Grillo DX175 Use And Maintenance

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QUAD GRILLO

DX175

EDIZIONE 2004

USE AND MAINTENANCE

CONTENTS

Introduction ……………………………………………………………………….. II

Maintenance coupons ………...………………………………………………… III

Drive instructions ……………………………..…………………………………. XIII

Use and maintenance manual …………………………………………………. 1

Location of the “warning and specification labels …………...……………. 2

Security information ………………………..……………………………………. 4

Description and machine identification ………………………………………. 5

Progressive identification numbers… ………………………………………… 6

Control functions………………………………………………………………….. 7

Pre-operation check ……………………………………………………………… 14

Operation ………….……………………………………………………………….. 19

Technical characteristics ………………………………………………………... 30

Maintenance works list …………………………………………………………… 36

Suggested oil ………………………………………………………………………. 37

INTRODUCTION

Thanks for having choose QUAD GRILLO DX 175

This use manual has been prepared in details to show you the working and the necessary operations

for a safe use of the vehicle.

IT’S NECESSARY TO READ IT CAREFULLY, BEFORE USING THE VEHICLE.

Grillo S.p.A. do not assume any responsibility for possible undergone damages, or for damages

caused by the non-observance of this information.

CAUTION

IT’S COMPULSORY THE HELMET USE

NEVER operate this ATV if you are under age 18.

“The warranty recognition is subordinated to the regular execution of the operations, prevented by the following maintenance coupons, against payment, and by the relative coupon dispatch to Grillo S.p.A.“

1° SCHEDULED SERVICE COUPON

within the first 500 km or at least within 6 months

 Replace engine oil

 Replace transmission oil

 Clean fuel filter

 Check valves clearance

 Check battery

 Check bolts and nuts

 Check brakes

 Check engine fuel

 Check and lubricate primary and secondary chain

CUSTOMER COPY Date ____________________

1° SCHEDULED SERVICE COUPON

within the first 500 km or at least within 6 months

 Replace the engine oil

 Replace the transmission oil

 Check the fuel filter

 Check the valves clearance

 Check the battery

 Check bolts and nuts

 Check the brakes

 Check engine fuel

 Check and lubrication primary and secondary chain

Grillo S.p.A. COPY Date ____________________

CAUTION:

The warranty do not

cover possible

damages due to a

lack of engine oil.

CAUTION:

The warranty do not

cover possible

damages due to a

lack of engine oil.

1° SCHEDULED SERVICE COUPON

After-Sales & Service Centre stamp

Customer/vehicle datum

SURNAME …………………………………………………………….

NAME …………………………………………………………………..

ADDRESS ……………………………………………………………..

…………………………………………………………………………...

MODEL ….……………………………………………………………..

FRAME N. ……………………………………………………………..

Send to Grillo S.p.A. – Via Cervese, 1701 (FC) – ITALY

Tel. (0039) 0547 381.333

1° SCHEDULED SERVICE COUPON

After-Sales & Service Centre stamp

2° SCHEDULED SERVICE COUPON

within the first 1.500 km

 Replace engine oil

 Clean fuel filter

 Check valves play

 Check advance ignition

 Check battery

 Check bolts and nuts

 Check brakes

 Check and lubricate primary and secondary chain

CUSTOMER COPY Date ____________________

2° SCHEDULED SERVICE COUPON

within the first 1.500 km

 Replace engine oil

 Clean fuel filter

 Check valves play

 Check ignition advance

 Check battery

 Check bolts and nuts

 Check brakes

 Check and lubricate primary and secondary chain

Grillo S.p.A. COPY Date ____________________

CAUTION:

The waranty do not

cover possible

damages due to a

lack of engine oil..

CAUTION:

The waranty do not

cover possible

damages due to a

lack of engine oil..

2° SCHEDULED SERVICE COUPON

After Sales & Service Centre stamp

Customer/vehicle datum

SURNAME …………………………………………………………….

NAME …………………………………………………………………..

ADDRESS ……………………………………………………………..

…………………………………………………………………………...

MODEL ….……………………………………………………………..

FRAME N. ……………………………………………………………..

Send to Grillo S.p.A. – Via Cervese, 1701 (FC) – ITALY

Tel. (0039) 0547 381.333

2° SCHEDULED SERVICE COUPON

After Sales & Service Centre stamp

3° SCHEDULED SERVICE COUPON

within the first 2.500

 Replace engine oil

 Replace transmission oil

 Replace petrol filter

 Replace fuel filter

 Clean spark plugs

 Check battery

 Check transmission belt

 Check clutch

 Check brakes

 Check bolts and nuts

 Check engine fuel

 Check and lubricate primary and secondary chain

CUSTOMER COPY Date ____________________

3° SCHEDULED SERVICE COUPON

within the first 2.500

 Replace engine oil

 Replace transmission oil

 Replace petrol filter

 Replace fuel filter

 Clean spark plugs

 Check battery

 Check transmission belt

 Check clutch

 Check brakes

 Check bolts and nuts

 Check engine fuel

 Check and lubricate primary and secondary chain

Grillo S.p.A. COPY Date ____________________

CAUTION:

The warranty do not

cover possible

damages due to a

lack of engine oil.

