Textron ALTERRA TBX 700 EPS 2018, ALTERRA MUD PRO 700 LTD EPS 2018 Operator's Manual

YOUR ATV CAN BE HAZARDOUS TO OPERATE.

A collision or rollover can occur quickly, even during routine maneuvers such as turning and driving on hills or over obstacles, if you fail to take proper precautions.

For your safety, it is important to understand and follow all the warnings contained in this Operator’s Manual and the labels on your ATV prior to riding.

This Operator’s Manual should be considered a permanent part of the vehicle and must remain with the vehicle at the time of resale. If the vehicle changes ownership more than once, contact Textron Off Road, Service Department, P.O. Box 810, Thief River Falls, MN 56701, for proper registration information.

Labels should be considered as permanent parts of the vehicle. If a label comes off or becomes hard to read, contact your authorized dealer for a replacement.

FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.

For your safety, it is important all operators be properly trained to operate an ATV. Training is available: U.S. owners, call 800-887-2887; Canadian owners, call 613-739-1535.

Un cours d’instruction est disponible: pour les propriétaires canadiens, composez le 613-739-1535.

Particularly important information is distinguished in this manual by the following notations:

California Proposition 65

The Safety Alert Symbol means ATTENTION! BE ALERT! YOUR SAFETY IS INVOLVED.

WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

! WARNING

CAUTION, without the safety alert symbol, is used to address practices not related to personal injury.

CAUTION

 NOTE:

A NOTE provides key information to make procedures easier or more clear.

! WARNING

This product contains or emits chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Foreword

Congratulations and thank you for purchasing a Textron Off Road All-Terrain Vehicle (ATV). Built with American engineering and manufacturing knowhow, it is designed to provide superior ride, comfort, utility, and dependable service.

You have chosen a quality vehicle designed and built to give dependable service. Be sure, as the owner/operator of this vehicle, to become thoroughly familiar with its basic operation, maintenance, and storage procedures. Read and understand the entire Operator’s Manual before operating the ATV to ensure safe and proper use. Always operate the ATV within your level of skill and current terrain conditions.

This Operator’s Manual is furnished to ensure that the operator is aware of safe operating procedures. It also includes information about the general care and maintenance of your vehicle.

Carefully read the following pages. If you have any questions regarding this vehicle, contact a Textron Off Road authorized dealer

(hereinafter “authorized

dealer(s)”)

for assistance. Remember, only authorized dealers have the knowledge and facilities to provide you with the best service possible.

• Know all local, state/provincial riding laws,

• Respect your ATV,

• Respect the environment, and

• You will gain the respect of others.

We also advise you to strictly follow the recommended maintenance program as outlined. This preventive maintenance program is designed to ensure that all critical components on this ATV are thoroughly inspected at various intervals.

All information in this manual is based on the latest product data and specifications available at the time of printing. We reserve the right to make product changes and improvements which may affect illustrations or explanations without notice.

Some illustrations used in this manual are used for clarity purposes only and are not designed to depict actual conditions. Because we constantly refines and improves its products, no retroactive obligation is incurred.

Textron Specialized Vehicles, Inc.

and the ATV Safety Institute recommend that all ATV operators ride the appropriate-sized ATV according to age.

Protect Your Sport

Parts and Accessories

When in need of replacement parts, oil, or accessories for your ATV, be sure to use only GENUINE PARTS, OIL, AND ACCESSORIES. Only

genuine parts, oil, and accessories are engineered to meet the standards and requirements of your ATV. For a complete list of accessories, refer to the current ATV/ROV Accessory Catalog.

To aid in service and maintenance procedures on this ATV, a Service Manual and an Illustrated Parts Manual are available through your local authorized dealer.

CategoryAge

(Years)

Speed

Limitations

(MPH)

NOTES

Y-12+ 12 or

Older

15 - Limited

30 - Maximum

Operate Under Adult Supervision

T-14 14 or

Older

20 - Limited 30 - Limited

38 - Maximum

Operate Under Adult Supervision

G & S 16 or

Older

According to

Local Regula-

tions

—

Table of Contents

Foreword .................................................. 1

Parts and Accessories............................ 1

Division I - Safety

ATV Safety Alert ...................................... 4

Rider Training Course............................. 5

Warning Labels & Information ............6-8

Hangtag .................................................... 9

Warnings ........................................... 10-18

Prevention......................................... 19-22

Safe Riding Clothing and Gear ............ 19

ATV Condition ...................................... 20

First Aid and Survival ........................... 21

Active Riding ......................................... 23

Sound Judgment .............................. 24-27

Environment ......................................... 24

Those Around You................................ 25

Equipment ............................................ 25

............................................................. 26

Speedrack............................................ 26

Personal Choices................................. 26

Supervision............................................ 28

Taking Responsibility............................ 28

Inexperienced/Untrained Riders ....... 28

Experienced/Trained Riders.............. 28

Division II - Operation/ Maintenance

ATV Specifications ................................ 29

Location of Parts and Controls ............ 30

ATV Operation .................................. 31-39

Basic Operating Maneuvers................. 31

Starting a Cold Engine ...................... 31

Starting the Engine ........................... 31

Handling the ATV (Active Riding

Techniques)....................................... 33

Tips ...................................................... 38

General Information ......................... 40-49

Control Locations and Functions.......... 40

Power Steering..................................... 42

Speedometer/LCD ............................... 43

Oil Level Stick....................................... 45

Seat Latch............................................ 45

Tailgate Latch (TBX)............................. 46

Cargo Box Latch Handles (TBX).......... 46

Side Storage Compartment (TBX) ....... 46

Safety Flag Bracket .............................. 46

Rack Loading (Front and Rear)............ 46

Trailering and Towing............................ 46

Transporting ......................................... 47

Gasoline-Oil-Lubricant ......................... 48

Engine Break-In ................................... 49

Burnishing Brake Pads......................... 49

General Maintenance .......................50-63

General Maintenance........................... 50

Liquid Cooling System ......................... 51

Shock Absorbers.................................. 52

General Lubrication.............................. 53

Hydraulic Hand Brake .......................... 54

Brake Fluid........................................ 54

Brake Lever Lock .............................. 54

Brake Hoses ..................................... 55

Brake Pads........................................ 55

Rear Foot Brake................................... 55

Gas Hoses ........................................... 55

Protective Rubber Boots ...................... 55

Battery.................................................. 56

Jump-Starting....................................... 57

Spark Plug............................................ 59

Throttle Cable Adjustment.................... 59

Air Filter................................................ 59

Air Filter Housing Drain(s).................... 60

Draining V-Belt Cover........................... 60

Tires ..................................................... 61

Wheels ................................................. 61

Muffler/Spark Arrester .......................... 61

Light Bulb Replacement ....................... 62

Checking/Adjusting Headlight Aim ....... 62

Fuses ................................................... 63

Electrical Output Terminals .................. 63

Storage Compartment/Tools ................ 63

Preparation for Storage ........................ 64

Preparation after Storage ..................... 65

Limited Warranty ................................... 66

Warranty Procedure/Owner

Responsibility.................................... 67

U.S. EPA Emission Control Statement/

Warranty Coverage (U.S. Only) ........ 68

Maintenance Record ............................. 69

Change of Address, Ownership, or

Warranty Transfer .............................. 70

Identification Numbers Record ......Inside

Back Cover

! WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Division I - Safety

AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE.

• Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.

• Never operate on excessively rough, slippery, or loose terrain.

• Always follow proper procedures for turning as described in this manual. Practice turning at slow speeds before attempting to turn at faster speeds. Do not turn at excessive speed.

• Always have the ATV checked by an authorized dealer if it has been involved in an accident.

• Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills.

• Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before you start up any hill. Never climb hills with slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. Never go over the top of any hill at high speed.

• Always follow proper procedures for going down hills and for braking on hills as described in this manual. Check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle which would cause the ATV to lean sharply to one side. Go straight down the hill where possible.

• Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid hills with slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you have mastered the turning techniques described in this manual on level ground. Avoid crossing the side of a steep hill if possible.

• Always be careful of skidding or sliding. On slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.

• Always use proper procedures if you stall or roll backward when climbing a hill. To

avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to either side if pointed straight uphill. Turn the ATV around and mount following the procedure described in this manual.

• Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual.

• Never operate an ATV in fast flowing water or in water deeper than the footrests. Remember that wet brakes may have reduced stopping capability. Test your brakes after leaving water. If necessary, apply them lightly several times to let friction dry out the pads.

• Always be sure there are no obstacles or people behind you when you operate in reverse. When it is safe to proceed in reverse, go slowly. Avoid turning at sharp angles in reverse.

• Always use the size and type tires specified in this manual. Always maintain proper tire pressure as described in this manual.

• Never improperly install or improperly use accessories on this ATV.

• Never install a twist grip throttle on this AT V.

• Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer and allow greater distance for braking.

• No one under the age of 16 should operate this ATV. Some operators at the age of 16 may not be able to operate an ATV safely. Parents should supervise the use of the ATV at all times. Parents should permit continued use only if they determine that the operator has the ability to operate the ATV safely.

FOR MORE INFORMATION ABOUT ATV SAFETY, call the ATV Safety Institute at 1-800-887-2887 (U.S.) or 1-613-739-1535 (Canada).

! WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

ATV Safety Alert

The Consumer Product Safety Commission has concluded that ALL-TERRAIN VEHICLES (ATV’s) may present a risk of DEATH or SEVERE INJURY in certain circumstances. Accidents may occur for many reasons:

*** Over 2041 people, including many

children, have died in accidents associated with ATV’s since 2011.

*** Many people have become severely

paralyzed or suffered severe internal injuries as a result of accidents associated with ATV’s.

*** Every month thousands of people are

treated in hospital emergency rooms for injuries received while riding an AT V.

You should be aware that AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles, including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and driving on hills and over obstacles, if you fail to take proper precautions.

TO AVOID DEATH OR SEVERE PERSONAL INJURY:

*Always read the Operator’s Manual

carefully and follow the operating procedures described. Pay special attention to the warnings contained in the manual and on all labels.

* Never

operate an ATV without proper instruction. Take a training course. Beginners should complete a training course.

*Always

follow these age recommen-

dations:

• A Y-12+ is intended for use by children age 12 or older, and a T-14 is intended for use by an operator age 14 or older.

• A child under 16 years old should never operate an ATV without adult supervision. Children need to be observed carefully because not all children have the strength, size, skills, or judgment to operate an ATV safely.

*Never carry a passenger on an ATV.

Carrying a passenger may upset the balance of the ATV and may result in loss of control.

*Always

avoid paved surfaces. ATV’s are not designed to be used on paved surfaces and may seriously affect handling and control.

*Never

operate an ATV on a public road, even a dirt or gravel one, because you may not be able to avoid colliding with other vehicles. Also, operating an ATV on a public road may be against the law.

*Never

operate an ATV without an approved motorcycle helmet, eye protection, boots, gloves, long pants, and a long-sleeved shirt or jacket.

*Never

consume alcohol or drugs before or while operating an ATV.

*Never

operate an ATV at excessive speeds. Go at a speed which is proper for the terrain, visibility conditions, and your experience.

*Never

attempt to do wheelies, jumps, or other stunts.

*Always

be careful when operating an ATV, especially when approaching hills, turns, and obstacles and when operating on unfamiliar or rough terrain.

*Never

lend an ATV to anyone who has not taken a training course or has not been driving an ATV for at least a year.

! WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Rider Training Course

The Textron Specialized Vehicles division of Textron, Inc. (hereinafter “the manufacturer”) sponsors a free Rider Training Course to teach ATV riding skills or to reinforce current riding skills. First-time purchasers without any previous ATV riding experience will receive a $100.00 coupon from the manufacturer through the SVIA/ASI after completing the training course (U.S. owners only, one incentive, and free rider training courses for appropriate immediate family members per ATV purchase). See an authorized dealer for details or call (800) 887-2887 for training course information.

In Canada, the Canada Safety Council (CSC) provides an ATV Rider’s Course to teach safe ATV operating skills. They also provide a special ATV Rider’s Course for children under 14 years of age with parental supervision. Call the CSC at 1-613-739-1535 ext. 227 for more details. Also available is a bilingual computer-based safety training program on a CD-ROM from CATV - call toll-free at 1-877-470-2288.

Au canada, le conseil canadien de la sécurité (CSC) offre un cours de conduite de VTT pour enseigner les habiletés d’opération sécuritaires de VTT. Un cours spécial de conduite de VTT est également offert aux enfants de moins de 14 ans avec la surveillance d’un parent. Communiquez avec le CSC en composant le: 1-613-739-1535, poste 227 pour de plus amples informations. Un programme de formation bilingue informatisé sur la sécurité est aussi disponible sur disque optique compact par CATV; composez sans frais le: 1-877-470-2288.

FOR MORE INFORMATION ABOUT ATV SAFETY, in the U.S., call the Consumer Product Safety Commission at (800) 638-2772 or the ATV Distibutors’ Safety Hotline at (800) 852-5344 or in Canada, call the Canada Safety Council at 1-613-7391535 ext. 227.

Visit the manufacturer’s website for additional product information.

! WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Warning Labels & Information

This vehicle comes with several labels containing important safety information. Anyone who rides the ATV should read and understand this information before riding. The labels should be considered as permanent parts of the ATV. If a label comes off or becomes hard to read, contact your authorized dealer for a replacement.

 NOTE: The location and content of labels on the ATV you have purchased

may differ from those shown on this page.

TXA018A

TXA019A

CF751A

1411-865

0411-576

4411-836

1411-809

4411-818

Mud Pro

TBX

C (Mud Pro)

! WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Warning Labels & Information

0411-426

0411-966

1411-574

1411-932

1411-804

4411-550

! WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Warning Labels & Information

0411-975

4411-787

0411-648

L (TBX)

M (TBX)

N (Mud Pro)

! WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Hangtag

This vehicle comes with a hangtag containing important safety information. Anyone who rides the ATV should read and understand this information before riding.

Pour commander des Étiquettes de Mise en Garde gratuites, voyez votre concessionnaire agréé pour le numéro de pièce

2436-558.

! WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Warnings

! WARNING

POTENTIAL HAZARD

Operating this ATV without proper instruction.

WHAT CAN HAPPEN

The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain.

HOW TO AVOID THE HAZARD

Beginning and inexperienced operators should complete the certified training course offered. They should then regularly practice the skills learned in the course and the operating techniques described in this Operator’s Manual.

For more information about the training course, contact an authorized dealer or call 1-800-887-2887 (U.S.) or 1-613-739-1535 (Canada).

! WARNING

POTENTIAL HAZARD

Allowing anyone under age 16 to operate this ATV.

WHAT CAN HAPPEN

Use of an ATV by children can lead to severe injury or death of the child. Children under the age of 16 may not have the skills, abilities, or judgment needed

to operate the ATV safely and may be involved in a serious accident.

