Textron PROWLER 500 2018 Operator's Manual

This vehicle can be hazardous to operate.
A collision or rollover can occur quickly, even during what you think are routine maneuvers such as driving or turning on flat terrain, driving on hills, or crossing obstacles, if you fail to take proper precautions. For your safety, understand and fol­low all the warnings contained in this Operator’s Manual and on the labels on this vehicle.
FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.
Particularly important information is distinguished in this manual by the following notations:
FREE ROV TRAINING
Free training is available for Recreation Off-Highway Vehicles (ROV) operators and passengers from Recreational Off-Highway Vehicle Association (ROHVA). The manufacturer recommends that you complete this course before you first use your new ROV.
This web-based course takes approximately two hours to complete and presents you with a certificate of accomplishment as soon as you complete the course. The course does not have to be completed all at one time. It will remember where you left off and bring you back to that point when you return.
To receive this free training, visit www.ROHVA.org.
California Proposition 65
Always use common sense when operating this vehicle.
!
The Safety Alert Symbol means ATTENTION! BE ALERT! YOUR SAFETY IS INVOLVED.
! WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
CAUTION, without the safety alert symbol, is used to address practices not related to per­sonal injury.
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 an Textron Off Road Prowler
500. Built with American engineering and manufacturing know-how, it is designed to provide superior ride, com­fort, utility, and dependable service.
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 this vehicle.
Carefully read the following pages. If you have any questions regarding this vehicle, contact an authorized Textron Off Road (hereinafter “authorized dealer(s)”) for assistance. Remember, only authorized dealers have the knowl­edge and facilities to provide you with the best service possible.
• Become familiar with all local and state/provincial laws governing ROV operation,
• Respect your vehicle,
• Respect the environment, and
• Respect private property and do not trespass.
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 vehicle 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.
You have chosen a quality vehicle designed and manufactured 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 this vehicle to ensure safe and proper use. Always operate the vehicle within your level of skill and current terrain condi­tions.
Division II of this manual covers opera­tor-related maintenance, operating instructions, and storage instructions. If major repair or service is ever required, contact an authorized dealer for profes­sional service.
At the time of publication, all informa­tion and illustrations in this manual were technically correct. Some illustrations used in this manual are used for clarity purposes only and are not designed to depict actual conditions. Because we con­stantly refine and improve our products, no retroactive obligation is incurred.
Operation of this vehicle is restricted to people 16 years of age and older who possess a valid driver’s license. Passen­gers must be able to place both feet flat on the floor while keeping their back against the back of the seat and holding on to an available hand hold.
Protect Your Sport
Parts and Accessories
When in need of replacement parts, oil, or accessories for this vehicle, 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 this vehicle. For a complete list of accessories, refer to the current ATV/ ROV Accessory Catalog.
To aid in service and maintenance pro­cedures on this vehicle, a Service Man­ual is available through your local authorized dealer.
2
Table of Contents
Foreword .................................................. 1
Parts and Accessories............................ 1
Division I - Safety
Safety Alert .............................................. 4
Warning Labels..................................... 5-6
Location of Parts and Controls .............. 7
Warnings ............................................. 8-16
Division II - Operation/ Maintenance
Specifications ........................................ 17
Vehicle Operation ............................. 18-22
General Information ......................... 23-32
Control Locations and Functions.......... 23
Occupant Side Restraints .................... 25
Speedometer/LCD (Digital) .................. 25
Diagnostic Trouble Codes .................... 28
Oil Level Stick....................................... 29
Load Capacity Ratings Chart ............... 29
Trailering and Towing ........................... 29
Transporting ......................................... 30
Gasoline-Oil-Lubricant ......................... 31
Engine Break-In ................................... 32
Burnishing Brake Pads......................... 32
General Maintenance ....................... 33-54
Maintenance Schedule......................... 33
Liquid Cooling System ......................... 34
Shock Absorbers.................................. 34
General Lubrication.............................. 35
Hydraulic Brake.................................... 36
Gas Hoses ........................................... 37
Protective Rubber Boots ...................... 37
Battery.................................................. 38
Spark Plug............................................ 41
Air Filter/Housing Drain ........................ 41
Draining V-Belt Cover........................... 42
Tires ..................................................... 43
Wheels ................................................. 43
Muffler/Spark Arrester .......................... 43
Light Bulb Replacement ....................... 44
Checking/Adjusting Headlight Aim ....... 45
Fuses ................................................... 46
Electrical Output Terminals .................. 46
Storage Compartments/Tools............... 46
Seat Belts............................................. 47
Occupant Side Restraints .................... 47
ROPS ................................................... 47
Preparation For Storage ....................... 48
Preparation After Storage..................... 49
Maintenance Record ........................50-51
Limited Warranty ................................... 52
Warranty Procedure/Owner
Responsibility.................................... 53
U.S. EPA Emission Control Statement/
Warranty Coverage - ROV (U.S. Only)54
Change of Address, Ownership, or
Warranty Transfer.............................. 55
Identification Numbers Record ......Inside
Back Cover
! WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
3
Division I - Safety
This vehicle 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 this vehicle.
•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 vehicle checked by an authorized dealer if it has been involved in an accident.
•Never
operate on hills too steep 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. Never
depress the accelerator suddenly or make gear changes while moving. 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. Never
go down a hill at high speed. Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side. Go straight down the hill where possible.
•Always
be careful when you decide to climb or descend a hill and never turn on a hill. Drive straight up or down inclines and not across them. If you must cross the side of a hill, drive slowly and stop or turn downhill if you feel the vehicle may tip over.
•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.
•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.
•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.
•Never
operate this vehicle in fast flowing water or in water deeper than the floorboard. 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 improp-
erly use accessories on this vehicle.
•Never
exceed the stated load capac­ity for this vehicle. 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.
• Operation of this vehicle is restricted to people 16 years of age and older who possess a valid driver’s license. Passengers must be able to place both feet flat on the floor while keep­ing their back against the back of the seat and holding on to an available hand hold.
! WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
4
Safety Alert
You should be aware that THIS VEHI­CLE IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. This vehicle handles differently from other vehicles, including motorcycles and cars. A collision or rollover can occur quickly, even during what you think are routine maneuvers such as turning, driving on hills, and going over obstacles, if you fail to take proper precautions.
TO AVOID SERIOUS INJURY OR DEATH:
*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.
*Always
wear the seat belt when oper-
ating or riding in this vehicle.
*Always
follow these age recommen-
dations:
• Operation of this vehicle is restricted to people 16 years of age and older who possess a valid driver’s license. Passengers must be able to place both feet flat on the floor while keep­ing their back against the back of the seat and holding on to the hand hold.
* Never carry a passenger in the cargo
box of this vehicle.
* Never
operate this vehicle on a public road, even a dirt or gravel one, because you may not be able to avoid colliding with other vehicles.
* Never
operate this vehicle 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 this vehi­cle.
*Never
operate this vehicle 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 this vehicle, especially when approaching hills, turns, and obsta­cles and when operating on unfamil­iar or rough terrain.
*Never
operate this vehicle with the
cargo box lifted or removed.
*Never
operate this vehicle in fast flowing water or in water deeper than the floorboard.
*Never
operate this vehicle with the ROPS (Roll Over Protective Struc­ture) removed. The ROPS provides a structure helping to limit intrusions by branches or other objects and may reduce your risk of injury in acci­dents.
*Never
put your hands or feet outside the vehicle for any reason while the vehicle is in motion. Do not hold onto the ROPS or hip restraint bar. If you think or feel the vehicle may tip, do not put your hands or feet outside the vehicle as they will not be able to pre­vent the vehicle from tipping. Any part of your body (arms, legs, or head) outside the vehicle can be crushed by passing objects, the vehi­cle, or ROPS.
* Always fasten occupant side
restraints prior to moving the vehicle.
! WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
5
Warning Labels
Pour commander des Étiquettes de Mise en Garde gratuites, voyez votre concessionnaire agréé pour le numéro de pièce
1436-444.
