Use of Off-Highway Vehicles Can Cause Severe Injury or Death

Be Prepared

•Fasten seatbelts.

•

Wear anappr oved h el m et an dp rotec tiv ege ar.

•

Eachrider must beablet os it withback ag ai ristseat, feetflatonfloor[andfootrests],andhandsonsteering wheel or handhold[s ](,wh ereequ ippedl, S1ay

completely inside t he vehicle.

Drive Respons ibly

Avoid losso fcontro l and rollovers:

•

Avoidabruptm aneuvers, sidew ayss lld ing, sklddi ng, orfishta iling, andneverdodonuts.

• Slowdownbeforeenteringaturn.

•

Avoidh arda cceleration whentu rning, even

from a stop.

•

Pla nfor hills, rou ghterrai n, rut s, andoth er changesintractionan d te rrain. Avoid

Rollovers have caused

paved surfaces.

seyerein juriesand death,

•

Avoidsidehilling( r idingacrossslopes ).

eYeno n fl at, open areas,

Sure Riders

Pay

Attent

i on and

Plan

Ahead

If youthinkorfeelthe vehiclemayti por roll, reduceyour risk to injury:

•

Keep afi rmgriponthesteeringwheelor handholdsa ndbrace yourself.

•

Donot putanyp art ofyour b odyoutsideofthevehi cl ef oranyreason .

Require Proper Us e of Y our V e hicle

Doyou r part toprevent in1ur1es VER

•

Donot all ow carelessorreck less driving

•

Mak esureope rato

arel

6orolder w1t ha vahd

U R

drivers license

•

Donot let peopl ed n ve or nd e after usmgalc oh ol or dr u gs

• Donot al l

owope

rat 1

ononpub l1

croads(unlessdes 1gnated

for

off-highwayvehicleaccess)··collisionswithcarsandtruckscanoccur.

•

Donot exceeds eatingcapacity: !passenger.

[Locate and] Rea d [ Owner 's Manual]

Follo w All I nstruct i on and Warning s

[ Reserve d for Ref ere nce t o Oth er Sou re s of Saf ety I nf o rmat i on ]

WARNING

•Improperly loading a

trailer and fail ure to use extra care when pulling

trailer can cause an

accident or injury.

•

Never load more than

1101b s

(50kg) tongue weight on the to wing

bracket.

• Do not tow more than

1200lbs (544kg) rolling weight (trailer plus cargo).

• Operate in low-range

gears only, allow for increased braking distance, and use extreme caution when operating on inclines.

• Read carefully the

loading information and trailer hitch sections in the owners manual.

1-5 Location of the Warning and Safety Labels

'14

---

WA-RN-ING

--'---

A.WARNING

You could be severely injured if you try to stop

a vehicle roll over using your arm or leg.

If vehicle st arts to rollover, keep arms and legs inside vehicl e.

Operation takes more effort whil e the veh icle

is in 4W D -LOCK.

When in 4WD-LOCK ope ra te a t a slo w

speed

and allow extra time and di stance for

turns to

avoid loss of control.

Select gear "L"on rough terrain and sloped terrain.

ACAUTION

AWARNING

•

Do not drive in the water deeper than 15 in

•

Turn speed not to exceed 18 MPH/30 KPH

Safety Information 2-1

Operation

General O p eration

Read, understand, and follow all instructions on the vehicle and in the manual before attempting to operate or service vehicle.

Keep this manual in a safe place for future and regular r eference and for ordering replacement parts.

This is an off-road utility vehicle and it should not be operated on public highways. Know and comply with all laws and

regulations governing the use of off-highway vehicles in your area.

This vehicle handles and maneuvers differently than a normal passenger car. Sharp high speed turns and abrupt maneuvers

can cause vehicle to roll over or go out of control. Slow down when turning and avoid abrupt maneuvers.

Handling and maneuvering characteristics of vehicle change depending upon cargo load. Heavy loads affect steering, braking,

stability, and overall handling of vehicle.

Be familiar with all instructions and controls and their proper operation before starting vehicle.

Never allow adults to operate this vehicle without proper instruction.

2-2 Safety Information

Never allow children under 16 years old to operate this vehicle. Children 16 years old and over should read and understand the

operation instructions and safety rules in this manual and should be trained and supervised by a parent.

Watch for traffic when operating near or crossing roadways. This vehicle is not intended for use on any public roadway.

Do not operate this vehicle while under the influence of alcohol or drugs.

Never carry more passengers than the vehicle is designed to carry. Do not allow any passengers to ride in the cargo bed. All

passengers must be seated with their seat belts fastened at all times..

Keep all body parts (i.e. head, arms, hands, legs, feet) inside vehicle when vehicle is in motion.

Always remain seated and keep both hands on the steering wheel when driving the vehicle.

Sit on the center of the seat and keep both feet within the foot platform perimeter. Clean foot platform if dirty and remove any

debris from around foot controls, e.g. brake pedal.

Do not misuse the utility vehicle. It is an utility vehicle, not a recreation vehicle or toy. Recreational riding can lead to accidents,

severe bodily injury or death.

Safety Information 2-3

Inspect area around vehicle before moving, especially in reverse. Back up slowly. Always look down and behind before and

while backing to avoid a back-over accident. Keep bystanders out of area.

Avoid driving through water, since loss of control may occur. Drive belt may slip if exposed to water thus reducing vehicle

pulling power and stopping vehicle entirely.

Always use vehic le lights while operating inlow l ight situations.

Do not mount or leave vehicle while it is in motion or in actual operation.

Avoid sudden starts, stops, or turns and always use a level turn-around area.

Never leave vehicle unattended with the key in the ignition. Always turn key to the "Stop" position, set the parking brake and

remove key.

Check overhead clearances carefully before driving under low hanging tree branches, wires, power lines, bridges, before entering or

leaving buildings, or in any other situation where the operator and/or operator protective structure (OPS) may be struck, which could result in serious injury.

2-4 Safety Information

Use the operator protective structure (OPS) and seat belt for safe operation. Overturning the utility vehicle without an operator

protective structure (OPS), or with an operator protective structure (OPS) and the seat belt unfastened, can result in death or injury.

Always use the s eat belt, except if the operator protective structure (OPS) has been removed.

The doors and nets are designed to assist in keeping the operator and passenger inside the vehicle during operation. Do not

operate vehicle without doors and nets in place and properly secured.

Improper use of the vehicle or failure to properly maintain it could result in decreased vehicle performance or personal injury.

Engine must be stopped when cleaning, servicing, adjusting, repairing, or installing attachments on utility vehicle.

After striking foreign objects stop the unit and shut off the engine. Inspect for damage and repair the damage before restarting

and operating equipment.

Do not start or operate vehicle in an inside area, unless it is adequately ventilated. Engine exhaust contains carbon monoxide

fumes, which are very poisonous and can be deadly.

Do not change engine governor setting or over -speed the engine. The governor is set at the factory for safe operating speed.

Safety Information 2-5

Assure safety interlock switch is adjusted correctly so engine cannot be started unless gearshift is in the neutral position.

Do not touch engine or muffler while engine is running or soon after it is stopped. They will be hot and can cause a burn.

Always inspect your vehicle each time you use it to make sure it is in safe operating condition. Always follow the inspection and

maintenance procedures and schedules described in this manual.