HOW TO AVOID THE HAZARD

A child under 16 should never operate this ATV.

! WARNING

POTENTIAL HAZARD

Carrying a passenger on this ATV.

WHAT CAN HAPPEN

Greatly reduces your ability to balance and control this AT V.

Could cause an accident, resulting in injury or death to you and/or your passenger.

HOW TO AVOID THE HAZARD

Never carry a passenger. The long seat is to allow the operator to shift positions as needed during operation. It is not for carrying passengers.

! WARNING

POTENTIAL HAZARD

Attempting wheelies, jumps, and other stunts.

WHAT CAN HAPPEN

Increases the chance of an accident including a rollover.

HOW TO AVOID THE HAZARD

Never attempt stunts, such as wheelies or jumps. Don’t try to show off.

! WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

! WARNING

POTENTIAL HAZARD

Operating this ATV on paved surfaces.

WHAT CAN HAPPEN

The ATV’s tires are designed for off-road use only, not for use on pavement. Paved surfaces may seriously affect handling and control of the ATV and may cause the ATV to go out of control.

HOW TO AVOID THE HAZARD

Whenever possible, avoid operating the ATV on any paved surfaces including sidewalks, driveways, parking lots, and streets. If operating on paved surfaces is unavoidable, travel slowly (less than 10 MPH) and avoid sudden turns and stops.

! WARNING

POTENTIAL HAZARD

Operating this ATV without wearing an approved helmet, eye protection, and protective clothing.

WHAT CAN HAPPEN

Operating without an approved helmet increases your chances of a severe head injury or death in the event of an accident.

Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident.

Operating without protective clothing increases your chances of severe injury in the event of an accident.

HOW TO AVOID THE HAZARD

Always wear an approved helmet that fits properly. You should also wear: Eye protection (goggles or face shield)

Gloves Boots Long sleeved shirt or jacket Long pants

! WARNING

POTENTIAL HAZARD

Failure to use extra care when operating on rough, slippery, or loose terrain.

WHAT CAN HAPPEN

Could cause loss of traction or control of the ATV which could result in an accident including a rollover.

HOW TO AVOID THE HAZARD

Do not operate on rough, slippery, or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain.

Always be especially cautious on these kinds of terrain.

! WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

! WARNING

POTENTIAL HAZARD

Operating this ATV after or while consuming alcohol or drugs.

WHAT CAN HAPPEN

Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident.

HOW TO AVOID THE HAZARD

Never consume alcohol or drugs before or while driving this ATV.

! WARNING

POTENTIAL HAZARD

Operating this ATV at excessive speeds.

WHAT CAN HAPPEN

Increases your chances of losing control of the ATV, which can result in an accident.

HOW TO AVOID THE HAZARD

Always ride at a speed that is proper for the terrain, visibility and operating conditions, and your experience.

! WARNING

POTENTIAL HAZARD

Failure to inspect the ATV before operating. Failure to properly maintain the ATV.

WHAT CAN HAPPEN

Increases the possibility of an accident or equipment damage.

HOW TO AVOID THE HAZARD

Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition.

Always follow the inspection and maintenance procedures and schedules described in this Operator’s Manual.

! WARNING

POTENTIAL HAZARD

Removing hands from handlebar or feet from footrests during operation.

WHAT CAN HAPPEN

Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off the ATV. If you remove a foot from a footrest, your foot or leg may come into contact with the wheels, which could injure you or cause an accident.

HOW TO AVOID THE HAZARD

Always keep both hands on the handlebar and both feet on the footrests of your ATV during operation.

! WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

! WARNING

POTENTIAL HAZARD

Failure to use extra care when operating the ATV on unfamiliar terrain.

WHAT CAN HAPPEN

You can come upon hidden rocks, bumps, or holes without enough time to react.

Could result in the ATV overturning or going out of control.

HOW TO AVOID THE HAZARD

Go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.

! WARNING

POTENTIAL HAZARD

Improperly crossing hills or turning on hills.

WHAT CAN HAPPEN

Could cause loss of control or cause the ATV to overturn.

HOW TO AVOID THE HAZARD

Avoid crossing the side of a hill or turning on a hill whenever possible. Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in this Operator’s Manual. Practice first on level ground. Be very careful when turning on any hill.

If crossing the side of a hill or turning on a hill is unavoidable:

Always follow proper procedures as described in this Operator’s Manual. Avoid hills with slippery or loose surfaces. Shift your weight to the uphill side of the ATV.

! WARNING

POTENTIAL HAZARD

Going down a hill improperly.

WHAT CAN HAPPEN

Could cause loss of control or cause the ATV to overturn.

HOW TO AVOID THE HAZARD

Always follow proper procedures for going down hills as described in this Operator’s Manual.

Always check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the ATV to lean sharply to

one side. Go straight down the hill where possible.

! WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

NEVER OPERATE UP OR DOWN HILLS STEEPER THAN 25°

! WARNING

POTENTIAL HAZARD

Turning improperly.

WHAT CAN HAPPEN

ATV could go out of control, causing a collision or rollover.

HOW TO AVOID THE HAZARD

Always follow proper procedures for turning as described in this Operator’s Manual.

Practice turning at slow speeds before attempting to turn at faster speeds. Do not turn at excessive speed.

! WARNING

POTENTIAL HAZARD

Climbing hills improperly.

WHAT CAN HAPPEN

Could cause loss of control or cause the ATV to overturn.

HOW TO AVOID THE HAZARD

Always follow proper procedures for climbing hills as described in this Operator’s Manual.

Always check the terrain carefully before you start up any hill. Never climb hills with slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. The ATV could

flip over backwards. Never go over the top of any hill at high speed. An obstacle, a sharp drop, or

another vehicle or person could be on the other side of the hill.

! WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

! WARNING

POTENTIAL HAZARD

Operating on steep hills.

WHAT CAN HAPPEN

The ATV can overturn more easily on steep hills than on level surfaces or small hills.

HOW TO AVOID THE HAZARD

Never operate the ATV on hills too steep for the ATV or for your abilities.

Practice on smaller hills before attempting larger hills.

! WARNING

POTENTIAL HAZARD

Stalling, rolling backwards, or improperly dismounting while climbing a hill.

WHAT CAN HAPPEN

Could result in the ATV overturning.

HOW TO AVOID THE HAZARD

Use proper gear and maintain steady speed when climbing a hill. If you lose all forward speed:

Keep weight uphill. Apply the brakes. Engage the brake lever lock after you are stopped.

If you begin rolling backwards:

Keep weight uphill. Gradually apply the brakes while rolling backwards. When fully stopped, engage the brake lever lock. Dismount on uphill side or to a side if pointed

straight uphill. Turn the ATV around and mount following the

procedure described in this Operator’s Manual.

! WARNING

POTENTIAL HAZARD

Overloading the ATV or carrying or towing improperly.

WHAT CAN HAPPEN

Could cause changes in ATV handling, which could lead to an accident.

HOW TO AVOID THE HAZARD

Never exceed the stated load capacity for the ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking. Always follow the instructions in this Operator’s Manual for carrying cargo or pull-

ing a trailer.

! WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

! WARNING

POTENTIAL HAZARD

Improperly operating over obstacles.

WHAT CAN HAPPEN

Could cause loss of control or a collision. Could cause the ATV to overturn.

HOW TO AVOID THE HAZARD

Before operating in a new area, check for obstacles. Never attempt to ride over large obstacles, such as large rocks or fallen trees. When you go over obstacles, always follow proper procedures as described in this

Operator’s Manual.

! WARNING

POTENTIAL HAZARD

Skidding or sliding.

WHAT CAN HAPPEN

You may lose control of the ATV. You may also regain traction unexpectedly, which may cause the ATV to overturn.

HOW TO AVOID THE HAZARD

Learn to safely control skidding or sliding by practicing at slow speeds and on level, smooth terrain.

On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.

! WARNING

POTENTIAL HAZARD

Operating the ATV with improper modifications.

WHAT CAN HAPPEN

Improper installation of accessories or modification of the ATV may cause changes in handling which could lead to an accident.

HOW TO AVOID THE HAZARD

Never modify the ATV through improper installation or improper use of accessories. All parts and accessories added to this ATV should be genuine ATV components designed for use on the ATV and should be installed and used according to instructions. Never install a twist grip throttle. If you have questions, consult an authorized dealer.

! WARNING

POTENTIAL HAZARD

Improperly operating in reverse.

WHAT CAN HAPPEN

You could hit an obstacle or person behind you, resulting in serious injury.

HOW TO AVOID THE HAZARD

Before you engage reverse gear, make sure there are no obstacles or people behind you. When it is safe to proceed, go slowly.

! WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

! WARNING

POTENTIAL HAZARD

Operating this ATV on public streets, roads, or highways.

WHAT CAN HAPPEN

You can collide with another vehicle.

HOW TO AVOID THE HAZARD

Never operate this ATV on any public street, road, or highway, even a dirt or gravel one.

In many states it is illegal to operate an ATV on public streets, roads, or highways.

! WARNING

POTENTIAL HAZARD

Operating the ATV with improper tires or with improper or uneven tire pressure.

WHAT CAN HAPPEN

Use of improper tires on the ATV or operation of the ATV with improper or uneven tire pressure may cause loss of control increasing your risk of accident.

HOW TO AVOID THE HAZARD

Always use the size and type tires specified in this Operator’s Manual for this ATV. Always maintain proper tire pressure as described in this Operator’s Manual.

! WARNING

POTENTIAL HAZARD

Operating the ATV through deep or fast flowing water.

WHAT CAN HAPPEN

Tires may float, causing loss of traction and loss of control, which could lead to an accident.

HOW TO AVOID THE HAZARD

Never operate the ATV in fast flowing water or in water deeper than the footrests. Remember that wet brakes may have reduced stopping capability. Test your brakes after leaving water. If necessary, apply them several times to dry

out the pads.

! WARNING

POTENTIAL HAZARD

Application of excessive throttle.

WHAT CAN HAPPEN

May cause wheelies, flip-overs, or loss of control resulting in serious injury or death.

HOW TO AVOID THE HAZARD

Do not accelerate rapidly or in an uncontrolled manner on any terrain. Use extra care when going uphill.

Slowly apply throttle in a controlled manner. Release throttle lever as necessary to maintain control.

! WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

! WARNING

POTENTIAL HAZARD

Operating the ATV with differential lock engaged.

WHAT CAN HAPPEN

The increased steering effort and reduced maneuverability caused by the locked differential could result in loss of control and an accident.

HOW TO AVOID THE HAZARD

Never exceed 10 MPH (16 KPH) with the differential lock engaged. Always disengage the differential lock as soon as not needed for additional traction.

! WARNING

POTENTIAL HAZARD

Failure to release the brake lever lock before driving the ATV

WHAT CAN HAPPEN

Driving the ATV with the brake lever lock engaged could cause a change in handling or loss of brakes and cause an accident.

HOW TO AVOID THE HAZARD

Always release the brake lever lock before driving the ATV.

! WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Prevention

Overview

When using an ATV, prevention is the name of the game. “Had you only known” something could go wrong, you would have prevented it. If you don’t notice your conditions and surroundings before riding your ATV, you give up control over the situation. Using ATV prevention techniques helps you forecast potential hazards before they injure you or damage your ATV.

Following the safety instructions and warnings in this manual will help you “P.A.S.S.” the safety test. P.A.S.S. stands for “Prevention,” “Active Riding,” “Sound Judgment,” and “Supervision.” Remembering P.A.S.S. and what it stands for will help you have a safe, predictable ride every time you go out on your ATV.

Always wear clothing suited to the type of riding you are doing. ATV riding requires special protective clothing which will make you feel more comfortable and reduce chances of injury.

You’ll find it important to dress correctly for ATV riding in order to prevent scraped skin and serious head injuries. It’s easy and could save you time in the long run not having to contend with an injury. Of course, it also makes sense to remember the seasons. Wear a hat under your helmet and a snowmobile suit in the winter and lighter, protective clothing in the summer. Following is the minimum protection you need to wear during every ride.

ATV-0004

Helmet

Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injury. There are several types of helmets on the market, but make sure you wear a helmet that complies with the current standards of the U.S. Department of Transportation (DOT), The Snell Memorial Foundation, or the American National Standards Institute (ANSI). Helmets that comply with one or more of these agency’s standards have a sticker on the inside or outside of the helmet.

These helmets should provide full-face protection.

If you drop or damage your helmet, get a new one immediately. Your helmet may not protect your head from injury if it has cracks, fissures, or other damage to its outside or core padding.

Remember, your helmet won’t do you any good if the chin strap isn’t fastened.

Gloves

Your hands are targets for flying objects and branches. Along with providing skin protection, gloves will shield your hands from harsh weather. Wear gloves that are weather resistant and have a gripping surface to keep them from sliding off the handlebars. Off-road style gloves with knuckle pads are the best for comfort and protection.

Safe Riding Clothing and Gear

Helmets should have one of these:

1. DOT label

2. Snell label

3. ANSI Z90.1 label

! WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Boots/Ankle Protection

Wear a boot that covers the largest possible area of your leg (preferably up to your knee) and can handle significant impact. Choosing boots with low heels and a good tread will help prevent your feet from slipping off the footrests in wet or rugged conditions or getting hurt if they get hit by rocks, dirt, or branches.

Eye Protection

Wear eye protection, such as goggles, to completely surround your eyes to prevent getting dirt or other items in your eyes. Do not depend on sunglasses for proper eye protection. Sunglasses are not recommended; they don’t prevent objects from flying in through the sides.

Long Pants and Long Sleeved Shirt

The goal is to protect your body from branches, long grass, airborne objects, or anything else that could scrape your skin. The more thick and durable the material, the better protection it’ll provide. Riding pants with kneepads, a jersey, and shoulder pads provide the best protection.

The second step in Prevention is checking the condition of your ATV. Chances are good that you’ll be using your ATV in some rough terrain, and there’s no way you want your brakes to go out when riding downhill. You need to check the following parts on your ATV before every ride.

1. Tires and Wheels

2. Controls and Cables

3. Lights and Electric

4. Oil and Fuel

5. Chassis

6. Miscellaneous Items

1. Tires and Wheels

Correct tire pressure is crucial. Consult the ATV Specifications section of this Operator’s Manual for tire pressure guidelines. Incorrect tire pressure can cause poor handling, instability, and a loss of ATV control.

While checking the tire pressure, inspect the tread and sidewalls of the tires for cracks, cuts, or other damage that could indicate they need to be replaced.

2. Controls and Cables

With the engine running and brake applied, check all transmission positions: forward, neutral, and reverse.

A. Brakes

Squeeze the hand brake lever. If it feels soft or “squishy,” it could be low on fluid or have a leak — refer to the General Maintenance section of this Operator’s Manual for instructions. Don’t use the ATV until the brakes are operating normally.