PK015B
4411-964
A
4411-883
B
4411-965
C
3411-970
D
! WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
6
Warning Labels
TXR003B
4411-961
A
4411-960
B
4411-963
C
4411-962
D
! WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
7
Location of Parts and Controls
TXR003A
PK016A
PK015A
PK014A
1. Accelerator Pedal
2. Brake Pedal
3. In-Dash Storage Compartment
4. DC Power Outlets
5. Reverse Override Switch
6. Drive Select Switch
7. Ignition/Start Switch
8. Headlight Switch
9. Shift Lever
10. Headlights
11. Passenger Side Restraint Latch
12. Operator’s Manual Location
13. Passenger Seat Belt
14. Passenger Side Restraints
15. Gas Tank Cap
16. Outboard Passenger Hand Hold
17. Battery
18. Under-Hood Storage Compartment
19. Fuses
20. Cargo Box Latch Handle
21. Driver Seat Belt
22. Tilt Steering Lever
23. Tool Kit
24. Driver Side Restraint
25. Driver Side Restraint Latch
26. Hitch Receiver
27. Under-Seat Storage Compartment
28. Tailgate Latch
29. Tailgate Storage Latch
30. Taillight/Brakelight
! WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
8
Warnings
! WARNING
POTENTIAL HAZARD
Operating this vehicle without proper instruction.
WHAT CAN HAPPEN
The risk of an accident is greatly increased if the operator does not know how to operate this vehicle properly in different situations and on different types of terrain.
HOW TO AVOID THE HAZARD
All operators of this vehicle must read and understand this Operator’s Manual and all warning and instruction labels prior to operating this vehicle.
! WARNING
POTENTIAL HAZARD
Allowing anyone under age 16 to operate this vehicle.
WHAT CAN HAPPEN
Use of this vehicle by children can lead to serious injury or death of the child. Children under the age of 16 may not have the skills, abilities, or judgment needed
to operate this vehicle safely and may be involved in a serious accident.
HOW TO AVOID THE HAZARD
Only people 16 years of age or older with a valid driver’s license should operate this vehicle.
! WARNING
POTENTIAL HAZARD
Operating or riding in the vehicle without wearing a properly-secured seat belt.
WHAT CAN HAPPEN
Serious injury or death. Occupants can strike objects in the passenger compart­ment, fall out of the vehicle during maneuvers, or be crushed or otherwise injured in the event of an accident.
HOW TO AVOID THE HAZARD
ALWAYS WEAR YOUR SEAT BELT and require others to wear their seat belts. See the Operation/Maintenance section of this manual for more information on using your seat belt and both operator and passenger wearing an approved hel­met.
! WARNING
POTENTIAL HAZARD
Operating this vehicle on public streets, roads, or highways.
WHAT CAN HAPPEN
You can collide with another vehicle.
HOW TO AVOID THE HAZARD
Never operate this vehicle on any public street, road, or highway. In many states it is illegal to operate a vehicle of this type on public streets, roads,
or highways. Always check state and local laws and regulations.
! WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
9
! WARNING
POTENTIAL HAZARD
Operating or riding in this vehicle without wearing an approved helmet, eye protection, and protective cloth­ing.
WHAT CAN HAPPEN
Operating or riding without an approved helmet increases your chances of a serious head injury or death in the event of an accident.
Operating or riding without eye protection can result in an accident and increases your chances of a serious injury in the event of an accident.
Operating or riding without protective clothing increases your chances of serious 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
Operating this vehicle 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 vehicle.
! WARNING
POTENTIAL HAZARD
Allowing passengers to ride in the cargo bed.
WHAT CAN HAPPEN
Serious injury or death. This vehicle is not designed to carry passengers in the cargo bed. Passengers in the cargo bed can be thrown around or from the vehicle during operation or in an accident.
HOW TO AVOID THE HAZARD
Do not permit passengers to ride in the cargo bed. Do not install any seating in the cargo bed.
! WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
10
! WARNING
POTENTIAL HAZARD
Operating or riding in the vehicle without occupant side restraints properly secured.
WHAT CAN HAPPEN
Serious injury or death. Occupants or their body parts can strike objects outside the vehicle, be crushed by the vehicle, or fall out of the vehicle during maneuvers or in the event of an accident.
HOW TO AVOID THE HAZARD
Do not remove the occupant side restraints. Make sure both driver and passenger occupant side restraints are secure before operating or riding in the vehicle. Stay seated with your seat belt and helmet on and keep your body completely inside the vehicle during operation. See the Operation/Maintenance section of this manual for more information.
! WARNING
POTENTIAL HAZARD
Failing to keep all parts of your body inside the passenger compartment during operation.
WHAT CAN HAPPEN
Serious injury or death. Body parts could strike objects outside of vehicle or be crushed in the event of a rollover or accident.
HOW TO AVOID THE HAZARD
Do not place your head, arms, hands, legs, or feet outside of the passenger com­partment during operation. Stay seated with your seat belt and helmet on and occupant side restraints properly secured. Keep your feet and legs inboard of the foot restraints at all times. Do not attempt to stop movement or tipping of the vehi­cle with your hands or feet. If you feel the vehicle tipping, brace your feet flat on the floor, keep hands firmly gripping the steering wheel and hand holds, and keep all body parts inside the passenger compartment.
! WARNING
POTENTIAL HAZARD
Operating this vehicle at excessive speeds.
WHAT CAN HAPPEN
Increases your chances of losing control of the vehicle, which can result in an acci­dent.
HOW TO AVOID THE HAZARD
Always ride at a speed that is proper for the terrain, visibility, load, and operating conditions.
! WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
11
! WARNING
POTENTIAL HAZARD
Attempting abrupt maneuvers, sideways sliding, skidding, fishtailing, or donuts.
WHAT CAN HAPPEN
Increases the chance of an accident including a rollover.
HOW TO AVOID THE HAZARD
Never attempt abrupt maneuvers, sideways sliding, skidding, fishtailing, or donuts. Don’t try to show off.
! WARNING
POTENTIAL HAZARD
Failure to inspect this vehicle before operating. Failure to properly maintain this vehicle.
WHAT CAN HAPPEN
Increases the possibility of an accident or equipment damage.
HOW TO AVOID THE HAZARD
Always inspect this vehicle each time you use it to make sure it is in safe operating condition.
Always follow the inspection and maintenance procedures and schedules described in this Operator’s Manual.
! WARNING
POTENTIAL HAZARD
Failure to use extra care when operating this vehicle on unfamiliar terrain.
WHAT CAN HAPPEN
You can come upon hidden rocks, bumps, or holes without enough time to react. Could result in the vehicle 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 this vehicle.
! 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, 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 this vehicle 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.
12
! WARNING
POTENTIAL HAZARD
Failing to use care in turns; turning too sharply or aggressively.
WHAT CAN HAPPEN
The vehicle could go out of control causing a collision, tip over, 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 or too sharply for the conditions and for your experi­ence level. See the Operation/Maintenance section of this manual for more infor­mation on turning on flat ground, hills, sand, ice, mud, or water.
! WARNING
POTENTIAL HAZARD
Operating on steep hills.
WHAT CAN HAPPEN
This vehicle can overturn more easily on steep hills than on level surfaces or small hills.
HOW TO AVOID THE HAZARD
Never operate the vehicle on hills too steep for the vehicle or for your abilities. Practice on smaller hills before attempting larger hills.
! WARNING
POTENTIAL HAZARD
Operating with the ROPS removed.
WHAT CAN HAPPEN
Could lead to serious injury or death.
HOW TO AVOID THE HAZARD
Never operate this vehicle with the ROPS removed.
! WARNING
POTENTIAL HAZARD
Going down a hill improperly.
WHAT CAN HAPPEN
Could cause loss of control or cause the vehicle 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. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the vehicle 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.
13
Never Operate Up Or Down Hills Steeper Than 15°
! WARNING
POTENTIAL HAZARD
Climbing hills improperly.
WHAT CAN HAPPEN
Could cause loss of control or cause the vehicle 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. Never open the throttle suddenly or make sudden gear changes. The vehicle 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
POTENTIAL HAZARD
Crossing hills or turning on hills.
WHAT CAN HAPPEN
Could cause loss of control or cause the vehicle 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 vehicle around on any hill. If you must cross the side of a hill, drive slowly and stop or turn downhill if you feel the vehicle may tip.
! WARNING
POTENTIAL HAZARD
Stalling, rolling backwards, or improperly dismounting while climbing a hill.
WHAT CAN HAPPEN
Could result in the vehicle overturning.
HOW TO AVOID THE HAZARD
Use proper gear and maintain steady speed when climbing a hill. If you lose all forward speed:
Apply the brakes. Place the transmission in park after you are stopped. If you begin rolling backwards: Gradually apply the brakes while rolling backwards. When fully stopped, place the transmission in park.
! WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
14
! WARNING
POTENTIAL HAZARD
Improperly operating over obstacles.
WHAT CAN HAPPEN
Could cause loss of control or a collision. Could cause the vehicle 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
Improperly operating in reverse.
WHAT CAN HAPPEN
You could hit an obstacle or person behind you, resulting in serious injury or death.
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
POTENTIAL HAZARD
Skidding or sliding.
WHAT CAN HAPPEN
You could lose control of the vehicle. You could also regain traction unexpectedly, which may cause the vehicle to over-
turn.
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
Overloading the vehicle or carrying or towing improperly.
WHAT CAN HAPPEN
Could cause changes in handling, which could lead to an accident.
HOW TO AVOID THE HAZARD
Never exceed the stated load capacity for this vehicle. Cargo should be properly 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.
! WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
15
! WARNING
POTENTIAL HAZARD
Operating this vehicle 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 this vehicle in fast flowing water or in water deeper than the floor­board.
Remember that wet brakes may have reduced stopping capability. Test the brakes after leaving water. If necessary, apply them several times to dry
out the pads.
! WARNING
POTENTIAL HAZARD
Operating the vehicle with improper tires or with improper or uneven tire pressure.
WHAT CAN HAPPEN
Use of improper tires on the vehicle, or operating the vehicle with improper or uneven tire pressure, could 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 vehi­cle.
Always maintain proper tire pressure as described in this Operator’s Manual.
! WARNING
POTENTIAL HAZARD
Operating this vehicle with improper modifications.
WHAT CAN HAPPEN
Improper installation of accessories or modification of the vehicle may cause changes in handling which could lead to an accident.
HOW TO AVOID THE HAZARD
Never modify this vehicle through improper installation or improper use of accesso­ries. All parts and accessories added to this vehicle should be approved compo­nents designed for use on this vehicle and should be installed and used according to instructions. If you have questions, consult an authorized dealer.
! WARNING
POTENTIAL HAZARD
Failing to avoid pinch-points when lowering the cargo box.
WHAT CAN HAPPEN
Fingers, hands, or arms could be seriously injured when lowering the cargo box.
HOW TO AVOID THE HAZARD
Always be aware of and avoid lowering cargo box until everyone is clear of pinch­points.
16
! WARNING
POTENTIAL HAZARD
Operating through or over thick or sharp brush, timber, debris, or rocks.
WHAT CAN HAPPEN
Serious injury or death. Brush, branches, debris, and rocks can enter or penetrate the passenger compartment and strike occupants. Running over sharp branches, rocks, or other large objects can also cause loss of control.
HOW TO AVOID THE HAZARD
Be alert. Slow down. Wear all recommended protective gear specified in this Oper­ator’s Manual. Avoid operating through or over thick brush, timber, debris, or large rocks whenever possible. Watch for and avoid sharp branches, rocks, or other large objects that could impede or impact the vehicle or enter the passenger com­partment.
! WARNING
POTENTIAL HAZARD
Securing a person improperly in the vehicle due to physical size.
WHAT CAN HAPPEN
Serious injury or death. Occupant could strike objects in the passenger compart­ment, fall out of the vehicle during maneuvers, or be ejected and crushed in the event of an accident.
HOW TO AVOID THE HAZARD
Always make sure a passenger can sit with both feet flat on the floor and their back against the seat while being able to reach any provided hand holds.
! WARNING
POTENTIAL HAZARD
Operating this vehicle on paved surfaces.
WHAT CAN HAPPEN
The vehicle’s tires are designed for off-road use only, not for use on pavement. Paved surfaces may seriously affect handling and control of the vehicle and may cause the vehicle to go out of control.
HOW TO AVOID THE HAZARD
Whenever possible, avoid operating the vehicle 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.
17
Division II - Operation/Maintenance
Specifications
Specifications subject to change without notice.
ENGINE
Type Four-Cycle/Liquid Cooled
Bore x Stroke 89 mm x 71.2 mm (3.5 x 2.8 in.)
Displacement 443 cc (27.0 cu in.)
Spark Plug Type NGK CR6E
Spark Plug Gap 0.7-0.8 mm (0.028-0.031 in.)
Brake Type Hydraulic Disc (front);
Shaft-Mounted Hydraulic Disc (rear)
CHASSIS
Length (Overall) 270.3 cm (106.4 in.)
Height (Overall) 194.8 cm (76.7 in.)
Width (Overall) 143.3 cm (56.4 in.)
Suspension Travel (Front/Rear) 19 cm (7.5 in.)
Tire Size (Front) 25 x 8-12
Tire Size (Rear) 25 x 10-12
Tire Inflation Pressure 82.7 kPa (12 psi)
MISCELLANY
Dry Weight (Approx) 497 kg (1095 lb)
ROPS Tested Curb Weight 997.9 kg (2200 lb)
Gas Tank Capacity 32.2 L (8.5 U.S. gal.)
Coolant Capacity 2.5 L (2.64 U.S. qt)
Differential Capacity 250 ml (8.5 fl oz)
Rear Drive Capacity 230 ml (7.8 fl oz)
Engine Oil Capacity (Approx) (Change w/filter) 2.4 L (2.5 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
Reverse Light 12V/5W
Taillight/Brakelight 12V/5W/21W
Headlight 12V/55W/60W
Starting System Electric
18
Vehicle Operation
Pre-Start/Pre-Operation Checklist
Item Remarks
Brake System Pedal firm - near top of travel.
Fluid at proper level. Check for fluid leaks.
Controls Steering free - no binding - no excessive free-play.
Shift lever in park. Accelerator free - no binding - returns to idle position.
Fluids Coolant level to bottom of radiator neck and reservoir at least half
fill. Check oil level. Gas tank full of recommended gasoline. Differential/rear drive at proper level. Check for fluid leaks.
Suspension Ball joints/tie rod ends free - secure.
Shocks not leaking - mountings secure. Shock spring pre-load equal on left and right. Components free of all debris.
Lights/Switches Check headlight HI/LO beam - light switch to OFF.
Check taillight/brakelight - light switch to OFF. Check drive select switch - set to 2WD.
Air Filter Drain caps clear of all debris.
Ducting secure - no holes or tears.
Tires/Wheels Properly inflated - tread adequate.
Check tires for cuts or tears. Wheels secure to hubs - hubs secure to axles. Check wheels for cracked or bent rims.
Seat Belts/Restraints Check condition - proper operation - proper adjustment.
Nuts/Bolts/Fasteners Check for loose nuts - bolts - tighten as necessary.
Check fasteners - latches - ROPS. Secure hood, cargo box, seats.
19
Vehicle Operation
Starting the Vehicle
Always start with the vehicle on a flat, level surface. Carbon monoxide poison­ing can kill you, so keep the vehicle out­side while it’s running. Follow these steps to start it up:
NOTE: This vehicle is equipped
with a driver’s seat belt sensor. If the driver’s seat belt is not fastened, the vehicle speed is limited to 15 mph and the seat belt indicator on the gauge will illuminate. The seat belt indicator will remain illuminated until the driver’s seat belt is fastened.
HDX323A
1. Step into the vehicle and sit down; then fasten the operator seat belt and the passenger seat belt (if applica­ble) and strap on your approved hel­met and require your passenger to do the same (if applicable). Check that the occupant side restraints are secured in place.
2. Place the transmission in park; then depress the brake pedal.
3. Turn the ignition switch clockwise to the START position; then when the engine starts, release to the RUN position. Do not increase engine
RPM above idle.
4. Let the engine warm up.
Shifting
NOTE: The CVT is fully automatic
and shifts as a function of engine RPM and vehicle loading.
PK059
1. To select reverse gear from park, move the shift lever forward one position until the letter “R” is dis­played on the LCD gauge.
2. To select neutral from reverse, move the shift lever forward one position until the letter “N” is displayed on the LCD gauge.
3. To select high range from neutral, move the shift lever forward one position until the letter “H” is dis­played on the LCD gauge.
4. To select low range from high range, move the shift lever forward one position until the letter “L” is dis­played on the LCD gauge.
! WARNING
Falling from a moving vehicle could result in serious injury or death. Always fasten your seat belt securely and ensure the passenger seat belt is properly and securely fastened prior to operating or riding in this vehicle.
CAUTION
Increasing engine RPM above idle while in Park will cause belt damage.
