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BRISTERS TRAIL WAGON Operator's Manual

2 wheel & 4 wheel drive models
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Brister's Utility Vehicles
2 Wheel & 4 Wheel Drive Models
Operator's Manual
Copyright
January 1, 2007

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Summary of Contents for BRISTERS TRAIL WAGON

  • Page 1 Brister’s Utility Vehicles 2 Wheel & 4 Wheel Drive Models Operator’s Manual Copyright January 1, 2007...
  • Page 2 IN EX Section 1 Introduction pages 3-4 Serial Number Plate Location page 4 Section Safety pages 5- Pre-Delivery Steps page 9 Dealer Inspection Checklist page 10 ection 3 Assembly Instructions pages 11-13 Seat Back, Brush guard, Bumper page 12 Steering wheel page 12 Cargo Bed page 13...

  • Page 3: Section 1 Introduction

    Toll Free PH: 1-866-646-5278 from this vehicle. Fax: 1-866-329-5278 Safety First www.bristers.com Brister’s is fully aware of the need for safe operating procedures around all of our equipment. We hope yo Terminology will make a sincere effort to put safety above a...
  • Page 4 Product Support Brister’s Design & Manufacturing Co. LLC If you are still unsatisfied, seek out the owner or general P.O. Box 649 manager of the dealership. Roseland, LA 70456 Toll Free PH: 1-866-646-5278 For further assistance write to Fax: 1-866-329-5278 service@bristers.com...
  • Page 5 Read These Important Rules for Safe Operation Note: The Operator, Passenger, Parent or Guardian must read, study and understand all the items contained within this owners/operators manual before operating utility vehicle. Failure to follow these instructions could endanger the personal safety of the Operator, Passenger and any Bystanders. Close adult supervision is required at all times! Pay close attention to all Caution and Warning labels Located on the Utility Vehicle...
  • Page 6 Section 2 Safety It is very important to read, understand, and follow all instructions and warnings located on the decals on your rister Utility Vehicle.
  • Page 7 Section 2 Safety Safe Operating Procedures The safe operation of any machinery is a big c oncern to ll consumers. Your Brister Utility Vehicle has been designed with many built-in safety features. However, no one sho uld operate this vehicle before carefully * Some conditions may warrant extra safety gear to be ading this Operator’s Manual.
  • Page 8 more when turning loaded with cargo or when pulling a * Use extreme caution when descending hills or runn cargo load. The heaver the cargo load, the slower the on loose slippery surfaces. Towing, braking, a nd tractive rn should be. apabilities are greatly diminished.
  • Page 9 * Always disconnect the negative battery terminal befo ealer Service and Inspection List making a djustments to the vehicle electrical system or Fully charge battery. Check battery voltage to verify elding on this vehicle. hat it is fully charged. * Battery fumes are explosive. A spark will ignite battery __ Check fuel valve lever to make sure it is in the fumes.

  • Page 10: Important Notice

    Toll Free PH: 1-866-646-5278 __ Engine Manual has been delivered to and reviewed Fax: 1-866-329-5278 by the custo mer. www.bristers.com __Warranty Policy limits and requirements have been explained to the c ustomer. __ Location and functions of vehicle controls have been explained.
  • Page 11 Section 3 Assembly Instructions Brister Utility Vehicle Utility Vehicle Assembly Instructions Your new Brister Utility Vehicle Utility vehicle should include the f ollowing items to be assembled: Item Item #8 black screw (steering cap) 5/8” x 4” Hex bolt ¼” x 1 ¾” Hex head bolts 5/8”...
  • Page 12 Section 3 Assembly Instructions Pre-Assembly Instructions Read O wner’s Manual. 2) Unpack all vehicle a nd assembly parts. Make sure you have everything list ed on the previous page. 3) If y u o have any questions or problems with your Brister's Design &...
  • Page 13 Cargo Bed Installation Locate rear frame stubs at the rear of frame. The bed pivot tube on the stub should be at the top. Insert 5/16” x 2” socket head bolt. Loosely install 5/16” center lock nut (do not tighten until after cargo bed is installed) Fenders installation (if Equipped, no fenders on TW265) Tilt the cargo bed up.
  • Page 14 Sec o ti n 4 Operating Instructions General Operation Start your Brister Utility Vehicle by following the starting procedures as noted below. 1. Depress brake pedal with your foot and hold. Pre-Start Check List Pull firmly up on the park brake lever with your Check tire pressure as indicated.

