gio Vyper 4WD 1100cc 2 seater, Vyper 4WD 1100cc 4 seater, Vyper 4WD 1100cc Owner's Manual

Owner’s Manual

Vyper 4WD 1100cc

4 seater

2 seater

GIO MOTORS

INTRODUCTION

Congratulations on your purchase of the GIO 1100cc Vyper UTV. With the
purchase of this UTV, you can now appreciate the high degree of
craftsmanship. This manual will provide you with a good basic understanding
of the features and operation of this UTV. This manual includes important
safety information. It provides information about special techniques and skills
necessary to ride your UTV. It also includes basic maintenance and inspection
procedures. If you have any questions regarding the operation or maintenance
of your UTV, please consult your dealer.

AN IMPORTANT SAFETY MESSAGE:

 Read this manual for the UTV rider 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 a UTV without proper training or instruction.
 This UTV, and any other UTV over 90cc, should not be ridden by anyone

under the age of 16.

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:

NOTE: A

NOTE provides key information to make procedures easier or clearer.

The Safety Alert Symbol means ATTENTION! BECOME
ALERT!

Failure to follow WARNING instructions could result in severe
injury or death to the machine operator, a bystander or a person
inspecting or repairing the machine.

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

IMPORTANT NOTICE

This UTV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe
to operate this UTV on any public street, road or highway. This UTV complies with all
applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the
time of manufacture. Please check your local riding laws and regulations before operating
this UTV.

TABLE OF CONTENTS

Introduction……………………………………………………………………………………1

SAFETY………………………………………………………………………………………3

Features and Controls…………………………………………………………………………21

Component Locations…………………………………………………………………………21

Indicator and warning lights…………………………………………………………………23
Switch…………………………………………………………………………………………24

Seats……………………………………………………………………………………………25

Seat Belts………………………………………………………………………………………25
Seat Belt Inspection……………………………………………………………………………26
Fuel cap …………………………………………………………………………………27

Ignition Switch ………………………………………………………………………………28
Gear Selector…………………………………………………………………………………29

Brake Pedal……………………………………………………………………………………30
Throttle Pedal…………………………………………………………………………………30

OPERATION…………………………………………………………………………………31

Vehicle break-in period………………………………………………………………………31

Pre-ride inspection……………………………………………………………………………33

Safe operation practices………………………………………………………………………34

Starting the engine……………………………………………………………………………35

Stopping the engine……………………………………………………………………………36

Braking…………………………………………………………………………………………36

Parking the vehicle……………………………………………………………………………36

New operator driving procedures……………………………………………………………37

Driving with a passenger………………………………………………………………………39

Driving on slippery surface……………………………………………………………………40

Driving uphill…………………………………………………………………………………42

Driving on a sidehill…………………………………………………………………………43

Driving downhill………………………………………………………………………………43

Driving through water…………………………………………………………………………44

Driving over obstacles…………………………………………………………………………45

Driving in reverse………………………………………………………………………………46

Parking on an incline…………………………………………………………………………47

MAINTENANCE………………………………………………………………………………48

Periodic maintenance chart …………………………………………………………………48

Engine oil ……………………………………………………………………………………51

Transmission (main gearcase)………………………………………………………………55

Spark plugs……………………………………………………………………………………56

CVT system ……………………………………………………………………………57

Filter system …………………………………………………………………………………66

Cooling system …………………………………………………………………………………68

Throttle system ………………………………………………………………………………69

EFI system ……………………………………………………………………………………71

Brakes…………………………………………………………………………………………73

Steering wheel inspection ……………………………………………………………………75

Shock spring adjustment ……………………………………………………………………75

Tires……………………………………………………………………………………………76

Vehicle immersion……………………………………………………………………………77

Battery…………………………………………………………………………………………78

Clearing and storage…………………………………………………………………………81
Malfunction analysis and elimination ………………………………………………………83

WARRANTY………………………………………………………………………97

SPECIFICATIONS…………………………………………………………………………100
Circuit Diagram…………………………………………………………………………105

1

INTRODUCTION

Failure to follow the warnings and safety precautions contained in this manual can result in severe
injury or death. Your vehicle is not a toy and can be hazardous to operate. This vehicle handles
differently than cars, trucks or other off-road vehicles. A collision or rollover can occur quickly, even
during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper
precautions.

● Read this owner’s manual. Understand all safety warnings, precautions and operating procedures
before driving the vehicle. Keep this manual with the vehicle.

● Never operate this vehicle without proper instruction.

● Always follow the age guidelines for your vehicle. Operation is prohibited for anyone age 16 and

under. Never operate with a passenger age 12 and under.

2

INTRODUCTION

Identification number records

Record the vehicle identification number and engine number in the spaces provided for assistance
when ordering spare parts from your dealer or for reference in case the vehicle is stolen.

800cc/1100cc: 1100cc:

800cc:

NOTE:The vehicle identification number
is used to identify your machine.

3

SAFETY

Equipment Modifications

Your vehicle is designed to provide safe operation when used as directed. Modifications to your
vehicle may negatively impact vehicle stability. Failure of critical machine components may result
from operation with any modifications, especially those that increase speed or power. This vehicle
may become less stable at speeds higher than those for which it is designed. Loss of control may
occur at higher speeds. Do not install on a vehicle any equipment that may increase the speed or
power of the vehicle, or make any other modifications to the vehicle for these purposes. Any
modifications to the original equipment of the vehicle create a substantial safety hazard and increase
the risk of bodily injury. The warranty on your vehicle is terminated if any equipment has been added
to the vehicle, or if any modifications have been made to the vehicle, that increases its speed or power.
The addition of certain accessories may change the handling characteristics of the vehicle. Use only
our company approved accessories, and familiarizes yourself with their function and effect on the
vehicle.

4

SAFETY

Safe Riding Gear

Always wear appropriate clothing when riding this vehicle. Wear protective clothing for comfort and

to reduce the chance of injury.

5

SAFETY

Safe Riding Gear

Helmet

Wearing a helmet can prevent a severe head injury. Whenever riding this vehicle, always wear a
helmet that meets or exceeds established safety standards.
Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.

Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a vehicle, always
wear shatterproof goggles or use a shatterproof helmet face shield.
Gloves
Wear gloves for comfort and for protection from sun, cold weather and other elements.
Boots
Wear sturdy footwear. Do not ride a vehicle with bare feet.
Clothing
Wear long sleeves and long pants to protect arms and legs.

6

SAFETY

Safety Warnings

Failure to operate this vehicle properly can result in a collision, loss of control, accident or overturn,
which may result in serious injury or death. Be sure to read all of the following warnings about driving
hazards and how to avoid them. These warnings are provided for your safety.
Operating Without Instruction
Operating this vehicle without proper instruction increases
the risk of an accident. The operator must understand how to
operate the vehicle properly in different situations and on
different types of terrain.
Age Restrictions
Operation is prohibited for anyone age 16 and under. Never
operate with a passenger age 12 and under. Make sure any
passenger is tall enough to comfortably and safely reach the
hand holds and place both feet on the floor.

7

SAFETY

Safety Warnings

Rider Height

Some riders may be too tall to ride safely in this vehicle.
Do not operate or ride in this vehicle if the clearance
between the top of your helmet and the overhead cab
frame is less than 2 inches (5 cm).

Failure to Inspect Before Operating
Failure to inspect and verify that the vehicle is in safe
operating condition before operating increases the risk
of an accident. Always inspect the vehicle before each
use to make sure it's in safe operating condition. Always
follow the inspection and maintenance procedures and
schedules described in the owner's manual.
Accessories
Installing non-approved accessories may seriously affect
vehicle handling and stability, which could result in loss
of control or an accident. Never install accessories not
approved by our company for use on this vehicle.

8

SAFETY

Safety Warnings

Protective Apparel

Riding in this vehicle without wearing an approved
helmet and protective eyewear increases the risk of
serious injury in the event of an accident. Operator
and passenger must always wear an approved helmet
that fits properly and eye protection (goggles or face
shield).
Seat Belts
Riding in this vehicle without wearing the seat belt increases the risk of serious injury in the event of
an accident or sudden stop. Riders must wear seat belts at all times. Seat belts reduce the severity of
injury in the event of a sudden stop or accident. Always make sure the seat belts are secured for both

the operator and passenger before riding.
Using Alcohol or Drugs
Riding in this vehicle after consuming alcohol or drugs
could adversely affect operator judgment, reaction time,
balance and perception. Never consume alcohol or drugs
before or while operating or riding in this vehicle.

9

SAFETY

Safety Warnings

Carrying a Passenger

Never carry a passenger until you have operated this vehicle for at least four hours.
Carrying Multiple Passengers
Carry more than limitative passengers of the labels of the 800/1100UE or
800/1100UEL can affect the operator’s ability to steer and operate the
controls, which increases the risk of loss of control and accident or overturn.
Never carry more than limitative passengers in this vehicle.