If situations occur which are not covered in this manual, use care and good judgment. Contact your local service center or call

toll free 1-877-282-8684for the name of your nearest service center.

Occupant Size and Capacity

Make sure operat ors are at least 16 years old and have a valid driver' s license.

Each occupant should be able to sit with their back against the seat, feet flat on the floor, and hands on the steering wheel or

handholds.

The operator should be tall enough to wear the seat belt properly and reach all contr ols.

Passengers should also be tall enough for the seat belt to fit properly and be able to brace themselves, as necessary, by placing

both feet firmly on the floor while gripping the handholds. Keep all body parts completely inside the vehicle.

2-6 Safety Information

Dress Properly

Slope Operation

Do:

Avoid slopes with slippery, loose, or bumpy surfaces as they are especially hazardous.

Safety Information 2-7

Use extra care while carrying c argo.It may affect the stabili ty of the vehicle. Spread the load evenly or tie down.

Do Not:

Do not travel near drop-offs, ditches or embankments. The vehicle could suddenly overturn if a wheel is over the edge of a cliff,

ditch, or if an edge caves in.

Do not stop or start suddenly when going uphill or downhill. Be especially cautious when changing direction on slopes.

Do not turn sideways to the hill.The vehicle may roll over. If you must turn, go slow and do so carefully and gradually.

Do not carry cargo on steep slopes or tow loads.

Towing

Always use an approved hitch and hitch point provided on the utility vehicle.

Do not tow more than 1200 lbs. rolling weight (i.e. trailer plus cargo).

Never load more t han 110 lbs. tongue wei ght on tow bracket provided.

2-8 Safety Information

Cargo Box Loading/Operation

Safety Information 2-9

Avoid sudden starts, stops, and turns which could cause load to shi ft.

Cargo Box Lift

Stop vehicle on level ground and set Parking Brake before raising cargo box.

On manual lift units, unload cargo box before raising cargo box.

Do not operate vehicle with c argo box in raised position.

Do not operate vehicle with c argo box latch unlatched. Always re-latch upon manuall y lowering cargo box.

Safety Frame (OPS)

Your vehicle is equipped with a operator protective structure (OPS) which must be maintained in a fully functional condition.

Use care when driving through doorways or spaces with a low overhead.

Never modify the OPS in any way.

2-10 Safety Information

Never attempt to straighten or re-weld any part of the main frame or retaining brackets that have been damaged.

Doing so may weaken the structure and endanger your safety.

Never secure any parts other than Cub Cadet approved accessories on the main frame or attach the safety frame with

anything other than the special fasteners specified.

Never attach ropes, chains, or cables to the OPS for pulling purposes.

Although the OPS, when used with a properly secured seat belt, provides a crush-protective environment in the event

of a tip-over or rollover, never take unnecessary risks.

Children

Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the vehicle. They

do not understand the dangers. Never assume that children will remain where you last saw them. Avoid run-over accidents.

Safety Information 2-11

Keep children out of the immediate area of the vehicle and in watchful care of a responsible adult other than the

operator.

Be alert and turn t he vehicle off if a child enters t he area.

Before and while backing, look behind and down for small children.

Never carry s m all children, t hey m ay fall off and be seriously injur ed or interfere with safe vehicle operation.

Use extreme care while approaching blind corners, doorways, shrubs, trees or other objects that may block your vision

of a child who may run into the path of the vehicle.

Remove key when ve hicle is unattended to prevent unauthorized operation.

Never allow children under 16 years old to operate this vehicle. Children 16 years old and over should read and understand the

operation instructions and safety rules in this manual and should be trained and supervised by a parent.

Do not let children ride in the cargo box, in the driver's or passenger's lap or anywhere other than the passenger seat. Never

give small children a ride; not even in the passenger seat. They may fall off.

2-12 Safety Information

Safe Handling Of Fuel:

Safety Information 2-13

Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. Do

not use a nozzle lock-open device.

Extinguish all cigarettes, cigars, pipes and other sources of ignition.

Never fuel machine indoors.

Never remove gas cap or add fuel while the engine is hot or running. Allow engine to cool at least two minutes before

refueling.

Never overfill fuel tank Fill tank to no more than½ inch below bottom of filler neck to allow space for fuel expansion.

Replace fuel cap and tighten securely.

If fuel is spilled, wipe it off the equipment. Move unit to another area. Wait 5 minutes before star ti ng the engine.

To reduce fire hazards, keep engine compartment and exhaust system free of grass, leaves, or other debris build-up.

Clean up oil or fuel spillage and r em ove any fuel soaked debris.

Never store the machine or fuel container inside where there is an open flame, spark or pilot light as on a water heater,

space heater, furnace, clothes dryer or other gas appliances.

2-14 Safety Information

General Service

Never run an engine indoors or in a poorly ventilated area. Engine exhaust contains carbon monoxide, an odorless, and deadly

gas.

Before cleaning, repairing, or inspecting, make certain all moving parts have stopped. Disconnect the spark plug wires and

ground against the engine to prevent unintended starting.

Check brake oper ation frequently as it is subject ed to wear during nor m al operation. Adjust and service as required.

If equipped, the cooling system is under pressure. Never remove the radiator cap when the system is hot. Slowly turn the cap to

the first stop to release pressure before removing the cap.

Keep all nuts, bolts, and sc r ews tight to be sure th e eq u i pm e nt i s i n saf e w o rking condition.

Never tamper with the safety interlock system or other safety devices. Check their proper operation regularly.

Never attempt to make adjustments or repairs to the machine while the engine is running.

Do not change the engine governor settings or over-speed the engine. The governor controls the maximum safe operating

speed of the engine.

Maintain or replace safety and instruction labels, as necessary.

Safety Information 2-15

According to the Consumer Products Safety Commission (CPSC) and the U.S. Environmental Protection Agency (EPA), units in

this product category have an Average Useful Life of seven (7) years, or approximately 400 hours of operation. To extend the life of your unit, and specifically after (7) years of ownership or at 400 hours of operation, have the unit inspected annually by an authorized service dealer to ensure that all mechanical and safety systems are working properly and not worn excessively. Failure to do so can result in accidents, injuries or death. See Section 5 of this Operators Manual for Maintenance and Service schedules.

Observe proper disposal laws and regulations for gas, oil, etc. to prot ect the environment.

Prior to disposal, determine t he proper method to di spose of waste from your local Environmental Protection Agency.

Recycling centers are established to properly dispose of mater ials in an environm entally safe fashion.

Use proper containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking

from them. Properly dispose of the containers immediately following the draining of fluids.

2-16 Safety Information

DO NOT pour oil or other fluids into the ground, down a drain or into a stream, pond, lake or other body of water. Observe

Environmental Protection Agency regulations when disposing of oil, fuel, coolant, brake

fluid,

filters, batteries, tires and

other harmful waste.

Do not modify engine

To avoid serious injury or death, do not modify engine in any way. Tampering with the governor setting can lead to a runaway

engine and cause it to operate at unsafe speeds. Never tamper with factory setting of engine governor.

Notice Regarding Emissions

Where applicable, this vehicle is certified to federal EPA and California Air Resources Board (CARB) emissions standards for

Off-Highway Recreational Vehicles (OHRV). The engine owner's manual is supplied by the engine manufacturer, and provides additional information relating to the emission system, warranty, and maintenance of the engine in accordance with EPA and/or CARB regulations. Consult your engine manual for the fuel requirements for your engine.