CAUTION:

The warranty do not

cover possible

damages due to a

lack of engine oil.

3° SCHEDULED SERVICE COUPON

After Sales & Service Centre stamp

Customer/vehicle datum

SURNAME …………………………………………………………….

NAME …………………………………………………………………..

ADDRESS ……………………………………………………………..

…………………………………………………………………………...

MODEL ….……………………………………………………………..

FRAME N. ……………………………………………………………..

Send to Grillo S.p.A. – Via Cervese, 1701 (FC) – ITALY

Tel. (0039) 0547 381.333

3° SCHEDULED SERVICE COUPON

After Sales & Service Centre stamp

4° SCHEDULED SERVICE COUPON

within the first 3.500

 Replace engine oil

 Replace spark plugs

 Check valves play

 Check advance ignition

 Check bolts and nuts

 Check brakes

 Check and lubricate primary and secondary chain

CUSTOMER COPY Date ____________________

4° SCHEDULED SERVICE COUPON

within the first 3.500

 Replace engine oil

 Replace spark plugs

 Check valves play

 Check advance ignition

 Check bolts and nuts

 Check brakes

 Check and lubricate primary and secondary chain

Grillo S.p.A. COPY Date ____________________

CAUTION: The warranty do not cover the possible damages due

to a lack of engine oil.

CAUTION: The warranty do not cover the possible damages due

to a lack of engine oil.

4° SCHEDULED SERVICE COUPON

After Sales & Service Centre stamp

Customer/vehicle datum

SURNAME …………………………………………………………….

NAME …………………………………………………………………..

ADDRESS ……………………………………………………………..

…………………………………………………………………………...

MODEL ….……………………………………………………………..

FRAME N. ……………………………………………………………..

Send to Grillo S.p.A. – Via Cervese, 1701 (FC) – ITALY

Tel. (0039) 0547 381.333

4° SCHEDULED SERVICE COUPON

After Sales & Service Centre stamp

5° SCHEDULED SERVICE COUPON

within the first 4.500

 Replace engine oil

 Replace transmission oil

 Replace petrol filter

 Replace fuel filter

 Clean petrol filter

 Check distribution chain

 Check battery

 Check transmission belt

 Check clutch

 Check brakes

 Check bolts and nuts

 Check engine fuel

 Check and lubricate primary and secondary chain

CUSTOMER COPY Date ____________________

5° SCHEDULED SERVICE COUPON

within the first 4.500

 Replace engine oil

 Replace transmission oil

 Replace petrol filter

 Replace fuel filter

 Clean petrol filter

 Check distribution chain

 Check battery

 Check transmission belt

 Check clutch

 Check brakes

 Check bolts and nuts

 Check engine fuel

 Check and lubricate primary and secondary chain

Grillo S.p.A. COPY Date ____________________

CAUTION:

The warranty do not

cover possible

damages due to a

lack of engine oil.

CAUTION:

The warranty do not

cover possible

damages due to a

lack of engine oil.

5° SCHEDULED SERVICE COUPON

After Sales & Service Centre stamp

Customer/vehicle datum

SURNAME …………………………………………………………….

NAME …………………………………………………………………..

ADDRESS ……………………………………………………………..

…………………………………………………………………………...

MODEL ….……………………………………………………………..

FRAME N. ……………………………………………………………..

Send to Grillo S.p.A. – Via Cervese, 1701 (FC) – ITALY

Tel. (0039) 0547 381.333

5° SCHEDULED SERVICE COUPON

After Sales & Service Centre stamp

MAIN RULES FOR THE INJURIES PREVENTION

1) The caution is the main mean in the injuries prevention. Reduce the speed and avoid doing dangerous manoeuvres.

2) Always wear the helmet.

3) Wear appropriate clothes: helmet, protection glasses, mouth protection,

thorax protection, long sleeves, gloves, long trousers, boots, etc..

4) The tires pressure is very important for the grip and for the machine handling (check the value on the use and maintenance manual).

5) Never use this ATV if you are under age 16.

6) On disconnected roads travel at a low speed.

7) Reduce your speed in the bends, above all sloping down.

8) It’s very dangerous to action the handlebar brusquely.

9) When you fill up with fuel switch off the engine, get off the vehicle and clean all spills before starting the engine.

10) Keep in working order the vehicle, above all the brakes.