Operating on Pavement
Operating this vehicle on paved surfaces (including sidewalks, paths,
Parking lots and driveways) may seriously affect handling and control of the vehicle, and may cause
the vehicle to go out of control. This vehicle's tires are designed for off-road use only, not for use on
pavement. Avoid operating the vehicle on pavement. If you must operate on a paved surface, travel
slowly and do not make sudden turns or stops.
Operating on Public Roads
Operating this vehicle on public streets, roads or highways
could result in a collision with another vehicle. Never
operate this vehicle on any public street, road or highway,
including dirt and gravel roads. In many areas it's unlawful
to operate vehicles of this type on public streets, roads and
highways.

10

SAFETY

Safety Warnings

Operating at Excessive Speeds

Operating this vehicle at excessive speeds increases the

operator's risk of losing control. Always operate at a speed
that's appropriate for the terrain, the visibility and operating

conditions, your skills and your passenger’s skills.

Turning Improperly

Turning improperly could cause loss of traction, loss of control, accident or overturn. Never turn

abruptly or at sharp angles. Never turn at high speeds. Practice turning at slow speeds before

attempting to turn at faster speeds.

Physical Control of the Vehicle

Removing hands from the steering wheel or hand holds or removing feet from the floor while riding

increases the risk of loss of control and accident or overturn. The operator should always keep both

hands on the steering wheel during operation. A passenger should always be seated in the passenger

seat with both feet on the floor and with both hands securely grasping the hand holds. Always keep

hands and feet inside the vehicle at all times.

11

SAFETY

Safety Warnings

Jumps and Stunts

Exhibition driving increases the risk of an accident or

overturn. DO NOT do power slides, “donuts”, jumps

or other driving stunts. Avoid exhibition driving.

Driving Downhill Improperly

Driving down a hill improperly could cause
loss of control or overturn. Always follow
proper procedures for driving down a hill as described in the owner's manual.

● Always drive down a hill with the transmission in

forward gear. Never drive down a hill with the
transmission in neutral.

● Never operate the vehicle on hills steeper

than 15 degrees.

● Always check the terrain carefully before driving down a hill

● Never travel down a hill at high speed.

● Avoid traveling down a hill at an angle, which would cause the vehicle to lean sharply to one side.

Travel straight downhill.

12

SAFETY

Safety Warnings

Improper Hill Climbing

Improper hill climbing could cause loss of control or overturn.
Use extreme caution when operating on hills. Always follow
proper procedures for hill climbing as described in the owner's
manual.

Stalling While Climbing a Hill

Stalling or rolling backwards while climbing a hill could cause

an overturn. Maintain a steady speed when climbing a hill.

If you lose all forward speed:

Apply the brakes gradually until the vehicle is fully stopped.

Place the transmission in reverse and slowly allow the vehicle

to roll straight downhill while applying light brake pressure to

control speed.

Crossing Hillsides

Driving on a sidehill is not recommended. Improper procedure

could cause loss of control or overturn. Avoid crossing the side

of any hill unless absolutely necessary.

13

SAFETY

Safety Warnings

Operating in Unfamiliar Terrain

Failure to use extra caution when operating on unfamiliar terrain

could result in an accident or overturn.

Unfamiliar terrain may contain hidden rocks, bumps, or holes that

could cause loss of control or overturn.

Travel slowly and use extra caution when operating on unfamiliar

terrain. Always be alert to changing terrain conditions.
Operating on Sand or Slippery Terrain
Operating on sand or on excessively rough, slippery or loose
terrain could cause loss of traction, loss of control, accident
or overturn. Always use extra caution when operating on
sand or on rough, slippery or loose terrain. Do not operate on
excessively rough, slippery or loose terrain.

14

SAFETY

Safety Warnings

Operating Improperly in Reverse

Improperly operating in reverse could result in a collision with
an obstacle or person. Always follow proper operating procedures
as outlined in this manual. Before shifting into reverse gear, always
check for obstacles or people behind the vehicle. When it's safe to
proceed, back slowly.

Operating Over Obstacles

Improperly operating over obstacles could cause loss of control or

overturn. Before operating in a new area, check for obstacles. Never

attempt to operate over large obstacles such as rocks or fallen trees.

Always follow the proper procedures outlined in this manual when

operating over obstacles.

Skidding or Sliding

Skidding or sliding can cause loss of control or overturn (if tires regain traction unexpectedly).

Always follow proper procedures for operating on slippery surfaces as described in the owner's

manual. When operating on slippery surfaces such as ice or loose gravel, reduce speed and use extra

caution to reduce the chance of skidding or sliding. Do not operate on excessively slippery surfaces.

15

SAFETY

Safety Warnings

Operating Through Water

Operating through deep or fast-flowing water can cause loss

of traction, loss of control, overturn or accident. Never operate

in fast-flowing water or in water that exceeds the floor level.

Always follow proper procedures for operating in water as

described in the owner's manual. Wet brakes may have reduced

stopping ability. After leaving water, test the brakes. Apply them
lightly several times while driving slowly. The friction will help
dry out the pads.
Overloading the Vehicle
Overloading the vehicle or carrying/towing loads may cause changes in stability and handling, which
could cause loss of control or an accident.

● Never tow objects or carry loads with this vehicle.

● Never exceed the maximum weight capacity for this vehicle.

16

SAFETY

Safety Warnings

Operating a Damaged Vehicle

Operating a damaged vehicle can result in an accident with serious injury or death. After any overturn
or accident, have a qualified service dealer inspect the entire vehicle for possible damage, including
(but not limited to) brakes, throttle and steering systems.
Operating on Frozen Bodies of Water
Operating on frozen bodies of water can result in the vehicle
and/or riders falling through the ice. Never operate this
vehicle on a frozen body of water.

17

SAFETY

Safety Warnings

Handling Gasoline

Gasoline is highly flammable and is explosive under certain conditions. Always exercise extreme

caution whenever handling gasoline.

● Never allow a child to refuel or handle gasoline.

● Always stop the engine when refueling.

● Always refuel outdoors or in a well ventilated area.

● Do not smoke or allow open flames or sparks in or near the refueling area or where gasoline is

stored.

● Never refuel while a person is in the vehicle.

● Do not over fill the tank. Do not fill the tank neck.

● If gasoline spills on your skin or clothing, immediately wash it off with soap and water and change

clothing.

● Turn the fuel valve off whenever the vehicle is stored or parked.

Exposure to Exhaust

Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time.

Never start the engine or let it run in an enclosed area. Operate this vehicle only outdoors or in

well-ventilated areas.

18

SAFETY

Safety Warnings

Hot Exhaust Systems

Exhaust system components are very hot during and after use of the vehicle. Hot components can

cause burns and fire. Do not touches hot exhaust system components. Always keep combustible

materials away from the exhaust system.

Use caution when traveling through tall grass, especially dry grass. Always inspect the underside of

the vehicle and areas near the exhaust system after driving through tall grass, weeds, brush and other

tall ground cover. Promptly remove any grass or debris clinging to the vehicle.

Unauthorized Use of the Vehicle

Leaving the keys in the ignition can lead to unauthorized use of the vehicle, which could result in an

accident or overturn. Always remove the ignition key when the vehicle is not in use.
Safety Labels and Locations
Warning labels have been placed on the vehicle for your protection. Read and follow the instructions
on each label carefully. If any of the labels shown in this manual differ from the labels on your vehicle,
always read and follow the instructions of the labels on the vehicle. If an informational or graphic
label becomes illegible or comes off, contact your dealer to purchase a replacement.

19

SAFETY

Safety Labels and Locations

Warning Label

WARNING

Improper vehicle use can result in SEVERE INJURY or DEATH

NEVER allow vehicle to be operated:

● Without all occupants first viewing and understanding safety
warning labels.

● With more than one passenger.

● On hills steeper than 15 degrees

● On paved surfaces - pavement may seriously affect handling

and control.

● With non-approved accessories ,they may seriously
affect stability.

● At speeds that are too fast for the operator’s skills, the conditions
and/or the terrain.

ALWAYS require operator and passenger to:

● Wear seat belts, grab hand holds (passenger) and plant feet firmly

on the floor.

● Keep hands and feet inside vehicle.

● Avoid quick turns of the steering wheel and driving stunts such as

jumps, donuts or power slides.

● Reduce speed and use extra caution when carrying a passenger.

20

● Watch for branches or other hazards that could enter vehicle.

SAFETY

Safety Labels and Locations

Warning Label
WARNING

Operation of this vehicle by children age 16 and under increases the risk of severe injury or death.
NEVER permit children age 16 and under to operate or ride in this vehicle.
WARNING
VEHICLE OVERTURN could cause severe injury or death. The cab frame is not designed or
intended to provide rollover protection.

TIRE PRESSURE IN PSI (KPa):

27′ Front: 14±0.5(96.5±3.5) Rear: 14±0.5(96.5±3.5)
26′ OPTIONAL Front: 12±0.5(82.5±3.5) Rear: 12±0.5(82.5±3.5)

MAXIMUM WEIGHT CAPACITY：990 lbs. (450 Kg)

INCLUDES WEIGHT OF OPERATOR, PASSENGER AND ACCESSORIES.
LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND
WARNINGS. IF OWNER’S MANUAL IS MISSING, CONTACT YOUR DEALER FOR
A REPLACEMENT.

21

FEATURES AND CONTROLS

Component Locations

22

FEATURES AND CONTROLS

Component Locations

23

FEATURES AND CONTROLS

Indicator and warning lights

1. AWD indicator 2. Tachometer 3. Temperature warming light 4.Low battery and Over

Voltage 5. Fuel indicator 6. turning indicator 7.Engine malfunction warming light

8. Fuel

warming light 9.Water temperature warming light 10. High beams indicator 11.Gear indicator

12.Oil pressure low warming light 13. Parking indicator light

24

FEATURES AND CONTROLS

Switch

1. Meter adjust button

2. Driver model turn switch

3. Turning switch

4. Light switch

5. Low beams/High beams turn

6. Horn switch

7. Warning indicator light switch

8.

Wiper switch (optional)

9. Spot light

(optional)

10. Cigarette lighter

11.

Winch switch (optional)

12. Auxiliary DC jack (12V 120W/10A)

25

FEATURES AND CONTROLS

Seat

Seat Removal

Pull up on the front of the seat and slide it toward the front of the vehicle.
Install the seat by sliding the tabs into the rear of the seat base. Push down firmly on the front of the
seat until the pins are fully seated into the grommets.
Seat Belts
This vehicle is equipped with three-point lap seat belts for
the operator and passenger. Always make sure the seat belts
are secured for both the operator and passenger before riding.
To wear the seat belt properly, follow this procedure:

1. Take up the seat belts which are located on the edges of

seat and across your shoulders just like wear a coat. The

buckle is in front of your abdomen. Make sure the belt is
not twisted.

Tip: The position of the shoulder strap can be adjusted

to the height of the operator.

2. Push the latch plate into the buckle until it clicks.

3. Press the red release latch on the buckle to release

the seat belt.

26

FEATURES AND CONTROLS

Seat Belt Inspection

Inspect all seat belts for proper operation before each use of the vehicle.

1. Push the latch plate into the buckle until it clicks. The latch plate must slide smoothly into the

buckle. A click indicates that it's securely latched.

2. Push the red release latch in the middle of the buckle to make sure it releases freely.

3. Inspect the full length for any damage, including cuts, wear, fraying or stiffness. If any damage is

found, or if the seat belt does not operate properly, have the seat belt system checked and/or

replaced by an authorized dealer.

4. To clean dirt or debris from the seat belts, sponge the straps with mild soap and water. Do not use

bleach, dye or household detergents.

27

FEATURES AND CONTROLS

Fuel Tank Cap

Never allow a child to refuel or handle gasoline.

The fuel tank filler cap is located on the right-hand

side of the vehicle behind the passenger seat. When refueling,

always use unleaded gasoline.

28

FEATURES AND CONTROLS

Ignition Switch

(1) Turn the key switch to “ST” position. The engine can be started only at this position and the

key can not be removed.

(2) Turn the key switch to “ON” position, the engine will turn off. When turn the key switch

to “OFF” position ,the electric was cut off and the key can be removed.

Cigarette Lighter

The cigarette lighter installed on the vehicle. The socket also can be used for phone charging
and external power supply.

Note: The voltage of the socket is 12V DC. Please check the electrical power, so as

to avoid damage.

29

FEATURES AND CONTROLS

Gear Selector

1100cc: R: Reverse 800cc: R: Reverse

N: Neutral N: Neutral
L: Low gear H: High gear

H: High gear L: Low gear
The gear selector is located on the right of the steering wheel.
To change gears, stop the vehicle, and with the engine idling,
move the lever to the desired gear. Do not attempt to shift gears
with engine speed above idle or while the vehicle is moving.
Tip: Maintaining shift linkage adjustment is important to assure proper transmission function. See
your dealer if you experience any shifting problems.
NOTICE: Do not attempt to shift the transmission while the vehicle is moving or damage to the
transmission could result. Always shift when the vehicle is stationary and the engine is at idle.
Parking Brake

1. Apply the brakes.

2. When the vehicle is fully stopped, pull the parking brake lever rearward as far as possible to set the

parking brake.

3. Stop the engine.

4. To release the parking brake, apply the brakes and push the lever toward the passenger seat and

forward.

30

FEATURES AND CONTROLS

Tip: Always set the parking brake whenever the vehicle is left unattended.

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

Brake Pedal

Depress the brake pedal to slow or stop the vehicle. Apply
the brakes while starting the engine.

Throttle Pedal

Push the pedal down to increase
engine speed. Spring pressure
returns the pedal to the rest position when released. Always
check that the throttle pedal returns normally before starting
the engine. Make sure there's adequate throttle pedal freeplay.
See page 60 for throttle pedal adjustment procedures.
If the throttle cable should stick in an open position when the.
operator releases the throttle pedal, the engine will stop and power to the rear wheels will cease.

31

OPERATION

Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn,

which may result in serious injury or death. Read and understand all safety warnings outlined in the

safety section of this owner’s manual.

Vehicle Break-in Period

The break-in period for your new vehicle is defined as the first ten hours of operation, or the time it

takes to use the first two full tanks 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 in more efficient performance and longer life for these

components. Perform the following procedures carefully.

NOTICE: Excessive heat build-up during the first three hours of operation will damage close-fitted

engine parts and drive components. Do not operate at full throttle or high speeds during the

first three hours of use.

Mixing brands or using a non-recommended oil may cause serious engine damage. Always use the

recommended oil. Never substitute or mix oil brands.

32

OPERATION

Vehicle Break-in Period

Engine and Drivetrain Break-in

1. Fill the fuel tank with gasoline. Always exercise extreme caution whenever handling gasoline.

Never allow a child to handle gasoline.

2. Check the oil level. See page 52. Add the recommended oil as needed to maintain the oil level in

the safe operating range.

3. Complete the New Operator Driving Procedures outlined on pages 37-38.

4. Avoid aggressive use of the brakes. See Brake System Break-in below.

5. Vary throttle positions. Do not operate at sustained idle.

6. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride inspection

checklist. See page33.

7. Change the engine oil at 10 hours or one month.

Brake System Break-in

Apply only moderate braking force for the first 50 stops. Aggressive or overly forceful braking when
the brake system is new could damage brake pads and rotors.

CVT Break-in (Clutches/Belt)

A proper break-in of the clutches and drive belt will ensure a longer life and better performance.
Break in the clutches and belt by operating at slower speeds during the break-in period as
recommended. Avoid aggressive acceleration and high speed operation during the break-in period.

33

OPERATION

Pre-Ride Inspection

Failure to inspect and verify that the vehicle is in safe operating condition before operating increases
the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating
condition.

Item Remarks Page

Brake Ensure proper operation 73

Steering Ensure free operation 75

Engine oil Ensure proper levels 51 52 53 54
Air filter Inspect, clean

66 67

Seat Belts Check length of belt for damage,

check latches for proper operation

25

Brake fluid Ensure proper level 74

Tires Inspect condition 76

Throttle system Ensure proper operation

69 70

Gearcase fluid Ensure proper levels 55

Spark plug Inspect condition 56

34

OPERATION

Safe Operation Practices

1. Complete the New Operator Driving Procedures outlined on pages 37-38.

2. Do not ride at night or when visibility is poor (rain, fog, dusk). Your vehicle doesn't have lights that

are designed for driving in these conditions.

3. Never tow objects or carry loads with this vehicle.

4. Engine exhaust fumes are poisonous. Never start the engine or let it run in an enclosed area. Never

allow a child to handle gasoline.

5. Never install accessories not approved by our company for use on this vehicle.

6. Never operate the vehicle on pavement or on any public street, road or highway, including dirt and

gravel roads.

7. Drive in a manner appropriate for your skills and operating conditions. Never operate at excessive

speeds. DO NOT attempt to do power slides, “donuts”, jumps or other driving stunts. Keep both

hands on the steering wheel at all times.

8. Never consume alcohol or drugs before or while operating this vehicle.

9.Always use the size and type of tires specified for your vehicle. Always maintain proper tire

pressure.

10.Never operate a damaged vehicle. After any overturn or accident, have a qualified service dealer

inspect the entire machine for possible damage.

11. Never operate the vehicle on a frozen body of water.

12. Do not touch hot exhaust system components. Always keep combustible materials away from the

exhaust system.

13. Always remove the ignition key when the vehicle is not in use to prevent unauthorized use.

35

OPERATION

Starting the Engine

1. Sit in the driver's seat and fasten the seat belt.

2. Place the transmission in neutral. Set the parking brake.

3. Apply the brakes.

4. Do not press the throttle pedal while starting the engine.

5. Turn the ignition key to the “ST” position. Engage the starter for a maximum of five seconds.

Release the key when the engine starts.

NOTICE: Operating the vehicle immediately after starting could cause engine damage. Allow the

engine to warm up for several minutes before operating the vehicle.

6. If the engine does not start within five seconds, return the ignition switch to the “ON” position and

wait five seconds. Repeat steps 5 and 6 until the engine starts.

Tip: If a warm engine has cooled to a point where it does not readily start, intermittent use of the

choke (pulled half way out) may be necessary. If the engine is over-choked when warm, depress

the throttle lever fully while cranking to aid in starting. Release the throttle lever immediately

after the engine starts. If the engine does not start and all conditions are favorable, change the

spark plug and try again.

7. Vary the engine RPM slightly with the throttle to aid in warm-up until the engine idles smoothly.

8. Release the parking brake before driving.

36

OPERATION

Stopping the Engine

1. Release the throttle pedal completely and brake to a complete stop.

2. Place the transmission in neutral.

3. Set the parking brake.

4. Stop the engine.

Braking

1. Release the throttle pedal completely. (When the throttle pedal is released completely and engine

speed slows to near idle, the vehicle has no engine braking.)

2. Press on the brake pedal evenly and firmly. Practice starting and stopping (using the brakes) until

you're familiar with the controls.

Parking the Vehicle

1. Stop the vehicle on a level surface. When parking inside a garage or other structure, be sure that the

structure is well ventilated and that the vehicle is not close to any source of flame or sparks,

including any appliance with pilot lights.

2. Place the transmission in neutral.

3. Set the parking brake.

4. Stop the engine.

5. Remove the ignition key to prevent unauthorized use.

37

OPERATION

New Operator Driving Procedures

1. Read and understand the owner's manual and all warning and instruction labels before operating this
vehicle.

2. Review the section of this owner’s manual about starting the engine, stopping the engine, braking
and parking (pages 35-36).

3. Perform the pre-ride inspection (page 33).

4. Wear appropriate riding gear, including an approved helmet and eye protection (goggles or face
shield).

5. Select a level open area to practice driving.

6. Sit in the driver's seat and fasten the seat belt.

7. Do not operate or ride in this vehicle if the
clearance between the top of your helmet and the

overhead cab frame is less than 2 inches (5 cm).

8. Do not carry a passenger until you have at least

four hours of driving experience with this vehicle.

See page39.

38

OPERATION

9. Set the parking brake.

10. Place the transmission in neutral.

11. Start the engine.

12. Apply the brakes and shift into gear.

13. Release the parking brake.

14. Check your surroundings. Make sure the area is clear of people and obstacles.

15. Keeping both hands on the steering wheel, slowly release the brakes and press the throttle with
your right foot to begin driving.

16. Drive slowly at first. Practice starting, stopping, turning, using the throttle and brakes and driving

in reverse. Learn how the vehicle handles when making both left and right turns at a slow speed.

17. Increase speed only after mastering all maneuvers at a slow speed.

18. After you become skilled at making turns and begin to operate at faster speeds, follow these
precautions:

● Avoid sharp turns. Make turns gradually.

● Never turn while applying heavy throttle.

● Never turn the steering wheel abruptly.

● Operate at speeds appropriate for your skills, the conditions and the terrain.

● Do not attempt to do power slides, “donuts”, jumps or other driving stunts.

39

OPERATION

Driving with a Passenger

1. Complete the New
Operator Driving
Procedures outlined on
Pages 37-38.

2. Perform the pre-ride
inspection. See page

33.

3. Do not carry a
passenger until you
have at least four hours
of driving experience
with this vehicle.

4. Never operate with a passenger age 12 and under. Make sure the passenger is tall enough to

comfortably and safely sit in the passenger seat with the seat belt secured, put both feet on the
floor and grasp the hand holds.

5. Make sure the passenger has at least 2 inches (5 cm) of clearance between his helmet and the top of

the cab frame.

6. Never carry more than one passenger in this vehicle.

40

OPERATION

7. Never allow a passenger to ride on the back of the vehicle. Allow a passenger to ride only in the

passenger seat.

8. Make sure the passenger is wearing appropriate riding gear, including an approved helmet and eye

protection. See page 5.

9. Make sure the passenger secures the seat belt.

10. Tell your passenger to always keep hands and feet inside the vehicle at all times.

12. Drive slowly. Vehicle handling may change with a passenger on board. Always travel at a speed

appropriate for your skills, your passenger's skills, and operating conditions. Avoid unexpected or
aggressive maneuvers that could cause discomfort or injury to a passenger.

13. Always follow all operating guidelines as outlined on safety labels and in this manual.

Driving on Slippery Surfaces

When driving on slippery surfaces such as wet trails, loose gravel, sand or ice, be alert for the
possibility of skidding and sliding.

Skidding or sliding can cause loss of control or overturn, especially if tires regain traction

unexpectedly. When operating on slippery surfaces such as ice or loose gravel, slow down and
use extra caution to help prevent skidding or sliding. Always use extra caution when operating on
sand or on rough, slippery or loose terrain. Do not operate on excessively rough, slippery or loose
terrain.

41

OPERATION

Follow these precautions when driving in slippery conditions:

1. Slow down before entering slippery areas.

2. Be alert, watch the path ahead and avoid quick turns, which can cause skids.

3. Correct a skid by turning the steering wheel in the direction of the skid. Never apply the brakes

during a skid.

42

OPERATION

Driving Uphill

Whenever traveling uphill, follow these
precautions:

1. Always check the terrain carefully
before ascending a hill.

2. Avoid steep hills （15° maximum).

3. Drive straight uphill.

4. Never climb hills with excessively
slippery or loose surfaces.

5. Drive at a steady rate of speed. Never

press the throttle suddenly.

6. Avoid unnecessary changes in speed
or direction.

7. Never go over the crest of a hill at a high speed. An obstacle, a sharp drop, or another vehicle or
person could be on the other side of the hill.

8. If the vehicle stalls while climbing a hill, apply the brakes. Place the transmission in reverse and
slowly allow the vehicle to roll straight downhill while applying the brakes lightly to control speed.

43

OPERATION

Driving on a Sidehill (Sidehilling)

Driving on a sidehill is not recommended. Driving on a sidehill improperly cause loss of control or
overturn.

If crossing a hill is unavoidable, follow these precautions:

1. Drive slowly and use extreme caution.

2. If the vehicle begins to overturn, or if it feels as if it may overturn, immediately turn downhill.

3. Avoid obstacles and changes in terrain that may lower or raise one side of the vehicle or cause the
vehicle to slide.

4. If the vehicle begins to slide downhill, immediately turn downhill to stop the slide.

Driving Downhill

Whenever driving down a hill, follow these precautions:

1. Avoid steep hills (15° maximum).

2. Slow down. Never travel down a hill at high speed.

3. Always check the terrain carefully before driving down a hill.

4. Always drive down a hill with the transmission in forward gear. Never “coast” or drive down a hill

with the transmission in neutral.

5. Avoid driving down a hill at an angle, which would cause the vehicle to lean sharply to one side.

Always drive straight downhill.

6. Apply the brakes lightly to keep speed slow.

44

OPERATION

Driving Through Water

Your vehicle can drive through
shallow water. Make sure the
water is no deeper than the floor
of the vehicle. Follow these
precautions when driving
through water:

1. Check water depth. Never
drive through water that is
deeper than the floor level.

2. After driving through water,
test the brakes. Apply them
lightly several times while
driving slowly. The friction
will help dry out the pads.

NOTICE

: Major engine damage can result if the vehicle is not thoroughly inspected after operation in

water. Perform the services outlined in the maintenance chart. See page 49-50. Give special
attention to engine oil, transmission oil and all grease fittings. If your vehicle is operated in
water deeper than the floor level, take it to your dealer for service before starting the engine.
If it's impossible to bring the vehicle to your dealer before starting the engine, perform the
service outlined on page 76, and take the vehicle to your dealer as soon as possible.

45

OPERATION

Driving Over Obstacles

Follow these precautions when driving over obstacles:

1. Always check for obstacles before driving in a new area.

2. Look ahead and watch the terrain. Always be alert for hazards such as logs, rocks and low hanging
branches.

3. Drive slowly and use extra caution when driving on unfamiliar terrain. Obstacles are not always
clearly visible.

4. Do not drive over large obstacles such as rocks and fallen trees. If it’s unavoidable, use extreme
caution and drive slowly.

5. Always have a passenger dismount and move away from the vehicle before driving over an obsta­cle that could cause an overturn.

46

OPERATION

Driving in Reverse

Follow these precautions when driving in reverse:

1. Always check for obstacles or people behind the vehicle.

2. Apply the throttle lightly. Never apply the throttle suddenly.

3. Back slowly.

4. Apply the brakes lightly for stopping.

5. Avoid making sharp

47

OPERATION

Parking on an Incline

A rolling vehicle can result in serious injury. Avoid parking on an incline. If parking on an incline is
unavoidable, follow these precautions:

1. Place the transmission in neutral.

2. Set the parking brake.

3. Stop the engine.

4. Always block the rear wheels on the downhill side.

48

MAINTENANCE

Periodic Maintenance Chart

Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition.
Inspection, adjustment and lubrication of important components are explained in the periodic
maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection
reveals the need for replacement parts, use genuine parts available from your dealer.
Service and adjustments are important for proper vehicle operation. If you're not familiar with safe
service and adjustment procedures, have a qualified dealer perform these operations. Maintenance
intervals in the following chart are based upon average riding conditions and an average vehicle speed
of approximately ten (10) miles per hour. Vehicles subjected to severe use must be inspected and
serviced more frequently.

Severe Use Definition

● Frequent immersion in mud, water or sand

● Racing or race-style high RPM use

● Prolonged low speed operation

● Extended idle

● Short trip cold weather operation

Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants
collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor
the oil level, and if it continues to rise, discontinue use and determine the cause or see your dealer.

49

MAINTENANCE

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

Maintenance Interval
(whichever comes first)

Item

Hours Calendar

Miles(Km)

Remarks

Ⅱ

Steering

－ Daily

－

Tires － Daily

－

Ⅰ

Brake fluid level － Daily

－

Brake system

－ Daily －

Ⅰ

Brake pedal travel

－ Daily －

Wheels/fasteners

－ Daily －

Frame fasteners

－ Daily －

Ⅰ Engine oil level － Daily －

Check each day before driving the vehicle. Make
adjustments as needed. See the Pre-Ride Checklist
on page33.

Ⅰ

Engine oil

change(break-in)

25

1 M

－

Perform a break-in oil change at one month

Engine oil change 100

6 M

－

Perform a break-in oil change at one month

Ⅰ

Air filter, main element

－

Weekly

－

Inspect; replace as needed

Ⅰ
Ⅱ

Brake pad wear

10 Monthly 100 (160) Inspect periodically

Idle speed － Check; adjust as needed

50

MAINTENANCE

Periodic Maintenance Chart

Maintenance Interval

(whichever comes first)

Item

Hours Calendar

Miles(Km)

Remarks

Ⅰ

Front Suspension 50H 6M 500 (800) Lubricate

Ⅰ

Rear Suspension 50H 6M 500 (800) Lubricate

Ⅰ

Spark plug

100

12M

600 (1000)

Inspect; replace as needed

Ⅱ

Front wheel bearings

100 H 12M －

Inspect; replace as needed

Shift Linkage

50H 6M 500 (800)

Inspect, lubricate, adjust

Battery

25 Monthly 250 (400)

Check terminals; clean; test

Ⅱ

Toe adjustment

－

Inspect periodically; adjust when parts are replaced

Headlight aim

－ Adjust as needed

Ⅱ

Choke

10 Monthly 100 (160)

Check for proper operation; see dealer for
adjustments

Ⅰ

Main gearcase oil 25 Monthly 250 (400) Inspect level; change yearly

Ⅰ Perform these procedures more often for vehicles subjected to severe use.

Ⅱ Have an authorized dealer perform these services.

Remark：1.If the Odometer indication is large, please repeat this maintenance.

2.If operate this vehicle at special wet or dusty area, you had better shorten the maintenance

interval.

51

MAINTENANCE

3.If you vehicle often operate on rough terrain ,you must maintenance to maintain

your vehicle’s performance.

4.Change every two years , have a qualified dealer perform these operations.

Engine Oil

Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart
beginning on page 49. Oil may need to be changed more frequently if the recommended oil is not
used.

Oil Recommendations

NOTICE: Mixing brands or using a non-recommended

oil may cause serious engine damage. Always
use the recommended oil. Never substitute or

mix oil brands.

Engine oil classification of the UTV

52

MAINTENANCE

Engine Oil 1100cc:

Oil Check

Maintain the oil level within the
safe range on the dipstick. Do not overfill.

1. Position the vehicle on a level surface.

2. Remove the dipstick. Wipe it dry with
a clean cloth.

3. Reinstall the dipstick completely.

4. Remove the dipstick and check the oil level.

800cc:

Tip: A rising oil level between checks in cool

weather driving can indicate contaminants
such as gas or moisture collecting in the
crankcase. If the oil level is over the full/safe
mark, change the oil immediately.

5. Add the recommended oil as needed.

6. Reinstall the dipstick.

53

MAINTENANCE

Engine Oil

Oil and Filter Change

Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page49.Always

change the oil filter whenever changing oil.

1100cc:

The engine drain plug is located on the bottom of the crankcase.

1. Position the vehicle on a level surface. Set the parking brake.

2. Start the engine. Allow it to idle for two to three minutes, Stop

the engine.

3. Clean the area around the drain plug.

CAUTION: Hot oil can cause burns to skin. Do not allow hot oil

to contact skin.

4. Place a drain pan under the engine crankcase.

5. Remove the drain plug. Allow the oil to drain completely.

800cc:

NOTE: The sealing surfaces on drain plug and crankcase

should be clean and free of burrs or scratches.

6. Using a cap-style oil filter wrench, turn the oil filter cartridge to

remove it.

7. Using a clean dry cloth, clean the filter sealing surface on the crankcase.

8. Lubricate the o-ring on the new filter with a film of fresh engine oil.

Check to make sure the o-ring is in good condition.

54

MAINTENANCE

Engine Oil

Oil and Filter Change

9. Install the new oil filter cartridge with an oil filter wrench ,and then tighten it to the specific torque
with a torque wrench .Oil filter cartridge tightening torque:20N·m (20m·kgf, 14ft·lbf).

10. Reinstall the sealing washer on the drain plug.

11. Reinstall the drain plug. Add the recommended engine oil.

12. Place the transmission in PARK. Apply the brakes.

13. Start the engine. Allow it to idle for one to two minutes.

14. Stop the engine. Inspect for leaks.

15. Re-check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark

on the dipstick.

16. Dispose of used filter and oil properly.

55

MAINTENANCE

Transmission (Gearcase)

Oil Check Rear Gearcase

The fill plug is located on the rear of the gearcase. Access the
fill plug through the right rear wheel well. Maintain the oil
level at the bottom of the fill plug hole.

1. Position the vehicle on a level surface.

2. Remove the fill plug.

3. Check the oil level.

4. Add the recommended oil as needed.

5. Reinstall the fill plug.

Oil Change

The drain plug is located on the bottom of the gearcase.

1. Remove the fill plug.

2. Place a drain pan under the drain plug.

Front Gearcase

3. Remove the drain plug. Allow the oil to drain completely.

4. Clean the drain plug.

5. Reinstall the drain plug with a new o-ring.

6. Add

SAE 80W/90 GL-5 of the recommended

oil to the fill hole. Maintain the oil level at the
bottom of the fill plug hole. Do not overfill.

7. Reinstall the fill plug.

8. Check for leaks.

9. Discard used oil properly.

56

MAINTENANCE

Spark Plugs

Spark Plug Gap/Torque

Type Electrode Gap

Plug Tightening Torque

1100cc 0.9~1.1mm 14.3 ft. lbs. (20±1.5 Nm)

800cc 0.7~0.8mm 14.3 ft. lbs. (20±1.5 Nm)

NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use our

company recommended spark plugs.
Spark plug condition is indicative of engine operation. The spark plug firing end condition should be
read after the engine is warmed up and the vehicle is driven at higher speeds. Immediately check the
spark plug for correct color.

A hot exhaust system and engine can cause burns. Wear protective gloves when removing a
spark plug for inspection.

Specified spark plug: K6RTG (1100cc); DCPR8E (800cc)

Spark Plug Removal and Replacement

1.Remove the spark plug cap.

2.Using the spark plug wrench provided in the tool kit, remove the plug by rotating it
counterclockwise.

3.Reverse the procedure for spark plug installation.

57

MAINTENANCE

CVT System(1100cc)

CVT---main technical parameter and specification

NO. main technical parameters

1.

CVT type Rubber PulleyCVT

2. Sheave angle of driving plate(°) 26

3.

Sheave angle of driven plate(°) 28

4.

Grooved surface angle ° 28

5.

Adjustment scope on speed

3.28～0.84

6. Dimension(a×b×h) mm 473×245×221

7.

Net weight kg

约 11

Tightening torque

No code Name Spe.

Torque

（N·m）

Assembly position

Thread
fastening agent

1 GB/T5789-1986

Plate bolt 10.9
level

M6x16 11±1 Torque cam

2 GB/T 5783-2000 Plate bolt 10.9 level M6x45 11±1 Driving wheel cover
3 21102-T02-0000 Locking nut M32x1.5 40±1

Combination of fixed

disk driving wheel

○

4 GB/T6184-2000 Locking nut M5 6±1 Swing block shaft
5 21001-T02-0000

Driving chain
connection bolt

M12x1.25 120±10 Engine crankshaft

6 21004-T02-0000

Driven/driving chain
connection bolt

M12x1.25

(Left-spin)

80±10 Gearbox input shaft

58

MAINTENANCE

CVT System(1100cc)

Usage and maintenance

When assemble CVT and gearbox, if the CVT driving plate is not accord with the center of
driven plate will serious effect the operating life of belt and performance of vehicle.
So after pulley assembly, you should use exclusive check tool to check whether the CVT

driving plate is accord with the center of driven plate.（The distance between driving plate and
driven plate is 39.8±0.15 checked by exclusive check tool for CVT assembly）refer to

picture3-1-1:

（Picture 3-1-1）

59

MAINTENANCE

CVT System(1100cc)

Usage and maintenance

If there is space between CVT and check tool, use the gasket to adjust between input shaft of
gearbox and CVT. The thickness of every gasket is 0.5mm. refer to picture 3-1-1-2

60

MAINTENANCE

CVT System(1100cc)

Usage and maintenance

Belt Assembly：After the belt assembly is finished, the belt tension should be appropriate. Too
loose or too tight will obvious effect the operating life of belt. So the verticality of loose edge
should be checked after the belt assembly is finished, the drooping height is 10~~15mm, refer

to picture 3-1-2

61

MAINTENANCE

CVT System(1100cc)

Usage and maintenance
Running-in: Running-in or not of CVT is very important, will affect the operating life of belt

a lot. t. 1000 km is stipulated as running-in mileages, during in the running-in mileages, the
rpm of engine should not more than 2/3 of max rpm, and throttle should not more than 60% of
full opening.

Cleaning：CVT is high-speed rotating member, any filth item are forbidden into it, which will
reduce to lock or shorten the operating life of parts.
Especial for the belt, any filth item will rapid decline the operating life of belt. So before CVT
assembly or change, please clean it firstly.

Belt: The belt should be changed, when vehicle run more than 15000 Kilometers, the abrasion
and verticality of belt need to be checked, if it is serious abrasion or the loose edge verticality
of belt is more than 15mm.

WARNING

The driving, driven parts have been checked by dynamic balance (combine gain weight with
remove weight), so it is forbidden to disassemble. Any disassemble will due to dynamic
balance is unqualified and the balance will be invalid when high speed; what is more, which
will seriously decline the operating life of CVT components and relative engine and gearbox.
If indeed need to disassemble, the parts need to professional dynamic balance check after
assembly.

62

MAINTENANCE

CVT System(1100cc)

CVT Maintenance and Check List

Please maintenance and check the CVT as below chart.

maintenance Period（As anyone is firstly expired ）

Item

Time（h）

Month Distance

Driving、driven part

100 12 1500 Check, clean, change the abrasion

parts

Belt 100 12 1500 Check, change if needs

Countermark position

63

MAINTENANCE

CVT System(1100cc)

Appearance、installation dimension map

64

MAINTENANCE

CVT System

WARNING

Failure to comply with the instructions in this warning can result in severe injury or death.
Do not modify any component of the CVT system. Doing so may reduce its strength so that a failure
may occur at a high speed. The CVT system has been precision balanced. Any modification will cause
the system to be out of balance, creating vibration and additional loads on components. The CVT syst­em rotates at high speeds, creating large amounts of force on clutch components. Extensive enginee­ring and testing has been conducted to ensure the safety of this product. However, as the owner, you
have the following responsibilities to make sure this system remains safe:

● This CVT system is intended for use on our company products only. Do not install it in any other
product.

● Always make sure the CVT housing is securely in place during operation.

65

MAINTENANCE

CVT Drying

There may be some instances when water is accidently ingested into the CVT system. Use the
following instructions to dry it out before operating.

1. Remove the CVT cover. Allow the water to drain. Reinstall the CVT cover.

2. Shift the transmission to neutral. Set the parking brake.

3. Start the engine. Apply varying throttle for 10-15 seconds to expel the moisture and air-dry the belt
and clutches. Do not hold the throttle wide open for more than 10 seconds.

4. Allow the engine RPM to settle to idle speed.

5. Test for belt slippage. If the belt slips, repeat the process.

6. Take the vehicle to your dealer for service as soon as possible.

NOTICE: Exposure to salt water will cause corrosion to metal components. If your vehicle is

operated in salt water areas, rinse it off frequently with fresh water.

66

MAINTENANCE

Filter Systems 1100cc:

Air Filter

Always change the air filter at the
intervals outlined in the Periodic
Maintenance Chart beginning on
page 49.

1. Loose the air filter fixed card

and remove the tail cover 5 .

2.Remove the filter element of the air filter 4
from the primary cover.

4.Wash the filter element in warm soapy

water, then rinse and let dry. If the filter

element is damaged, install a new filter.

1.

JOINT,AIR CLEANER 2. CIRCLIP

3.

PRIMARY COVER 4. FILTER ELEMENT

5. TAIL COVER

67

MAINTENANCE

Filter Systems 800cc:

Air Filter

5. Clean away any oil or sediments in the air box.

6. Reinstall the filter element and tail cover. Secure
the fixed card.

NOTICE

: Never operate the vehicle with the filter

element removed. Dirt will enter the engine, causing
rapid wear and severe damage to the engine.

7. Reinstall rear decorative board.

68

MAINTENANCE

Cooling system

1.Place the vehicle on a level surface.

2.Check the coolant level in the coolant reservoir when the engine is cold as the coolant level will vary
with engine temperature.

3.If the coolant is at or below the minimum level mark, remove the reservoir cap, add coolant to the
maximum level mark, install the reservoir cap.

Don’t removing the radiator cap when the engine and
radiator are still hot, or you could be burned by hot fluid
and steam blown out under pressure. Wait for the engine
to cool before removing the radiator cap. Always use a
thick rag over the cap. Allow any remaining pressure to
escape before completely removing the cap.

NOTE:

The coolant should be between the minimum
and maximum level marks.

69

MAINTENANCE

Throttle System

WARNING

Failure to check or maintain proper operation of the throttle system can result in an accident and lead
to serious injury or death if the throttle pedal sticks during operation.
Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal.
Immediately contact your dealer for service if throttle problems arise.
Always check the pedal for free movement and return before starting the engine and occasionally
during operation.

Throttle Freeplay

If the throttle pedal has excessive play or misadjustment,
it will cause a delay in throttle response, especially at low
engine speed. The throttle may also not open fully. If the
throttle pedal has no freeplay, the throttle may be hard to
control, and the idle speed may be erratic. Check the
throttle pedal freeplay at the intervals outlined in the
Periodic Maintenance Chart beginning on page 49.
Adjust the freeplay if necessary.

70

MAINTENANCE

Throttle System

Throttle Freeplay Inspection

1. Place the transmission in neutral. Set the parking brake.

2. 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 to 1/8 inches (1.5-3 mm).

71

MAINTENANCE

EFI system (1100cc)

The throttle body control inhalation engine cylinder's air

Volume, thus achieves controls engine's rotational speed

and the load. the throttle body have two channel constit-

-utions, namely main channel and by-pass channel. The

accelerator pedal controls main channel's damper opening
through the accelerator back guy, reduces expenses to enter
engine cylinder's gas flow amount; the damper opening
transmits from the damper position transducer to engine
control unit ECU. Flows through the by-pass canal the gas
flow amount by the unit motor control, meets the system
requirements the idling regime goal rotational speed.

NOTE: The idle speed limit screw does not allow the

adjustment, the engine idle speed depend on the EFI
system adjustment completely, does not hand adjust
the idle s

peed

limit screw.

72

MAINTENANCE

EFI system (800cc)

The throttle body control inhalation engine cylinder's air

Volume, thus achieves controls engine's rotational speed

and the load. the throttle body have two channel constit-

-utions, namely main channel and by-pass channel. The

accelerator pedal controls main channel's damper opening
through the accelerator back guy, reduces expenses to enter
engine cylinder's gas flow amount; the damper opening
transmits from the damper position transducer to engine
control unit ECU. Flows through the by-pass canal the gas
flow amount by the unit motor control, meets the system
requirements the idling regime goal rotational speed.

① Crankcase Position Sensor ②Intake air Temperature

﹠Pressure Sensor ③Fuel Injector ④Water Temperature

Sensor ⑤

Throttle body position sensor ⑥Throttle body

NOTE: The idle speed limit screw does not allow the

adjustment, the engine idle speed depend on the EFI
system adjustment completely, does not hand adjust
the idle s

peed

limit screw.

73

MAINTENANCE

Brakes

Always check brake pedal travel and the brake fluid reservoir level before each use of the vehicle.
When applied, the brake pedal should feel firm. Any sponginess would indicate a possible fluid leak or
low brake fluid level, which must be corrected before riding. See page74 for brake fluid information.
If you discover any irregularities in brake system operation, including excessive pedal travel, contact
your dealer for proper diagnosis and repairs.

Operating the vehicle with a spongy brake pedal can result in loss of braking, which could cause an

accident resulting in severe injury or death. Never operate the vehicle with a spongy-feeling brake

pedal.

Brake Inspection

1. Check the brake system for fluid leaks.

2. Check the brake pedal for

excessive travel or a spongy feel.

3. Check the friction pads for

wear, damage and looseness.

4. Inspect the brake pad wear

surface for excessive wear.

5. Change pads when worn to 3/64" (1 mm).

74

MAINTENANCE

Brakes

Brake Fluid

Inspect the level of the brake fluid before each operation. If the fluid level is low add DOT 3 or DOT

4 brake fluid.

After opening a bottle of brake fluid, always discard any unused portion. Never store or use a
partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The

moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake

fade and the possibility of accident or severe injury.
Change the brake fluid every two years and any time the fluid becomes contaminated, the fluid level
is below the minimum, or if the type and brand of the fluid in the reservoir are unknown. Access the
brake fluid reservoir through the left front wheel well.

1. Position the vehicle on a level surface.

2. Place the transmission in neutral. Set the parking brake.

3. View the brake fluid level in the display mirror, the

level should be between the minimum and the
maximum. Level below the minimum, you must add
the brake fluid.

4. Apply the brake forcefully for a few seconds and Maximum=H Minimum=1/4H
Check for fluid leakage around the fittings.

75

MAINTENANCE

Steering Wheel Inspection

1. Position the vehicle on level ground.

2. Lightly turn the steering wheel left and right.

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

4. If there is excessive freeplay or strange noises, or the steering feels rough or catchy, have the
steering system inspected by an authorized dealer.

Shock Spring Adjustment

The front and rear shock absorber springs are adjustable to increase or decrease spring tension. Rotate
the adjuster either clockwise or counterclockwise to make adjustments. Always apply the same
adjustment setting to all four wheels.

WARNING! Uneven adjustment may cause
poor handling of the vehicle, which could
result in an accident. Always adjust both the
left and right spring preloads equally or have
your dealer perform the adjustments.

76

MAINTENANCE

Tires

Operating your vehicle with worn tires will increase the possibility of skidding, loss of control and an
accident, which could result in serious injury or death. Always replace tires when the tread depth mea­sures 1/8" (3 mm) or less. Improper tire inflation or the use of non-standard size or type of tires may
adversely affect vehicle handling, which could result in vehicle damage or personal injury. Always
maintain proper tire pressure. When replacing tires, always use original equipment size and type.

Tire Tread Depth

Always replace tires
when tread depth is
worn to 1/8" (3 mm)or less.

Front Wheel Hub Tightening

Front wheel bearing tightness and spindle nut
retention are critical component operations.
All service must be performed by your authorized dealer.

Wheel Removal

1. Position the vehicle on a level surface.

2. Place the transmission in neutral. Set the parking brake. Stop the engine.

3. Loosen the wheel nuts slightly.

4. Elevate the side of the vehicle by placing a suitable stand under the frame.

5. Remove the wheel nuts. Remove the wheel.

77

MAINTENANCE

Vehicle Immersion

NOTICE: If your vehicle becomes immersed, major engine damage can result if the machine is not

thoroughly inspected. Take the vehicle to your dealer before starting the engine

.

If it's impossible to take your vehicle to a dealer before starting it, follow the steps outlined below.

1. Move the vehicle to dry land.

2. Check the air box. If water is present, dry the air box and replace the filter with a new filter. Thor­oughly dry the air filter. See page66.

3. Remove the spark plugs.

4. Turn the engine over several times.

5. Dry the spark plugs and reinstall

them, or install new plugs.

6. Attempt to start the engine. If necessary,

repeat the drying procedure.

7. Take the vehicle to your dealer for service as soon as possible,

whether you succeed in starting it or not.

8. If water has been ingested into the transmission follow the procedure on page 65 for drying.

78

MAINTENANCE

Battery

This machine is equipped with a sealed-type battery. Therefore it is not necessary to check the
electrolyte or add distilled water in the battery. If the battery seems to have discharged, consult your
dealer.
CAUTION: Do not try to remove the sealing caps of the

battery cells. You may damage the battery.
Failure to handle batteries or battery electrolyte carefully.
You could be poisoned and severely burned by the
sulfuric acid in battery electrolyte. Batteries produce
explosive gases. So you should avoid contact with skin, eyes
or clothing. Always shield eyes when working near batteries.
Keep out of reach of children.
If contract with you body, take the follow measures:
EXTERNAL: Flush with water
INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or
vegetable oil. Get prompt medical attention.
EYES: Flush with water for 15 minutes and get prompt medical attention.
Keep batteries away from sparks, flames, cigarettes or other sources of ignition. Ventilate when
charging or using in a closed.

1. Negative battery terminal

2. Positive battery terminal

79

MAINTENANCE

Battery

CAUTION:A special battery charger (constant voltage/ampere or constant voltage) is required for

recharging a sealed type battery. using a conventional battery charger may shorten the
battery life.

Fuse replacement

1.The fuses are under the garnish cover of the engine cover.

2. If a fuse is blown, turn off the main switch and the switch of the circuit in question. then, install a

new fuse of the specified amperage. Turn on the main switch. If the fuse immediately blows again,
consult your dealer.

80

MAINTENANCE

Battery

1. When the machine is not used for a month or longer, removes the battery and stores it in a cool,

dark place. Completely recharge the battery before reinstallation.

2. Always make sure the connections are correct when putting the battery back in the machine.

WARNING: Do not use an improper fuse, because an improper fuse can cause damage to the

electrical system which could lead to a fire. Always use a fuse of the specified rating.
Never use a material in place of the proper fuse.

CAUTION:

To prevent accidental short-circuiting, turn off the main switch when checking

or replacing a fuse.

81

MAINTENANCE

Cleaning and Storage 1100cc:

Washing the Vehicle

Keeping your vehicle clean will not only
improve its appearance but it can also extend
the life of various components.
Before washing the vehicle, must pay attention
prevents the water to enter inside CTV system
from the CVT side cover.

NOTICE:

Water in the CVT system could cause the drive

belt to become wet and slip in the clutches. Always avoid

800cc:

spraying water directly toward the CVT inlet and outlet
ducts when washing the vehicle from the rear. High water
pressure may damage components. We recommend washing
the vehicle by hand or with a garden hose, using mild soap.
Certain products, including insect repellents and chemicals,
will damage plastic surfaces. Do not allow these types of
products to contact the vehicle.

The best and safest way to clean your vehicle is with a
garden hose and a pail of mild soap and water.

1. Use a professional-type washing cloth, cleaning the

upper body first and the lower parts last.

2. Rinse with clean water frequently.

3. Dry surfaces with a chamois to prevent water spots.

82

MAINTENANCE

Cleaning and Storage

Storage

Long term storage (60 days or more) of your machine will require some preventive procedures to
guard against deterioration. After thoroughly cleaning the machine, prepare for storage as follows:

1. Drain the fuel system.

2. Remove the spark plug, pour about one tablespoon of SAE 10W30 or 20W40 motor oil in the spark

plug hole and reinstall the spark plug. Ground the spark plug wire and turn the engine over several
times to coat the cylinder wall with oil.

3. Block up the frame to raise all wheels off the ground.

4. Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering.

5. If storing in a humid or salt-air atmosphere, coat all exposed metal surfaces with a light film of oil.

Do not apply oil to any rubber parts or the seat cover.

6. Remove the battery and charge it. Store it in a dry place and recharge it once a month. Do not store

the battery in an excessively warm or cold place (less than 0 °C (30 °F) or more than 30 °C (90 °F)).

83

Malfunction analysis and elimination

（I）Engine malfunction

Malfunction

phenomenon

Malfunction

system

Reason

Solving method

1. pressure in

cylinder is too

low.

① Cylinder wear out
② Piston wear out.
③ Leakage on Washer of cylinder.
④ Wearing on Pipe of air valve or

seat of valve is not suitable.

⑤ plug is loose.
⑥ Starting motor is too slow.
⑦ Air circulation is not right.
⑧ Gap of valve is not suitable.

change
change
change

Repair or change
Tighten
Check electric system.
Adjust
Adjust

Start

difficultly or

could not start

2. No ignition

generated from

plug

① Dirt on spark plug
② Wet on plug or smudge
③ Ignition coil problem
④ Touch loop got open or short

circuit

⑤ Magneto problem

⑥ ECU problem

Clean or change
Clean, dry or Change
Change
Change

Change
Change

84

3. No fuel in

Throttle body

① Vent hole on tank jammed

②Problem or blocked in Injector

③Hight-pressure fuel pump do not

work.