Safety Information 2-17

Gasoline powered products may be equipped with the following emission control systems: Please contact Customer Support

for information regarding the evaporative emission control configuration for your model.

Spark Arrestor

WARNING: This unit is equipped with an internal combustion engine and should not be used on or near any unimproved

forest-covered, brush-covered or grass-covered land unless the engine's exhaust system is equipped with a spark arrestor meeting applicable local or state laws (if any).

If a spark arrestor is used, it should be maintained in effective working order by the operator. In the State of California the above is

required by law (Section 4442 of the California Public Resources Code). Other states may have similar laws. Federal laws apply on federal lands. A spark arrestor for the muffler is available through your nearest engine authorized service dealer or contact the service department, P.O. Box 361131 Cleveland, Ohio 44136-0019.

2-18 Safety Information

3-1 Description and Vehicle Identification

1. Headlights

2. Front shock absorber assembly adjusting ring

3. Brake fluid reservoir

4. Air filter element(engine and air intake duct)

5. V-belt case

6. Driver seat

7. Driver seat belt

8. Spark plug

9. Cargo bed

10. Tail/brake lights

11. Rear shock absorber assembly adjusting ring

12. Cargo bed release levers

13. Spark arrester

14. Passenger seat belt

15. Passenger seat

16. Oil filter cartridge

17. Engine oil dipstick

18. Battery

19. Fuses

20. Coolant reservoir

21. Radiator cap

22. Fuel tank cap

NOTE:

The vehicle you have purchased may differ slightly from those in the figures of this manual.

Description and Vehicle Identification 3-2

23. Light switch

24. Steering wheel

25. Starter

26. Main switch

27. On-Com mand four-wheel-drive and differential lock switches

28. Multi-function meter unit

29. Auxiliary DC jack

30. Drive select lever

31. Parking brake lever

32. Accelerator pedal

33. Brake pedal

3-3 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.

1. VEHICLE IDENTIFICATION NUMBER:

2. MO DEL LABEL INFORMATION

Vehicle Identification Number

The Vehicle Identification Number (VIN) is stamped int o the frame.

1. Vehicle identification number

NOTE:

The vehicle ident ification number (VIN) is used to identify your vehicle.

CONTROL FUNCTIONS Combination switch

Light switch / / ”

High beam switch

Low beam switch

Position lamp

Turning light switch

Control Functions 4-1

Emergency light button

● Set the switch to ”，t o turn on the low beam。

● Set the switch to ”，to turn on the high beam。

● Set the switch to “OFF” to turn off all the lights.。

● Set the switch to ”，to turn on the little light in F/R headlights and taillights

L/R turning li ght switch

Place the L/R turning switch, the related turn signal flash, and a buzzer may ring.

Emergency light switch

Press down the emergency light switch. Four turning lights flash, and a buzzer ring.

4-2 Control Functions

Main switch

1. Main switch

Functions of the respective switch positions are as follows:

ON:

All electrical circuits are supplied with power, and the headlights and taillights come on when the light switch is on.

OFF:

All electrical circuits ar e switched off. The key can be removed in this po sition.

KEY：

Turning the steering w heel can lock the steering wheel directio n and the key can be removed.

START:

The electric starter is en gaged by turning and holding the key in this pos it ion. Release the key when the engine starts.

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 bet ween 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.)

Horn switch

1.Horn switch button

Press this button to activate the horn.

Control Functions 4-3

Indicator and Warning Lights

1. Four-wheel drive lock indicator light

2. EPS System Fault indicator light

3. Differential gear lock indicator

4. Coolant temperature warning light

5. Hazard light indicator

6. Reverse indica tor light “R”

7. Neutral indicator light “N”

8. High Gear indicator light “H”

9. Low Gear indicator light “L”

10. Seatbelt Warning light

11. Mechanical parking brake indicator light ”

12. Posit ion indic ator

13. High Beam light indicator

4-4 Control Functions

Low-Range Indicator Light “L”

This indicator light co me s on w hen t he drive select lever is in the “L” po s ition.

Mechanical Parkin g Br ake Indicator Light “ ”

This indicator light co me s on w hen t he mechanical parking brake is applied.

High-Range Indi cator Light “H”

This indicator light co me s on w hen t he drive select lever is in the “H” p osition.

Neutral Indica tor Light “N”

This indicator light co me s on w hen t he drive select lever is in the “N” p osition.

Reverse Indicator Li g ht “R”

This indicator light comes on when the drive select lever is in the “R” reverse position.

Coolant Tem pe r ature Warnin g Li ght ”

When the coolant temperature reaches a specified level, this light comes on to warn that the coolant temperat ur e is too hot. If the light comes on during oper at ion, stop the engine as soon as it is safe t o do so and allow the engine to cool dow n for about 15 minutes.

CAUTION:

 The engine may overheat if the vehicle is

overloaded. If this happens, reduce the load to specification.

 After restarting, make sure that the light

is out. Continuous use while the light is on may cause damage to the engine.

High beam indi cator

The light being on means headlight is at high beam mode.

Position light indicator

The light being on means that the position light fixed in the front headlight has been turned on.

Emergency ”

The light being on means em er gency lamp is on.

Control Functions 4-5

Speedometer Unit

1. Speed indicator

2. Clock/Hour/ Fault code meter

3. RPM indicator

4. Metric/mile button

5. “TRIP/ODO” button

6. Right turn indicator light

7. Left turn indicator light

8. Clock/Hour/ Fault cod e res et button

4-6 Control Functions

Speedometer unit fun ct ions include:

 a speedometer (which show s t he speed)  an odometer (which show s t he total

distance covered)

 a tripometer (which can b e cleared and

then show any new distances traveled)

 an RPM indicator (which s how s t he

revolutions per minute of the engine)

 a clock  an EFI fault code indicator ( w hich show s

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. Quickly pressing the button on the left side toggles t he display

from the odometer, to the tripometer, and then to the hours meter; then it starts the cycle over. The odometer displays the total distance traveled by the UTV. The tripometer records distances for a specific trip and can record distances from 0 through 999.9 miles. To reset a trip meter, select it by pressing the left button, Press left button to switch to small mileage (Trip/ODO), press the right button for a long time to reset. The tripometer can be used to estimate the distance that can be traveled with a full tank of fuel. This information will enable you to judge the fuel consumption. To change the display from miles per hour to kilometers per hour pres s the right side

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 t o set the hour.

2. Press the left button again and the clock goes into the minute ‘set’ mode.

3. Press the right button t o set the minutes.

4. Press the left button again and the clock will exit the ‘set’ mode.

Control Functions 4-7

Four-wheel drive indicat or ”

There are two 4WD indicators on the display panel. The left 4WD indicator has a blinking circle on the front axle when the unit is in 4WD. When the grey 4WD selector button is pressed the “ 4WD ” function has been

activated. This position also indicates that the 4WD is NOT locked. This allows the wheels on the left and right sides to rotate at different speeds to accommodate turning.