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
Always come to a complete stop before attempting to shift from one range to the other or into reverse. Always shift on level ground.
20
NOTE: The high range is for nor-
mal driving 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.
5. To select park, move the shift lever completely down until the letter “P” is displayed on the LCD gauge.
Driving the Vehicle
Once the engine is warm, the vehicle is ready to be driven.
1. With the engine idling, press the foot brake pedal to apply the brake; then select the appropriate operating range and/or direction with the shift lever.
2. Release the foot brake pedal and press the accelerator to slowly add power to start moving.
3. To slow down or stop, release the accelerator and press the foot brake pedal as necessary to slow or stop the vehicle.
Braking/Stopping
Always allow plenty of room and time to stop smoothly. Sometimes quick stops are inevitable, so always be prepared. Whether you’re stopping slowly or stop­ping quickly, do this:
1. Release the accelerator; then press the foot brake pedal to apply the brake.
2. If the wheels lock, release them for a second; then apply them again. On surfaces such as ice, mud, or loose gravel, pump the brake pedal rapidly.
3. Never “ride” the brake. Even main­taining minimal pressure on the brake pedal 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 vehicle stops, shift into park.
2. Turn off the ignition.
3. If you have to park on a hill, block the wheels on the downhill side.
Basic Turns
Steering effort is at its lowest in two­wheel drive (2WD). Greater effort is needed when in four-wheel drive (4WD). The greatest effort is needed when in four-wheel drive and the differential (if equipped) is locked.
Slow down before entering a turn. The basic turning technique is to drive at low speed and gradually adjust the amount of steering to suit the driving surface. Do not make sudden sharp turns on any sur­face. Refer to the sub-sections Driving Uphill, Driving Downhill, Crossing Obstacles, Driving in Reverse, Skidding or Sliding, Crossing Water, or Crossing Roads for more information.
If your vehicle ever skids sideways during a turn, steer in the direction of the skid. Also, avoid hard braking or acceler­ating until you have regained directional control.
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 V-belt failure or in damage to related drive system components.
CAUTION
Never increase engine speed above idle RPM when in park or belt damage will occur.
! 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 serious injury or death.
21
Driving Uphill
Always drive straight up the hill and always avoid hills steeper than 15°.
1. Keep both hands on the wheel.
2. Prior to starting the climb, shift into low range, select four-wheel drive for traction, and gradually press the accelerator; then maintain a constant speed.
3. If the vehicle stalls on a hill, press the foot brake pedal to apply the brake, shift into reverse, and slowly back down the hill. Do not attempt to turn around on a hill.
NEVER OPERATE UP OR DOWN HILLS STEEPER THAN 15°
Driving Downhill
Always drive straight down the hill and always avoid hills steeper than 15°.
1. Keep both hands on the wheel.
2. Prior to descending the hill, shift into low range and release the accel­erator to allow maximum engine braking. Do not use four-wheel drive when descending a hill. Engine braking can cause the front wheels to slide reducing steering control.
NOTE: Use minimum braking (as
necessary) to maintain a slow speed.
Crossing Obstacles
Crossing obstacles can be hazardous. There is always the possibility of the vehicle tipping. If you cannot go around an obstacle, follow these guidelines:
1. Stop the vehicle and place the trans­mission in park. Go out to inspect the obstacle thoroughly from both your approach side and the exit side. If you believe you can cross the obstacle safely, select four-wheel drive (4WD).
NOTE: Selecting the LOCK posi-
tion on the differential lock control may be beneficial; however, steering effort will be increased.
2. Approach the obstacle as close as possible to 90° to minimize vehicle tipping.
3. Keep speed slow enough to maintain control but fast enough to maintain momentum.
4. Use only enough power to cross the obstacle but still give yourself plenty of time to react to changes in condi­tions. Crawl over the obstacle.
! WARNING
Use care in turns - turning the steer­ing wheel too far or too fast can result in loss of control or a rollover. Exces­sive speed, driving aggressively, or making abrupt maneuvers, even on flat, open areas, can cause loss of control, tipping, or rollover. Uneven terrain, rough terrain, soft surfaces, slippery surfaces, and paved surfaces can also cause a loss of control or rollover in a turn. On loose or soft sur­faces, allow yourself more time and distance to turn and slow down.
! WARNING
Do not attempt to turn around on a hill.
! WARNING
Driving up hills improperly can cause loss of control of the vehicle resulting in serious injury or death. Use extreme care when driving in hilly ter­rain.
! WARNING
Do not attempt to turn around on a hill.
! WARNING
Driving down hills improperly can cause loss of control of the vehicle resulting in serious injury or death. Never drive downhill at a high rate of speed. Use extreme care when driving in hilly terrain.
22
NOTE: If there is any question
about your ability to cross the obsta­cle safely, you should turn around if the ground is flat and you have room or back up until you find a less diffi­cult path.
Driving in Reverse
When operating in reverse, avoid sharp turns and backing down a hill. When using reverse, follow these guidelines:
1. Back up slowly. It’s hard to see behind you.
NOTE: Avoid sudden braking while
backing up.
2. If possible, it is advisable to have someone “spotting” for you while backing up.
3. If you are unsure of what is behind the vehicle, place the transmission in park and get out and inspect the area
behind.
Skidding or Sliding
If you lose control after hitting sand, ice, mud, or water, follow these guidelines:
1. Turn the steering wheel into the direction of the slide.
2. Keep your foot off the brake until you’re out of the skid.
3. Stop and shift into four-wheel drive.
Crossing Water
This vehicle can only operate in water up to its floorboard. Stay away from fast moving rivers. This vehicle’s tires can be buoyant. In deep water, the vehicle may lose traction due to floating.
1. Physically check the depth and cur­rent of the water, especially if you can’t see the bottom. Also, check for boulders, logs, or any other hidden obstacles.
2. Keep speed slow while maintaining momentum.
3. Make sure you have a way out on the other side of the water.
4. Once you’ve cleared the water, briefly apply the brakes to make sure they work.
NOTE: Light pedal pressure or
pumping the brakes for a short dis­tance will aid in drying the brakes.
Crossing Roads
It may be necessary to cross a road or highway. If so, note the following guide­lines.
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; avoid it if at all possible.
4. Drive straight across to the opposite shoulder.
5. Take into account that this vehicle 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.
! WARNING
Striking hidden obstacles can cause serious injury or death. Reduce speed and proceed with care in unfamiliar terrain.
! 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.
! 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.
23
General Information
Control Locations and Functions
Ignition Switch Key
Two keys come with this vehicle. 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.
PK049
OFF position — All electrical circuits except the accessory are off. The engine will not start. The key can be removed in this position.
NOTE: The accessory plugs are
powered by the battery at all times.
RUN position — The ignition circuit is complete and the engine can run. The key cannot be removed in this position.
START position — The ignition circuit is complete and the starter is engaged. When the key is released, the switch will return to the RUN position. The key can­not be removed in this position.
NOTE: This vehicle has safety
interlock switches which prevent the starter motor from activating when the transmission is not in neutral. Depress and hold the brake pedal to engage starter when the transmis­sion is not in neutral.
Shift Lever
This vehicle has a dual-range Constant Variable Transmission (CVT) with reverse and park.
PK059
Drive Select Switch
PK019
This switch allows the operator to oper­ate the vehicle in either two-wheel drive (rear wheels) or four-wheel drive (all wheels) as well as mechanically lock the differential (if equipped) to apply equal power to both front wheels. For normal riding on flat, dry, hard surfaces, two­wheel drive should be sufficient. In situa­tions when additional traction is neces­sary, four-wheel drive would be the desired choice.
To select 2WD, depress the bottom of the switch. To select 4WD, move the switch to the middle position. To engage the dif­ferential lock, slide the switch latch slightly downward while pressing the top of the switch forward.
NOTE: When the differential lock is
engaged on equipped models, the indicator light will be illuminated.
CAUTION
Do not attempt to either engage or disengage the front differential while the vehicle is moving.
24
NOTE: The differential lock is
intended for use where minimum traction is available. Steering effort will increase with the front differen­tial lock engaged. Maneuverability and handling characteristics will dif­fer with the differential lock engaged.
Foot Brake
The foot brake should be applied when­ever braking is needed.
Apply the brake by pressing the brake pedal down.
Steering Wheel Tilt Latch
Pull on the lever located on the bottom of the steering column and move the steer­ing wheel to the desired position; then release the lever and make sure the steer­ing wheel locks securely.