④Low-pressure in hight-pressure

fuel pump

⑤blocked in hight-pressure fuel

pump strainer

Clean or change
Clean or change

Clean or change

Clean or change

Clean or change

Start

difficultly or

could not start

4.Miscellaneous

Gear is not in neutral Put gear on neutral

1. Mechanic

problem

① Valve gap no suitable
② Valve base is not suitable
③ Problem on air pipe
④ Broken on bush of swing arms
⑤IAC valve blocked in inlet 、

exhaust pipe.
⑥Adjust screw of idle sets wrong.

Adjust

Repair or Change

Change
Change

Adjust or Change
Adjust

Engine has no

idle speed or

uneven

2. Electric parts
problem

① Dirt on plug
② Gap of plug not correct
③ Ignition loop problem
④ ECU problem

Clean or Change
Change or Adjust
Change
Change

85

⑤ Magneto problem Change

Engine middle
and high
rotate speed is
uneven

Mechanical
problem

① The force of Valve spring is

weak.

② Cam axle worn out
③ Plug is dirty.
④ Gap of plug is too small.
⑤ Air circulation is not right.
⑥ Ignition loop problem
⑦ Air filter is dirty.
⑧ Block in fuel pipe cause fuel

supply problem

⑨ Fuel pipe problem

⑩ Underpressure in hight-pressure

fuel pump

Change

Change
Clean or Change
Adjust or change
Adjust or change
Change
Clean or change
Clean

Change

Adjust or change

Exhaust blue
smoke

Mechanical fault

① too many lube
② Piston ring worn out
③ Val v e p i p e wor n o u t
④ Cylinder wall scratched
⑤ Valve rod worn out
⑥ Seal of valve rod broken

Drain the extra lube
Change
Change
Change
Change
Change

1. Fuel supply

system fault

① Blocked in muzzle of throttle

body

② Air filter is dirty
③ Leakage on air intake pipe

Clean or change
Clean or change
Tighten or change
Drain the extra lube

86

④ Too many lube

⑤ Problem or blocked in Injector
⑥Low-pressure in hight-pressure

fuel pump

Clean or Change

Adjust or Change

2. Electrical parts
problem

① Dirt on plug
② Gap of plug not correct
③ Ignition loop problem
④ ECU problem
⑤ Magneto problem

Clean or Change
Change or Adjust
Change
Change
Change

Engine power
is not enough

3.Mechanical
problem

① Gap of Valve is not correct
② The force of valve spring is

weak.

③ Air circulation is not right.
④ Cylinder worn out
⑤ Piston Ring worn out
⑥ Valve base not correct
⑦ Swing arm or cam shaft worn

out

Change operation method
Check, remove or change

Adjust
Change
Change
Change or repair
Change

Engine
overheats

1. Fuel system fault ① Octane number is lower

② Fuel pass blocked
③ Fuel pump problem

Use the right fuel
Clean the fuel pass
Change

87

2. Electric System
problem

① Ignition time is late or early
②Spark is weak or no spark

Adjust ignition time
Check from plug to magneto

3. Air pass problem ①Leakage on engine

②Air filter is dirty
③Cylinder, piston, ring worn out
④Leakages on connecting face
⑤Block in exhaust pipe
⑥ Leakage on Air inlet pipe

Repair
Clean or change filter
Repair or change
Repair or change
Dredge
Repair or change

4. Engine cooling
system

① Block in water channel or radiator
② Air in Cooling system or coolant is

not enough

③ Water pump problem
④ Unsuitable coolant
⑤ Constant temperature unit problem
⑥ Fault on motor of fan or switch of

heat-sensor

Clear
Release air, refill
coolant
Change
Change
Change
Change

5. Miscellaneous ① Carbon accumulated on top of

piston

② Too many or less lube
③ Unsuitable lube used

Clear

Drain or Refill
Change

Noise from Noise on air valve ① Gap on valve is too big Adjust

88

② Spring on valve is broken
③ Swing arm or cam shaft worn out

Change
Change

Noise from piston ① Piston worn out

② Cylinder worn out
③ Carbon gathered in firebox
④ Piston pin or pin hole worn out
⑤ Piston ring or ring notch worn out

Change
Change
Clean
Change

Change
Noise from chain
of circulation

① Chain elongated
② Chain worn out
③Adjustor of chain problem

Change chain & sprocket

Change chain & sprocket

Repair & Change
Noise from clutch ① Spline of crankshaft damaged

②Spline of clutch damaged

Change crankshaft

Change clutch
Noise from
Crankshaft

① Bearing noise
②Needle bearing damaged
③ Gap too big

Change

Change

Change
Noise from CVT ① Belt loose or worn out

② Roller or main wheel damage

Change

Change

engine

Noise from
transmission
system

① Gear damaged
② Input and output shaft damaged
③ Bearing worn out
④ Bush worn out

Change

Change

Change

Change

Gasoline
engine lacks
power and
accelerating

1.Fuel system

happens
malfunction

①Octane number is too low

②Oil routine is blocked and oil supply

Change with gasoline

whose Octane number

accords with regulation

89

Clutch skiding is not smooth Clean oil routine

Clutch skiding Transmission

system

① Hoof of clutch worn out
② Spring on clutch is weak
③ Out wheel worn out
④ Belt worn out & loose

Change

Change

Change

Change

Gear change
not smooth or
got stuck

Gear box or Gear
change system

① Operating gear damaged
② Shift rod twisted
③ Shift drum worn out
④Shift pulling stick unsuitable

Change

Change

Change

Adjust
Starting problem ① Blocked in muzzle

② Blocked in muzzle channel
③Leakage on connecting part of

starting part

④ Starting pin not work properly

Clean

Clean

Tighten, Adjust or

change

Adjust

Throttle body
works not
properly

Idle and low speed
not stable

① Reducer valve blocked or loose
② Valve channel Blocked
③ Air inlet channel blocked
④ Air inlet bypass Blocked
⑤ Starting pin not closed completely
⑥ Idle screw not suitable
⑦ Height of floater not correct

Clean or tighten

Clean

Clean

Clean

Adjust

Adjust

Adjust

90

Engine
coolant
temperature is
lower

Cooling System ① Fault on heat sensor switch on fan

② Cold weather
③ problem on constant temperature

meter

Change

Cover the radiator

Change

Spark weak Ignition System ① Fault on starter

② problem on spark plug
③ Magneto problem
④ Voltage of battery is weak
⑤ Ignition loop problem
⑥ Starting loop problem

Change

Change

Change

Change

Change

Change

（II）Malfunction in transmission system

Vehicle speed
does not
increase by
engine speed

Transmission
system

①Shift belt slips
②Speed adjusting plate abrasion is too

much
③Speeding adjusting plate slipping is
blocked
④Spring force of adjuster is short

Change
Change

Repair or Change

Repair or Change

Out of gear Gear Box or Gear

shifting system

① Speed changing drum groove

worn out

Change

91

② Right and Left gear changing rods

bended

③High and Low driven gear groove
wear to taper
④Speed changing principal and
countershaft worn out

⑤Sector gear tooth worn out
⑥The force of spring of sector gear is

weak or broken.

Change

Change

Repair or Change

Repair or Change

Change

（III）Malfunction in running system, suspension and steering organization

Running is
leaning

Running
system

①Air pressure in left and right wheel is different
②Load of left and right wheel is different
③Spring force of left and right absorbing spring
④Front wheel location is wrong
⑤One side wheel is locked or brake could not

release

⑥Front and rear suspension parts have been
loosened, bent or damaged

Adjust air pressure in tyre
Adjust load
Adjust or Change
Check or adjust
Repair arrester

Screw or Change
suspension parts

92

Tyre is
abraded
abnormally or
greatly

Steering
organiza­tion,
running
system,
suspension

①Left and right absorber has been damaged,

spring force is short

②Tyre is not balance, and wheel hub is distorted
③Front wheel location is wrong
④Vehicle is over-load
⑤Tyre has not change its position
⑥Wheel hub bearing has been damaged or

adjustment is wrong

⑦Wheel assembly jump (axial, radial) is too

great

⑧Air pressure in tyre is too hig or too low

Adjust or Change

Change
Check or adjust
Check load
Change
Adjust or Change

Change

Adjust air pressure in tyre

Front wheel

shakes,
swing or
jump

Steering
organization,
running system

①Tyre and wheel is not balance

②Wheel hub bearing has been damaged or

adjustment is wrong

③Left and right swing arm ball head has been

abraded or loosened

④Drag pole tie-in has been abraded or

loosened

⑤Front wheel location is wrong

Balance wheel or
Change tyre
Change or adjust

Change

Change

Check、adjust