Differential gear lock indicator

The right 4WD symbol will show an ‘X’ over the center of the front axle when the rear differential is locked. T o lo ck the differential

4-8 Control Functions

unit must in in 4WD mode. The level is then moved to expose the Yellow differential lock button. The Yellow button must be pushed and in the out position for the rear differential to lock. When riding an UTV on muddy and slippery roads or when climbing a steep hill, make sure the 4WD lock indicator is on and the differential is loc ked. When riding on a flat road at a comparatively high speed, adjust the settings to “2WD/UNLOCK”. There should be no symbols in either of the 4WD i ndicators. Riding an UTV while the dif ferential is is NOT

CAUTION:

When the selector is set to 4WD and Locked

Differential, the right 4W D symbol front axle will have an ‘X’ in the middle. When riding on good surfaces you should use the 2WD drive mode. There should be no symbols

illuminated on the display

CAUTION:

If the display indicators flash or the speedometer does not show the speed while the UTV is in motion, Ask a dealer to check the speed sensor and circuits.

locked (UNLOCKED) may improve the stability and safety of the UTV operation.

Fault code indicator

When the EFI encounter s faults, the ECU will

send the fault code to the inst r ument display, and it will flash on the clock. If there is more than one fault code, they will be shown in a rolling sequence. When fault codes are present, in order to see the time press the clock button, the time will be shown. Then after five seconds, t he fa ult code returns again. Only after the fault is fixed, will the time show automatically. The description for the fau lt codes are shown in Chapter 11 of this manual.

Fuel level indicator

The fuel level display will indicate the fuel volume. When the fuel is getting low the fuel pump symbol will flash.

Control Functions 4-9

1. Fuel level indicator 2. Fuel level warning indicator

4-10 Control Functions

Switches

1. Light switch “OFF/ / ”

Light switch / ”

Set the switch to ”to turn on the low beam and the taillights.

Set the switch to ”to turn on the high beam and the taillights. Set the switch to “OFF” t o t ur n off all the

lights.

Do not use the headlights with the engine turned off for an extended period of time. The

battery may discharge t o t he point that the starter motor will not operate properly. If this happens, remove the battery and recharge it.

On-Command Four-Wheel–Drive and Differential Gear Lock Switches

1. On-Command four-wheel –drive switch “2WD”/ “4 WD”

2. Differential gear lock switch “LOCK”/ “4WD”

CAUTION:

Control Functions 4-11

This vehicle is equipped with an On-Command four–wheel-drive switch “2WD”/ “4WD”and a d ifferential gear lock switch “4WD”/ “LOCK”. Select the appropriate drive according to terrain and the conditions.

 Two-wheel drive (”2WD”): Power is sup-

plied to the rear wheels only.

 Four-wheel drive (“4WD’): Power is

supplied to the rear and front wheels.

 Four–wheel drive with the di ff er ent i al

gear locked (“4 WD-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 re gar dl es s of traction.

WARNING

POTENTIAL HAZARD

Changing from 2WD to 4WD or from 2WD to 2WD-Differential UNLOCK, or vice-versa while the vehicle is moving. WHAT CAN HAPPEN The vehicle handles differently in 4WD than in 2WD and in 2WD- Differential UNLOCK in some circumstances. Changing from 2WD to 4WD or from 2WD to 2WD–Differential UNLOCK, or vice-versa while moving may cause the vehicle to unexpectedly handle differently. This could di stract the operator and increase the risk of losing control and an accident. HOW TO AVOID THE HAZARD Always stop the vehicle before changing from 2WD to 4WD or from 2WD to 2WD–

Differential UNLOCK.

4-12 Control Functions

“2WD/4WD”

1. Select lever

2. On-Command four –wheel-drive switch “2WD/4WD”

To change from 2 WD to 4WD ,st op t he vehicle, and then set the s w it ch t o “4WD”.When the veh icl e is in 4WD, the 4WD indic a tor will come on in the multi-function meter unit display .To change from 4WD to 2WD .stop the vehicle ,be sure

then set the switch to “2WD”.

On-Command Differential Gear Lock Switch “4WD”/”LOCK”

1. On-Command differential gear lock switch “4WD”/ “LOCK”

2. Select lever

To lock the differential gear in 4WD, stop the vehicle, make sure the O n-Command four-wheel-drive swit ch i s set t o “ 4WD”, move the select lever t o , and then

On-Command four -wheel-drive switch

the select lever is set to position , and

set the switch to “LOCK”. Whe n t he differential gear is loc ked, t he differential gear lock indicator light w i ll come on along with the differential gear lock indicator in the multifunction meter unit display .To release the differential gear lock , stop the vehicle and set the switch to “4WD”.

Control Functions 4-13

NOTE:

 When the switch is set to “ LO CK”, the

differential gear loc k indi cator and indicator light will flash u nt il the differential gear is locked.

 When the indicator and indicator light are

flashing, turning the steering wheel back and forth will help the diffe r ent ial gear lock to engage.

 Riding before the differential gear lock

is properly engaged (e.g. , w hen the

HOW TO AVOID THE HAZARD Always ride at a slow speed when the vehicle is in 4WD-LOCK, and allow extra time and distance for maneuvers.

WARNING

POTENTIAL HAZARD Riding too fast while the vehicle is in

4WD-LOCK. WHAT CAN HAPPEN All wheels turn at the same speed when

the differential is locked, so it takes more effort to turn the vehicle. The amount of effort required is greater the faster you go. You may lose control and have an accident if you cannot make a sharp enough turn for the speed you are traveling.

4-14 Control Functions

indicator and indicator light are flashing) will cause the engine speed to be limited until engagement is complete.

Accelerator pedal

Press the accelerator p edal 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 starting the engine.

1. Accelerator pedal

Before starting the engi ne, check the accelerator pedal to be sure it is operating smoothly. Make sure t he accelerator pedal fully returns to the idle position as soon as it is released.

Control Functions 4-15

WARNING

1. Brake pedal

Parking brake lever

The parking brake lever is located at the right

side of the driver’s seat. It will help keep the vehicle from moving whi le parked.

To set the parking brake, pull the lever up

POTENTIAL HAZARD Malfunction of the accelerator pedal. WHAT CAN HAPPEN A faulty pedal that makes it difficul t to speed up or slowdown 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. Consult a service center if you cannot find or solve the problem yourself.

Brake pedal

Press the brake pedal to slow or st op the vehicle.

completely. To release the parking br ake, pull up on the lever, press the release b ut t on, and then

4-16 Control Functions

push the lever all the way dow n. Spring pressure helps return the lever to the released position. Be sur e to fully release the parking brake before start ing out, Failure to do so may result in poor performance and premature wearing of the rear brake and V-belt.

1. Parking br ake lever 2. Release button

Drive select lever

The drive select lever is u s ed to shift your vehicle into the low, high, neutral and reverse

positions. (Refer to pag es 6-4—6-6 for the drive select lever operation.)

1. Drive select lever

Fuel tank cap

Remove the fuel tank cap by turning it

Seats

Control Functions 4-17

counterclockwise.

1. Fuel tank cap

To remove a seat, pull its seat lock lever upward, lift the front of the s eat , and t hen slide the seat forward and up.

1. Driver seat 2. Passenger seat

3. Seat l ock lever (×2)

4-18 Control Functions

To install a seat, insert t he projection on the rear of the seat into the seat hold er s and push down on the seat at t he 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. Always wear the seat belt while riding in the vehicle.