PK020
Headlight Switch
PK021
With the ignition switch in the ON posi­tion, use the headlight switch to select off, running, low, or high beam.
Reverse Override Switch
This vehicle is equipped with a reverse speed limiter system. When additional RPM is needed in reverse, depress and hold the override switch located on the center console.
NOTE: The vehicle must be in 4WD
to activate the reverse override.
Accelerator Pedal
Press down on the pedal to increase engine RPM and vehicle speed; release the pedal to decrease engine RPM and vehicle speed.
NOTE: This vehicle 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.
Seat Latches
1. To remove the seat, raise the front of the seat and slide it forward.
2. To install the seat, slide the seat brackets under the frame rails; then press firmly on the front of the seat to engage both front seat studs into the receivers.
Seat Belts
This vehicle is equipped with seat belts for the operator and the passenger. To fasten and release the seat belt properly, use the following procedure.
! WARNING
Make sure the steering wheel is locked securely in place before mov­ing the vehicle, or steering wheel movement could occur causing loss of control.
! WARNING
Never activate the override switch while the throttle is open as a loss of control could result. Use caution when using the override switch as reverse speed can greatly increase.
! WARNING
Make sure the seat is secure before driving the vehicle. Serious injury or death could result if the seat is not properly secured.
25
1. Place the seat belt across your lap as low as possible without twisting the belt making sure the shoulder strap is below the neck and across the chest.
2. Push the latch-plate into the buckle slot until it “clicks” and latches securely. The belt will retract when the buckle is released.
Occupant Side Restraints
In addition to the seat belts, there are left­and right-side restraints to restrict arms or legs from extending outside the vehi­cle. The restraints should always be secured when the vehicle is moving.
To secure the restraint, connect the restraint buckle to the receiving latch on the front ROPS tube. To release the restraint, squeeze the locking tabs of the restraint buckle.
PK013A
Tailgate Latch
PK022
1. To open the tailgate, pivot the latch levers outward.
2. To close the tailgate, lift up and push forward firmly; then pivot the latch levers inward
Cargo Box Latch Handles
PK023
1. To raise the cargo box, pivot the latch forward; 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.
Speedometer/LCD (Digital)
WT103D
1. Left Button - Shifts top display through speedometer, RPM, and clock.
! WARNING
Only appropriate-sized passengers may ride in this vehicle. Passengers must be able to place both feet flat on the floor while keeping their back against the back of the seat and hold­ing on to the hand holds.
! WARNING
Falling outside a moving vehicle could result in serious injury or death. Always fasten your seat belt securely and ensure the passenger seat belt is properly and securely fastened prior to operating or riding in this vehicle.
26
2. Middle Button - Shifts middle dis­play through speedometer, RPM, clock, odometer, trip 1, trip 2, and engine hours.
3. Right Button - Shifts bottom display through coolant temperature, bat­tery voltage, intake air temperature, and fuel level.
4. Speedometer/Tachometer/Clock Display - Indicates approximate vehicle speed in MPH or KM/H when speedometer function is selected, RPM when tachometer function is selected, or time when clock is selected. Press the Left But­ton to change which parameter is being displayed. With speedometer selected, press and hold the Left Button to shift between standard (MPH/miles/Fahrenheit) and metric (km/h/kilometers/Celsius).
With the clock mode selected, press and hold the Left Button to set the clock. The option of selecting the 12-hour or 24-hour clock is avail­able; press the Left Button to alter­nate between the two modes. Next, press the Middle Button to set the clock. Press the Left or Right to set the hours; then press the Middle Button to set the minutes. Press the Left or Right Button to set the min­utes. When the proper time has been set, press the Middle Button to return to the main gauge display.
5. Engine Hour Meter/Odometer/Trip Meter/Speedometer/Tachometer/ Clock Display - Displays engine hours, odometer, trip meter, speed­ometer, tachometer, or clock. Press the Middle Button to change which parameter is being displayed. The Engine Hour Meter and Odometer cannot be reset. To reset the trip meter, select the Trip Meter; then press and hold the Middle Button until the trip meter display reads 0.
NOTE: The engine hour meter will
not activate until engine speed exceeds 500 RPM.
NOTE: An item can only be dis-
played in this position if it is not already being displayed in the top display. To set the clock when the clock is in this position, press and hold the Middle Button; then use the procedure found in step 4.
6. Coolant Temperature/Battery Volt­age/Intake Air Temperature/Fuel Level Display - Displays coolant temperature, battery voltage, intake air temperature, and fuel quantity. Press the Right Button to change which parameter is being displayed. Press and hold the Right Button to see the actual values associated with the mode selected.
NOTE: High engine RPM, low vehi-
cle speed, or heavy load can raise engine temperature. Decreasing engine RPM, reducing load, and selecting an appropriate transmis­sion gear can lower the temperature.
NOTE: Debris in the engine com-
partment (or packed between the cooling fins of the radiator) can reduce cooling capacity. Using a gar­den hose, wash the radiator and the engine to remove any debris pre­venting air flow.
7. Gear Position Indicator - Indicates which gear is selected.
CAUTION
Continued operation with high engine temperature may result in engine damage or premature wear.
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.
27
8. EFI Malfunction Indicator - A diag­nostic code (see list below) and engine icon will be displayed on the LCD whenever an EFI error is detected. The LCD will be normal, but the code and engine icon will continue to be displayed on the LCD until the error is corrected.
WT114C
NOTE: Take the vehicle to an
authorized dealer to have the error corrected and the system error reset as soon as possible.
9. Drive Select Indicator - Displays 4WD when selected by the drive select switch.
10. Seat Belt Reminder Indicator - Each time the ignition switch is turned ON, the indicator will illuminate until the driver’s seat belt is fas­tened.
! WARNING
The seat belt indicator does not indi­cate that all seat belts are properly secured. It is the operator’s responsi­bility to ensure all vehicle occupants are properly seated with seat belts secure and side restraints are prop­erly latched. Serious injury or death could occur as a result of falling out­side a moving vehicle.
28
Diagnostic Trouble Codes
Display Fault Description
C0063 Tilt Sensor Circuit High C0064 Tilt Sensor Circuit Low/SG/Open C1263 Backup/Reverse-Light Circuit Open C1264 Backup/Reverse-Light Circuit High C1265 Backup/Reverse-Light Circuit Low/SG C1400 Fuel Level Sender Open C1418 Memory Power Failure P0030 O2 Heater Intermittent/Open P0031 O2 Heater Low/SG P0032 O2 Heater High/SP P0107 MAP Sensor Circuit Low/SG/Open P0108 MAP Sensor Circuit High/SP P0112 Intake Air Temp Sensor Circuit Low/
SG
P0113 Intake Air Temp Sensor Circuit High/
Open
P0114 Intake Air Temp Sensor Circuit Inter-
mittent
P0116 Engine Coolant Temp Sensor Circuit
Range/Performance
P0117 Engine Coolant Temp Sensor Circuit
Low/SG
P0118 Engine Coolant Temp Sensor Circuit
High/Open/SP
P0119 Engine Coolant Temp Sensor Circuit
Intermittent
P0121 Throttle Position Sensor Range/Per-
formance
P0122 Throttle Position Sensor Circuit Low/
SG P0123 Throttle Position Sensor Circuit High P0130 O2 Sensor Intermittent/Open P0131 O2 Sensor Low/SG or Air-Leak P0132 O2 Sensor High/SP P0171 O2 Feedback Below Minimum Correc-
tion P0172 O2 Feedback Exceeds Maximum Cor-
rection P0219 Engine Over-Speed Condition P0231 Fuel Pump Relay Circuit Low/SG/
Open P0232 Fuel Pump Relay Circuit High P0233 Fuel Pump Relay Circuit P0261 Cylinder #1 Fuel injector Circuit Low/
SG P0262 Cylinder #1 Fuel injector Circuit High P0263 Cylinder #1 Fuel injector Balance/
Open P0264 Cylinder #2 Fuel injector Circuit Low/
SG P0265 Cylinder #2 Fuel injector Circuit High
P0266 Cylinder #2 Fuel injector Balance/
Open
P0336 Crankshaft Angle Sensor Synchroni-
zation P0337 Crankshaft Angle Sensor Circuit/SG P0339 Crankshaft Angle Sensor Intermittent/
Erratic P0340 Camshaft Angle Sensor Synchroniza-
tion P0341 Camshaft Angle Sensor Circuit/SG P0342 Camshaft Angle Sensor Intermittent/
Erratic P0480 Fan-Primary/Right Relay Control Cir-
cuit P0481 Fan-Secondary/Left Relay Control Cir-
cuit High P0482 Fan-Secondary/Left Relay Control Cir-
cuit Low/SG/Open P0483 Fan-Secondary/Left Relay Control Cir-
cuit P0484 Fan-Primary/Right Relay Control Cir-
cuit High P0485 Fan-Primary/Right Relay Control Cir-
cuit Low/SG/Open P0500 Vehicle Speed-Sensor P0508 Idle Air Control System Circuit Low/
SG P0509 Idle Air Control System Circuit High/
Open P0520 Engine Oil Sensor/Switch P0562 System Voltage Low P0563 System Voltage High P0601 ECM CAN Communication Shutdown P0615 Starter Relay Circuit P0616 Starter Relay Circuit Low P0617 Starter Relay Circuit High P0630 VIN Not Programmed or Incompatible P0642 Sensor Power Circuit Low P0643 Sensor Power Circuit High P2300 Ignition Coil #1 Primary Circuit Low/
SG/Open P2301 Ignition Coil #1 Primary Circuit High P2303 Ignition Coil #2 Primary Circuit Low/
Open P2304 Ignition Coil #2 Primary Circuit High P2531 Ignition Switch Circuit Low P2532 Ignition Switch Circuit High FUEL
OFF
Tilt Sensor Activation Code
Display Fault Description
29
Oil Level Stick
There is an oil level stick for checking the engine oil level. To check the oil level, use the following procedure.
NOTE: The vehicle should be on
level ground when checking the engine oil level.
1. Remove the seat.
2. Unscrew the oil level stick (located on the right-side of the engine) and wipe it with a clean cloth.
PK024A
3. Install the oil level stick.
NOTE: The oil level stick should be
threaded in for checking purposes.
4. Remove the oil level stick; the engine oil level should be within the operating range.
GZ461A
5. Add oil to the oil level stick opening until proper operating level is achieved.
6. Install the seat making sure it is securely latched.
Load Capacity Ratings Chart
This vehicle must always be loaded in accordance with the Load Capacity Rat­ings chart. Under no circumstances should the Vehicle Load Capacity rating ever be exceeded.
Vehicle Load Capacity - Total weight of operator, passenger, trailer tongue weight, accessories, cargo, and storage compartments.
Tongue Weight - Weight on trailer tongue.
Accessory Weight - Winch, gun scab­bard brackets, snow plow, etc.
Rear Tongue and Cargo Weight - Total weight on trailer tongue and cargo box.
Towing Capacity - Total weight of trailer and all cargo in the trailer.
Trailering and Towing
PK025
This vehicle is equipped with a rear frame-mounted receiver for a standard
5.1 cm (2 in.) receiver hitch. The stan­dard receiver hitch must be purchased separately.
CAUTION
Do not overfill the engine with oil. Always make sure the oil level is within the operating range but not above the FULL mark.
! WARNING
Overloading this vehicle could result in loss of control resulting in serious injury or death.
Item Specifications
(lb) (kg) Vehicle Load Capacity 1000 454 Front Storage Compartment
(max)
25 11
Tongue Weight 150 68 Cargo Weight (max) 500 227 Rear Tongue and Cargo
Weight (max)
650 295
Towing Capacity 1500 680
30
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 vehicle must be in its normal operating position (on all four wheels) and the following procedure must be used.
1. Place the transmission in park.
2. Secure the vehicle with load rated hold-down straps.
PK083A
PK025A
NOTE: Suitable hold-down straps
are available from your authorized dealer. Ordinary rope is not recom­mended because it can stretch under load.
! 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 vehicle weight restrictions.
! WARNING
Driving this vehicle without extra cau­tion when towing a trailer will be haz­ardous. Trailer towing can affect the handling and braking of the vehicle. Tow only at low speeds and never exceed 10 mph. Avoid sudden accel­erations and stopping of the vehicle. 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 place the transmission in park could allow the vehicle to roll 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 vehicle.
CAUTION
Always buckle the side restraints when transporting to prevent buckle damage to body panels.
31
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.
1. To remove the gas tank cap, flip the lid down; then rotate the cap coun­terclockwise ¼ turn.
PK061
2. After filling the tank, position the lid towards the right side of the filler neck and rotate the lid ¼ turn clock­wise to secure. Flip the lid up.
Recommended Gasoline
The recommended gasoline to use in this vehicle 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
! WARNING
Always fill the gas tank in a well-venti­lated area. Never add gasoline to the 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 castor-based oils.
32
Recommended Front Differential/Rear Drive Lubricant
NOTE: The manufacturer recom-
mends the use of genuine lubri­cants.
The recommended front differential/rear drive lubricant is SAE approved 80W-90 hypoid. This lubricant meets all of the lubrication requirements of this vehicle.
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 vehicles and engines require a “break-in” period. The first month is most critical to the life of this vehicle. Proper operation during this break-in period will help assure maximum life and performance from this vehicle.
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.
1. Choose an area sufficiently large to safely accelerate to 30 mph and to brake to a stop.
2. Accelerate to 30 mph; then release the accelerator pedal and press brake pedal to decelerate to 0-5 mph.
3. Repeat procedure twenty times.
CAUTION
Any lubricant used in place of the rec­ommended lubricant could cause serious front differential/rear drive damage.
! 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.
33
General Maintenance
NOTE: Proper maintenance of this
vehicle is important for optimum per­formance. Follow the Maintenance Schedule and all ensuing mainte­nance instructions/information.
If, at any time, abnormal noises, vibra­tions, or improper functioning of any component of this vehicle is detected, DO NOT OPERATE THE VEHICLE. 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.
NOTE: The following instructions
and information refer to specific items in the maintenance and care of this vehicle.
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 100
miles
Every 100
miles
Every 300
miles
Every 500
miles
Battery 38 I I
* Engine nuts and bolts I I
* Valve clearance I I
Spark plug 41 I I
41 Replace every 4000 miles (6436 km) or 18 months
Liquid cooling system 34 I Inspect every time before operating
Gas Hoses 29 I Inspect every time before operating
Engine/transmission oil and filter 35 R R**
Air filter 41 I I
Gear lubricant (front differential - rear drive)
35 R I I
V-belt 42 I I
Spark arrester/muffler 43 C
Tires/air pressure 43/17 I Inspect every time before operating
* Brake components 36 I Inspect every time before operating
Brake fluid 36 I Inspect every time before operating
Brake hoses 36 I Inspect every time before operating
* Steering I Inspect every time before operating
* Suspension (Ball joint boots, drive axle boots front and rear, tie rods, differential and rear drive bellows)
I Inspect every time before operating
* Chassis nuts and bolts I T
Wheel lug nuts 43 T T
Frame/welds/racks I I
Electrical connections I I
Headlight/taillight-brakelight 44 I Inspect every time before operating
Air filter drains I Inspect every time before operating
Accelerator pedal 24 I Inspect every time before operating
ROPS 47 Inspect every time before operating
Occupant side restraints 47 Inspect every time before operating
Wheel nuts 43 I I
34
Liquid Cooling System
NOTE: Debris in the engine com-
partment 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 specification 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 vehi-
cle 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 coolant/water mixture 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, remove the bleed plug on the coolant pipe at the front of the engine allowing trapped air to escape. When pure coolant (no air) flows from the bleed hole, install the bleed plug, tighten securely, and then fill the cooling system to the bottom of the stand pipe in the radiator neck. Run the engine for five minutes after the ini­tial fill; then shut off the engine and recheck coolant level.
NOTE: Use a good quality, biode-
gradable glycol-based, automotive­type antifreeze.
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 vehicle is oper-
ated 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.
This vehicle is equipped with adjustable shock absorbers to allow for different driving and loading conditions.
Adjustments can be made with a special spanner wrench to increase or decrease coil spring tension.
To adjust the spring force, loosen the lock collar; then rotate the pre-load adjust­ment sleeve with a suitable spanner wrench until desired spring tension is achieved.
NOTE: For normal operating con-
ditions, we recommend the pre-load settings be set to full-soft on all four shock absorbers.
CAUTION
Do note 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 vehicle with high engine temperature may result in engine damage or premature wear.
! WARNING
Never check the coolant level when the engine is hot or the cooling sys­tem is under pressure.