  • Page 15: Engine Maintenance

    Section 5 Maintenance Fuel Type The fuel tank is located under seat. TW11, TW 413, CW11, CW413 Fuel Capacity is 5 Gal. W-265 & TW265 Fuel capacity is 6.1 Liters hen filling the fuel tank, place the gear shift in forward or reverse, set the park b rake, turn off the engine, and move ignition key.
  • Page 16 Section 5 Maintenance Foam element – Clean foam element with detergent in warm water or in a nonflammable solvent. Do not wring element. Squeeze excess cleaning fluids out. Allow time for the element to dry and then soak it ith clean engine oil. Squeeze excess oil out. Excess oil ft in the filter will cause engine to smoke briefly when rst started.

  • Page 17: Engine Oil

    4. Fill to edge of oil fill hole with recommended oil Section 5 Maintenance when oil levels are low. 5. Replace filler cap/dipstick and tighten secure Engine Oil A general description for engine oil maintenance, Engine Oil Change recommendations, and capacities is provided below Warms oil drains quickly and completely.

  • Page 18: Transaxle Oil Type/Fill/Drain

    Section 5 Maintenance Transaxle Oil A general description for transaxle oil maintenance, recomm endations, and capacities is provided below. NOTE: Running vehicle low on transa xle oil can Transaxle Oil Change damage transaxle a nd void warranty. Refer to Figure 5-5B Warm oil drains quickly and completely.

  • Page 19: Drive Belt

    Section 5 Maintenance Drive Belt The dive belt is considered a wearable item. Replacement intervals depend on vehicle use and environment. If your belt is slipping you may need to replace it. 1. P ark vehicle on a level surface, set park brake, place shifter in Neutral, turn off ignition switch, and remove switch key.
  • Page 20 In the event that the fuel valve is left open while tran sp rting or towing this Bris ter Utility Vehicle it is www.bristers.com sible that fuel has leaked down into th e cylinder ity. f this has occurred the engine wi l not start.
  • Page 21 Supp lement: Brister 4x4 Utility Vehicle CW-413, T W-413 This supplement covers the addi tional features, ration and maintenance of th e Brister Utility Vehicle Maint enance raulic Brakes – Hydraulic Brakes use fluid atures pressur e to transfer the braking force to the wheels. ore riving the vehicle each day, check the fluid •...
  • Page 22 (part #20843). Torque the oil drain plug to 9 1. Remove the oil drain plug located on the ft*lbs. bottom of the gearcase using a ¼” hex key Remove the oil fill plug using a 5/16” hex key nch. wrench. 2.

  • Page 23: Cable Adjustment

    Brister’s Utility Vehicle Shifter Trouble Shooting Notice: Always check transmission oil level. Dip a clean screwdriver straight down in the fill hole to t he bottom of the gear case. There should be about 2 ½ inches of oil on the screw diver. If oil ds to be added, use SAE 30 motor oil.
  • Page 24 icles with serial number less than 17063. (See brass tag near top of left rear shock absorber) Loose n the cable adjusters behind the dash board. (photo on left) 2. Place the selector lever on the dashboard in forward. 3. Make sure the transmission is fully engaged in forward. The top of the shift lever on the transmission should be toward the passenger side.
  • Page 25 Vehicles with serial number greater than 17063. (See brass tag near top of left rear shock absor e b r) 1. Put the vehicle in neutral. 2. Loosen the cable adjusters behind the dash board. (photo on left) 3. Make sure the selector lever on the dashboard is in neutral. 4.
  • Page 26 Section 6 Troubleshooting...
  • Page 27 Tro b u le Shooting Steerin g feels funn y/pulling to one side/hard to steer (Call normally for 4wd) ba le Cause: • One side may still be engaged in 4wd with the switch off. Possible Remedy: • Put unit in reverse and back up straight a few feet to get the axle to release.
  • Page 28 Gas in oil Probable Cause • Unit may have been transported with fuel valve on. Every time a unit is transported on a trailer or in a truck the fuel must be shut off using the shut off valv e on th e side of the engine.

  • Page 29: Wiring Diagram

    Wiring Diagram All Mod...

  • Page 30: Terminal Block Wiring

    Terminal Block Wiring...
  • Page 31 Section 7 Parts Brister’s 2-wheel drive Utility Vehicle Parts Breakdown...

  • Page 35: Pars List

    5/16 x 2-1/4" USS Socket Head bolt 50007 nut, 5/16 nylock 50702 bent washer 5/16 45413 bumper, CW - black 45432 Bumper, Trail Wagon – Black 50167 bolt, 5/16 x 2 50007 nut, 5/16 nylock 50702 bent washer 5/16 70208...
  • Page 36 Reference Part Quantity Part Description – 2WD Models Number Number Required 50060 Lug nuts, ½” 70301 Shock, Heavy duty #1 50400 Bolt, 10 mm x 40mm 50065 Nut, 10mm nylock 30122 Rim/Tire Assembly, UTV 22/9-10” Left 30123 Rim/Tire Assembly, UTV 2 2/9-10”...
  • Page 37 Reference Part Quantity Part Description – 2WD Models Number Number Required 11180 Brake Rod, with clevis 50215 bolt, 3/8 x 1 ¼ 50010 nut, 3/8” nylock 50801 cotter pin 1/8” x 1 45417 parking brake ba r, CW – black 50806 Clevis, 5/16 rod end 50170...
  • Page 38 Reference Part Quantity Part Description – 2WD Models Number umbe Required 45414 Battery strap, CW (8 ¾”) – black 50083 bolt, ¼ x 7 ½ 50002 nut, ¼” wing 70055 Light Switch 70052 Key Switch 70060 Key, 1 pair 70080 Accessory Plug 70081 Accessory Plug cap...
  • Page 39 Reference Part Quantity Part Description – 2WD Models Number Number Required 55060 Fuel Tank 55063 Elbow Fuel Inlet w/ #200 Mesh Screen 55062 Fuel Fitting Grommet 55061 Cap Fuel Tank 50163 bolt, 5/16 x 3/4" NC 50706 Washer, 5/16 fender 50703 Washer, 5/16 lock 10754...
  • Page 40 Reference Part Quantity Part Description - 2WD Models Number Number Required 18312 Roof, green 18301 Roof, Red 18351 Roof, Camo 18391 Roof, Top Vinyl Trim 18390 Roof, Hardware bolt kit 50847 Clamp-Tube-vinyl coated 1-3/4" 50087 bolt, 1/4" x 1 50718 Washer, ¼”...
  • Page 41 Reference Part Quantity Part Description - 2WD Models Number Number Required 50722 1/2" Lock Washer 50721 1/2" Uss Flat Washer Key stock – Special Key – 3/16” X 1/4” X 31/2” 45431 Tension Mount Engine, CW - Black 50157 5/16x 3/4" Bolt Hex Hd NF 50703 5/16"...
  • Page 42 Reference Part Quantity Part Description - 2WD Models Number Number Required 11086 Differential Control Assembly w/ cable all models after serial # 22187 11083 Knob 11091 Differential Control Cable Only used on all models after serial # 22187 50053 nut, #10-24 Keps nut 50616 screw, #10-24 X 3/4"...
  • Page 43 Brister 265cc Utility Vehicle Parts Breakdown...
  • Page 47 5/16 x 2-1/4" USS Socket Head bolt 50007 nut, 5/16 nylock 50702 bent washer 5/16 45413 bumper, CW - black 45432 Bumper, Trail Wagon – Black 50167 bolt, 5/16 x 2 50007 nut, 5/16 nylock 50702 bent washer 5/16 70208...
  • Page 48 Reference Part Quantity Part Description – 265cc 2WD Models Number umbe Required 30623 dust cap 30622 castle nut, 1” 30621 cotter pin 50060 Lug nuts, ½” 70301 Shock, Heavy duty #1 50400 Bolt, 10 mm x 40mm 50065 Nut, 10mm nylock 30142 Rim/Tire Assembly, UTV 22/11-8”...
  • Page 49 Reference Part Quantity Part Description – 265cc 2WD Models Number Number Required 11180 Brake Rod, with clevis 50215 bolt, 3/8 x 1 ¼ 50010 nut, 3/8” nylock 50801 cotter pin 1/8” x 1 45417 parking brake bar, CW – black 50806 Clevis, 5/16 rod end 50170...
  • Page 50 Reference Part Quantity Part Description – 265cc 2WD Models Number Number Required 45414 Battery strap, CW (8 ¾”) – black 50083 bolt, ¼ x 7 ½ 50002 nut, ¼” wing 70055 Light Switch 70052 Key Switch 70060 Key, 1 pair 70080 Accessory Plug 70081...
  • Page 51 Reference Part Quantity Part Description – 265cc 2WD Models Number Number Required 10754 Seatback 43 ½ x 17 ½ 50619 #14 X 1-3/4” Pan head-Tapping screw 10803 Headrest – UTV 9 x 6 ½ 50085 bolt, ¼ x 1 ½” 10755 Seat bottom 43 ½...