1. Seat belt (×2) 2. Latch plate (×2)

3. Buckle (×2)

To wear the seat belt proper ly, 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.

Control Functions 4-19

2. Push the latch plate into the buckle until it clicks. Pull up on the latch plat e t o m ake sure it is secure.

1. Buckle 2. Latch plate

3. Put the lap portion of the belt low on your hips. Push down on the buckle end of the belt as you pull up on the shoulder part so the belt is snug across your hips.

4. Position the shoulder belt over your shoulder and across y our chest . The

4-20 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 pr ess t he release button.

1. Buckle 2. Release button

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 accide n t. HOW TO AVOID THE HAZARD Always wear your seat belt when riding in the vehicle. Be sure the seat belt is close fitting across your hips and chest and is latched securely.

Glove compartment

CAUTION:

To protect from damage, do not put metal products, like tools or sh arply edged products directly in the glove compartment. If they must be stored, wrap them in appropriate cushion material.

Cargo bed

Control Functions 4-21

a. Unlock b. Open.

1. Cargo bed 2. Tailgate

3. Cargo hook(×4)

4-22 Control Functions

Opening and closing the tai lgate

1. Tailgate 2. Latch (×2)

To open

Unhook the latches, and then lower the tailgate.

To close

Place the tailgate in the or igi nal position, and then hook the latches.

Lifting and lowering the cargo bed

1. Cargo bed release lever

To lift

Push down cargo bed rele ase lever on left or right side of the vehicle; sl owly lift up cargo bed until it stops.

To lower

Lower cargo bed slowly t o it s or ig inal position and be sure it locks into place.

Maximum load limit: 350lb ( 159kg)

Control Functions 4-23

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, frame, and OPS.

WARNING

POTENTIAL HAZARD Overloading the cargo bed WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated maximum load limit for this cargo bed. Cargo should be properly distrib uted and securely attached. Reduce speed when carrying cargo.

Allow greater distance for braking.

4-24 Control Functions

WARNING

POTENTIAL HAZARD Carrying a passenger in the cargo bed WHAT CAN HAPPEN The passenger could fall, be thrown out, or be struck by objects in the cargo bed. HOW TO AVOID THE HAZARD Never carry a passenger in the cargo bed. This cargo bed is designed to carry cargo only.

Front and Rear Shock Adjustment(Option 1)

The spring preload can be adjusted to suit the operating conditio ns. You can reduce preload f or a softer r ide, or increase preload if frequent bottoming out of the UTV occurs.

CAUTION:

Frequent or severe bott oming out of the UTV can cause increased we ar or dam age t o the vehicle.

Adjust the spring prelo ad as follows. To increase the spring preload, turn the adjusting ring in directi on . To decrease the spring preload, turn the adjusting ring in directi on .

Control Functions 4-25

1. Spring preload adjusting ring

2. Position indicator

NOTE:

A special wrench can be obtained at a service center to make t hi s adju stment.

1. Special wrench

Standard position: B

A-Minimum(soft) E-Maximum(hard)

4-26 Control Functions

Front and Rear Shock Adjustm ent(Option 2)

WARNING

These shock absorber assemblies

contain highly pressurized nitrogen gas,

read and understand the following information before handling the shock

absorber assemblies.

Do not tamper with or attempt to open

the cylinder assemblies.

Do not subject the shock absorber

assemblies to an open flame or other

high heat source. This may cause the unit

to explode due to excessive gas

pressure.

Do not deform or damage the cylinders in any way. C ylinde r damage will result in poor damping performance.

WARNING

POTENTIAL HAZARD Improper shock absorber adjustment. WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability, which could lead to an accident. HOW TO AVOID THE HAZARD Always adjust the shock absorbers o n the left and right side to the same setting.

Control Functions 4-27

Spring preload

The spring preload, rebound damping and compression damping forces of the front and rear shock absorber assemblies can be adjusted to suit the operating conditions.

NOTE:

Never turn an adjusting mechanism beyond the minimum and maxi mu m settings.

1. Loosen the locknut.

2. Turn the spring preload adjusting nut in direction ⓐ to increase the spring

preload and thereby harden the suspension, and in direction ⓑ to decrease the spring preload and thereby soften the suspension.

1. Locknut 2. Spring preload adjusting nut

3. Special wrench

Do not dispose of a damaged or worn

out shock absorber assembly yourself. Take the shock absorber assembly to an authorized dealer for any service.

4-28 Control Functions

A special wrench can be obtained at an

authorized dealer to make this adjustment.

The spring preload setting is determined by measuring distance A, shown in the illustration. The shorter distance A is, the lower the spring preload; the longer distance A is, the higher the spring preload. With each complete turn of the adjusting nut.

1. Distance A

3. Tighten the locknut.

NOTE:

Always tighten the locknut against the adjusting nut, and then tighten it to the specified torque.

Rebound damping force

Turn the rebound damping force adjusting screw in direction S to increase the rebound damping force and there by harden the

Spring travel setting(Fr ont)

Minimum(soft): 412mm(16.22 in) Maximum(hard): 426mm(16.77 in)

Spring travel setting(Rear)

Minimum(soft): 330mm(12.99in)

Maximum(hard): 430mm(16.93 in)

damping, and in direction F to decrease the rebound damping force and thereby soften the damping.

1. Rebound damping force adjusting screw

Control Functions 4-29

Compressio n damping force

Turn the compression damping force adjusting screw (use 3.0 a lle n w r ench) in

direction ⓐ to increase the com pr ession damping force and there by harden the

damping, and in direct ion ⓑ to decrease the compression damping force and thereby soften the damping.

a) C ompres si on damping force adjusting screw

4-30 Control Functions

WARNING

Suspension components become hot during operation. Never touch the compression damping force adjusting screw, the rebound damping force

adjusting screw or the oil reservoir with your bare hand or skin until suspension components have cooled.

Always adjust

the shock absorber

assemblies on the left and right side to the same setting. Unev en adjustment can cause poor handling and loss of stability, which could lead to an accident.

Trailer hitch bracket

This vehicle is equipped with a 1 ¼ in receiver bracket for a st andard trailer hitch. Trailer towing equipm ent can be obtained at a service center. (See pa ges 6-12 - 6-14 for precaution information.)

1. Trailer hitch bracket

Auxiliary DC jack

The auxiliary DC jack is lo cat ed at t he r ight side of the front panel. The auxiliary DC jack can be used for suitable wor k light s , r adi os, etc. The auxiliary DC jack should only be used when the engine is r unning.

Control Functions 4-31

1. Auxiliary DC jack cap

1. Set the light switch to “OFF”.

2. Start the engine. (See pages 6-1 - 6-3.)

1. Auxiliary DC jack

3. Open the auxiliary DC jack cap, and then insert the accessory power plug into the jack.

Maximum rated capac it y for the auxiliary

DC jack:

DC 12V, 120W (10 A)

4-32 Control Functions

4. When the auxiliary DC jack is not being used, cover it with the cap.

CAUTION:

 Do not use accessories requir ing more

than the above maximum capacity. This may overload the circuit and cause the fuse to blow.

 If accessories are used wit hout t he

engine running or with the headlights turned on, the battery will lose its charge and engine starting may become difficult.