CAUTION
After operating the vehicle for the ini­tial 5-10 minutes, stop the engine, allow the engine to cool down, and check the coolant level. Add coolant as necessary.
35
PK082
NOTE: Before attempting to adjust
suspension, clean dirt and debris from the threads and remove load from the suspension; then use the spanner wrench to adjust the pre­load.
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
NOTE: Refer to the recommended
oil viscosity chart (on page 31) in this manual for the proper engine oil.
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 vehicle on level ground.
2. Remove the seat.
3. Loosen the oil level stick. Be careful not to allow contaminants to enter the opening.
PK024A
4. Remove the drain plug from the bot­tom of the engine and drain the oil into a drain pan.
5. Using the oil filter wrench and a ratchet handle (or a socket or box­end 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.
6. 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.
7. Install the engine drain plug and tighten it securely. Pour the recom­mended oil into the level stick open­ing. Install the level stick.
8. Start the engine (while the vehicle is outside on level ground) and allow it to idle for a few minutes.
9. Turn the engine off and wait approx­imately one minute. Recheck the oil level.
10. Inspect the area around the drain plug and oil filter for leaks.
11. Install the seat making sure it is securely latched.
Front Differential/Rear Drive Gear Lubricant (Inspecting/Changing)
Inspect and change the gear lubricant in each according to the Maintenance Schedule. When changing the lubricant, use the appropriate hypoid oil and use the following procedure.
1. Place the vehicle on level ground.
2. Remove each check plug.
PK027A
Front
36
PK028A
NOTE: The lubricant level should
be visible at the check plug threads.
3. Drain the oil into a drain pan by removing the drain plug from each gear case.
PK029A
4. After all the oil has been drained, install the drain plugs and tighten to 45 in.-lb.
5. Pour recommended oil into each fill hole.
6. Install the fill plugs and tighten to 16 ft-lb.
Hydraulic Brake
Brake Fluid
PK030A
1. Check the brake fluid level in the brake fluid 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.
NOTE: The brake fluid reservoir is
located on top of the master cylinder under the front body panel.
2. Press the brake pedal several times to check for firmness.
3. If the pedal is not firm, the system must be bled.
NOTE: Take the vehicle to an
authorized dealer for this service.
Brake Hoses
Carefully inspect the hydraulic brake hoses for cracks or other damage. If found, take the vehicle 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.
CAUTION
Inspect the oil for any signs of metal filings or water. If found, take the vehicle 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.
Rear
Front
CAUTION
Be careful not to spill any fluid when filling the brake fluid reservoir. Wipe away spilled fluid immediately.
37
3. If thickness of either brake pad fric­tion material is less than 1.0 mm (0.039 in.), take the vehicle to an authorized dealer to have brake pads replaced.
PK004A
4. Install the wheel and tighten the wheel nuts in 20 ft-lb increments to a final torque of 45 ft-lb (steel wheel), 60 ft-lb (aluminum wheel w/ black nuts), or 80 ft-lb (aluminum wheel w/chrome nuts).
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)
PK005A
1. Secure the vehicle on a support stand to elevate the front wheels.
2. Remove both front wheels.
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)
1. Secure the vehicle on a support stand to elevate the front wheels.
2. Remove both front wheels.
3. Inspect the 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.
PK006A
5. If boot damage is present or tie rod end free-play seems excessive, con­tact an authorized dealer for service.
Drive Axle Boots
PK006B
1. Inspect all drive axle boots for cracks, tears, or perforations.
2. If boot damage is present, contact an authorized dealer for service.
38
Battery
The battery is located under the seat on the driver’s side.
PK007
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 lead-acid batteries. 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.
Maintenance Charging
NOTE: Use of the CTEK Multi US
800 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.
1. When charging a battery in the vehi­cle, be sure the ignition switch is in the OFF position.
NOTE: Be sure to maintain the
fluid of the battery at the UPPER LEVEL. Use only distilled water when adding fluid to these batteries.
2. Clean the battery terminals with a solution of baking soda and water.
3. Be sure the charger and battery are in a well-ventilated area and ensure the battery charger cables will not contact any battery acid. Be sure the charger is unplugged from the 110­volt electrical outlet.
4. 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.
5. Plug the battery charger into a 110­volt electrical outlet.
6. 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) at the bottom illu­minates. The Normal Charge Indica­tor (C) should illuminate on the upper portion of the battery charger.
800A
NOTE: 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.
39
3300C
NOTE: Not using a battery charger
with the proper float maintenance will damage the battery if connected over extended periods.
Charging
NOTE: Use of the CTEK Multi US
800 or the CTEK Multi US 3300 for battery maintenance charging is rec­ommended.
1. Be sure the battery and terminals have been cleaned with a baking soda and water solution.
2. Be sure the charger and battery are in a well-ventilated area and ensure the battery charger cables will not contact any battery acid. 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.
4. Plug the charger into a 110-volt elec­trical outlet.
5. By pushing the Mode button (A) on the left side of the charger, select the Normal Charge Icon (E). The Nor­mal Charge Indicator (C) should illuminate on the upper left portion of the charger.
6. The battery will charge to 95% of its capacity at which time the Mainte­nance Charge Indicator (D) will illu­minate.
NOTE: For optimal charge and per-
formance, leave the charger con­nected to the battery for a minimum 1 hour after the Maintenance Charge Indicator (D) illuminates. If the bat­tery becomes hot to the touch, stop charging. Resume after it has cooled.
7. 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.
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.
! WARNING
Improper handling or connecting of a battery may result in serious injury including acid burns, electrical burns, or blindness as a result of an explo­sion. Always remove rings and watches.
! 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.
40
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.
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.
! 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 or death.
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 could 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.
41
Spark Plug
This vehicle comes equipped with a spec­ified spark plug. See the specifications chart for the correct spark plug. A light brown insulator indicates that the plug is correct. A white or dark insulator indi­cates that the engine may need to be ser­viced. Consult an authorized dealer if the plug insulator is not a light brown color. To help prevent cold weather fouling, make sure to thoroughly warm up the engine before operating.
To maintain a hot, strong spark, keep the plug free of carbon.
ATV-0051
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.
Adjust the gap (see specifications chart) for proper ignition. Use a feeler gauge to check the gap.
ATV-0052
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.
Air Filter/Housing Drain
The air filter inside the air filter housing must be kept clean to provide good engine power and gas mileage. If the vehicle is used under normal conditions, service the filter at the intervals speci­fied. 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.
NOTE: To access the air filter, the
seat must be removed.
1. Remove dirt and debris from around the filter housing.
2. Unsnap the seven spring-clips and remove the air filter cover; then loosen the clamp securing the air filter.
PK008A
3. Remove the Phillips screw to sepa­rate the air filter holders from the air filter.
PK321
4. Slide out the air filter screen; then separate the inner and outer air filter elements to thoroughly clean.
CAUTION
Failure to inspect the air filter fre­quently if the vehicle is used in dusty, wet, or muddy conditions can dam­age the engine.
42
PK322
5. Place each element in a pan larger than the elements and spray all sides generously with cleaning solvent. Let sit approximately three minutes.
6. In a pan larger than each 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).
NOTE: Foam Filter Cleaner and
Foam Air Filter Oil Aerosol are avail­able.
7. Rinse off any remaining soap.
8. Remove any excess water from the element by matting with a towel.
9. Allow each element to dry com­pletely. Place the outer element over the inner air filter element.
10. Spray oil generously onto air filter and work the oil into the element.
11. Squeeze the element to remove excess oil.
12. Clean any dirt or debris from inside the filter housing.
13. Inspect the drain cap beneath the main housing for debris and for proper sealing.
PK009
14. Insert the air filter screen into the inner element; then secure the air fil­ter holders with the Phillips screw.
15. Install the air filter cover and secure with the clamp. Install the air filter cover and secure with the spring­clips. Install the seat and make sure it is securely latched.
Draining V-Belt Cover
NOTE: If the vehicle has been
driven through water, the V-belt cover must be drained of any water.
1. Place the vehicle on a level surface.
2. Remove the drain bolt from the cover (located on the bottom of the V-belt cover) and allow the water to drain out.
NOTE: The drain bolt can be
accessed through the bottom of the skid plate.
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 clutches
should be inspected every 500 miles and the belt replaced (if necessary).
CAUTION
A torn air filter can cause damage to the 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.
CAUTION
Do not attempt to clear water with the vehicle in park. The transmission is locked and belt or clutch damage could occur.
43
Tires
Tire Tread Condition
0732-649
The use of worn-out tires on this vehicle 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.
Tire Replacement
This vehicle has low-pressure tubeless tires. Air is sealed by the contact surfaces of the inner wheel rim and the tire bead. If either the inner wheel rim or tire bead is damaged, air may leak. Be extremely careful not to damage these areas when replacing tires.
It is very important to use the proper tools when repairing or replacing tires to prevent damage to the tire bead or wheel rims. If proper tools and related items are not available, 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 vehicle 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 vehicle on level ground and engage the differential lock.
2. Loosen the lug nuts on the wheel to be removed.
3. Elevate the vehicle.
4. Remove the lug nuts.
5. Remove the wheel.
6. Install the wheel and install the lug nuts.
7. Install the wheel and tighten the wheel nuts in 20 ft-lb increments to a final torque of 45 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.
! WARNING
Always use the size and type of tires as specified. Refer to the specifica­tions chart for proper tire inflation pressure, and always maintain proper tire inflation pressure.
! WARNING
The use of worn-out tires is danger­ous and can increase the risk of an accident.
CAUTION
When breaking the tire bead loose from the wheel, be extremely careful not to damage the inner wheel sur­face or the tire bead.
! WARNING
Use only approved tires when replac­ing tires. Failure to do so could result in unstable operation.
! WARNING
Wait until the muffler cools to avoid burns.
44
PK010
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 to 50 in.-lb.
Light Bulb Replacement
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 back of the headlight bulb counterclockwise, disconnect the wiring harness, and discard the bulb.
PK062A
2. Connect the new headlight bulb to the wiring harness and insert into headlight assembly. Turn clockwise to secure the bulb.
3. Adjust the headlight (see Checking/ Adjusting Headlight Aim in this sub-section.
To replace the taillight/brakelight or reverse light bulb, use the following pro­cedure.
1. Disconnect the taillight/brakelight connector.
2. Remove the two nuts and cap screws securing the steel tie-down to the cargo box.
PK063A
3. Remove the six plastic screws secur­ing the rear fender to the cargo box. Remove the rear fender.
TXR004A
4. Remove the taillight/brakelight socket by rotating the socket counter-clockwise. Rotate the bulb counter-clockwise to remove from socket.
CAUTION
Use only specified bulbs indicated in the Specifications 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.
45
5. Remove the reverse light housing by removing the two screws and nut; then remove the two machine screws. Rotate the bulb counter­clockwise to remove from socket.
PK065A
PK066
6. To install the taillight/brakelight, insert the bulb into the socket and turn clockwise. Insert the socket into the taillight assembly and turn clockwise.
7. To install the reverse light, insert the bulb into the socket and turn clock­wise. Insert the socket into the reverse light housing and secure with the two machine screws.
8. Secure the reverse light housing into the taillight assembly with the two screws and nut.
9. Place the rear fender onto the cargo box and secure with the six plastic screws. Secure the tie-down with the two nuts and cap screws.
10. Connect the taillight/brakelight con­nector.
Checking/Adjusting Headlight Aim
The headlights can be adjusted vertically. The geometric center of the HIGH beam light zone is to be used for aiming.
1. Position the vehicle on a level floor so the headlights are approximately
6.1 m (20 ft) from an aiming surface (wall or similar aiming surface).
0748-733
NOTE: There should be an average
operating load on the vehicle 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. Loosen the headlight adjustment screw; then adjust the headlight up or down as required. Tighten the headlight adjustment screw.
PK081A
46
Fuses
The fuses are located under the front access panel. If there is any type of elec­trical system failure, always check the fuses first.
PK012
NOTE: To remove the fuse, com-
press the locking tabs on either side of the fuse cover and lift out.
UTV-253
Electrical Output Terminals
Three output terminals for electrical accessories are located on the wiring har­ness. An accessory plug is located on the dash board.
NOTE: The rear output terminal is
located above the bottom frame rail behind the right rear tire. The front output terminal is located behind the left front fender well. A third output terminal is located under the seat.
PK067A
Storage Compartments/ Tools
A basic tool kit (located in the glove box) is provided with this vehicle. Maintain the tool kit with the vehicle at all times.
NOTE: There are a total of five
storage compartments.
1. To access the front storage compart­ment, lift up firmly on the front of the cover to remove. To install, align the tabs of the storage cover into the front panel slots.
PK084
2. To open the glove box (if unlocked), squeeze the locking tabs together and pivot the lid downward or insert the key and rotate 1/8 turn counter­clockwise and pivot the lid down­ward. To lock the glove box, close the lid, insert the key, and rotate it ¼ turn clockwise. Remove the key.
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.
47
PK085
3. To access the dual under-seat stor­age, remove the seat; then remove the lid from the top of the storage compartment on the driver’s side. There is additional storage space on the passenger side of the vehicle.
PK086
4. To open the tailgate compartment, pull outward on the locking lever and allow the tailgate storage cover to pivot downward. To secure the tailgate storage cover, pivot the cover upwards and press firmly on both left and right hands sides.
TXR005
Seat Belts
Inspect the seat belts for frayed or torn edges. Check that the belts extend and retract smoothly and fully without bind­ing or catching. Check that the latch plate locks securely in place in the buckle and releases when the button is pressed. Wash off any dirt and make sure the retractors are free of debris. Do not grease or oil the retractors.
Occupant Side Restraints
Inspect the occupant side restraints for frayed edges, cuts, or separation of seams. Wash off any dirt and make sure the latch straps lock securely into the receiver located on the front ROPS tube.
PR013A
ROPS
Inspect the Rollover Protection Structure (ROPS) for any deformation, twisting, cracking, missing or damaged fasteners, loose fasteners, modification to the pro­duction form, missing ROPS label, unau­thorized repair or welding, and/or improper installation. If any of these cir­cumstances are discovered, do not oper­ate and immediately bring the vehicle to an authorized dealer for service.
48
Preparation For Storage
We recommend the following procedure to prepare the vehicle for storage. An authorized dealer should perform this service; however, the owner/operator may perform this service if desired.
1. Clean the seat cushion with a damp cloth and allow to dry.
2. Clean the vehicle thoroughly by washing dirt, oil, grass, and other foreign matter from the entire vehi­cle. Allow the vehicle 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 plungers of the shock absorbers.
7. Tighten all nuts, bolts, cap screws, and screws. 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 vehicle indoors in a level position.
CAUTION
Prior to storing this vehicle, 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 vehicle causing rusting.
49
Preparation After Storage
Taking this vehicle out of storage and correctly preparing it will assure many miles and hours of trouble-free riding. We recommend the following procedure.
1. Clean the vehicle 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, taillights, brakelights, 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.
50
Maintenance Record
DATE MILEAGE SERVICE PERFORMED/NOTES
51
Maintenance Record
DATE MILEAGE SERVICE PERFORMED/NOTES
52
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 Shock Absorber(s)*
* Limited to one (1) year of “normal” riding conditions - replace for defective or leaking shock, corroded or
pitted shaft, peeling chrome.
NOTE: Vehicles that are factory equipped with Fox, Elka, or JRI shocks and experience a shock failure of workmanship or material within the factory warranty period must not be tampered with. Only the air pressure valve (p/n 2603-511 - Fox shocks only) is serviceable during the warranty period. Any other tampering with the shock will void warranty.
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/fuel, 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.
12. Use of starting fuel (ether) for cold starts.
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, contact us at (U.S.) 1-218-681-9851 or (Canada) 1-204-982-1656.
53
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 vehicle 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 vehicle, follow all safety and service tips. We will NOT warrant non-emissions 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.
54
U.S. EPA Emission Control
Statement/Warranty Coverage - ROV
(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.
55
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 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 WARRANTY DEPT. P.O. BOX 810 THIEF RIVER FALLS, MN 56701
Place
Stamp
Here
Identification Numbers Record
This vehicle 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 name, VIN, and ESN 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 this vehicle 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 behind the front right tire.
3. ENGINE SERIAL NUMBER:
The ESN is located on the front-right side of the crankcase.
PK047
PK048
p/n 2261-468
Vehicle Capacity: 1 Operator, 1 Passenger with seat belts
©2017 Textron Specialized Vehicles, a division of Textron, Inc.
™ ®Trademarks of Textron Specialized Vehicles
Loading...