  • Page 52 Reference Part Quantity Part Descri ptio n - 265cc 2WD Models Number Number Required 20016 Engine, Subaru 265cc 50202 3/8-16 x 1 3/4" Hex Hd Bolt 50740 3/8" Flat washer, USS 20869 Dana Transaxle – 265 mode 70057 Neutral Safety Switch 51500 Shims –...
  • Page 53 Reference Part Quantity Part Descri ption - 265cc 2WD Models Number Number Required 18012 shifter cable lever, 50084 1/4-20 x 3/4" Hex Hd Bolt 50000 1/4" Keps Nut 50715 1/4" Flatwasher, USS 11103 Brake Cables 50150 5/16-18 x 1" Hex Hd Bolt 50007 5/16"...
  • Page 54 Brister 4-wheel drive Utility Vehicle Parts Breakdown...
  • Page 58 5/16 x 2-1/4" USS Socket Head bolt 50007 nut, 5/16 nylock 50702 bent washer 5 45413 Bumper, CW - black 45433 Bumper, Trail Wagon – with grill guard - Black 50167 bolt, 5/16 x 2 50007 nut, 5/16 nylock 50702 bent washer 5/16 70208...
  • Page 59 Reference Part Quantity Part Description – 4x4models Number Numb Required 30124 Rim/Tire Assembly, UTV 22/11-10" Left 30125 Rim/Tire Assembly, UTV 22/11-10 " Right 30480 Wheel rim, 10" x 6" 30194 Tire, Pathfinder 22/11-10" 20851 CV half shaft (axle) – (Left or Right) 20868 Boot CV 20839...
  • Page 60 Reference Part Quantity Part Description – 4x4models Number Number Required 11123 master cylinder 50167 bolt, 5/16 x 2 50005 Nut, 5/16 keps 50806 Clevis, 5/16 rod end 50077 Nut, 5/16" Hex SAE 11124 brake caliper 11167 brake pads (2 pads required per wheel) 11168 brake pins 11169...
  • Page 61 Reference Part Quantity Part Description – 4x4models Number Number Required 45414 Battery strap, CW (8 3/4") - black 50083 bolt, 1/4 x 7 1/2 50002 nut, 1/4" wing 70055 Light Switch / 4x4 switch 70052 Key Switch 70060 Key, 1 pair 70080 Accessory Plug 70081...
  • Page 62 Reference Part Quantity Part Description – 4x4models Number Number Required 10754 Seatback 43 1/2 x 17 1/2 50619 #14 X 1-3/4" Pan head-Tapping screw 10803 Headrest - UTV 9 x 6 1/2 50085 bolt, 1/4 x 1 1/2" 10755 Seat bottom 43 1/2 x 17 1/2 45416 seat bar, CW (17 1/2") - black 50609...
  • Page 63 Reference Part Quantity Part Description – 4x4models Number Number Required 45502 Swing arm, CW - Black 4x4 45430 Motor Plate, CW - Black 18023 Throttle Guard Laser 50086 1/4-20 x 1 1/4" Hex Hd Bolt 50082 1/4-20 x 2 1/4" Hex Hd Bolt 50000 1/4"...
  • Page 64 Reference Part Quantity Part Description – 4x4models Number Number Required 11804 Spring #80704 Black painted 65500 fuel hose 3/16" dia - 24" 50849 hose clamps - small 18313 Belt Guard Plastic UTV - Front 18314 Belt Guard Plastic UTV - Rear 18315 Belt Guard Plastic UTV - Bottom 50624...
  • Page 65 BDM’s One (1) - year Limited Warranty Policy. To locate the authorized dealer nearest you please call BDM customer service at 1-866-646-5278 or (985)-748-4889, or visit our website at www.bristers.com for more information. This One (1) - Year Limited Warranty in not transferable and can only be used by the original owner.
  • Page 66 Design & Manufacturing directly. Brister’s Dealer: To locate the authorized dealer nearest you please call Brister’s Design & Mfg. customer service at 1-866-646-5278 or (985)-748-4889, visit our website www.bristers.com or contact your place of purchase. Mail: Customer Support c/o Brister’s Design & Manufacturing Co., LLC.

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