 Do not use an automotive cigarette

lighter or other accessory with a plug that gets hot because the jack can be damaged.

Pre Operation Checks 5-1

Before using this vehicle, check the following items:

ITEM ROUTINE PAGE

Brakes

●

Check operation, free play, fluid level and fluid leakage

●

Fill with DOT 4 brake fluid if necessary

5-2 - 5-3， 8-35

Parking brake

●

Check for proper operation, condition and free play

6-8 - 6-9

Fuel

●

Check fuel level

●

Fill with fuel if necessary

5-4 - 5-5

ORS / OPS

●

Check for wear or Damage

5-10

Engine/Gear box oil

●

Check oil level

●

Fill with oil if necessary

5-5

Coolant reservoir

●

Check coolant level

●

Fill with coolant if necessary

5-6，8-21 - 8-22

Final gear oil / Differential gear oil

● Check for leakage

5-7

Accelerator pedal

●

Check for proper accelerator pedal operation

5-8

Seat belts

●

Check for proper operation and belt wear

5-10

Steering

●

Check for proper operation

5-10

Fittings and fas teners

●

Check all fittings and fasteners

5-11

Lights and switches

●

Check for proper operation

5-11

Wheels and tires

●

Check tire pressure, wear and damage

5-11 - 5-13，8-41- 8-42

Axle boots

●

Check for damage

8-23

Instrument

●

Check for complete and correct display

4-2 - 4-8

Light/Indicator

●

Check for light / indicator operation

4-2 - 4-8

5-2 Pre Operation Checks

Brakes

Check for correct brake pedal free play. If the brake pedal free play is incorrect, have a service center adjust it. (See pages 8-37 8-38.)

Check the operation of the brake pedal. It should move smoothly and there should be a firm feeling when the brakes are applied. If not, have the vehicle inspected by a service center.

Brake fluid level

Check the brake fluid level. Add fluid if necessary. (See pages 8-34)

Recommended bra ke fl ui d: DOT 4

WARNING

POTENTIAL HAZARD Failure to inspect the vehicle before operati ng. Fa il ure to properly maintain the vehicle. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection and maintenance proce dure s and schedules described in the Owner’s Manual.

Pre Operation Checks 5-3

Brake fluid leakage

Check to see if any brake fluid is leaking out of the hydraulic brake lines, fittings, or the brake fluid reservoir. Apply the brakes fir mly for one minute. If there is any leakage, have the vehicle inspected by a service center.

Brake operation

Test the brakes at slow speed after starting out to make sure they are working properly. If the brakes do not provide proper braking performance, inspect the brake system. (See pages 8-33 - 8-37.)

WARNING

POTENTIAL HAZARD Driving with impro perly opera ting br akes . WHAT CAN HAPPEN You could l ose braking ability which could lead to an accident. HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride. Do not operate the vehicle if you find any problem with the brakes. If a problem cannot be corrected by the adjustme nt pro ced ures pr ovide d in this manual, have the vehicle inspected by a service center.

5-4 Pre Operation Checks

Fuel

Make sur e ther e is sufficient gasoline in the tank.

Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system.

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.

Gasohol

The UTV uses an electric fuel injection system, and its emissions meet the requirements of the US Environment Protection Agency. Never use E-85 fuel or any fuel containing great er than E-10 Ethanol. Fuels cont aining greater than E-10 Ethanol will damage the engine and void any warranties.

Recommended fuel:

Unleaded Non Ethanol 91 Octane or higher gasoline only. E-10 Max Fuel Fuel tank capacity:

7.7 gal (29L)

CAUTION:

Pre Operation Checks 5-5

Engine oil

Make sure the engine oil is at the specified level. Add oil as necessary. (See pages 8-12)

CAUTION:

 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. In addition, do not use oils labeled “ENERGYCONSERVING II” or

higher.

 Make sure that no foreign material

enters the crankcase.

WARNING

POTENTIAL HAZARD Improper care when refueling. 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. Be careful not to spill fuel, especially on the engine or exhaust pipe. Wipe up any spilled fuel immediately. Be sure the fuel tank cap is

closed securely.

5-6 Pre Operation Checks

Recommended engine oil type and quantity:

See page 11-2

CAUTION:

Hard water or salt water is harmful to the

engine.

You may use soft water if you cannot get

distilled water.

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. Change the coolant every two years. (See pages 8-21 - 8-22 for details)

Coolant reservoir cap acity

(up to the maximum level mark):

0.37 qt, (0.35L)

Pre Operation Checks 5-7

WARNING

Final gear oil

Make sure the final gear oil is at the specified level. Add oil as necessary. (See pages 8-17 8-18 for details)

Recommended oil:

SAE 80 API GL -4 Hy poid gear oil

If desired, an SAE 80W90 hypoid gear oil may be used for all conditions.

NOTE:

GL-4 is a quality and additive rating, GL-5 or GL-6 rated hypoid gear oils may also be used.

Differential gear oil

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 befor e removing the radiator cap. Always use a

thick rag over

the cap. Allow any remaining pressure to escape before completely removing the cap.

Make sure the differential gear oil is at the specified level. Add oil as necessary. (See pages 8-19 - 8-20 for details.)

5-8 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 st art or operate this vehicle if it has a sticking or improperly oper ating 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.

Throttle Pe dal

Check to see that the accelerator pedal operates correctly. It must operate smoothly and fully spring back to the idle position when released. Have a service center repair as necessary for proper operation.

Throttle Freeplay

If the throttle pedal has excessive play due to cable stretch or mis-adjustment, it will cause a delay in t hrottle 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.

Recommended oil:

SAE 80 API GL -5 Hy poid gear oil

Pre Operation Checks 5-9

Throttle Freeplay Adjust m e nt

1. Remove both seats. Remove the middle cover of the engine. (see PAGE 8-9 )

2. Loosen the nut of throttle cable on the valve,

3. Spin the throttle cable inside (A)/ outside (B) to increase the thrott le pedal’s moving distance to 1/16 to 1/ 8 inches (1.5-3mm).

1．Accele rator Cable column nut

4. Tighten the the nut.

5. Reinstall the center cover and seats to their correct and locked positions.

Steering Wheel Ins pection

Check the steering wheel for specified freeplay and smooth operation.

1. Position the vehicle on level ground.

Throttle Freeplay Inspec t ion

1. Set the parking brake .

2. Apply the brakes. Start the engine. Allow it to warm up thoroughly.

3. Measure the distance the throttle pedal moves before the engine begins to pick up speed. Freeplay should be 1/16 t o 1/8 inches (1.5-3mm).

5-10 Pre Operation Checks

2. Lightly turn the steering wheel left and right.

3. There should be 0.8″-1.0″ (20-25 mm) of freeplay.

If there is excessive freeplay, unusual noises, or the steering feels rough or″catchy, ″have the steering system inspected by an authorized service center。

Seat belts

Make sur e that b oth seat belts are not frayed or damaged. The seat belt must move smoothly when pulled out and retract on its own when released. The latch plate should click securely into the buckle and release when the release button is pushed firmly. Wash off any dirt or mud which could affect operation. Have a service center repair as necessary for proper operation. Also check any netting in the ORS

system and the OPS stru cture for integrity.