11) While climbing, drive staying on feet, moving the body forwards to avoid to turn over.

12) Sloping down drive the vehicle staying on feet, mowing the body behind.

13) Bending mowing the body weight forwards inside the bend.

USE AND MAINTENANCE MANUAL

QUAD DX 175

This manual contains important safety information: read it carefully!

LOCATION OF THE “WARNING AND SPECIFICATION LABELS”

Read and understand all of the labels on your quad. They contain important information for safe and proper operation of your quad. In case of doubt, consult the distributor or an authorized dealer.

Never remove any labels from your quad. If a label becomes difficult to read or comes off, a replacement label is available from your dealer.

1 – WARNING 2 – WARNING

4 – WARNING

Some information, which are contained in the 1, and 4 labels, that you find on your vehicle, are referred to the Countries where the ATV is not homologated for the employment on road or for the passenger transport. Even if in Italy it is not compulsory, the use of the helmet is advisable. NEVER use the vehicle under the effect of substances, which may alter the driving abilities.

5 – WARNING

NEVER operate this ATV if you are under age 18.

The label is not referred to the Countries where the vehicle is NOT homologated for the passenger transport.

LOADING LIMIT/ WARNING

(Front luggage-rack)

30kg (66 lbs)

NEVER sit in this point.

LOADING LIMIT/WARNING

(Rear luggage-rack)

45 kg (99 lbs)

NEVER sit in this point.

I N D

I E T R O

A V A N T

Improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death. OPERATING TIRE PRESSURE: set with tires cold.

 Recommended:

FRONT 0,25 bar = kgf/cm². REAR RE 0,25 bar = kgf/cm².

 Minimum

FRONT 0,22 bar = kgf/cm².

REAR 0,22 bar = kgf/cm².

 Never set tire pressure below

minimum. It could cause the tire to dislodge from the rim.

LOADING/TRAILER TOWING

CHECK IF THE TOWING OF A BARROW IS ALLOWED.

 Cargo or a trailer can affect stability

and handling. Read owner’s manual before loading or towing.  When loading with cargo or towing a

trailer, reduce speed and allow more

room to stop.

 Avoid hills and rough terrain.  Maximum Vehicle Load: 180 kg,

(396 lbs), includes weight of operator,

cargo and accessories (and if

applicable, trailer tongue weight).

SECURITY INFORMATIONS

WHEN YOU DRIVE AN ATV YOU MUST BE VERY CAREFUL

An ATV reacts differently from the other vehicles, like motorcycle and cars. The wrong use may cause rapidly a crash or the tipping, both during the normal manoeuvres and bending or overtaking hills and obstacles.

THE NON-OBSERVANCE OF THE FOLLOWING DIRECTIONS COULD CAUSE SERIOUS INJURIES

 Read carefully the manual and the labels, following the procedures that are described.  NEVER use an ATV without an adequate period of apprenticeship.  If you are under the age of 16, you should not use an ATV with a higher displacement than 50 c.c.  The passenger transport needs more caution.  Driving on roads opened to traffic or on asphalted surfaces needs a particular care.  It is advisable the use of the helmet and of adequate cloths, which are composed by gloves, robust shoes, a jacket with sleeves and long

trousers.

 NEVER use the vehicle, after having substances, which may alter the driving ability.  Do not drive, keeping an excessive speed, compared to your abilities and to the route conditions.  NEVER do jumps, rearings, or other acrobatics.  Always check your ATV, before using it, to verify its security.  Using the ATV, always keep both the hands on the handlebar and the feet on the running boards.  Do not use the ATV in rivers with strong currents or in deeper waters than 25 cm. (10 inch.).  Always use tires of the type and the measures, which are specified in this manual and pump them at the pressure indicated in the manual.  Do not change the ATV, installing or using unsuitable accessories.  Do not exceed the loading capacity, which is established for your ATV. The loading must be suitably arranged and fixed. Regulate the speed

and follow the instructions of this manual, regarding the loading and the towing of a barrow. Keep a bigger security distance in case of braking.

WARNING

 Always switch off the engine, during the refuelling.  Do not start the engine or drive the vehicle in closed places to avoid potential risks.

DESCRPTION AND MACHINE IDENTIFICATION

1. Battery

2. Front headlight

3. Rear brake pedal

4. Gearbox pedal

5. Seat lock

6. Rear bumper

7. Handlebar

8. Clutch pedal

9. Starter knob (choke)

10. Main switch

11. Speed limiter

12. Front brake lever

13. Throttle lever

9 10 11

IDENTIFICATION NUMBERS RECORD

2. ENGINE I.D. NUMBER

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

1. VEHICLE IDENTIFICATION NUMBER

NOTE: the vehicle identification number is used to identify your ATV. The information of vehicle identification number and engine I.D. number will be needed to order spare parts from your dealer.