Test the brake lever lock and see if it locks the hand brake lever into position; then disengage it to release the brake. Be sure the rear foot brake near the footrest is working; your brakes could fail during a ride if they’re not maintained.

B. Throttle

Before starting the ATV, push the throttle lever several times. The throttle should have a free, smooth range of motion. If it seems to “stick” at any point, refer to the General Maintenance section of this Operator’s Manual for instructions. Driv-

ing your ATV with a sticking throttle can turn your leisurely ride into an unwelcome accident. Don’t drive your ATV if the throttle sticks.

ATV Condition

Check:

1. Tire pressure

2. Tire surface (tread and sidewalls)

Check:

1. Forward

2. Neutral

3. Reverse

Check:

1. Hand brake lever

2. Rear foot brake

3. Brake lever lock

Check:

1. Free, smooth range of motion

! WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

3. Lights and Electric

Turn the hi-beam and lo-beam on and off to make sure they work. At the same time, check that the taillight and brakelight work. Also, check the status/warning indicators (reverse, neutral, and hi-lo beam) on the handlebar when you start the ATV. Don’t drive the ATV unless all systems are working. Check the ignition switch and emergency stop switch.

4. Oil and Fuel

Start with a full tank of gas before every ride, and while you’re at it, top off the oil. Don’t forget to check for fluid leaks around the ATV. Watch the overheat indicator to ensure the engine coolant level is adequate.

5. Chassis

Grass and leaves can gum-up your suspension and shocks. Clear and clean the suspension arms, shock springs, and fenders. Check smoothness by turning the handlebar full-left and full-right. Check that there is no binding, restrictions, free-play, or looseness in steering components.

6. Miscellaneous Items

Inspect your air filter. Look for debris or damage that may indicate you need to replace it. A clogged filter can stop an engine. Check your battery terminals for corrosion. Also, be sure to tighten any loose parts, nuts, or bolts.

You need to prepare for the unexpected. Emergencies and accidents are traumatic enough, but they’re even worse when you’re not prepared for them. At the minimum during every ATV ride, you should have the following items on board:

• Tools

• Water

• Identification

• First Aid Kit

For rides that are longer in duration and distance, the following additional items are recommended:

• Cellular Phone

• Maps/GPS

• Emergency Kit with Flashlight and First

Aid Kit

Tools

Routine maintenance will generally eliminate the need for emergency repairs. Riding on rough terrain could cause loosening of nuts, bolts, and fasteners. Especially on long rides, carrying the right tools can prevent an inconvenience from becoming a crisis.

Water

Water is so important that you need to carry it regardless of the duration of your ride. Heat exhaustion and heat stroke can creep up suddenly and can take you out of commission. If you become dehydrated, you could find yourself physically unable to safely operate your ATV.

Identification

If something does happen to you, the emergency personnel will want to know who you are and whom to contact. It’s possible you may be in no condition to give them that information. Put your I.D. in your pocket before you ride. Without it, you’re anonymous.

Cellular Phone

It may be necessary to make an urgent phone call.

Check:

1. Hi-beam

2. Lo-beam

3. Taillight/brakelight

4. Status/warning indicators

5. Ignition switch

6. Emergency stop switch

Check:

1. Gas

2. Oil

3. Fluid leaks

Check:

1. Suspension arms

2. Shock springs

3. Fenders

4. Steering

Check:

1. Air filter

2. Battery

3. Tighten parts, nuts, and bolts

First Aid and Survival

Carry these items on your ATV:

1. Bulbs

2. Duct tape

3. Rope

4. Spark plugs

5. Spare parts

6. Tool Kit

! WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Maps/GPS (Global Positioning System)

Maps may be unnecessary when you’re familiar with the area. But when you’re riding on unfamiliar trails, it’s good to know where you are, what’s coming up, and how to get back.

Emergency Kit with Flashlight and First Aid Kit

You’ll need several items in your Emergency Kit including a flashlight. The matches will come in handy if you need to start a fire to stay warm. Flares are appropriate for signaling help. A first aid kit is very important if an injury of some type should happen. A good First Aid Kit should include bandages, antiseptic spray, gauze, tape, etc.

Carry these items:

1. Flashlight

2. Matches

3. Flares

4. First Aid Kit

5. Money

! WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Active Riding

Overview

“Active Riding” is the second part of “P.A.S.S.” It involves an understanding of how your body weight, balance, gravity, and physical forces affect the handling of the ATV. Knowing how to shift your weight is necessary to avoid rolling or flipping the AT V.

For complete operating instructions, see ATV Operation sub-section in this manual.

! WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Sound Judgment

Overview

You are not invincible. Knowing that the first “S” in “P.A.S.S.” stands for “Sound Judgment” means you need to use yours.

The environment you operate an ATV in is often harsh and sometimes dangerous if you don’t take proper precautions.

Weather

You need to consider the weather. It is dangerous to ride your ATV when the weather is bad or potentially bad. Keep abreast with weather forecasts.

Terrain

Always pay close attention to the terrain you’re on, even if it is familiar to you. You can’t assume that the landscape you’re used to doesn’t change. Changes to landscape can happen at nearly any time. Fences can be constructed and excavations dug in a short period of time. Weather, climate, and development take their toll.

The thing about terrain is that sometimes you don’t know it’s changed until you get there. Whether it’s familiar or not, check out your surroundings before and during your ride.

Night Riding

Riding at night can be very hazardous. Obstacles and other hazards (that are easily identified during daytime) are much more difficult to see and avoid. When night riding, make sure the lights are properly adjusted and in good working order. Reduce speed; do not over-drive the headlights. Never travel in an unfamiliar area or blaze a new trail at night. Always carry a flashlight or flare for signaling an emergency.

Paved Surfaces

Avoid whenever possible. The ATV isn’t designed for pavement. Its handling becomes more difficult on paved surfaces. If operating on paved surfaces is unavoidable, travel slowly (less than 10 MPH) and avoid sudden turns and stops.

Trail Riding

Use sound judgment when trail riding; that means riding on a trail that fits your ability level. If the trail is pretty rugged, standing up on your footrests will make it easier for you to endure the rough terrain.

Make yourself visible by using headlights and taillights, and pull completely off the trail if you need to stop.

Outsloped trails (trails that slant to allow rain to run off) make trail riding a bit more challenging. Keep your weight shifted into the slope.

It also helps to know which trails you can legally ride and who else might be on those same trails. These are signs currently used in some areas to designate trail types and restrictions.

ATV-0068A

Environment

Trail Signs

! WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

People do all kinds of things that you can’t predict or control.

Riding Companions

Leave a lot of space between you and other riders, especially in dusty and dirty conditions, because it’ll be difficult to see the riders in front of you stopping.

Do not carry a passenger on any ATV designed for single-rider use. These ATV’s do not have appropriate equipment (handholds, footrests, etc) to accommodate riders. Additionally, the added weight and weight shift can make the vehicle difficult to control.

Other Vehicles

Depending on where you’re riding, you might encounter other ATV’s, bikes, or motor vehicles on public lands. Respect the presence of cars if you’re crossing roads or riding in public areas and make yourself be seen. If you can’t see other vehicles coming, that means you’re invisible, too.

Hikers

With the renewed interest in hiking, camping, and other outdoor activities, people can show up in remote areas where you would never expect them. For their sake, keep your eyes open.

Animals and Nature

Respect the outdoors that you love. Don’t use your ATV to chase animals or birds. Drive around young trees rather than over them. Keep clear of streams and ditches with standing water.

Tread Li gh tl y

and leave it as you found it.

The last thing you expected was that your ATV would break down in the middle of the field... it’s usually so reliable that sometimes you forget the ATV has its limits.

ATV Maintenance

You have to maintain your ATV. The General Maintenance section of this Operator’s Manual tells you about taking care of your ATV. If, at any time, abnormal noises, vibrations, or improper functioning of any component of this ATV is detected, DO NOT OPERATE THE ATV. Take the vehicle to an authorized dealer for inspection and adjustment or repair.

Cargo Limitations

One reason why passengers are prohibited on ATV’s is because their presence throws off the weight and balance of the ATV. Cargo can do the same if it weighs too much. Limit the ATV to the load capacity ratings identified in the following chart for the particular model being operated. So if you’re weighing in at over 215 lb (97 kg) when you ride, leave some of that extra cargo at home. The combined weight limit, including you, your rack cargo, and your trailer, is a specified amount, so consult the ATV Load Capacity Ratings chart and monitor it carefully.

Extra weight on the ATV will also throw you off balance if it’s not distributed evenly, sideto-side and front-to-rear. If you have 160 lb (73 kg) on the rear rack only and you’re heading up an incline, shifting your own weight forward isn’t going to do enough to compensate for that cargo sitting over the back tires.

Cargo has such a huge affect on ATV handling that you need to pay a lot of attention to your speed. Even on really level areas, you should keep it under 10 mph (16 kph) if you’ve got a trailer attached. Avoid uneven terrain. Also, consider that your braking distance is going to increase with the more weight you carry.

Those Around You

Equipment

Think about these when dealing with cargo:

1. Rack weight limit

2. Trailer weight limit

3. Weight distribution

4. ATV speed

! WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Load Capacity Ratings Chart

Max Load Capacity - Total weight of operator, accessories, tongue weight, and cargo on front and rear racks.

Tongue Weight - Weight on trailer tongue.

Rear Rack and Tongue Weight

- Total weight on trailer tongue, Speedpoint, and rear rack.

Rear Rack/Cargo Box and Tongue Weight - Total weight on trailer tongue,

Speedpoint, and rear rack/cargo box. Towing Capacity - Total weight of

trailer and all cargo in the trailer.

 NOTE: Tongue and accessory

weight (winch, snowplow, Speedpoint, gun scabbard brackets, etc.) must be included as part of the front and rear rack/cargo box weights.

Speedrack

When installing Speedrack accessories, read and carefully follow the instructions provided in each kit.

 NOTE: Use extra caution when

operating an ATV with additional loads such as accessories and/or cargo. Handling of the ATV may be adversely affected. Reduce speed when adding additional loads.

A safe, enjoyable ride is dependent on many personal choices. An ATV, like all motorized vehicles, can be dangerous to operate if you choose to ignore safety precautions, take unnecessary chances, or ride beyond your ability or your vehicle’s capability. Don’t allow the thrill of freedom or adventure to affect your ability to make good, safe choices.

Alcohol and Drug Consumption

It’s extremely dangerous and often illegal to drink alcoholic beverages and ride.

Item

Specifications

(lb) (kg)

Max Load Capacity - Mud Pro Max Load Capacity - TBX

515 600

233 272

Front Rack (Max) 100 45

Rear Rack (Max) 200 91

Rear Cargo Box - TBX (Max) 300 135

Side Storage Box (each) TBX (Max)

20 9

Tongue Weight 35 16

Rear Rack and Tongue Weight (Max)

200 91

Rear Cargo Box and Tongue Weight - TBX (Max)

300 135

Towing Capacity 1050 477

! WARNING

POTENTIAL HAZARD

Overloading the ATV or carrying or towing cargo improperly.

WHAT CAN HAPPEN

Could cause changes in ATV handling, which could lead to an accident.

HOW TO AVOID THE HAZARD

Never exceed the stated load capacity fo r t he ATV.

Cargo should be properly distributed and securely attached.

Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking.

Always follow the instructions in this Operator’s Manual for carrying cargo or pulling a trailer.

Personal Choices

Substances to avoid when riding:

1. Alcohol

2. Over-the-counter or prescription drugs

3. Illegal/mood altering drugs

Be aware of prescription and over-thecounter medications. Drowsiness and impaired judgment can be caused by a wide variety of medications. The same is true of allergy, cold, flu, and headache medications. Your physical size and weight can’t protect you... just one antihistamine tablet can affect your judgment.

Don’t use alcohol or drugs before or during your ATV ride.

Your Physical Condition

Your physical condition is critical to safe ATV operation. Don’t ride when tired and consider your health when planning longer rides.

Reckless Riding

Where excessive or high speed is a factor, the potential for personal injury is greatly increased. Ride within reason and your skill level. Avoid maneuvers that are reckless. Don’t show off.

Laws and Regulations

Any police officer will tell you that ignorance of the law is no defense. Your best defense is to check out your local, state, or provincial ATV laws before riding. It’ll also make sure that you can continue to ride in your favorite areas. The quickest way to have a land area closed is by riding over the regulations.

Group Behavior

When riding in a group, it is human nature to try to keep up with or out-do those around you. We can all be competitive and that can lead to risk taking resulting in serious injury or equipment damage. Know your limitations and don't be afraid to slow the pace down.

Alcohol - Effects*

The Number of Drinks that Impair

Mental and Physical Abilities

1-2 DRINKS

Mental processes such as restraint, awareness, concentration, and judgment affected; reaction time slowed; inability to perform complicated tasks.

3-4 DRINKS

Depth perception, glare recovery, eye movement, and focus affected; decreased judgment and control.

5+ DRINKS

Coordination deteriorates, loss of critical judgment, and impaired memory and comprehension.

*According to the ATV Safety Institute.

Don’t ride:

1. When you’re tired

Supervision

Overview

You’re responsible for supervising those who ride your ATV. Your wisdom is valuable... it’ll bring them all back safely— your friends, your family, your relatives, and your ATV. It’s crucial that you consider yourself a supervisor for all riders of your ATV. Whether you accept responsibility or not, the truth is that you are responsible for others riding your ATV.

You’re to the last letter in “P.A.S.S.”...“Supervision.” You’ve just gone through the manual, and you’ve seen what’s involved. That puts you in a good position to be confident about what you know. So now it’s time to use your knowledge and supervise others who ride your ATV.

Inexperienced/Untrained Riders

You can’t let people ride your ATV who don’t know what they’re doing. Unless they’ve had over a year of experience with ATV riding or taken an ATV training course, it’s your responsibility to keep them off your ATV. It can be dangerous (especially for under-aged children)—all the more reason for you to be firm.

Experienced/Trained Riders

If anyone is going to borrow your ATV, you are responsible for their supervision. Before they ride, have them take the training course, have them watch the safety video, have them read the Operator’s Manual, and train them.

ATV’s are all a little different from the handling to the stability to the controls. So regardless of how much experience your family members have with ATV’s, they don’t have experience with your ATV. Let experienced riders get familiar with your ATV—show them the basics before they take off. You don’t want it on your conscience that someone got hurt because you didn’t tell them how to use your ATV.

Remember that regardless of experience, you should never let anyone under the age of 16 operate your ATV.

The manufacturer and the ATV Safety Institute recommend that all ATV operators ride the appropriate-sized ATV according to age.

Taking Responsibility

Category

Age

(Years)

Speed

Limitations

(MPH)

NOTES

Y-12+ 12 or

Older

15 - Limited

30 - Maximum

Operate Under Adult Supervision

T-14 14 or

Older

20 - Limited 30 - Limited

38 - Maximum

Operate Under Adult Supervision

G & S 16 or

Older

According to

Local Regula-

tions

—

Division II - Operation Maintenance

ATV Specifications

Specifications subject to change without notice.

ENGINE

Type Four-Cycle/Liquid Cooled OHC Bore x Stroke

102 mm x 85 mm (4.01 x 3.35 in.)

Displacement

695 cc (42.4 cu in.)

Spark Plug Type

NGK CPR8E

Spark Plug Gap

0.5-0.6 mm (0.019-0.024 in.)

Brake Type

Hydraulic w/Brake Lever Lock and Rear Foot Brake

CHASSIS

Length (Overall)

215.4 cm (84.8 in.) - Mud Pro 249 cm (98.00 in.) - TBX

Height (Overall)

122.0 cm (48.0 in.) - TBX

131.6 cm (51.8 in.) - Mud Pro

Width (Overall)

120.7 cm (47.5 in.)

Suspension Travel (Front/Rear)

25.4 cm (10 in.)

Tire Size (Front)

25 x 8-12 - TBX

28 x 9-14 - Mud Pro

Tire Size (Rear)

25 x 10-12 - TBX

28 x 11-14 - Mud Pro

Tire Inflation Pressure (w/operator)

34.5 kPa (5.0 psi)

Tire Inflation Pressure (w/operator and cargo)

48.3 kPa (7.0 psi) - Mud Pro 69 kPa (10 psi) - TBX

MISCELLANY

Dry Weight (Approx)

357.4 kg (788 lb) - TBX

363 kg (800 lb) - Mud Pro

Gas Tank Capacity

21.6 L (5.7 U.S. gal.) - Mud Pro

22.0 L (5.8 U.S. gal.) - TBX

Coolant Capacity

2.9 L (3.0 U.S. qt)

Differential Capacity

198 ml (6.7 fl oz)

Rear Drive Capacity

198 ml (6.7 fl oz)

Engine Oil Capacity (Approx.)

1.9 L (2.0 U.S. qt)

Gasoline (Recommended)

87 Octane Regular Unleaded

Engine Oil (Recommended)

ACX All Weather (Synthetic)

Front Differential/Rear Drive Lubricant

SAE Approved 80W-90 Hypoid

Brake Fluid

DOT 4

Taillight/Brakelight

12V/8W/27W

Headlight

12V/27W (4)

Starting System

Electric

Location of Parts and Controls

TXA020A

TXA021A

FI016I

739-569D

1. Battery

2. Headlights

3. Hand Brake Lever

4. Power Distribution Module

5. Radiator Access Panel

6. Seat Latch

7. Storage Compartment

8. Reverse Override Switch

9. Rear Foot Brake

10. Brake Lever Lock

11. Key Switch

12. Shift Lever

13. Throttle Limiter

14. Throttle Lever

15. DC Power Outlet

16. Taillight/Brakelight

17. Operator’s Manual Location

18. Headlight HI/LO Switch

19. Starter Button

20. Emergency Stop Switch

21. Drive Select Switch

22. Tailgate Latch (TBX)

23. Storage Compartment (TBX)

24. Cargo Box Latch Handle (TBX)

 NOTE: The ATV you have pur-

chased may differ slightly from those shown in the figures of this manual.

ATV Operation

Active riding and basic maneuvers are the foundation of your ATV ride. Without basic skills, it’s impossible to execute active riding. These are your basic maneuvers:

• Mounting the ATV

• Starting the Engine

• Starting a Cold Engine

•Shifting

• Braking/Stopping

• Parking

• Dismounting the ATV

Mounting the ATV

To get seated:

1. From the left side, grab the left-side handlebar, apply the brake, and put your left foot on the footrest.

2. Grab the right-side handlebar.

3. Swing your leg over the seat and set your right foot down on the rightside footrest.

4. Get seated in a comfortable position.

5. Always keep your feet planted on the footrests.

Starting the Engine

Always start with the ATV on a flat, level surface. Carbon monoxide poisoning can kill you, so keep your ATV outside while it’s running. Follow these steps to start it up:

1. Mount the ATV and sit down.

2. Engage the brake lever lock.

3. Turn on the ignition.

4. Shift into neutral.

5. Move the emergency stop switch to RUN.

6. Press the starter button.

7. Let the engine warm up.

Starting a Cold Engine



NOTE: It is very important not to touch or compress the throttle lever during the starting procedures.

1. Turn off all electrical accessories (hand warmer, lights, etc.); then rotate the ignition switch key to the first position (ON) leaving the headlights OFF. Note that the N is indicated on the LCD.

2. Press on the starter button.

 NOTE: Do not touch the throttle

lever until the engine has run for at least 3 minutes.

3. Allow the engine to warm up for approximately 2-3 minutes or until the ATV will accelerate without hesitating.

Shifting

1. To engage any gear position from park, move the shift lever upward to the desired position. R (reverse), N (neutral), H (high range), or L (low range).

Basic Operating Maneuvers

CAUTION

Do not run the starter motor for more than eight seconds per starting attempt. The starter motor may overheat causing severe starter motor damage. Allow 15 seconds between starting attempts to allow the starter motor to cool.

CAUTION

EFI012A

2. To engage the P (park), come to a complete stop; then shift the transmission into park.

 NOTE: The high range is for nor-

mal riding with light loads. The low range is for carrying heavy loads or trailer towing. Compared to HIGH range, the LOW range position provides slower speed and greater torque to the wheels.

3. To engage reverse gear from neutral, move the shift lever outward and rearward into the R position.

Braking/Stopping

Always allow plenty of room and time to stop safely. Sometimes quick stops are inevitable, so always be prepared. Whether you’re stopping slowly or stopping quickly, do this:

1. Squeeze the brake lever on the left handlebar to apply both the front and rear brakes.

2. If your wheels lock, release them for a second; then apply them again.

3. Never “ride” the brake. Even maintaining minimal pressure on the brake lever will cause the brake pads to drag on the disc and may overheat the brake fluid.

Parking

Parking involves following the previous rules for braking; then:

1. After the ATV stops, shift into neutral.

2. Stop the engine using the emergency stop switch.

3. Turn off the ignition.

4. If you have to park on a hill, shift the ATV into low gear or park (if applicable).

5. Engage the brake lever lock.

Dismounting the ATV

After you’ve followed the procedure for parking, it’s time to dismount:

1. Double check that the brake lever lock is engaged.

2. Swing your right leg over to the left side of the seat.

3. Step to the ground on the left side of the ATV.

CAUTION

Always shift into low range when operating on wet or uneven terrain, when towing or pushing heavy loads, and when using a plow. Failure to follow this caution may result in premature Vbelt failure or in damage to related drive system components.

CAUTION

Always come to a complete stop before attempting to shift from one range to the other or into reverse. Always shift on level ground, or engage the brake lever lock before shifting into another range or into reverse.

! WARNING

Excessive repetitive use of the hydraulic brake for high speed stops will cause overheating of the brake fluid and premature brake pad wear which will result in an unexpected loss of brakes.

! WARNING

Use only approved brake fluid. Never substitute or mix different types or grades of brake fluid. Brake loss can result. Check brake fluid level and pad wear before each use. Brake loss can result in severe injury or even death.

Active riding involves moving your body. You must learn to lean and shift your weight into your turns to maintain control.

Your safety depends on using safe riding techniques. Statistics from the U.S. Consumer Product Safety Commission (CPSC) say that inexperienced riders who don’t use safe riding techniques are

13 times more likely to have an ATV accident than riders who have over 1

month of experience. Safe riding techniques include:

•Riding

• Leaning, Weight Shift, and Balance

•Wide Turns

• Sharp Turns

•K-Turns

• Riding Uphill

• Riding Downhill

• Sidehilling/Traversing

•Swerving

• Crossing Obstacles

Riding

Once the engine’s warm, the ATV is ready to go.

ATV-0012

1. Keep your feet on the footrests and both hands on the handlebar.

2. Hold the brake lever, and release the brake lever lock.

3. Shift into gear.

4. Release the brake slowly and apply the throttle.

Leaning, Weight Shift, and Balance

When you turn, the trick is to move forward and slide over to the side of the seat that’s on the inside of the turn. Support your body weight on the outside footrest. At the same time, lean your body to the inside of the turn. Pay attention to the handling—if you feel the tires coming off the ground, reduce speed, shift more of your body weight to the side that’s lifting, and make the turn wider if possible.

ATV-0013

ATV-0024

ATV-0025

Wide Turns

Many ATV accidents happen during turns. If you don’t understand turning techniques, it’s easy for the ATV to get away from you by losing traction, plowing, or tipping. Use this method for wide turns:

Handling the ATV (Active Riding Techniques)

ATV-0046

ATV-0045

ATV-0044

1. Ease off the throttle as you approach the turn to slow down.

2. Use the principles of leaning, weight shifting, and balancing—shift your body weight to the inside of the turn.

3. Gradually increase your speed as you come out of the turn.

Sharp Turns

After mastering wide turns, practice the advanced skill of sharp turns.

ATV-0038

ATV-0039

ATV-0040

1. Ease off the throttle as you approach the turn to slow down.

2. Use the principles of leaning, weight shifting, and balancing—shift your body weight to the inside of the turn.

3. You might have to lean into the turn more than you do in a wide turn.

4. If shifting your weight and balance aren’t enough to keep the ATV tires on the ground, straighten out the handlebar as much as you can.

5. Gradually increase your speed as you come out of the turn.

K-Turns

Use K-turns if you accidentally stall while riding uphill; you need to take action before the ATV rolls backward down the hill.

ATV-20 4

1. Stop where you are, apply the brakes, and shift to neutral.

2. Shut off the engine.

3. Keep your body weight shifted forward.

4. Get off the ATV on the uphill side.

5. If you’re to the left of the ATV, turn the handlebar all the way left.

6. Partially release the brake, but lightly hold the brake lever.

7. Let the ATV roll to your right side until it faces slightly downhill.

8. Reapply the brakes.

9. Get back on the ATV from the uphill side, and keep your weight shifted uphill when you sit down.

10. Start the engine and follow the method for riding downhill.

Riding Uphill

Many accidents happen while riding on hills and as a result of the ATV rolling or flipping. So, obviously, use extreme caution and follow this method for riding uphill.

ATV-0019

ATV-0032

ATV-0033

1. Shift down and accelerate before you start climbing; then maintain a steady pace.

2. Lean as far forward as possible. For steeper hills, come off your seat to stand and lean forward.

3. If you lose speed, release the throttle (so your front tires don’t lift), OR

4. If that doesn’t work and you still have forward motion and the terrain permits, do a U-turn, go back down, and try climbing again, OR

5. If you have lost all forward motion, follow the K-turn procedure.

NEVER OPERATE UP OR DOWN HILLS STEEPER THAN 25°

Riding Downhill

Success in riding downhill depends on how well you know your brakes—take it easy on them, or you could flip over.

ATV-0018

ATV-0030

ATV-0031

1. Shift your body weight as far back on the seat as possible.

2. Keep it in a low gear; stay out of neutral.

3. Lightly apply the brake and ease up on the throttle.

Sidehilling/Traversing

Sidehilling is considered an advanced skill; it’s really tricky and unpredictable. So, whether your skills are advanced or not, try to avoid this kind of riding. If you’re in a situation where you absolutely have to sidehill, follow this method:

ATV-0017

ATV-0028

ATV-0029

1. Keep your speed low and consistent.

2. Shift all your body weight to the uphill side of the seat; also, support your weight on the uphill footrest.

3. Steer like you’re driving into the hill.

4. If the ATV feels like it’s tipping, turn the handlebar downhill. If that’s not possible because of the terrain or other conditions or if it just doesn’t work, stop and get off. Dismount the ATV on the uphill side.

Swerving

Swerving is usually an emergency reaction to avoid an obstacle.

ATV-0043

1. Ease off the throttle as you approach the obstacle.

2. Turn the handlebar. At the same time, shift your weight and balance as you swerve. Use the principles of leaning, weight shifting, and balancing—shift your body weight to the inside of the turn.

3. Keep your hand off the brake until the emergency is over and you’re back in control.

Crossing Obstacles

Crossing obstacles is risky; avoid it if possible. Riding over logs, rocks, and ruts means combining all the active riding skills into one big motion. Your ATV will respond differently for different obstacles (logs, ruts, etc.), but these are general guidelines for overcoming twotrack (both tires contacting the obstacle at the same time) obstacles:

ATV-0016

ATV-0026

ATV-0027

1. Keep your speed way down; less than 5 mph.

2. Approach the obstacle head-on.

3. Come up off the seat.

4. Keep your weight on the footrests.

5. Apply a little throttle when the front tires make contact with the obstacle.

6. Lean forward and release the throttle when the front tires clear the obstacle.

7. Keep your body loose to absorb any shock.

8. If the ATV starts tipping, shift your weight to keep it in balance.

To clear a single-track (only one tire contacts) obstacle, follow the same rules except:

1. Use the ATV’s momentum to clear the obstacle.

2. Don’t pull up on the handlebar.

3. Don’t apply the throttle.

Driving an ATV and a car have some similarities; however, there are a few situations that require special attention:

• Reversing

• Skidding or Sliding

• Parking on a Hill

• Stalling on a Hill

• Crossing Water

• Crossing Roads

• Stopping the ATV

• Stopping the Engine

Reversing

It’s tough to see things behind you.

1. Go slowly. It’s hard to see behind you.

2. Keep your handlebar straight.

3. Backing down hills is a bad idea; do a U-turn or K-turn instead to turn around.

Skidding or Sliding

If you lose control after hitting sand, ice, mud, or water:

1. Turn your handlebar into the direction of the slide.

2. Keep your hand off the brakes until you’re out of the skid.

3. Shift your weight forward.

Sometimes your ATV may not respond and goes straight ahead instead of letting you turn. Here’s how to handle it:

1. Slow down.

2. Move forward on the seat.

3. Lean to inside of turn.

4. Turn handlebar.

Parking on a Hill

This shouldn’t be necessary, but if it is:

1. Keep it in gear.

2. Engage the brake lever lock.

3. Find something to block the rear tires.

Stalling on a Hill

If you use the right method for riding uphill, this shouldn’t happen. But if you have a problem, do this:

1. If the ATV hasn’t started rolling backwards yet, follow the procedure for the K-Turn, OR

2. If the ATV is already rolling backward, lean as far forward as possible standing up on the footrests.

3. Nice and easy, apply the hand brake lever.

4. When you come to a stop, follow the procedure for the K-turn.

5. If the ATV continues to roll backward, dismount immediately on the uphill side.

Crossing Water

Your ATV can only handle water up to its footrests. Any more than that and you risk engine damage and/or personal injury. Stay away from fast moving rivers. ATV tires can be buoyant, so if the water is too deep, you might find the ATV suddenly afloat.

1. Physically check the depth and current of the water, especially if you can’t see the bottom. You’re also checking for boulders, logs, or any other hidden obstacles.

2. Keep your speed slow.

Tips

! WARNING

Never activate the override while the throttle is open as a loss of control may result. Use caution when using the override switch as reverse speed can greatly increase.

3. Make sure you have a way out on the other side of the water.

4. If you get stuck in the sludge or mud, try rocking the ATV from side to side.

5. Once you’ve cleared the water, briefly apply the brakes to make sure

they work.

Crossing Roads

Crossing roads on your ATV is also a bad idea, so avoid it. If you can’t:

1. Stop completely on the shoulder of the road.

2. Check both directions for traffic.

3. Crossing near a blind corner or intersection is dangerous; don’t do it.

4. Drive straight across to the opposite shoulder.

5. Take into account that your ATV could stall while crossing; give yourself enough time to get off the road.

6. You have to assume that oncoming cars don’t see you, and if they do, they won’t be able to predict your actions.

7. It’s illegal to cross public roads in some places. Know your local laws.

Stopping the ATV

To stop the ATV, first release the throttle lever. Next, apply the brake.

Stopping the Engine

To stop the engine, turn the ignition switch key to the OFF position or set the emergency stop switch to the OFF position.

 NOTE: Leaving the ignition switch

key in the ON position could result in a discharged battery.

! WARNING

Do not operate this vehicle on a frozen body of water unless you have first verified the ice is sufficiently thick to support the vehicle, cargo, and participants. The vehicle could break through the ice causing serious injury or death.

General Information

Control Locations and Functions

Ignition Switch Key

Two keys come with the ATV. Keep the spare key in a safe place. An identifying number is stamped on each key. Use this number when ordering a replacement key.

Ignition Switch

The ignition switch has three positions.

ATV-0056

OFF position — All electrical circuits except the accessory plug are off. The engine will not start. The key can be removed in this position.

 NOTE: The accessory plug is pow-

ered by the battery at all times.

ON position — The ignition circuit is complete and the engine can run. The key cannot be removed in this position.

LIGHTS

position — The ignition circuit is complete and headlights and taillight are on. The key cannot be removed in this position.

Shift Lever

EFI012A

This ATV has a dual-range automatic transmission with reverse and park.

Drive Select Switch

FI475A

This switch allows the operator to operate the ATV in either two-wheel drive (rear wheels) or four-wheel drive (all wheels). For normal riding on flat, dry, hard surfaces, two-wheel drive should be sufficient. In situations of aggressive trail conditions, fourwheel drive would be the desired choice.

To either engage or disengage the front wheels, move the switch to the 4WD position or to the 2WD position.

The 4WD lock allows the operator to mechanically lock the front differential to apply equal power to both front wheels. To engage the lock from 4WD, slide the switch up and move fully to the left. To disengage the lock, move the switch lever to the right.

CAUTION

Leaving the ignition switch in the ON or LIGHTS position for a long period of time when the engine is not running may cause the battery to discharge. Always leave the ignition switch in the OFF position when engine is not running.

CAUTION

Do not attempt to either engage or disengage the 4WD lock while the ATV is moving.

Hand Brake Lever/Brake Lever Lock

CF301A

The hand brake is considered to be the normal operating (main) brake. It should be applied whenever a braking situation is needed.

Apply the brake by compressing the brake lever toward the handlebar.

To engage and release the brake lever lock, use the following procedure.

1. Squeeze the hand brake two or three times and release it.

2. Depress and hold the brake lever lock.

3. While holding in on the brake lever lock, squeeze the brake lever.

 NOTE: It will click as it engages

and the brake lever will not return to its released position.

4. Attempt to push the ATV. Check to make sure the brake lever lock engages properly and that the brake (when engaged) locks the wheels.

 NOTE: The brake lever lock must

lock the wheels. If it doesn’t, take the vehicle to an authorized dealer for service.

5. Release the brake lever lock by squeezing the brake lever. It will return to its released position.

Headlight HI/LO Switch

CF245A

Use the headlight HI/LO switch to select the high or low headlight beam when the ignition switch is in the LIGHTS position. When the switch is in the HI position, the high beam will illuminate. When the switch is in the LO position, the low beam will illuminate.

Emergency Stop Switch

OFF position — The ignition circuit is off. The engine cannot be started or will not run. If the emergency stop switch is used to stop engine without turning off ignition switch, the battery may discharge.

RUN position — The ignition circuit is on. The engine can start and run.

In an emergency, slide the switch to the OFF position to stop the engine. Apply the brakes to stop the wheels.

! WARNING

The 4WD lock is intended for use where minimum traction is available. NEVER EXCEED 10 MPH (16 kph)

with the lock engaged. Maneuverability and handling characteristics will differ with the lock engaged.

! WARNING

Always check to be sure that the brake lever lock has been disengaged before operating the ATV. An accident could result if the brake lever lock is left engaged while the ATV is operated. The brake may relax if left engaged for a long period of time. This could cause an accident; therefore, do not leave the ATV on a hill depending on the brake lever lock. Always block the downhill side of the wheels if leaving the ATV on a hill or park the ATV in a sidehill position.

Starter Button

Pushing in on this button activates the starter motor. Before starting the engine, make sure the ignition switch is in the ON position, the transmission is in neutral, and the brake lever lock is engaged.



NOTE: This ATV has safety interlock switches which prevent the starter motor from activating when the transmission is not in neutral. To start the ATV while in gear, depress the rear foot brake or compress the brake lever; then depress the starter button.

Reverse Override Switch

This ATV is equipped with a reverse speed limiter system. When additional RPM is needed in reverse, depress and hold the override switch.

 NOTE: The reverse override switch

is active in 4WD only.

Throttle Lever

FI475B

Control engine RPM with the position of the throttle lever. Operate this lever with the thumb. Pushing it forward increases engine RPM and allowing it to retract decreases engine RPM.

Throttle Limiter Screw

XR233A

Throttle lever travel may be limited by adjusting the throttle limiter screw. The throttle limiter should be adjusted according to the operator’s skill and experience. To adjust the throttle limiter, use the following procedure.

1. Loosen the jam nut.

2. Turn the throttle limiter screw clockwise to decrease engine RPM maximum or counterclockwise to increase engine RPM maximum.

3. Tighten the jam nut securely.

 NOTE: The ATV is equipped with

an RPM limiter that retards ignition timing when maximum RPM is approached. When the RPM limiter is activated, it could be misinterpreted as a high-speed misfire.

Rear Foot Brake

TXA002A

Pressing the rear foot brake downward will apply the brake to the rear wheels.

Power Steering

Certain models were produced with an Electronic Power Steering (EPS) system to reduce steering effort and driver fatigue over a broad range of operating conditions.

! WARNING

Never activate the override switch while the throttle is open as a loss of control may result. Use caution when using the override switch as reverse speed can greatly increase.

The EPS system engages when the ignition switch is turned to the ON position and disengages after approximately five minutes (to conserve battery power) if the engine is not running.

This system is entirely maintenance-free: no adjustment or servicing is required. There are no fluids to check or change, and the EPS system is entirely self-contained and sealed to protect it from the elements.

The EPS system is battery system powered; therefore, the battery must be in good condition and fully charged. Power delivery and overload protection is provided by an EPS relay and 30-amp fuse located under the passenger seat in the Power Distribution Module (PDM).

The system is self-monitored and will display a malfunction code on the LCD gauge/speedometer should an EPS system control circuit problem occur. Do not operate the ATV with an EPS malfunction code displayed.

 NOTE: Turn the key switch to the

OFF position then back to the ON position to reset the malfunction code. If the code continues to be displayed, take your vehicle to an authorized dealer for EPS system servicing before resuming operation.

In the event of electrical power failure, the EPS system becomes disabled (similar to an automobile with the engine shut off). Steering effort increases but steering control can be maintained.

Speedometer/LCD

TXA022A

TXA023A

Code Fault Description

C1301 Over Current C1302 Excessive Current Error C1303 Torque Sensor Range Fault C1304 Torque Sensor Linearity Fault C1305 Rotor Position Encoder C1306 System Voltage Low C1307 System Voltage High C1308 Temperature Above 110° C C1309 Temperature Above 120° C C1310 Vehicle Speed High C1311 Vehicle Speed Low C1312 Vehicle Speed Faulty C1313 Engine RPM High C1314 Engine RPM Low C1315 Engine RPM Faulty C1316 EEPROM Error C1317 CAN Bus Error C1318 Internal CRC Error C1319 Boot Counter Exceeded C1320 Incorrect Vehicle Speed-to-RPM

Ratio C1321 Vehicle Speed Erratic C1322 Engine RPM Lost C1323 "EPS OFF" Gauge Display C1324 Loss of CAN communication with

EPS unit

C1325 Dual Loss C1326 Rotor Position Encoder C1327 Voltage Converter Error (Low) C1328 Voltage Converter Error (High) C1329 Internal Data Error

CAUTION

Never operate this ATV with an EPS code indicated on the LCD gauge/ speedometer. This indicates a malfunction in the EPS system control circuit and could result in a loss of power steering assist.

Code Fault Description

Mud Pro

700 TBX

1. Speedometer/Tachometer/Condition Warning Display - Indicates the approximate vehicle speed (MPH or km/h) or RPM. Warns of a system error condition requiring attention.

The LCD will go blank except the word VOLT will flash on the LCD whenever a low voltage (<9 DC volts) or a high voltage (>16 DC volts) is detected. When voltage returns to normal, the gauge must be reset by turning the ignition key to the OFF position and then to the ON position.

The letters EFI (digital/analog gauge) or a diagnostic trouble code (DTC) (digital gauge) will flash on the LCD whenever an EFI system error is detected. After 30 seconds, the gauge will return to normal, but the letters or code will continue to flash until the malfunction is corrected.

 NOTE: Take the vehicle to an

authorized dealer to have the error corrected and the system error reset as soon as possible.

2. Fuel Level Indicator - Indicates approximate amount of gasoline in the gas tank.

 NOTE: When the bottom segment

flashes, approximately 3.5 L (0.92 U.S. gal.) of gasoline remains in the tank.

3. Mode Button - Press and release to shift the gauge between MPH or km/ h and RPM. Press and hold to switch between MPH and km/h.

4. Set/Reset Button - Press and release to shift between Odometer, Trip 1, Trip 2, Engine Hour Meter, and Clock. Press and hold while Trip 1 or Trip 2 are selected to clear the selected trip. The odometer cannot be reset.

5. Odometer/Trip Meter/Clock/Engine Hour Meter - Displays odometer (total distance the vehicle has traveled) or one of two trip meters used to measure trips or trip legs corresponding to the function selected (MPH or km/h). The clock function indicates time in the 12 hour mode. The hour meter indicates the total time the ATV has run and cannot be reset to zero. To set the clock, use the following procedure.

A. With the ignition switch ON, press

and release the Mode Button (3) until the Clock/Engine Hour Meter (1) is displayed; then (if necessary) press and release the Set/Reset Button (4) to the clock display.

B. Press and hold Set/Reset Button (4)

until minutes stop scrolling and the hour display starts to scroll. Momentarily release when correct hour is displayed; then repeatedly press and release Set/Reset Button until correct minutes are displayed.

 NOTE: Approximately two seconds

after releasing either Button, the LCD will return to normal operation.

 NOTE: Clock memory power is

supplied through the 10-amp memory fuse and verified during gauge “power-up” and reset. In the event of clock memory power failure (blown fuse, etc.), the gauge will “powerup,” reset, and shut down repeatedly until clock memory power is restored. Always check the 10-amp memory fuse if this gauge condition is noted.

 NOTE: The engine hour meter will

not activate until engine speed exceeds 500 RPM.

6. Gear Position Indicator - Indicates which gear is selected - R (reverse)/ N (neutral)/H (high range)/L (low range)/P (park).

 NOTE: An E will be displayed if

there is an error caused by a no-shift position signal.

7. Engine Hour Meter Indicator - Indicates engine hour meter mode is selected on the display.

8. Speedometer/Tachometer Indicator Indicates which mode (MPH, km/h, or RPM) is being displayed.

9. 4WD Lock Indicator - Displays LOCK when the front differential lock has been engaged.

10. Drive Select Indicator - Displays 4WD when selected by the drive select switch or when the 4WD lock is engaged. The display is blank when in 2WD.

11. High Beam Indicator - Appears when the headlights are on high beam.

12. Temperature Indicator - The speedometer/tachometer needle will sweep full scale and the LCD will go blank except the high temperature icon will flash. After 30 seconds, the speedometer/tachometer needle and LCD will return to normal, but the temperature icon will continue to flash. The icon should not be visible during normal operation. For more information see Liquid Cooling System.

13. Odometer/Trip Meter Indicator Display - Displays which function (ODO, Trip, or Trip 2) is selected.

14. Speedometer/Tachometer Needle (digital/analog gauge) - Indicates approximate vehicle speed in MPH or km/h when speedometer function is selected or RPM when tachometer function is selected. Sweeps fullscale whenever an EFI system error is detected.

15. Wrench Indicator (digital gauge) Displayed in conjunction with a DTC whenever an EFI system error is detected.

Oil Level Stick

XR234A

There is an oil level stick for checking the engine oil level. To check the oil level, use the following procedure.

 NOTE: The ATV should be on level

ground when checking the engine oil level.

1. Unscrew the oil level stick and wipe it with a clean cloth.

2. Install the oil level stick and thread into the engine case.

 NOTE: The oil level stick should be

threaded in for checking purposes.

3. Remove the oil level stick; the engine oil level should be within the operating range, not above or below.

Seat Latch

AL676A

1. To remove the seat, lift up on the latch release (located at the rear of the seat); then raise the rear of the seat and slide it rearward.

CAUTION

Do not overfill the engine with oil. Always make sure the oil level is within the operating range.

2. To lock the seat into position, slide the front of the seat into the seat retainers and push down firmly on the rear of seat. The seat should automatically lock into position.

Tailgate Latch (TBX)

739-569A

1. To open the tailgate, pull the latch (located at the center of the tailgate).

2. To close the tailgate, press forward firmly. The tailgate will latch automatically.

Cargo Box Latch Handles (TBX)

739-569B

1. To raise the cargo box, rotate either handle upward; then raise the cargo box.

2. To lower the cargo box, push down firmly on the front of the box. The box will automatically lock into position.

Side Storage Compartment (TBX)

TB013

1. To open a compartment, lift the straps off the hatch lugs.

2. To close a compartment, pull the straps over the hatch lugs.

Safety Flag Bracket

A bracket is provided for mounting a flag at the rear of the ATV.

Rack Loading (Front and Rear)

The front rack and rear rack are designed to carry specified load capacities. Always refer to the ATV Load Capacity Ratings chart for proper capacities.

Trailering and Towing

This vehicle is equipped with a framemounted receiver for a standard 5.1 cm (2 in.) receiver hitch. The standard receiver hitch must be purchased separately.

! WARNING

Make sure the seat is secure before mounting the ATV. Severe personal injury may result if the seat is not properly secured.

! WARNING

Make sure the loads on the front and rear racks will not interfere with the ATV controls or obstruct the view of the operator. Also, make sure the loads are evenly distributed, properly secured, and will not shift while operating the ATV.

! WARNING

Never use the racks as a towing or trailering point.

738-424A

When loading a trailer properly, two items are critical: Gross Trailer Weight (the weight of the trailer plus cargo) and Trailer Tongue Weight.

Trailer Tongue Weight is the downward force exerted on the hitch by the trailer coupler when the trailer is fully loaded and the coupler is at its normal towing height. Refer to the Load Capacity Ratings chart for tongue weight information.

Always maintain a slow speed when trailering and towing and avoid sudden accelerations, quick maneuvers, and sudden stops. Braking distance will be affected when towing a trailer. When towing a trailer, always maintain slow speed and allow more stopping distance than when not towing a trailer.

Transporting

When transporting the ATV, the ATV must be in its normal operating position (on all four wheels) and the following procedure must be used.

1. Engage the brake lever lock and place the transmission in gear.

2. Secure the ATV with load rated hold-down straps.

 NOTE: Suitable hold-down straps

are available from your authorized dealer. Ordinary rope is not recommended because it can stretch under load.

CF755A

CF754A

! WARNING

Make sure that the load in the trailer is properly secured and will not shift while moving. Also, do not overload the trailer.

! WARNING

Never exceed any of the ATV weight restrictions.

! WARNING

Riding an ATV without extra caution when towing a trailer will be hazardous. Trailer towing can affect the handling and braking of the ATV. Never tow a trailer without a rigid tongue and never exceed 10 mph. Avoid sudden accelerations and stopping of the ATV. Do not make quick maneuvers. Avoid uneven surfaces and do not tow on hills.

! WARNING

Never tow people in or on any device except when towing a disabled vehicle with operable brakes and steering or on a trailer designed for passengers that has a rigid tow bar.

CAUTION

Failure to engage the brake lever lock and place the transmission in gear could result in the ATV rolling off the trailer in the event of tie-down strap failure.

CAUTION

If using additional hold-down straps in any other areas, care must be taken not to damage the ATV.

Gasoline-Oil-Lubricant

Filling Gas Tank

Since gasoline expands as its temperature increases, the gas tank must be filled to its rated capacity only. Expansion room must be maintained in the tank particularly if the tank is filled with cold gasoline and then moved to a warm area.

Allow the engine to cool before filling the gas tank. Care must be taken not to overfill the tank. If overfilled, gas may leak onto the engine creating a fire hazard.

Tighten the gas tank cap securely after filling the tank.

Recommended Gasoline

The recommended gasoline to use in this ATV is 87 minimum octane regular unleaded. In many areas, oxygenates are added to the gasoline. Oxygenated gasolines containing up to 10% ethanol or 5% methane are acceptable gasolines.

When using ethanol blended gasoline, it is not necessary to add a gasoline antifreeze since ethanol will prevent the accumulation of moisture in the fuel system.

Recommended Engine/ Transmission Oil

The recommended oil to use is ACX All Weather synthetic engine oil, which has been specifically formulated for use in this engine. Although ACX All Weather synthetic engine oil is the only oil recommended for use in this engine, use of any API certified SM 0W-40 oil is acceptable.

OILCHARTJ

Recommended Front Differential/Rear Drive Lubricant



NOTE: The manufacturer recom-

mends the use of genuine lubricants.

The recommended lubricant (front differential and rear drive) is SAE approved 80W-90 hypoid. This lubricant meets all of the lubrication requirements of this AT V.

! WARNING

Always fill the gas tank in a well-ventilated area. Never add gasoline to the ATV gas tank near any open flames or with the engine running or hot. DO NOT SMOKE while filling the gas tank.

! WARNING

Do not over-flow gasoline when filling the gas tank. A fire hazard could materialize. Always allow the engine to cool before filling the gas tank.

! WARNING

Do not overfill the gas tank.

CAUTION

Do not use white gas. Only approved gasoline additives should be used.

CAUTION

Any oil used in place of the recommended oil could cause serious engine damage. Do not use oils which contain graphite or molybdenum additives. These oils can adversely affect clutch operation. Also, not recommended are racing, vegetable, non-detergent, and castorbased oils.

CAUTION

Any lubricant used in place of the recommended lubricant could cause serious front differential/rear drive damage.

Engine Break-In

After the completion of the break-in period, the engine oil and oil filter should be changed. Other maintenance after break-in should include checking of all prescribed adjustments and tightening of all fasteners. At the discretion and expense of the owner/operator, the vehicle may be taken to an authorized dealer for this initial service.

New ATV’s and renewed ATV engines require a “break-in” period. The first month is most critical to the life of this ATV. Proper operation during this break-in period will help assure maximum life and performance from the ATV.

During the first 10 hours of operation, always use less than ½ throttle. Varying the engine RPM during the break-in period allows the components to “load” (aiding the engine/transmission component mating process) and then “unload” (allowing components to cool). Although it is essential to place some stress on the engine components during break-in, care should be taken not to overload the engine too often. Do not pull a trailer during the break-in period.

When the engine starts, allow it to warm up properly. Idle the engine several minutes until the engine has reached normal operating temperature. Do not idle the engine for excessively long periods of time.

Burnishing Brake Pads

Brake pads must be burnished to achieve full braking effectiveness. Braking distance will be extended until brake pads are properly burnished.

To properly burnish the brakes, use following procedure:

1. Choose an area sufficiently large to safely accelerate ATV to 30 mph and to brake to a stop.

2. Accelerate to 30 mph; then compress brake lever to decelerate to 0-5 mph.

3. Repeat procedure twenty times.

! WARNING

Failure to properly burnish the brake pads could lead to premature brake pad wear or brake loss. Brake loss can result in severe injury.

! WARNING

Do not attempt sudden stops or put yourself into a situation where a sudden stop will be required until the brake pads are properly burnished.

General Maintenance



NOTE: Proper maintenance of the ATV is important for optimum performance. Follow the Maintenance Schedule and all ensuing maintenance and care instructions/information.

 NOTE: Proper maintenance proce-

dures for each item can be found on the corresponding page indicated.

If, at any time, abnormal noises, vibrations, or improper functioning of any component of this ATV is detected, DO NOT OPERATE THE ATV. Take the vehicle to an authorized dealer for inspection and adjustment or repair.

A repair shop or person of the owner's choosing may maintain, replace, or repair emission-control devices and systems.

If the owner/operator does not feel qualified to perform any of these maintenance procedures or checks, take the vehicle to an authorized dealer for professional service.

I=Inspect and clean, adjust, lubricate,

replace as necessary

T=Tighten, R=Replace, C=Clean

* Dealer maintenance ** When using ACX

All Weather synthetic oil, oil change interval can be increased to every 1,000 miles or every year.

Maintenance Schedule

Item Page

Initial

Service

(100 miles)

1 month 3 months 6 months

Battery 56 II * Engine nuts and bolts - II * Valve clearance - II Spark plug 59 III

59 Replace every 4000 miles or 18 months Liquid cooling system 51 I Inspect every time before riding Throttle cable 53/59 I Inspect every time before riding Gas Hoses 45 I Inspect every time before riding Engine/transmission oil and filter 53 RR** Air filter 59 II Air filter housing drain(s) 60 I Inspect every time before riding Gear lubricant (Front differential -

rear drive)

54 RI

54 Replace every 2 years or 2000 miles V-Belt 60 II Spark arrester/muffler 61 C Tires/air pressure 61/

I Inspect every time before riding

* Brake components 54 I Inspect every time before riding Brake fluid 54 I Inspect every time before riding Brake hoses 55 I Inspect every time before riding * Steering - I Inspect every time before riding * Suspension (Ball joint boots, drive

axle boots front and rear, tie rods, differential and rear drive bellows) - I Inspect every time before riding

* Chassis nuts and bolts - IT Frame/welds/racks - II Electrical connections - II Headlight/taillight-brakelight 62 I Inspect every time before riding Wheel nuts 61 II

Liquid Cooling System



NOTE: Debris in front of the engine or packed between the cooling fins of the radiator can reduce cooling capability. Using a garden hose, wash the radiator to remove any debris preventing air flow.

The cooling system capacity can be found in the specifications chart. The cooling system should be inspected daily for leakage and damage. If leakage or damage is detected, take the vehicle to an authorized dealer for service. Also, the coolant level should be checked periodically.



NOTE: High engine RPM, low vehicle speed, or heavy load can raise engine temperature. Decreasing engine RPM, reducing load, and selecting an appropriate transmission gear can lower the temperature.

When filling the cooling system, use a 60/40 coolant/water mixture or a ratio which will satisfy the coldest anticipated weather conditions of the area in accordance with the coolant manufacturer’s recommendations. While the cooling system is being filled, air pockets may develop; therefore, run the engine for five minutes after the initial fill, shut the engine off, and then fill the cooling system to the bottom of the stand pipe in the radiator neck.

Checking/Filling

1. On the TBX, remove the two screws from the front of the radiator access panel.

FI465A

2. On the TBX, lift the front of the access panel; then slide the panel forward to disengage the two rear tabs; then move the panel rearward until free of the rack.

3. On the Mud Pro, remove four cap screws securing the snorkel housing to the front inspection panel; then remove two cap screws from the rear of the snorkel housing.

TXA025A

MP007A

4. Separate the front of the snorkel housing from the rear; then remove the snorkel housing.

CAUTION

Do not use a pressure washer to clean the radiator core. The pressure may bend or flatten the fins causing restricted air flow, and electrical components on the radiator could be damaged. Use only a garden hose with spray nozzle at normal tap pressure.

CAUTION

Continued operation of the ATV with high engine temperature may result in engine damage or premature wear.

TBX

MP003

5. Remove two reinstallable rivets and remove the splash guard. The radiator cap can now be accessed in front of the snorkels.

6. Carefully rotate the radiator cap counterclockwise to release pressure; then remove the cap.

CF142A

7. Add coolant as necessary; then install the radiator cap and access panel or snorkel housing.

 NOTE: Use a good quality, biode-

gradable glycol-based, automotivetype antifreeze.

Maintenance

When operating in muddy conditions, it is extremely important to clean the radiator core frequently. The manufacturer requires inspecting and/or flushing the radiator core before each use to prevent overheating resulting in severe engine damage. After cleaning, shine a light through the radiator core while observing from the opposite side to determine if all dirt and debris have been removed.

 NOTE: It is necessary to remove

four machine screws securing the protective screen to the front of the radiator and move it forward to properly flush the radiator core. Make sure to secure the screen to the radiator after cleaning.

Shock Absorbers

Each shock absorber should be visibly checked weekly for excessive fluid leakage (some seal leakage may be observed but it does not indicate the shock is in need of replacement), cracks or breaks in the lower case, or a bent shock rod. If any one of these conditions is detected, replacement is necessary.

 NOTE: When the ATV is operated

in extremely cold weather (-23°C/10°F or colder), a small amount of leakage may be present. Unless the leakage is excessive, replacement is not necessary.

! WARNING

Never check the coolant level when the engine is hot or the cooling system is under pressure.

CAUTION

After operating the ATV for the initial 510 minutes, stop the engine, allow the engine to cool down, and check the coolant level. Add coolant as necessary.

CAUTION

Failure to remove dirt and debris from the radiator prior to operating the ATV may cause overheating resulting in severe engine damage.

CAUTION

The shock absorber has a spring force adjustment sleeve with five adjustment positions to allow the spring to be adjusted for different riding and loading conditions. If the spring action is too soft or too stiff, adjust it according to the chart.

CD453

 NOTE: Before attempting to adjust

suspension, clean dirt and debris from the sleeve and remove load from the suspension; then use the spanner wrench to adjust the sleeve to the desired position.

General Lubrication

Cables

None of the cables require lubrication; however, it is advisable to lubricate the ends of the cables periodically with a good cable lubricant.

Engine/Transmission Oil and Filter

Change the engine oil and oil filter at the scheduled intervals. The engine should always be warm when the oil is changed so the oil will drain easily and completely.

1. Park the ATV on level ground.

2. Loosen the oil level stick. Be careful not to allow contaminates to enter the opening.

CF298A

3. Remove the drain plug from the bottom of the engine and drain the oil into a drain pan.

733-441A

4. Using the oil filter wrench and a ratchet handle (or a socket or box-end wrench), remove the old oil filter and dispose of properly. Do not re-use oil filter.

 NOTE: Clean up any excess oil

after removing the filter.

5. Apply oil to the new filter O-ring and check to make sure it is positioned correctly; then install the new oil filter. Tighten securely.

6. Install the engine drain plug and tighten to 20 ft-lb. Remove the oil filler plug being careful not to let contaminates enter the opening; then pour ACX All-Weather Synthetic oil in the filler hole. Install the level stick.

7. Start the engine (while the ATV is outside on level ground) and allow it to idle for a few minutes.

8. Turn the engine off and wait approximately one minute. Recheck the oil level.

9. Inspect the area around the drain plug and oil filter for leaks.

Position

Spring

Force

Setting Load

Stronger

Soft

Stiff

Light

Heavy

Front Differential and Rear Drive Gear Lubricant (Inspecting/Changing)

Inspect and change the gear lubricant in each according to the Maintenance Schedule. When changing the lubricant, use approved SAE 80W-90 hypoid oil and use the following procedure.

1. Place the ATV on level ground.

2. Remove each oil filler plug.

3. Drain the oil into a drain pan by removing in turn the drain plug from each.

CF107B

CF106C

4. After all the oil has been drained, install the drain plugs and tighten to 45 in-lb.

5. Pour recommended oil into each filler hole.

CF113A

 NOTE: The manufacturer recom-

mends the use of genuine lubricants.

6. Install the filler plugs.

Hydraulic Hand Brake

Brake Fluid

Check the brake fluid level in the brake fluid reservoir. If the level in the reservoir is not visible in the sight glass, add DOT 4 brake fluid.

CF295A

 NOTE: If the sight glass appears

dark, there is a sufficient amount of fluid in the reservoir.

Brake Lever Lock

 NOTE: The brake lever lock must

lock the wheels. If it doesn’t, take the ATV to an authorized dealer for service.

CAUTION

Inspect the oil for any signs of metal filings or water. If found, take the ATV to an authorized dealer for servicing.

! WARNING

Be sure to inspect the hydraulic brake system before each use. Always maintain brakes according to the Maintenance Schedule.

CAUTION

Be careful not to spill any fluid when filling the brake fluid reservoir. Wipe away spilled fluid immediately.

Brake Hoses

Carefully inspect the hydraulic brake hoses for cracks or other damage. If found, take the ATV to an authorized dealer to have the brake hoses replaced.

Brake Pads

The clearance between the brake pads and brake discs is adjusted automatically as the brake pads wear. The only maintenance that is required is replacement of the brake pads when they show excessive wear. Check the thickness of each of the brake pads as follows:

1. Remove a front wheel.

2. Measure the thickness of each brake pad.

3. If thickness of either brake pad friction material is less than 1.0 mm (0.039 in.), take the ATV to an authorized dealer to have brake pads replaced.

PR376B

4. Install the wheel; then using a crisscross pattern, tighten the wheel nuts in 20 ft-lb increments to a final torque of 40 ft-lb (steel wheel), 60 ft-lb (aluminum wheel w/black nuts), or 80 ft-lb (aluminum wheel w/chrome nuts).

Rear Foot Brake

The rear foot brake must be maintained to be fully functional.

1. Check the brake fluid level in the reservoir. The fluid level must be maintained between the MAX and MIN level marks. If the level in the reservoir is low, add DOT 4 brake fluid.

CD474A

 NOTE: The brake fluid reservoir is

located under the seat.

2. Press the rear foot brake several times to check for firmness.

3. If the brake is not firm, the system must be bled.

 NOTE: Take the ATV to an autho-

rized dealer for this service.

Gas Hoses

Inspect the gas hoses. Damage from aging may not always be visible.

Protective Rubber Boots

The protective boots should be inspected periodically according to the Maintenance Schedule.

Ball Joint Boots (Upper and Lower/Right and Left)

CF702A

1. Secure the ATV on a support stand to elevate the front wheels.

2. Remove both front wheels.

! WARNING

Be sure to inspect the rear foot brake system before each use. Always maintain brakes according to the Maintenance Schedule.

3. Inspect the four ball joint boots for cracks, tears, or perforations.

4. Check the ball joint for free-play by grasping the steering knuckle and turning it from side to side and up and down.

5. If boot damage is present or ball joint free-play seems excessive, contact an authorized dealer for service.

Tie Rod Boots (Inner and Outer/Right and Left)

CC792

1. Secure the ATV on a support stand to elevate the front wheels.

2. Remove both front wheels.

3. Inspect the four tie rod boots for cracks, tears, or perforations.

4. Check the tie rod end free-play by grasping the tie rod near the end and attempting to move it up and down.

5. If boot damage is present or tie rod end free-play seems excessive, contact an authorized dealer for service.

Drive Axle Boots

CF344B

1. Inspect all drive axle boots for cracks, tears, or perforations.

2. If boot damage is present, contact an authorized dealer for service.

Battery

The battery is located under the seat. After being in service, batteries require

regular cleaning and recharging in order to deliver peak performance and maximum service life. The following procedures are recommended for cleaning and maintaining a sealed battery. Always read and follow instructions provided with battery chargers and battery products.

 NOTE: Refer to all warnings and

cautions provided with the battery or battery maintainer/charger.

Loss of battery charge may be caused by ambient temperature, ignition OFF current draw, corroded terminals, self discharge, frequent start/stops, and short engine run times. Frequent winch usage, snowplowing, extended low RPM operation, short trips, and high amperage accessory usage are also reasons for battery discharge.

Charging/Maintenance Charging

 NOTE: Use of the CTEK Multi US

800 for charging or the CTEK Multi US 3300 for maintenance charging is recommended. Maintenance charging is required on all batteries not used for more than two weeks or as required by battery drain.

800A

 NOTE: When charging a battery in

the vehicle, be sure the ignition switch is in the OFF position.

1. Clean the battery terminals with a solution of baking soda and water.

 NOTE: The sealing strip should

NOT be removed and NO fluid should be added.

2. Be sure the charger and battery are in a well-ventilated area. Be sure the charger is unplugged from the 110volt electrical outlet.

3. Connect the red terminal lead from the charger to the positive terminal of the battery; then connect the black terminal lead of the charger to the negative terminal of the battery.

 NOTE: Optional battery charging

adapters are available from your authorized dealer to connect directly to your vehicle from the recommended chargers to simplify the maintenance charging process. Check with your authorized dealer for proper installation of these charging adapter connectors.

4. Plug the battery charger into a 110volt electrical outlet.

5. If using the CTEK Multi US 800, there are no further buttons to push. If using the CTEK Multi US 3300, press the Mode button (A) at the left of the charger until the Maintenance Charge Icon (B) or Normal Charge Icon (E) at the bottom illuminates. The Normal Charge Indicator (C) should illuminate on the upper portion of the battery charger.

3300C

 NOTE:

For optimal charge and performance, leave the charger connected to the battery for a minimum 1 hour after the Maintenance Charge Indicator (D) illuminates.

The maintainer/charger will charge the battery to 95% capacity at which time the Maintenance Charge Indicator (D) will illuminate and the maintainer/ charger will change to pulse/float maintenance. If the battery falls below 12.9 DC volts, the charger will automatically start again at the first step of the charge sequence.

If the battery becomes hot to the touch, stop charging. Resume after it has cooled.

 NOTE: Not using a battery charger

with the proper float maintenance will damage the battery if connected over extended periods.

6. Once the battery has reached full charge, unplug the charger from the 110-volt electrical outlet.

 NOTE: If, after charging, the bat-

tery does not perform to operator expectations, bring the battery to an authorized dealer for further troubleshooting.

Jump-Starting

 NOTE: Jump-starting a vehicle

with a dead battery is not recommended but rather removing the battery, servicing it, and correctly charging it; however, in an emergency, it may be necessary to jumpstart a vehicle. If so, use the following procedure to carefully and safely complete this procedure.

! WARNING

Improper handling or connecting of a battery may result in severe injury including acid burns, electrical burns, or blindness as a result of an explosion. Always remove rings and watches.

1. On the vehicle to be jump-started, remove the battery cover and any terminal boots.

2. Inspect the battery for any signs of electrolyte leaks, loose terminals, or bulging sides. Leaking or bulging battery cases may indicate a frozen or shorted battery.

3. Inspect the vehicle to be used for jump-starting to determine if voltage and ground polarity are compatible. The vehicle must have a 12-volt DC, negative ground electrical system.

4. Move the vehicle to be used for the jump-start close enough to ensure the jumper cables easily reach; then shift into neutral, set and lock the brakes, shut off all electrical accessories, and turn the ignition switch OFF.

 NOTE: Make sure all switches on

the vehicle to be jump-started are turned OFF.

5. Disconnect all external accessories such as cell phones, GPS units, and radios on both vehicles.

6. Attach one clamp of the positive (red) jumper cable to the positive (+) terminal (1) of the dead battery (C) being careful not to touch any metal with the other clamp; then attach the other clamp of the positive (red) jumper cable to the positive (+) terminal (2) of the good battery (B).

0744-527

 NOTE: Some jumper cables may

be the same color but the clamps or ends will be color-coded red and black.

7. Attach one clamp of the negative (black) jumper cable to the negative (-) terminal (3) of the good battery (B); then attach the other clamp of the negative (black) jumper cable (4) to an unpainted metal surface (A) on the engine or frame well away from the dead battery and fuel system components.

8. Stand well away from the dead battery and start the vehicle with the good battery. Allow the vehicle to run for several minutes applying some charge to the dead battery.

9. Start the vehicle with the dead battery and allow it to run for several minutes before disconnecting the jumper cables.

! WARNING

Any time service is performed on a battery, the following must be observed: keep sparks, open flame, cigarettes, or any other flame away. Always wear safety glasses. Protect skin and clothing when handling a battery. When servicing battery in enclosed space, keep the area wellventilated. Make sure battery venting is not obstructed.

! WARNING

If any of these conditions exist, DO NOT attempt a jump-start, boost, or charge the battery. An explosion could occur causing serious injury.

CAUTION

Always make sure the electrical systems are of the same voltage and ground polarity prior to connecting jumper cables. If not, severe electrical damage may occur.

CAUTION

Failure to disconnect electronic accessories during jump-starting may cause system damage due to power spikes.

! WARNING

Never make the final connection to a battery as a spark could ignite hydrogen gases causing an explosion of the battery resulting in acid burns or blindness.

10. Remove the jumper cables in opposite order of hook-up (4, 3, 2, 1). Be careful not to short cables against bare metal.

 NOTE: Have the battery and elec-

trical system checked prior to operating the vehicle again.

Spark Plug

The ATV comes equipped with a specified spark plug. See the specifications chart for the correct spark plug. To help prevent cold weather fouling, make sure to thoroughly warm up the engine before operating.

Before removing the spark plug, be sure to clean the area around the spark plug. If you do not, dirt could enter engine when removing or installing the spark plug.

To maintain a hot, strong spark, keep the plug free of carbon.

ATV-0051

A light brown insulator indicates that the plug is correct. A white or dark-colored insulator indicates that the engine may need to be serviced. Consult an authorized dealer if the plug insulator is not a light brown color.

Adjust the gap to specified amount (see specifications chart) for proper ignition. Use a feeler gauge to check the gap.

ATV0052B

A new spark plug should be tightened 1/2 turn once the washer contacts the cylinder head. A used spark plug should be tightened 1/8 - 1/4 turn once the washer contacts the cylinder head.

Throttle Cable Adjustment

To adjust the throttle cable free-play:

1. Loosen the jam nut from the throttle cable adjuster.

2. Slide the rubber boot away and turn the adjuster until the throttle lever has proper free-play of 3-6 mm (1/8-1/4 in.).

CF297A

3. Tighten the jam nut against the throttle cable adjuster securely; then slide the rubber boot over the adjuster.

Air Filter

The air filter inside the air filter housing must be kept clean to provide good engine power and gas mileage. If the ATV is used under normal conditions, service the filter at the intervals specified in the Maintenance Schedule. If operated in dusty, wet, or muddy conditions, inspect and service the filter more frequently. Use the following procedure to remove the filter and inspect and/or clean it.

1. Remove the fasteners securing the storage compartment and remove the storage compartment.

2. Remove the air filter housing cover and the air filter/frame assembly.

CAUTION

Failure to inspect the air filter frequently if the ATV is used in dusty, wet, or muddy conditions can damage the engine.

3. Remove the foam element from the frame making sure not to tear the element.

FI705

4. Place the element in a pan larger than the element and spray both sides generously with cleaning solvent. Let sit approximately three minutes.

 NOTE: Foam Air Filter Cleaner and

Foam Air Filter Oil Aerosol are available.

5. In a pan larger than the element, with a mild detergent (dish soap) and water, wash all the dirt and oil off by squeezing the element not twisting it. (Wringing out or twisting the filter can cause damage.)

6. Rinse off any remaining soap.

7. Remove any excess water from the element by pressing it with a towel.

8. Allow the element to dry completely.

9. Spray oil generously onto air filter and work the oil into the element.

10. Squeeze the element to remove excess oil.

11. Clean any dirt or debris from inside the air cleaner.

12. Install the air filter/frame assembly and cover.

13. Install the storage compartment and cover.

Air Filter Housing Drain(s)

Inspect the drain(s) beneath the main housing for debris and for proper sealing.

TXA024A

Draining V-Belt Cover

 NOTE: If the ATV has been driven

through water, the V-belt cover must be drained of any water.

1. Place the ATV on a level surface.

2. Remove the drain bolt from the cover and allow the water to drain out.

CF110A

3. Shift the range lever to the neutral position; then start the engine.

4. Increase and decrease engine RPM several times to “blow out” any water; then stop the engine.

5. Install the drain bolt and tighten securely.

 NOTE: The V-belt and pulleys

should be inspected every 500 miles and the belt replaced (if necessary).

CAUTION

A torn air filter can cause damage to the ATV engine. Dirt and dust may get inside the engine if the element is torn. Carefully examine the element for tears before and after cleaning it. Replace the element with a new one if it is torn.

Tires

Tire Tread Condition

The use of worn-out tires on an ATV is very dangerous. A tire is considered to be worn out when the depth of the tread is less than 3 mm (1/8 in.). Be sure to replace the tires before reaching this minimum specification.

0732-649

Tire Replacement

The ATV has low-pressure tubeless tires. Have this maintenance performed by an authorized dealer or a qualified tire repair station.

Tubeless Tire Repair

Should a leak or flat tire occur due to a puncture, the tire may be repaired using a plug-type repair. If the damage is from a cut or if the puncture cannot be repaired using a plug, the tire must be replaced. When operating the ATV in areas where transportation or service facilities are not readily available, it is strongly recommended to carry a plug-type repair kit and a tire pump along.

Wheels

1. Park the ATV on level ground and engage the brake lever lock.

2. Loosen the lug nuts on the wheel to be removed.

3. Elevate the ATV.

4. Remove the lug nuts.

5. Remove the wheel.

6. Install the wheel and install the lug nuts.

7. Install the wheel; then using a crisscross pattern, tighten the wheel nuts in 20 ft-lb increments to a final torque of 40 ft-lb (steel wheel), 60 ft-lb (aluminum wheel w/black nuts), or 80 ft-lb (aluminum wheel w/chrome nuts).

8. Remove the jack.

Muffler/Spark Arrester

The muffler has a spark arrester which must be periodically cleaned. At the intervals shown in the Maintenance Schedule, clean the spark arrester using the following procedure.

1. Remove the cap screws securing the spark arrester assembly to the muffler.

TXA004A

! WARNING

Always use the size and type of tires as specified. Refer to the appropriate Specifications Chart for proper tire inflation pressure, and always maintain proper tire inflation pressure.

! WARNING

The use of worn-out tires can be dangerous and can increase the risk of an accident.

! WARNING

Use only approved tires when replacing tires. Failure to do so could result in unstable ATV operation.

! WARNING

Wait until the muffler cools to avoid burns.

TXA005

2. Using a suitable brush, clean the carbon deposits from the screen taking care not to damage the screen.

 NOTE: If the screen or gasket is

damaged in any way, it must be replaced.

3. Install the spark arrester assembly and secure with the cap screws. Tighten cap screws to 48 in.-lb.

Light Bulb Replacement

The wattage rating of each bulb is shown in the chart. When replacing a burned bulb, always use the same wattage rating.

Headlight

 NOTE: The bulb portion of the

headlight is fragile. HANDLE WITH CARE. When replacing the headlight bulb, do not touch the glass portion of the bulb. If the glass is touched, it must be cleaned with a dry cloth before installing. Skin oil residue on the bulb will shorten the life of the bulb.

To replace the headlight bulb, use the following procedure.

1. Rotate the bulb assembly counterclockwise and remove from the headlight housing; then disconnect from the wiring harness.

2. Connect the new bulb assembly to the wiring harness connector; then insert into the headlight housing and rotate fully clockwise.

Taillight/Brakelight

To replace the taillight/brakelight bulb, use the following procedure.

1. Rotate the socket counterclockwise and remove it from the housing.

CF135A

2. To remove the bulb from the socket, pull it straight out of the socket.

3. To install the bulb, push it straight into the socket.

CF132A

4. Insert the socket into the housing and rotate it clockwise.

Checking/Adjusting Headlight Aim

The headlights can be adjusted vertically and horizontally. The geometric center of the HIGH beam light zone is to be used for vertical and horizontal aiming.

1. Position the ATV on a level floor so the headlights are approximately 6.1 m (20 ft) from an aiming surface (wall or similar aiming surface).

Headlight 12V/27W (4)

Taillight/Brakelight 12V/8W/27W

CAUTION

Use only specified bulbs indicated in the chart as replacement bulbs.

CAUTION

When replacing the headlight bulb, be careful not to touch the glass portion of the bulb. Grasp the new bulb with a clean cloth.

ATV-0070

 NOTE: There should be an average

operating load on the ATV when adjusting the headlight aim.

2. Measure the distance from the floor to the mid-point of each headlight.

3. Using the measurements obtained in step 2, make horizontal marks on the aiming surface.

4. Make vertical marks which intersect the horizontal marks on the aiming surface directly in front of the headlights.

5. Switch on the lights. Make sure the HIGH beam is on. DO NOT USE LOW BEAM.

6. Observe each headlight beam aim. Proper aim is when the most intense beam is centered on the vertical mark 5 cm (2 in.) below the horizontal mark on the aiming surface.

7. Adjust each headlight until correct aim is obtained by turning the knob clockwise to raise or counterclockwise to lower the beam.

CD714A

Fuses

The fuses are located in a power distribution module under the seat. If there is any type of electrical system failure, always check the fuses first.

 NOTE: To remove the fuse, com-

press the locking tabs on either side of the fuse cover and lift out.

3411-968

Electrical Output Terminals

Two output terminals for electrical accessories are located on the front and rear wiring harnesses. The accessory plug is located on the instrument pod.

Storage Compartment/ Tools

A basic tool kit is provided with the ATV. Maintain the tool kit with the ATV at all times.

ATV-1097

The storage compartment is above the engine in front of the seat.

CAUTION

Always replace a blown fuse with a fuse of the same type and rating. If the new fuse blows after a short period of use, consult an authorized dealer immediately.

CAUTION

Always use electrical accessories less than 180W.

Preparation for Storage

We recommend the following procedure to prepare the ATV for storage. An authorized dealer should perform this service; however, the owner/operator may perform this service if desired.

1. Clean the seat cushion (cover and base) with a damp cloth and allow to dry.

2. Clean the ATV thoroughly by washing dirt, oil, grass, and other foreign matter from the entire ATV. Allow the ATV to dry thoroughly. DO NOT get water into any part of the engine or air intake.

3. Either drain the gas tank or add a fuel stabilizer to the gas in the gas tank.

4. Clean the interior of the air filter housing.

5. Plug the hole in the exhaust system with a clean cloth.

6. Apply light oil to the upper steering post bushing and plungers of the shock absorbers.

7. Tighten all nuts, bolts, cap screws, and screws. Make sure rivets holding components together are tight. Replace all loose rivets. Care must be taken that all calibrated nuts, cap screws, and bolts are tightened to specifications.

8. Fill the cooling system to the bottom of the stand pipe in the radiator neck with properly mixed coolant.

9. Disconnect the battery cables (negative cable first); then remove the battery, clean the battery posts and cables, and store in a clean, dry area.

 NOTE: For storage, use a battery

maintainer or make sure the battery is fully charged (see Battery section in this manual).

10. Store the ATV indoors in a level position.

CAUTION

Prior to storing the ATV, it must be properly serviced to prevent rusting and component deterioration.

CAUTION

Avoid storing outside in direct sunlight and avoid using a plastic cover as moisture will collect on the ATV causing rusting.

Preparation after Storage

Taking the ATV out of storage and correctly preparing it will assure many miles and hours of trouble-free riding. We recommend the following procedure to prepare the ATV.

1. Clean the ATV thoroughly.

2. Clean the engine. Remove the cloth from the exhaust system.

3. Check all control wires and cables for signs of wear or fraying. Replace if necessary.

4. Change the engine/transmission oil and filter.

5. Check the coolant level and add properly mixed coolant as necessary.

6. Charge the battery; then install. Connect the battery cables making sure to connect the positive cable first.

7. Check the entire brake systems (fluid level, pads, etc.), all controls, headlights, taillight, brakelight, and headlight aim; adjust or replace if necessary.

8. Check the tire pressure. Inflate to recommended pressure as necessary.

9. Tighten all nuts, bolts, cap screws, and screws making sure all calibrated nuts, cap screws, and bolts are tightened to specifications.

10. Make sure the steering moves freely and does not bind.

11. Check the spark plug. Clean or replace as necessary.

12. Check the air filter and the air filter housing. Clean or replace as necessary.

CAUTION

Before installing the battery, make sure the ignition switch is in the OFF position.

Limited Warranty

Textron Specialized Vehicles, a division of Textron, Inc. (the Company) extends a limited warranty as described below on each new vehicle it assembles and on each genuine part and accessory assembled and sold by an authorized dealer. The limited warranty on the vehicle is extended to the original retail purchaser for the time periods described below; however, the balance of the remaining warranty may be transferred to another party unless the purchase is for commercial use (see below). Warranty coverage is only available in the country in which the original retail purchase occurs to the original retail purchaser resident in that country or to a transferee resident in that country of the balance of the remaining warranty.

We warrant only the products we assemble and/or sell and do not warrant that other products will function properly when used with the vehicle or will not damage the vehicle. The Company does not assume any liability for incidental or consequential damages.

The Company will repair or replace, at its option, free of charge (including any related labor charges), any parts that are found to be warrantable in material or workmanship. This repair work MUST be done by an authorized dealer. No transportation charges, rental charges, or inconvenience costs will be paid by the Company. The warranty is validated upon examination of said parts by us or an authorized dealer. The Company reserves the right to inspect such parts at its factory for final determination if warranty should apply.

The warranty periods are as follows:

1. Six months from the date of sale — for a vehicle used for recreational purposes.

2. Ninety days from date of invoice — for a vehicle used for commercial purposes, including rental operations (non-transferable).

3. Thirty days from date of sale of vehicle on Company supplied batteries.

Exclusions to this warranty include normal wear, abuse, or corrosion and the following parts and

items:

Tires CV Boots Torn or Punctured Upholstery Oil Filter Drive Belt Cracks or Gouges in Body Panels Air Filter Brake Pads Drive/Driven Clutch Wear Parts Light Bulbs Spark Plug(s) Windshield

The following will VOID the warranty:

1. Failure to perform the proper break-in procedure and all related maintenance, storage procedures (if stored for extended periods), and/or service as recommended in the Operator’s Manual.

2. Repairs and/or adjustments by anyone other than an authorized dealer.

3. Use of improper carburetor jets.

4. Use of improper gasoline, lubricating oils, or spark plug(s).

5. An accident or subjecting the vehicle to misuse, abuse, or negligent operation.

6. Any modification, addition, or removal of parts unless instructed to do so by the Company.

7. Use of the vehicle in any way for racing purposes.

8. Removal of the engine for use in another vehicle.

9. Removal or mutilation of the Vehicle Identification Number or Engine Serial Number.

10. Use of parts not sold or approved by the Company.

11. Damage due to improper transportation.

The Company shall not be responsible for and this limited warranty excludes recovery of economic, punitive, consequential and incidental damages, lost profits, and loss of use. Some states or provinces do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation may not apply to you. Our aggregate liability may not exceed the price of the product. The law of the State of Minnesota shall apply to all claims or disputes, exclusive of its conflicts of law provisions.

IMPLIED WARRANTY EXCLUSION AND DISCLAIMER

To the fullest extent permitted by law, the Company excludes and disclaims all implied warranties of merchantability and fitness for a particular purpose.

If you are not satisfied with warranty service or repairs, you should contact us at (U.S.) 1-218-681-9851 or (Canada) 1-204-982-1656.

Warranty Procedure/Owner Responsibility

At the time of sale, an ATV Rider Training Certificate and Owner Registration form is to be completed by the selling dealer and consumer. The receipt of the form by the Company is a condition precedent to warranty coverage. It is the selling dealer’s responsibility to retain and/or submit appropriate copies of the form to the appropriate place(s) to initiate warranty coverage.

The dealer will furnish to the consumer a signed copy of the form which must be presented to the dealer when requesting warranty service. The registration form is the consumer’s proof of ownership and warranty eligibility. The form is used by the dealer to validate the warranty claim. Retain your copy of the form and keep it in a safe place.

When warranty repair is suspected, the ATV should be taken to the selling dealer, who has the primary responsibility to perform warranty repairs. Subject to the limitations set forth in the Limited Warranty, in the event the selling dealer has ceased to do business, you have moved, or you are in a location away from your selling dealer, warranty may be performed by any authorized dealer.

The authorized dealer will examine the vehicle or part to determine if, in his opinion, a warrantable condition exists. If a warrantable condition appears to exist, the dealer will repair or replace, at our option, free of charge, including any related labor costs, all parts that are found to be warrantable and any other parts which the warrantable part caused to be damaged. You, the owner, will then be asked to sign a warranty form to ensure the Company that the warranty work was actually performed.

It is the owner’s responsibility to maintain and service the vehicle in accordance with this Operator’s Manual. To protect yourself and your ATV, follow all safety and service tips. We will NOT warrant nonemissions related repairs required as a result of not performing standard operator maintenance, storage procedures, and service as outlined in the Operator’s Manual.

Should you have any questions concerning the warranty, contact an authorized dealer.

U.S. EPA Emission Control Statement/Warranty

Coverage (U.S. Only)

STATEMENT/WARRANTY

Textron Specialized Vehicles warrants to the original retail purchaser, and each subsequent purchaser, that all U.S. EPA-certified Textron Off Road vehicles are designed, built, and equipped to conform to all U.S. EPA Emission Control Regulations. Please read the following information completely.

Your authorized dealer will repair or replace any defective emission-related component at no cost to you during the warranty period. You may have non-warranty service performed by any repair establishment that uses equivalent components. The regulations provide significant civil penalties for tampering that causes your vehicle to no longer meet U.S. EPA emission standards.

Textron Specialized Vehicles further warrants that the engine and its emission-related components are free from defects in materials or workmanship that could cause the engine to fail to comply with applicable regulations during the warranty period.

If you have any questions about this information, or the emission warranty coverage statement, contact your authorized dealer.

WARRANTY PERIOD

The emission warranty period for this vehicle begins on the same date as the standard warranty coverage and continues for 30 months, 5000 kilometers (3107 miles), or 500 hours, whichever comes first.

COMPONENTS COVERED

I. For exhaust emissions, emission-related components include any engine parts related to the following systems:

Air-induction system. Fuel system.

Ignition system. Exhaust gas recirculation systems.

II. The following parts are also considered emission-related components for exhaust emissions:

Aftertreatment devices. Crankcase ventilation valves.

Sensors. Electronic control units.

III. The following parts are considered emission-related components for evaporative emissions:

Fuel Tank. Fuel Cap.

Fuel Line. Fuel Line Fittings.

Clamps*. Pressure Relief Valves*.

Control Valves*. Control Solenoids*.

Electronic Controls*. Vacuum Control Diaphragms*.

Control Cables*. Control Linkages*.

Purge Valves. Vapor Hoses.

Liquid/Vapor Separator. Carbon Canister.

Canister Mounting Brackets. Carburetor Purge Port Connector.

*As related to the evaporative emission control system.

OWNER’S RESPONSIBILITIES

The owner of any vehicle warranted under this Emission Control Statement is responsible for the proper maintenance and use of the vehicle as stated in the Operator's Manual. Proper maintenance generally includes replacement and service, at the owner's choosing, such items as air filter, oil and oil filter, or any other part, item, or device related to emissions control as specified in the Operator's Manual. It is the owner's responsibility to ensure that the vehicle is used in a manner for which it was designed.

Maintenance Record

DATE MILEAGE SERVICE PERFORMED/NOTES

Change of Address, Ownership, or Warranty

Transfer

Textron Specialized Vehicles, a division of Textron, Inc. keeps on file the current name and address of the owner of this vehicle. This allows us to reach the current owner with any important safety information which may be necessary to protect customers from personal injury or property damage. Please make sure a copy of this form is completed and returned to us if you move or if the vehicle is sold to another party.

This form may also be used to transfer the unused portion of the original warranty to a second party. In order to transfer warranty, fill out this form completely; then return a copy of this form to us. We will then process the application and issue warranty for the balance of the time remaining of the original warranty. Warranty coverage is only available in the country in which the original retail purchase occurs to the original retail purchaser resident in that country or to a transferee resident in that country of the balance of the remaining warranty.

 Address Change  Ownership Change  Warranty Transfer

CHANGE OF ADDRESS/OWNERSHIP/

WARRANTY TRANSFER TO:

Name _________________________________________

Address _______________________________________

City/State (Province)/Zip Code (Postal Code)___________

Phone # ( ) ___________________________________

Email __________________________________________

Year and Model _________________________________

Vehicle Identification Number (VIN) __________________

Before operating, you should take an ATV Rider Course to learn ATV riding skills or reinforce your current good riding skills. In U.S.A., call 1-800-887-2887 to enroll in the half-day ATV Rider Course nearest you or ask your dealer for assistance. The course instructor will charge a small fee

for each

person taking the course. In Canada, call (613) 739-1535.

Fold Back

CHANGE OF ADDRESS/OWNERSHIP

TEXTRON OFF ROAD

PRODUCT SERVICE AND

WA RR AN T Y DE PT.

P.O. BOX 810

THIEF RIVER FALLS, MN 56701

Place

Stamp

Here

NOTES

Identification Numbers Record

This ATV has two identification numbers: Vehicle Identification Number (VIN) and Engine Serial Number (ESN). These numbers are required by the dealer to complete warranty claims properly. No warranty will be allowed if the VIN or ESN is removed or mutilated in any way.

Always provide the ATV name, Vehicle Identification Number, and Engine Serial Number when contacting an authorized dealer for parts, service, accessories, or warranty. If a complete engine must be replaced, ask the dealer to notify the manufacturer for correct registration information.

Record the Vehicle Identification Number and Engine Serial Number in the spaces provided to assist you in ordering parts from your authorized dealer or for reference in case the ATV is stolen.

1. Key Identification Number:

The key identification number is stamped on the key as shown in the illustration. Record this number in the space provided for reference if you ever need a new key.

2. Vehicle Identification Number:

The VIN is located on the frame support rail within the left rear fender.

CF744

3. Engine Serial Number:

The ESN is located on the left-side rear of the engine crankcase.

PR053A

™ ®Trademarks of Textron Specialized Vehicles

p/n 2261-876

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