Fittings and fas teners

Always check the tightness of chassis fittings and fasteners before a ride. Take the vehicle to a service center or refer to the Service Manual for correct tightening torque.

Lights

Check the headlights and t ail/brake lights to make sure they are in working condition. Re pair as necessary for proper operation.

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, i ncre as ing y our risk of accident. HOW TO AVOID THE HAZARD

1. The tires listed below have be en approved by Manufacturer for this model. Other tire combinations are not recommended.

Pre Operation Checks 5-11

Tires

Type

Size

Front

26×8-12

6PR

Rear

26×10-12

6PR

WARNING

The tires should be set to the recommended pressure:

Front 10psi (70kpa, 0.7 kgf/cm

)

Rear 10psi (70kpa, 0.7 kgf/cm

) Check and adjust tire pressures when the tires are cold. Tire pressures must be equal on both sides.

Tire pressure below the minimum specified could cause the tire to dislodge from the r im under severe ridin g conditions. The following are minimums: Front 10psi (63 kpa, 0.64kgf/cm

)

Rear 10psi (63 kpa, 0.64kgf /cm

)

5-12 Pre Operation Checks

Set pressure with tires cold. Set tire pressures to the fol lowing specificatio ns:

Recommended

Pressure

Minimum Maximum

Front

10psi (70kpa

(0.70kgf/ cm2)

9 psi (63kpa,

0.64kgf/ cm2)

11 psi, (77kpa,

0.77kgf/

cm2)

Rear

10psi (70kpa (0.70kgf/ cm2)

9 psi (63kpa,

0.64kgf/ cm2)

11 psi, (77kpa,

0.77kgf/ cm2)

How to measure tire pressure

Use the tire pressure gau ge.

NOTE:

The tire pressur e gauge is included as standard equipment. Make two measurements of the tire pressure an d use the s econd reading. Dust or dirt in the gauge could cause the first reading to be incorrect.

1. Tire pressure gauge

5. Use no more tha n the foll owing pr essur es when seating the tire beads. Front 36psi ( 250kpa, 2.5kgf/cm

)

Rear 36psi (250kpa, 2.5kgf/cm

) Higher pressures may cause the tire to burst. Inflate the tires very slowly and carefully. Fast

inflati on coul d cause the tire to burst.

Pre Operation Checks 5-13

Tire wear limit

When the tir e groov e decreases to 0.12 in (3 mm) due to wear, replace the tire.

a. Tire wear limit

6-1 Operation

Starting the engine in low temperatures

1. Check the throttle cable, parking brake, and the reverse lock out c abl e, and make sure that they are not frozen.

2. Start the engine ( see P6-2).

WARNING

POTENTIAL HAZARD Freezing control cables due to cold weather conditions. WHAT CAN HAPPEN Loss of vehicle control, which coul d lead to an accident or collision . HOW TO AVOID THE HAZARD When riding in cold weather, always make sure all control cables work smoothly before you begin riding.

WARNING

POTENTIAL HAZARD Operating vehicle without being fam iliar with all controls. WHAT CAN HAPPEN Loss of control, which could cause an accident or injury. HOW TO AVOID THE HAZARD Read the Owner’s Manual carefully. If there is a control or function y o u d o n ot understand, ask your service center.

Starting the Engine

See the “Engine Brea k-In”sectio n pr ior t o operating the engine for the first time.

1. Turning the key to “ON”, the light in the display will turn on, and el ectronic injection system’s fue l 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. If the neutral

Operation 6-2

indicator light does not come on, ask a service center to inspect the electric circuit.

● The engine can be started in any gear i f

the brake is applied. However, it is recommended to shift into neutral ”N” before starting the engine.

4. With your foot off the acceler at or pedal, start the engine by tur ning t he key t o “START”.

NOTE:

If the engine fails to start, r elea se the key, and then try starting aga in . Wait a few seconds before the next attempt. Each cranking should be as sho r t as possible to preserve battery ener gy. Do not crank the engine more than 5 seconds on each

CAUTION:

6-3 Operation

attempt.

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 speed up when the voltag e of battery is low.

Place the gear on position ‘N’, and press

Warming Up

To get maximum engine li fe, alw ays warm up the engine before drivin g. Never accelerate hard with a cold engine! To see whether or not the engine is warm, check if it responds to the throttle normally .

1. Release the brakes and press the accelerator pedal gradually.

2. If the speed of the e ngine accelerates with pedal steadily, the engine is warm and the vehicle can been ridde n. Otherwise,

the throttle pedal to make the engine run at

2500RPM to charge the battery for 5-10 minutes; when the voltage of battery is over 12V, the idle speed will be normal. If the idle speed is still high, please contact your

service center.

go on with the third step.

3. Continue warming up the engine until it idles smoothly.

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, y ou must stop the UTV and return the throttle lever to the closed position; otherwise the trans mission may be damaged.

Operation 6-4

Shifting: Neutral to High and High to Low

1. Stop the vehicle. Keep your foot off the accelerator pedal.

2. Apply the brakes, and t hen shift by moving the drive select l ever along the shift guide.

NOTE:

Make sure that the driv e select lever is completely shifted into position.

CAUTION:

6-5 Operation

1. Drive select lever

3. Release the brakes and pr ess t he accelerator pedal gradually.

Shifting: Neutral to Reverse

1. Stop the vehicle. Keep your foot off the accelerator pedal.

2. Apply the brake pedal.

3. Shift from neutral to reverse or vice versa by moving the drive select lever along

the shift guide.

NOTE:

● Always depress the brake pedal before placing

the gearshift 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. Position pin 2.Cable 3. Adjust

1. Drive select lever

NOTE:

● When in reverse, the reverse indicator

light should be on. If the li ght does not come on, ask a service center to inspect the reverse indicator lig ht electrical circuit.

● Due to the synchronizing mecha nis m in

Operation 6-6

the engine, the light may not c ome on until the vehicle starts moving.

4. Check behind for people o r obst ac l es, and then release the brake pedal.

5. Press the accelerator p edal gradually and continue to watch to the rear while backing up.

6-7 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 obj ects. Never park the vehicle on hills that are too steep.

WARNING

POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN You could hit an obstacle or person behind you, resulting in serious injury. HOW TO AVOID THE HAZARD When you shift into reverse, make sure there are no obstacles or people behind you. When it is safe to proceed, go slowly.

Parking

a) When parking, stop the engine and shift

the drive select lever into t he neut r al position.

b) Push the brake pedal down, and pull the

parking brake to top position to park the vehicle

Parking on a Slope

Operation 6-8

1．Parking handbar

1. Bring the vehicle to a stop by applying the brakes.

2. Stop the engine.

3. With the brakes applied, set the parking brake.

6-9 Operation

1．parking handbar

NOTE:

Like many other vehicles, the parking brake acts on the rear wheels. F or t he parking brake to operate all four w heels, shift to 4WD before stopping the eng in e.

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. Careful treatment of a new engine and drive components will result i n more efficient performance and longer l if e for t hese components. Perfor m the following procedures carefully.

CAUTION:

● Excessive heat build-up dur ing t he first

three hours of operation will damage close-fitted engine parts and drive components. Do not op er at e at ful l throttle or high speeds during the first t hr ee hours

of use.