The vehicle identification number is stamped on the frame.

CONTROL FUNCTIONS

Main switch

Functions of the respective switch positions are as follows: ON: Engine can be started only at this position and the headlight and taillight come on when the light switch is on. OFF: All electrical circuits are switched off. The key can be removed in this position.

Warning lights

1. The “GREEN” warning light lights up when the transmission is in neutral.

2. The “RED” warning light lights up when the vehicle warning lights are switched on.

1. Starter knob for the cold-starting

2. Main switch

3. Green warning light “NEUTRAL”

4. “Reverse motion connection” red warning light

5. “Left arrow” warning light

6. “Parking lights” warning light

7. “Headlights” warning light

8. “Right arrow” warning light “

Handlebar switches

1. Emergency lights switch

2. Lights switch

3. Start button

Start button

Pressing this button, the starter starts the motor.

CAUTION: See starting instructions prior t starting engine.

Lights switch

Turn the lights switch t the position On to switch on the parking lights and the rear light.

CAUTION:

Do not use the half-lights when the motor is stopped for more than 15 minutes. The battery could discharge and for this reason the starter may not work correctly. If it will happen, remove the battery and recharge it.

Speed limiter

The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Screwing in the adjuster limits the maximum engine power available and decreases the maximum speed of the ATV.

Throttle lever

Once the engine is running, movement of the throttle lever will increase the engine speed. Regulate the speed of the engine by varying the throttle position. Because the throttle is spring-loaded, the engine will decelerate, and the engine will return to an idle any time the finger is removed from the throttle lever. Before starting the engine, check the throttle to be sure it is operating smoothly. Make sure it returns to the idle position as soon as the lever is released.

WARNING:

Do not turn the speed adjuster out more than 12 mm. Always make sure the throttle lever free play is 3-5 mm. (0,12-0,20 in.).

Locknut

djuster

Front brake lever

The front brake is located on the right handlebar. Pull it toward the handlebar to apply the front brake or parking brake.

Foot brake pedal

The brake pedal is located on the right side of the vehicle. Push down on the pedal to apply the rear brake.

Parking brake

Apply the brake lever while pushing the stopper, then push in the stopper to apply the parking brake. Squeeze the front brake lever to release the parking brake.

Clutch lever

Pull the lever towards the handlebar to detach the clutch when you have to change the connection.

Gearbox pedal

This ATV is engaged with a gearbox fitted with five speeds, both forwards and reverse. The pedals of the gearbox and of the reserve reducer are located on the left side of the engine.

Reverse pedal This pedal can be operated with the heel and it is used to connect the reverse motion. NOTE: Consult the paragraph dealing with the “Reverse driving”, before using the vehicle in reverse motion.

** Note: in the version with the starter, located on the right side of the body frame, the reverse pedal is absent.

Fuel tank cap

Remove the fuel tank cap by turning it counter clockwise. Automotive gasoline with octane number of 91 or higher may be used. After refuelling, be sure to tighten the tank cap firmly.

Reverse pedal

Gearbox pedal

Seat

To remove the seat, pull the seat lock lever upward and pull up the seat at the rear.

Starter (Choke)

The starting with cold engine needs a bigger air-petrol fuel. A separate start circuit (choke) provides to furnish this fuel. Pull outwards the knob (choke), used to action the starter. Push the knob to put out the starter. Consult the paragraph headline with the “Starting with cold engine” for a correct operation.

To install the seat, insert the lobe on the

seat front into the receptacle on the frame and push down the seat at the rear.

1 Completely opened 2 Half-opened 3 Closed A. Starter/choke.

Front shock absorber adjustment

The spring preload can be adjusted to suit the vehicle’s load and riding conditions. Spring preload adjustment: To increase the spring preload, turn the adjuster in direction e. To decrease the spring preloaded, turn the adjuster in direction a.

Rear shock absorber adjustment

A—Minimum (Soft) E—Maximum (Hard)

WARNING:

Uneven adjustment on different sides can cause poor handling and loss of stability.

A—Minimum (Soft) E—Maximum (Hard)

PRE-OPERATION CHECKS

Before using this ATV, check the following points:

ITEM ROUTINE

Brakes Check operation, free play, fluid level and fluid

leakage.

Fill with DOT 4 (or DOT 3) brake fluid if necessary. Parking brake Check operation, condition and cable free play. Fuel tank Check fuel level.

Fill with fuel if necessary. Engine oil Check oil level.

Fill with oil if necessary. Reverse reducer oil Check the presence of possible leaks. Throttle Check for proper throttle cable operation. Wheels and tires Check tires pressure, wear and damage. Fittings and fasteners Check all fittings and fasteners. Lights Check for proper operation. Battery Check fluid level.

Fill with distilled water if necessary. Primary chain (inverter) Lubricate. Secondary chain Lubricate and check the voltage.

ATTENTION:

Always check each item in the above list prior to operating your ATV.

Front and rear brakes

1. Check the operation and free play of the levers and pedal. They should move smoothly and there should be a firm feeling when the brakes are applied. If not, have the vehicle inspected by your dealer.

2. Brake fluid level. Check the brake fluid level. Add fluid if necessary. Recommended brake fluid: DOT 4. NOTE: -----------------------------------------If DOT 4 is not available, DOT 3 can be used.

-----------------------------------------------------

3. Brake fluid leakage. Check to see if any brake fluid is leaking out of the pipe joints or master cylinder. Apply the brakes firmly for one minute. If there is any leaking, have the vehicle inspected by your dealer.

4. Brake operation. Test the brakes at slow speed after starting to make sure they are working properly. If the brakes do not provide proper braking performance, inspect the brake pads for wear.

Fuel:

Make sure there is sufficient fuel in the tank. Fuel tank capacity: Total: 11 L.

The engine has been designed to use regular gasoline with RON of 91 or higher.

Engine oil: Make sure the engine oil is at the specified level. Add oil if necessary.

Recommended oil:

Recommended engine oil classification: API Service SE, SF, SG type or higher. ATTENTION: Do not add any anti-friction modifier to ensure proper clutch function. Oil quantity in the engine: 1 L.

N.B. See the recommended oil list at the end of the manual.

temperature

Throttle lever:

Check to see that the throttle lever operate correctly. It must open smoothly and spring back to idle position when released. Repair if necessary for proper operation.

Lights:

Check the headlight and taillight to make sure they are in working condition. Repair if necessary for proper operation.

Switches:

Check the operation of the headlight switch, engine stop switch and any other switches. Repair if necessary for proper operation.

Battery:

Check fluid level and top-off if necessary. Use only distilled water if refilling.

Tires:

In order to have the highest efficiency & safety operation, please pay attention to

The follows:

1. Use the following tires:

Producer MAXXIS KENDA LOAD STAR Front 23x7x10 22x8-10 205/65-10 Rear 22x11x10 22x11-10 225/50-10

2. The tires should be set to the recommended pressure. Recommended tire pressure: Front 0,25 bar = kgf/cm² Rear 0,25 bar = kgf/cm² Pressure check and regulation must be done with cold tires.

3. Tire pressure below the minimum specified could cause the tire to dislodge from the rim under severe riding conditions. Minimum tire pressure: Front 0,22 bar = kgf/cm² Rear 0,22 bar = kgf/cm²

4. ATTENTIONE! Use no more than following pressures when seating the tire beards. Front 2,5 bar = kgf/cm² Rear 2,5 bar = kgf/cm² Higher pressures may cause the tire to burst. Inflate the tires very slowly and carefully. Fast inflation could cause the tire to burst. At the end of the operation bring again the tires values at the values indicated in the points 2 and 3 (recommended 0,25 bar, minimum pressure 0,22 bar).

5. The wear limit. When the tire groove decreases to 3 mm (0,12 in.) due to wear, replace the tire.

OPERATION

7. Bring back the starter to the closure position and the release the throttle lever.

Position starter (choke)

1. Cold starter of the engine with an environmental pressure inferior to 5° C (40° F).

2. Cold starter of the engine with an environmental temperature included between 0° C (40° F), 30° C (90° F) and the heating position.

3. Cold starter of the engine with an environmental temperature over 25° C (80° F) and position to start the engine already warm.

ENVIROMENTAL TEMPERATURE / STARTER POSITION

WARNING: Operation ATV without being familiar with all controls is extremely dangerous. Freezing control cables in cold weather is extremely dangerous. Make sure everything is work smoothly before starting.

To start out:

1. Put the parking brake

2. Turn the main switch in the “ON” position.

3. Put the gearbox in the neutral position.

4. Pull the starter knob (choke) completely or at half, according to the environmental temperature (see the drawing).

5. Pull the starter button and in the meanwhile pull slightly the throttle.

6. Keep slightly accelerate the engine for

1.2 minutes and heat the engine carefully at minimum.

1 Completely opened 2 Half-opened 3 Closed A. Starter (Choke).

Starting with warm engine

To start the warm engine, you must refer to the “Starting of the warm engine” paragraph. The choke must NOT be used. The throttle must be opened carefully.

Engine heating

To assure the maximum mechanical life and to ensure the best capabilities, always heat the engine up, before operating. Never accelerate too much with the cold engine. To understand if the engine is warm enough, check if it normally responds to the throttle even if the starter is off.

Pedal working and reverse driving. CAUTION: before fitting in the reverse motion, stop the vehicle and put the throttle in the closure position, otherwise the transmission gear could be damaged.

1. Stop completely the ATV, pressing the brake pedal and releasing the throttle lever to the nonworking position.

2. Fit in the first gear and release the gear pedal.

3. Check, slightly releasing the clutch lever, which the gear is correctly fit in, than pull another time the clutch lever.

4. With the heel of the shoe, press the

reverse motion pedal and in the meanwhile progressively release the clutch lever, slightly accelerating (version with reverse motion pedal).

5. With the clutch lever completely released, the vehicle goes back, until the pedal is pressed. When you do not press the pedal, the ATV goes forward gear.

Gear

This ATV model is engaged with a 5-speed gearbox both in forward and reverse motion; this characteristic and the particular gear will permit you a very easy mobility on the soil.

CAUTION: during the reverse driving, be particularly careful and do NOT operate brusquely the drives. Do not forget that the stability and the steering respond, when the vehicle goes in reverse motion, are very different than the normal gear.

To start out:

1. Release the throttle lever.

ATTENTION: Always turn off the gas, changing the gears. Otherwise, the engine and the transmission gear may be damaged. CAUTION: To fit in the reverse motion the vehicle must be motionless and the engine must run at minimum, to avoid serious damages to the transmission gear. HOW TO USE THE GEAR To accelerate:

2. Open the gas gradually, progressively releasing the clutch lever.

3. Once the vehicle has attained adequate speed, release the throttle lever and pull the clutch lever.

4. Change in second gear, using the pedal and gradually release the clutch, avoiding the skidding.

5. Turn on gradually another time the gas.

6. Follow the same procedure when shifting to the next higher gear.

To decelerate:

When slowing down or stopping the vehicle, release the throttle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear, using the same procedure used before.

Be sure that the engine has sufficiently slowed before engaging a lower gear, gradually releasing the clutch.

DANGER

: fit in a reduced gear when the engine and the vehicle are travelling at a high speed, this may be very dangerous both for the passengers and for the transmission gear.

ENGINE BRAKE-IN

ATTENTION: The first 20 Hrs for engine brake-in are

very important, never exceed the funning conditions listened below:

1. 0-10 Hrs Avoid continuous operation above half throttle. Allow a cooling off period of life to ten minutes after every hour of operation. Vary the speed of the vehicle from time to time. Do not operate it at one set throttle position.

2. 10-20 Hrs Avoid prolonged operation above ¾ throttle. Rev the vehicle freely through the gears but do not use full throttle at any time.

3. After brake-in

Avoid prolonged full throttle operation. Vary speeds occasionally.

Parking:

When parking, stop the engine and shift into neutral. Turn the fuel cock to “OFF“ and apply the parking brake.

Parking on a slope:

Avoid parking on slopes. If you must park on an incline, put the engine in a reduced gear, apply the parking brake, and block the wheels with rocks or other objects.

ATTENTION: MAXIMUM LOADING LIMIT

Vehicle loading limit (total weight of cargo, rider, accessories and tongue weight): 180 kg. (397 lbs). Towing capacity: Towed cargo (total weight of sulky and of cargo): 200 kg (440 lbs).

ATTENTION: CHECK IF THE LAWS OF THE COUNTRY WHERE THE VEHICLE IS USED ALLOW THE CIRCULATION ON OPENED TRAFFIC ROADS. OTHERWISE, USE THE ATV ONLY FOR THE TOWING IN PRIVATE AREAS.

SCHEDULED SERVICE TABEL

Km 500 1500 2500 3500 4500 5500 6500 7500 8500 9500 10500 11500 12500

Engine oil S S S S S S S S S S S S S

Transmission oil S S S S S S S

Petrol filter S S S S S S

Oil filter CL CL CL CL CL CL CL CL CL CL CL CL CL

Fuel filter CL S S S S S S

Carburettor CH CH CH CH CH CH CH

Spark plug CL S S S S S

Valves play CH CH CH CH CH CH CH

Ignition timing CH CH CH CH

Gear drive chain

CH CH CH

Battery CH CH CH CH CH CH CH CH CH CH CH CH CH

Exhausted system

CH CH CH CH CH CH CH

Clutch CH CH CH CH CH CH CH CH CH CH CH CH CH

Brakes CH CH CH CH CH CH CH CH CH CH CH CH CH

Bolts and nuts CH CH CH CH CH CH CH CH CH CH CH CH CH

Tires CH CH CH CH CH CH CH CH CH CH CH CH CH

DO NOT SCATTER THE EXYAUSTED OIL IN THE ENVIROMENT, BUT BRING

IT IN THE PROPER COLLECTNG CENTER.

Inverter chain – Secondary chain

CH/L

When the mileage exceeds the indicated mileage, do the maintenance, conforming to the scheduled intervals. When the service for the oil replacement does not match the date of the scheduled servicing nevertheless you wish to replace it by your own, please follow the instructions on

this manual.

IMPORTANT: Check every 500 km the oil level and check it if necessary. ATTENTION: The warranty does not cover possible damages due to a lack of engine oil.

NOTE:

S: Substitute

CL: Clean

CH: Check

L: Lubricate

2. Engine oil replacement and oil strainer cleaning.

a. Place the vehicle on a level place. b. Warm up the engine for several minutes

and stop it. c. Place a container under the engine. d. Remove the dipstick (1), the oil filter cap

(2) and the discharging cap (3) to permit

to the oil to flow out. e. Clean the mantle oil filter with petrol and

dry with compressed air. f. Reassemble the oil filter cap and the

discharge cap. g. Put a litre of oil (page. 16).

Engine oil

Engine oil level measurement.

a. Place the vehicle on a level place. b. Warm up the engine for several minutes

and stop it.

c. Wait a few minutes until the oil level

settles before checking.

d. Remove the dipstick and wipe it off with a

clean rang. Insert the dipstick in the filter hole without screwing it in. Remove the dipstick and insert the oil level. e. Remove the dipstick and insect the oil

level. f. The oil level should be between the

maximum and the minimum marks. If the

level is low, add oil to raise it to the

proper level.

CAUTION: Be sure no foreign material enters the crankcase.

Reduction gear oil of the reverse motion

Substitute the oil every 12 months (page. 23). Check periodically the level through the observation of the proper window (a)

1. Warm up the engine

2. Put off the refilling cap (b)

3. Put off the discharge cap (c)

4. Let the oil completely leak.

5. Close the discharge cap.

6. Fill up with 400cc (page. 31 )

7. Close the refilling cap.

Fuel filter cleaning

At the top of the filter-box there is a check cover. If after the removal, you find the presence of water or dust, empty out the cover and clean the filter-box and the filtering element in the following way:

1. Put off the seat.

2. Put off the cover of the filter-box.

3. Put off the filtering element and disjoin the stand.

4. Clean carefully the filtering element with the proper solvent and if it is not enough, substitute the filtering element.

5. Squeeze the filter in order to remove the excessive solvent. Reassemble the filter when it will be dry.

NOTE: Regarding the use on dusting soil it is possible to improve the filter abilities of holding the impurities, soaking it with proper products or with a minimum quantity of fluid oil.

Throttle lever adjustment NOTE: Adjust the engine idling speed before

adjusting the throttle lever free play.

1. Loosen the locknut.

2. Turn the adjustment bolt until the throttle lever free play is 3-5 mm. (0.12-0.20 inc.)

3. Tighten the locknut.

Idle speed adjustment NOTE: for this operation a diagnostic instrument

must be used (rev. counter).

1. Start the engine and warm it up for a few minutes at approximately 1.000-2000 r/min. Occasionally rev the engine to 4.000 and 5.000 r/min. The engine is warm when it quickly responds to the throttle.

2. Connect the tachometer and set the idle to the specified idling speed by adjusting the throttle stop screw. Turn the screw into increase engine speed, and out to decrease engine speed.

SPECIFIED IDLE SPEED:

1.450 rpm +/- 100

1. Locknut 2. Adjusting bolt a. 3-5 mm. (0.12-0.20 inc.).

Inspecting the brake fluid level

Insufficient brake fluid may let air enter the brake system, possibly causing the brakes to become ineffective. Before riding, check that the brake fluid is above the lower level and replenish when necessary. Use only the designated quality brake fluid. Recommended brake fluid DOT 4.

NOTE:

If DOT 4 is not available, DOT 3 can be used.

Front brake lever free play adjustment

The front brake lever free play should be 20-25 mm. (0.80 – 1.0 inc.). If the free play is incorrect, adjust it as follows:

1. Adjust the screw under the brake lever with finger. Adjust same turns of screw on both side of brake.

1. Minimum level mark “LOWER”.

Brake level lubrication

Lubricate the pivot of each lever and pedal. Use SAE 10W30 motor oil.

Drive chain adjustment

Fuse replacement

If the fuse is blown, turn off the main switch and install a new fuse of the specified amperage. Then turn on the switches. If the fuse immediately blows again, consult your dealer. Specified fuse: 10 A.

1. Unlock the fastening screw of swing arm (a).

2. Swing the rear axle-bearing holder back and forth to reach suitable chain tension.

3. Lock the fastening screw of swing arm.

1. Main fuse.

WARNING:

Never use an improper fuse. An improper fuse can cause damages to the electrical system that could led to a fire.

CAUTION:

To prevent accidental short- circuiting, turn off the main switch when checking or replacing a fuse.

Replacing the battery fluid

A poorly maintained battery will corrode and discharge quickly. The battery fluid should be checked at least once a month.

1. The level should be between the upper and lower level marks. Use only distilled water if refilling is necessary.

Replacing the headlight bulb

If the headlight bulb is burnt, remove the headlight unit assembly, take out the defective bulb and replace a new one.

Spark plug inspection NOTE:

Standard spark plug: NGK D8EA or CHAMPION Spark plug gap: 0.6-0.7 mm. (0.024-0.028 inc.)

Inverter chain

Lubricate before each use

Secondary chain

Check at least every 300 km the voltage and after each output of water, dust or sand. Clean and lubricate another time the chain. N.B.: the voltage must be checked with the loaded vehicle.

1- Maximum level mark “UPPER LEVEL”. 2- Minimum level mark “MINIMUM LEVEL”.

TECHNICAL CHARACTERISTICS

MODEL DX 175

Dimensions:

Overall length 1.950 mm

Overall width 1.100 mm

Overall height 1.150 mm

Seat height 820 mm

Wheelbase 1.200 mm

Minimum turning radius 180 mm

Basic weight:

228 kg

Engine:

Engine type Forced air-cooled, 4 stroke, OHV.

Cylinder arrangement Forward inclined single cylinder

Displacement 168 cc

Bore x stroke 62 x 55,6 mm

Compression ratio 9,2: 1

Starting system Electric

Lubrication system Wet pump

MODEL DX 175

Engine oil 0° 10° 30° 50° 70° 90° Type temperature 110° 130° F

SAE 20W40

SAE 10W30

Classification of the recommended oils. See the suggested oils diagram at the end of the

manual.

Temperature

SAE 5W30

-20° -10° 0° 10° 20° 30° 40° 50° C

Quantity

Type API Service SE,SF,SG or higher

1.0 L

Reduction gear oil reverse motion

Type SAE 10W30 Quantity 400 cc Air filter

Dry element Fuel Type Unleaded fuel Fuel tank capacity 11 L

Carburettor

Type Keihin/PD-24D Spark plug Type/Manufacturer NGK o Champion Spark plug gap 0.6-0.7 mm

Chassis

Type Steel tube

Caster angle 4°

Forerun 19 mm

Toe-in 3-6 mm

MODEL DX 175

Transmission

Primary reduction system CVT , ratio 73/18 (4.056)

Secondary reduction system Chain

Secondary reduction ratio 38/15 x 20/14 (4.082)

Transmission type 5 speeds

Operation With pedal

Reduction ratio 1.a 36/13 (2.769)

2.a 32/17 (1.882)

3.a 28/20 (1.400)

4.a 26/23 (1.130)

5.a 23/26 (0.885)

Reverse motion as for front motion

Tires

Manufacturer

MAXXIS

KENDA

LOAD STAR

Forwards

23x7x10

22x8-10

205/65-10

Rear

22x11x10

22x11-10

225/50-10

MODELLO DX 175

Brakes: Front brake Type Dual drum brake Operation Right hand operation Rear brake Type Single disc brake Operation Right foot operation Suspension: Front suspension Double floating triangles Rear suspension Fork with single shock absorber Shock absorber Front Coil spring/oil damper Rear Coil spring/oil damper

Wheel travel:

Front 150 mm Rear 180 mm Electric system Ignition system CDI

MODEL DX 175

Battery type/voltage/capacity 12V – 12 ampere

Bulb voltage, wattage x quantity:

Headlight 12V, 30w/35W x 1

Taillight 12V, 21W/5W x 1

Dashboard warning light:

Neutral indicator 12V, 3,4W x 1

Lights ignition indicator 12V, 3,4W x 1

Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance work.

MAINTENANCE

INTERVAL

DATE OF SERVICE

MILEAGE SERVICING DEALER

NAME AND

SURNAME

REMARKS

1 month 2 months 3 months 4 months 5 months 6 months 12 months 18 months 24 months 30 months 36 months 48 months 54 months 60 months

WARNING: the use in particular conditions, for example driving on difficult soil, towing, renting (reaching a higher mileage in a short period of time) needs more maintenance interventions, to keep the vehicle in working order.

CAUTION

: to improve the product, the manufacturer reserves to change the building characteristics, without the notice duty.

If your vehicle building characteristics would be different than what is described in the previous pages or in case of doubt during the consultation of this manual, address to the dealer or to an authorized assistance centre.

GRILLO ADVICES OF USING THE WLADOIL PRODUCTS

Engine oil BLUE POWER

Gear oil SINT GEAR 2T

Brakes liquid MOTO BRAKE FLUID DOT 4

Gen. lubrication MOTO GREASE RS

Steering bushing MOTO GREASE RS

Transmission chain spray SUPER CHAIN LUBE

Grillo DX175 Use And Maintenance

Specifications and Main Features

Frequently Asked Questions

User Manual