● Use of any engine oil not mentioned in

this manual will cause severe dama ge 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 rea son, we ask that you carefully read the fo ll owing material. Because the engine is brand new, you must not put an excessive load on it for t he first several hours of running. During the first 25 hours, t he various parts in the engine wear and polish themselves to the correct operating cle ar ances. During this period, prolonged ful l thr ot t le operation or any condition which might result in excessive engine heating must be a voided. However,

Operation 6-10

momentary (2-3 seconds maximum) full throttle operation under load does not harm the engine. Each full throttle acceleration sequence should be followed with a subs t antial rest period for the engine by cr uis ing at l ow er engine speed so the engi ne can r id itself of the temporary build up of heat. If any abnormality is notice d during this period, consult a service center.

0-10 Hours:

Avoid continuous operation above half throttle. Allow a cooling off period of five to ten minutes after every hour of operation. Vary the speed of the vehic le from time to time. Do not operate it at one set t hr ottle position.

6-11 Operation

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 o per at ed normally.

Brake System Break-in

Apply only moderate bra king force for the first 50 stops. Aggress iv e 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 cl ut ches and drive belt will ensure a longer lif e and bet ter

performance. Break in t he clutches and belt by operating at slower sp eeds during the break-in period as reco m me nded. Pull only light loads. Avoid aggre ss i ve acceleration and high speed operation during the break-in period.

Accessories

Accessories can affect the handling and control of your vehicle. Keep the following in mind when considering an accessory or operating a vehicle that h as accessories.

● Choose only accessories designe d for

your vehicle. Your service center has a variety of genuine accessories. Other accessories may also be available on the market. It is not possible to test all

nonstandard accessories, nor have any control over the qual ity or suitability of them. Choose only genu ine accessories, or accessories which are equivalent in design and quality.

● Accessories should be rigidly and

securely mounted. An accessory that can shift position or come of f w hile you are operating could affect your ability to control the vehicle.

● Do not mount an accessory w her e it

could interfere with y our abil ity to control the vehicle. Examples in c l ude ( but ar e not limited to) an object t hat limits your ability to turn the steering wheel or one that limits your view.

● Use extra caution when driving a vehicle

Operation 6-12

with accessories. The vehicle may handle differently than it does without accessories.

Cargo or a trailer can change the stability and handling of a vehicle. Y ou mu s t use common sense and good judgment when carrying cargo or towing a trailer. Keep the following points in mind:

● Never exceed the weight limits sh own

below. An overloaded v ehicle can be unstable.

● Choose a trailer hitch drawbar designed

for use with a 1 ¼ in receiver.(See page 4-31 for more information)

● Do not exceed the maximum tongue

6-13 Operation

weight. You can measur e tongue weight with a bathroom scale. Put the tongue of the loaded trailer on the scale with the tongue at hitch height. A dj ust the load in the trailer, if necessar y, to reduce the weight on hitch. If you are carrying cargo and towing a trailer, include the tongue weight in the maximum v ehicle load limit.

MAXIMUM LOADING LIMIT

● Vehicle loading limit (total weight of

cargo, operator, passe nger and accessories, and tongue weight): 880 lb (399Kg)

● Cargo bed:350 lb (159Kg)

● Trailer hitch:

Pulling load (total weight of trailer and cargo): 1,212lbf (550Kgf) Tongue weight (vert ical weight on

trailer hitch point): 110 lbf (50Kgf)

● Load cargo in the cargo bed as close t o

the center of the vehicle a s possible and tie it down using the cargo hooks equipped on the cargo bed.

● Tie down cargo securely in the t r ailer.

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 y ou car r y, the slower you should go. Alt hough conditions vary, it is good pract ice not to exceed low range whenever you are carrying heavier loads or when towing a trailer.

● Allow more braking distance. A heav ier

vehicle takes longer t o stop.

● Avoid making sharp turns unless at v er y

slow speeds.

● Avoid hills and rough terrain. Choose

Operation 6-14

terrain carefully. Added weight affects the stability and handling of the vehicle.

6-15 Operation

WARNING

POTENTIAL HAZARD Overloading this vehicle or c ar ry ing 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 distrib uted and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance

for braking.

Your Vehicle 7-1

DRIVING YOUR VEHICLE

GETTING TO KNOW YOUR VEHICLE

This off-highway ut ility 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 Owner’

s Manual

completely and under st and all the features. Pay particular attenti on t o t he safety information on pages 2-1 - 2-18. Please read all the caution and warning labels on your vehicle. This vehicle is designed f or t he oper at or and one passenger. The driv er and passenger must always wear a seat belt. Never carry passengers in the cargo bed.

WARNING

POTENTIAL HAZARD Not wearing the seat belt. Wearing the seat belt improperly. WHAT CAN HAPPEN There is increased risk of being killed or seriously injured in an accide n t. HOW TO AVOID THE HAZARD Always wear your seat belt when riding in the vehicle. Be sure the seat belt is close fitting across your hips and chest and is latched securely.

7-2 Your Vehicle

The total weight of operator, passenger, accessories, cargo, tr ai ler tongue weight, and the vehicle itself must not exceed 1,880 lbs (853Kg).

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.

Your Vehicle 7-3

The driver and passenger must always wear

a seat belt, an approved motorcycle helmet,

eye protection and protective clothing, including over-the-ankle b oot s, gloves, a long-sleeved shirt or jacket, and long pants. Keep hands and feet ins id e t he vehicle at all times.

WARNING

POTENTIAL HAZARD

Overloading this vehicle or c ar rying or towing carg o improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HA ZARD Never exceed the state d load capacity for this vehicle. Cargo should be properly distributed and securely at t ached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking. Always fol low the instructions i n your Owner’s Manual for carr ying cargo or

pulling a trailer.

7-4 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.

HOW TO AVOID THE HAZARD

Always wear an approved motorcycle helmet that fits properly. You should al so wear:

eye protection (goggles or face shield) gloves boots long-sleeved shirt or jacket

long pants

Your Vehicle 7-5

LEARNING T O OPERATE YOUR VEHICLE

You should become fam il i ar w it h t he performance charact er istics of the vehicle in a large, flat area that is free of ob stacles and other vehicles. Pract ice control of the accelerator pedal, brakes, steering, and drive select lever. Drive at a slo w speed and become comfortable at that speed before gradually increasing your speed. Become familiar with the way t he vehicle feels in low and high ranges, first in two-wheel drive (2WD) and then in four-w heel drive (4WD) and four-wheel drive with the differential locked. Practice driv ing i n reverse. Take the time to learn basic operat i on before attempting maneuvers that are more difficult.

Perform the Pre-Operat ion Checks on pages 5-1 - 5-11. Set the parking brake, shift to neutral, and follow the in st r uct ions on page 6-1 to start the engine. Once it has w armed up you are ready to begin driving your vehicle. With the engine i dling, shift the drive select lever into low or hig h. Then r elease the parking brake. Press th e accelerator pedal slowly and smoothly . The cent r i fugal clutch will engage and you will st art to accelerate. Avoid higher speeds until you are thoroughly familiar with the operati on of your vehicle. When slowing down or stopping, take your foot off the accelerator pedal and smoothly press the brake pedal. Improper use of the brakes can cause the tires to lose traction, reducing control and incr easing the

Cub Cadet Challenger 500, Challenger 700 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual