Stels UTV800 Owner's Manual

4x4es

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UTV800

4×4ES

OWNER'S MANUAL

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Page 1 UTV800 4×4ES OWNER’S MANUAL...
Page 2 WARNING ● Operation of this UTV by children under the age of 16 Increase of the risk of severe injury or death. ● An adult supervision required always. ● Never permit children under age 16 to operate this UTV. ● Overloading can adversely affect vehicle handling. ●...
Page 3 FOREWORD Dear Customer, Congratulations and thank you for your purchase our All-Terrain Vehicle (UTV). It was designed and built to provide you with a superior ride, comfort, reliability, utility and safety. Your UTV was designed as a recreational UTV, for off-road use by one rider only. This Operator’s Manual is furnished to familiarize the operator of all proper operating procedures.
Page 4 All of the information in this manual is based on the latest product data and specifications available at the time of printing, the manufacturers of UTV’s reserve the right to make product changes and improvements, which may effect the illustrations or explanations without notice. If you have any other questions regarding our UTV’s operation or maintenance, any authorized dealer can readily answer them.
Page 5: Table Of Contents
Table of Contents PAY ATTENTION TO YOUR SAFETY· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10 GUIDELINES ON SAFE DRIVING·...
Page 6 CONTROL FUNCTIONS· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·32 Mains switch·...
Page 7 Gear Shift Adjustment· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 61 Auxiliary DC jack·...
Page 8 Accessories and loading· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·79 Loading·...
Page 9 Battery· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 102 Battery maintenance·...
Page 10 Valve Adjustment· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 126 Gearbox Oil·...
Page 11: Pay Attention To Your Safety
PAY ATTENTION TO YOUR SAFETY This section presents some of the most important information and recommendations to help you ride your UTV safely. Please take a few moments to read these pages. This section also includes information about the location of safety labels on your UTV.
Page 12 Ride off-road only Your UTV is designed and manufactured for off-road use only. The tires are not made for pavement, and the UTV does not have turn signals and other features required for use on public roads. If you need to cross a paved or public road, get off and walk your UTV across.
Page 13 Ride within your limits Pushing limits is another major cause of UTV accidents. Never ride beyond your personal abilities or faster than conditions warrant. Remember that alcohol, drugs, fatigue, and inattention can significantly reduce your ability to make good judgments and ride safely. Don’t drink and ride Alcohol and riding don’t mix.
Page 14: Guidelines On Safe Driving
GUIDELINES ON SAFE DRIVING 1． when approaching corners or bends to reduce speed. Upon the completion of turn, may gradually increase the speed. 2． when crossing the vehicles parked in front of, to be very careful. Because the driver of the vehicle may be invisible to you and the door opened, the forward block in your way.
Page 15: Introduction
INTRODUCTION Congratulations on your purchase of the UTV. It represents the result of many years of experience in the production of fine sporting, touring, and pace-setting racing vehicles. With the purchase of this, you can now appreciate the high degree of craftsmanship and reliability that have made a leader in these fields.
Page 16: Important Manual Information
IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! ! WARNING: Failure to follow WARNING instructions could result in severe injury or death to the vehicle operator, a bystander or a person inspecting or repairing the vehicle.
Page 17: Important Notice
IMPORTANT NOTICE This vehicle is designed and manufactured for off-road use only. It is illegal ● to operate this vehicle on any public street, road, or highway. Such use is prohibited by law. Check the laws and regulations in force before choosing where to operate ●...
Page 18: How To Identify Your Utv
HOW TO IDENTIFY YOUR UTV The main components of your vehicle(engine and frame) are identified by different serial numbers. It may sometimes become necessary to locate these numbers for warranty purposes or to trace your vehicle in the event of loss. These numbers are required by the authorized UTV dealer to complete warranty claims properly.
Page 19: Engine And Vehicle Identification Number Location
Engine and Vehicle Identification Number Location TYPICAL 1.EIN(Engine Identification Number on left side/under of the crankcase) 2.VIN(Vehicle Identification Number on right side/under of the frame ) - 18 -...
Page 20: Location Of The Warning And Specification Labels
LOCATION OF THE WARNING AND SPECIFICATION LABELS -19-...
Page 22 Read and understand all of the labels on you vehicle. They contain important information for safe and proper operation of your vehicle. Never remove any labels from your vehicle. If a label becomes difficult to read or comes off, a replacement label is available from your dealer. （1）...
Page 23 （2）（3） -21-...
Page 25 （5）（6）（4） -22-...
Page 26 （7）（8）（9） -23-...
Page 27: Safety Information
SAFETY INFORMATION This off-highway utility vehicle handles differently from other vehicles including cars and UTVs. SEVERE INJURY OR DEATH can result if you do not follow these instructions: Read this manual and all labels carefully and follow the operating procedures ●...
Page 28 Never consume alcohol or drugs before or while operating this vehicle. ● Never operate at speeds too fast for your skills or the conditions. Always go at a ● speed that is proper for the terrain, visibility, operating conditions, and your experience.
Page 29 could be injured if they are in the way of the steering wheel spokes. Always go slowly and be extra careful when operating on unfamiliar terrain. Always ● be alert to changing terrain conditions when driving the vehicle. Never operate on excessively rough, slippery, or loose terrain until you have ●...
Page 30 Always check terrain carefully before going down hills. Go as slowly as possible. ● Never go down a hill at high speed. Always check for obstacles before operating in a new area. ● Never operate the vehicle in fast flowing water or water deeper than the ●...
Page 31 ! WARNING transporting the vehicle in another vehicle, be sure it is kept in an upright POTENTIAL HAZARD position. or other sources of ignition Improper handling of gasoline. such as the pilot lights of water WHAT CAN HAPPEN heaters Otherwise, fuel may leak out Gasoline can catch fire and you of the carburetor or fuel tank.
Page 32 ! WARNING POTENTIAL HAZARD Starting or running the engine in a closed area. WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. HOW TO AVOID THE HAZARD Always operate your vehicle in an area with adequate ventilation.
Page 33: Description And Vehicle Idntification
DESCRIPTION AND VEHICLE IDNTIFICATION 1. Headlights 12. Cargo bed release levers 2. Front shock absorber assembly adjusting ring 13. Spark arrester 3. Brake fluid reservoir 14. Passenger seat belt 4. Air filter element (engine and air intake duct) 15. Passenger seat 5.
Page 34 NOTE: The vehicle you have purchased may differ slightly from those shown in the figures of this manual. 20 Light switch 21 Hazard warning lamp switch 22 Steering wheel 23 Auxiliary DC jack 24 Mains switch 25 2WD-4WD switch 26 Indicators & Display 27 Parking brake lever 28 Accelerator pedal 29 Brake pedal...
Page 35: Control Functions
CONTROL FUNCTIONS Mains switch All electrical circuits are supplied with power, and the headlights and taillights come on when the light switch is on. All electrical circuits are switched off. The key can be removed in this position. The electric starter is engaged by turning and holding the key in this position.
Page 36: Switches
Switches CAUTION Do not operate the electric starter ● continuously for more than 5 seconds, or starter damage could occur. Wait at least 5 seconds between each operation of the electric starter to let it cool. Do not turn the key to the “D” ●...
Page 37: On-Command Four-Wheel Drive And Differential Gear Lock Switches
On–Command four-wheel switch “2WD”/“4WD”and a differential drive and differential gear gear lock switch “4WD”/“LOCK”. Select lock switches the appropriate drive according to terrain and conditions. 1.On-Command four-wheel-drive switch “2WD”/“4WD” 2.On-Command differential gear lock switch “4WD”/“LOCK” This vehicle is equipped with an On-Command four-wheel-drive - 34 -...
Page 38: Indicators & Display
Indicators & Display - 35 -...
Page 39: Odometer
Odometer the hour and minute. Then adjust hours When selected, the odometer registers or minute by ascending or descending by continuing press button of mode of total distance traveled in miles while the “ Set/Reset” ,user can clean the record ignition is ON A.
Page 40 Other indicator light Km/h & mph mode change Coolant temperature indicator light Press the MODE button, choose either “ ” Km/h or mph needed. It indicates the temperature of coolant, If the temperature is above 102℃,stop engine immediately. Check coolant lever and add if low, see authorized dealer if temperature indicator stay on and overflow tank is full of coolant.
Page 41 ” Check engine indicator lamp“ After turning the ignition switch on, the lamp shall be on, and the lamp shall be off after starting the engine. If the lamp is on while the engine working, it indicates that the system failed. When some electric jet parts are found fault, check engine indicator lamp will also be ON, the vehicle still can keep...
Page 42: Accelerator Pedal
Before starting the engine, check the Accelerator pedal accelerator pedal to be sure it is Press the accelerator pedal down to operating smoothly. Make sure the increase engine speed. Spring accelerator pedal fully returns to the idle position as soon as it is released. pressure returns the pedal to the rest position when released.
Page 43: Brake Pedal
Brake pedal Parking brake lever Press the brake pedal to slow or stop Pull the parking lever up so that the unit the vehicle. can engage park brake. To release the unit, press button in the front end of parking lever, then push the parking lever to the bottom.
Page 44: Drive Select Lever
Drive select lever The drive select lever is used to shift your vehicle the L—H—N—R—P and reverse positions. CAUTION ● Never start the vehicle at N or R lever. ● Stop the vehicle fully when shifting to reverse. - 66 -...
Page 45: Fuel Tank Cap
Fuel tank cap Remove the tank cap by turning it counterclockwise. 1. Driver seat 2. Passenger seat 3. Seat lock lever (x2) 1. Fuel tank cap Seats To remove a seat, pull its seat lock lever upward, lift the front of the seat, and then slide the seat forward and up.
Page 46: Seat Belts
To install a seat, insert the projections Seat belts on the rear of the seat into the holders This vehicle is equipped with and push down on the seat at the front. three-point seat belts for both the operator and passenger. Always wear ! WARNING the seat belt while riding in the vehicle.
Page 47 sure the belt is not twisted and is not across your hips. caught on any portion of the vehicle, 4. Position the shoulder belt over your your clothing, or any equipment you shoulder and across your chest. The are carrying. shoulder belt should fit against your 2.
Page 48: Glove Compartment
Glove compartment ! WARNING CAUTION: POTENTLAL HAZARD To protect from damage, do not put Not wearing the seat belt. metal products, like tools or sharply Wearing the seat belt improperly. edged products directly in the glove WHAT CAN HAPPEN compartment. If they must be stored, There is increased risk of being wrap them in appropriate cushion killed or seriously injured in an...
Page 49: Cargo Bed
Cargo bed Opening and closing the tailgate 1. Cargo bed 2. Tailgate 1. Tailgate 2. Latch (x2) 3. Cargo hook (x4) To open Unhook the latches, and then lower the tailgate. To close Place the tailgate in the original position, and then hook the latches.
Page 50: Lifting And Lowering The Cargo Bed
Lifting and lowering the Maximum load limit: 50kg (110lbs) cargo bed ! WARNING POTENTLAL HAZARD Pinch points. WHAT CAN HAPPEN You or someone else could be pinched between the cargo bed and Cargo bed release lever To lift the frame when the bed is being Push down the cargo bed release lever lowered.
Page 51 ! WARNING ! WARNING POTENTLAL HAZARD POTENTLAL HAZARD Overloading the cargo bed Carrying a passenger in the cargo WHAT CAN HAPPEN Could cause changes in vehicle WHAT CAN HAPPEN handling which could lead to an The passenger could fall, be thrown accident.
Page 52: Trailer Hitch Bracket
This vehicle is equipped with a 5cm (2in) Before each drive, you need to make receiver bracket for a standard trailer sure you and your UTV800 are both hitch. Trailer towing equipment can be ready to drive. To help get you prepared, obtained at an dealer.
Page 53 can reduce the chance of injury then ! WARNING you drive. The following suggestions Operating this without wearing an will help you choose the proper driving approved motorcycle helmet, eye gear. protection and protective clothing could Helmets and eyes protection increase your chances of head or eye Your helmet is your most important injury, possibly death in the event of...
Page 54 Never driven other UTVs 800, take time to support with your hands to ground become familiar with hoe this UTV800 when the off highway recreational in a safe area to build your skills. Do not vehicle will turn over.
Page 55 UTV800. consult your to be sure it is safe to ! WARNING operate a vehicle after taking A child driving a UTV800 that is not medication. recommended for his/her age could ! WARNING lose UTV800 control and result in server injury or death.
Page 56 If your UTV800 has overturned or has Pre-drive Inspection been involved in a collision, do not drive Check the following items before you...
Page 57 ● Use a gauge to check the air Leaks, Loose Part pressure. Adjust if needed. Also look Walk around your UTV800 and look for signs of damages or excessive for anything that appears unusual, wear. such as a leak or loose cable.
Page 58 sticking, and snaps back sure engine stops. ● automatically when it is released. Steering Wheel ● Clutch pedal Check that the wheels turn properly Check the free play of clutch pedal as you turn the steering wheel. ● and adjust if needed. Press the clutch Cable cable to make sure it moves Check the cable housing for wear.
Page 59: Safe Driving Precautions
In many states it is and control of the UTV800, and may illegal to operate UTV800 on public cause the vehicle to go out of control.
Page 60 Operating this UTV800 on paced steering wheel and both feet on surfaces may seriously affect controls. When driving your UTV800, it handling and control of the UTV800, is important to maintain your balance and may cause the vehicle to go out and control of the UTV800.
Page 61 Operating this UTV800 at excessive Always keep both hands on the speeds increases your changes of steering wheel and both feet on the foot losing control of the UTV800, which can controls of your UTV800 during result in an accident. operation.
Page 62 Failure to take extra care when accident, including an overturn. operating this UTV800 on unfamiliar Do not operate on excessively rough, terrain could result in the UTV800, slippery or loose terrain until you have overturning or going out of control. learned and practiced the skills...
Page 63: Parking Adjustment
Parking Adjustment Do Not Perform Stunts You should always operate your UTV800 in a safe and reasonable manner. When driving always keep all wheels on the ground. ! WARNING Attempting wheelies and other stunts increases the chance of an accident, including an overturn.
Page 64: Gear Shift Adjustment
● Pull the park brake lever up so that the unit can engage park brake. ● To release the unit, press button on front end of parking lever then push the parking lever to the bottom. ● Adjust the parking cable if necessary. Gear Shift Adjustment Before operating the vehicle, check the shift lever as to change gearshift from 1...
Page 65 The first month is most important in the UTV800 and tighten the seat belts. life of your vehicle. Proper operation ● Testing the UTV800 in an open place during this break-in period will help at the beginning to learn how to start, assure maximum life and performance turn and stop.
Page 67: Auxiliary Dc Jack
Auxiliary DC jack 1. Set the light switch to “OFF”. The auxiliary DC jack is located at the 2. Start the engine. right side of the front panel. 3. Open the auxiliary DC jack cap, and The auxiliary DC jack can be used for then insert the accessory power plug suitable work lights, radios, etc.
Page 68: Pre-Operation Checks
PRE-OPERATION CHECKS 4. When the auxiliary DC jack is not Before using this vehicle, check the being used, cover it with the cap. following points CAUTION: ! WARNING Do not use accessories requiring ● POTENTLAL HAZARD move than the above maximum Failure to inspect the vehicle before capacity.
Page 69: Front And Rear Brakes
Front and rear brakes ! WARNING Brake fluid leakage POTENTLAL HAZARD Check to see if any brake fluid is Driving with improperly operating leaking out of the pipe joints or the brakes. brake fluid reservoir. Apply the brakes WHAT CAN HAPPEN firmly for one minute.
Page 70: Fuel
Fuel Gasohol Make sure there is sufficient gasoline There are two types of gasohol; gasohol in the tank. containing ethanol and that containing CAUTION: methanol. Gasohol containing ethanol can be used if ethanol content does not Use only unleaded gasoline. The use exceed 10%.
Page 71: Accelerator Pedal
Accelerator pedal ! WARNING Check to see that the accelerator pedal POTENTLAL HAZARD operates correctly. It must operate Improper care when refueling. smoothly and fully spring back to the WHAT CAN HAPPEN idle position when released. Have an Fuel can spill, which can cause a dealer repair as necessary for proper fire and severe injury.
Page 72: Steering
Steering Lights Park on level ground. Turn the Check the headlights and tail/brake steering wheel right and left. Check lights to make sure they are in working for excessive free play, abnormal condition. Repair as necessary for noises, or a rough feeling. Have an proper operation.
Page 73 Front & Rear WHAT CAN HAPPEN 25 kPa (0.25 kgf/cm , 10psi) Use of improper tires on this Check and adjust tire pressures vehicle, or operation of this vehicle when the tires are cold. with improper or uneven tire Tire pressures must be equal on both pressure, may cause loss of sides.
Page 74 How to measure tire pressure Set pressure with tires cold. Use the tire pressure gauge. Set tire pressures to the following NOTE: specifications: The tire pressure gauge is included Recommended as standard equipment. Make two Minimum Maximum pressure measurements of the tire pressure 25 kPa Front 22 kPa...
Page 75: Tire Wear Limit
OPERATION ! WARNING POTENTLAL HAZARD Operating vehicle without being familiar with all controls. WHAT CAN HAPPEN Loss of control, which could cause 1. Tire pressure gauge an accident or injury. Tire wear limit When the tire groove decreases to 3 HOW TO AVOID THE HAZARD mm (0.12 in) due to wear, replace the Read the Owner’s Manual carefully.
Page 76: Jump-Starting
Jump-starting positive lead to the positive terminal Jump-starting the vehicle should be of the charged battery. avoided. The battery should be removed and charged instead. however, if the vehicle must be jump-started, proceed as follows. Turn the key to “OFF”. Open the hood.
Page 77: Warming Up
! WARNING 7. After the engine starts, disconnect the negative lead of the jumper cable Do nor connect the negative lead from the vehicle and charged battery, of the jumper cable to the negative and then disconnect the positive lead terminal of the battery in the of the jumper cable from the charged vehicle.
Page 78: Shifting
Shifting: Neutral to Reverse 1. Stop the vehicle. Keep your foot off the accelerator pedal. 2. Apply the brake pedal. 3. Shift from neutral to reverse or vice versa by moving the drive select lever along the shift guide. 4. Check behind for people or NOTE: obstacles, then release the brake When in reverse, the revere...
Page 79: Engine Break
Engine break-in ! WARNING There is never a more important period POTENTLAL HAZARD in the life of your vehicle than the period Improperly operating in reverse. WHAT CAN HAPPEN between zero and 20 hours. You could hit an obstacle or For this reason, we ask that you person behind you, resulting in carefully read the following material.
Page 80 be avoided. However, momentary vehicle from time to time. Do not (2-3 seconds maximum) full throttle operate it at one set throttle position. operation under load does not harm 10-20 hours: the engine. Avoid prolonged operation above 3/4 Each full throttle acceleration throttle.
Page 81: Parking On A Slope
Parking on a slope ! WARNING POTENTLAL HAZARD Parking on a hill or other incline. WHAT CAN HAPPEN The vehicle could roll out of control, increasing the chance of an accident. HOW TO AVOID THE HAZARD Avoid parking on hills or other 1.
Page 82: Accessories And Loading
NOTE: accessories may also be available on the Like many other vehicles, the parking market. However, it is not possible for brake acts on the rear wheels. For the to test all control over the quality or parking brake to have the effect of suitability of them.
Page 83: Loading
that limits your view. designed for use with a 5 cm (2in) Use extra caution when driving a receiver. ● vehicle with accessories. The vehicle Do not exceed the maximum tongue ● may handle differently than it does weight. You can measure tongue weight without accessories.
Page 84 Make sure cargo in the trailer cannot weight affects the stability and handling move around. of the vehicle. A shifting load can cause an accident. ! WARNING Make sure the load does not ● POTENTIAL HAZARD interfere with controls or your ability to Overloading this vehicle or carrying or see where you are going.
Page 85 DRIVING YOUR VEHICLE ! WARNING GETTING TO KNOW YOUR VEHICLE POTENTLAL HAZARD This off-highway utility vehicle will Not wearing the seat belt. handle and maneuver differently from Wearing the seat belt improperly. an ordinary passenger car or other WHAT CAN HAPPEN vehicle.
Page 86 ! WARNING ! WARNING POTENTIAL HAZARD POTENTIAL HAZARD Overloading this vehicle orcarrying Carrying a passenger in the cargo or towing cargo improperly. bed. WHAT CAN HAPPEN WHAT CAN HAPPEN Could cause changes in vehicle The passenger could fall or be hand-ling which could lead to an struck by objects in the cargo bed.
Page 87 The driver and passenger must Operating without eye protection can always wear a seat belt and an result in an accident and increases your approved motorcycle helmet. Also chances of a severe injury in the event wear eye protection and protective of an accident.
Page 88 TURNING YOUR VEHICLE It is possible for the vehicle to roll over or go out of control if you attempt sharp, high-speed turns. You should also be careful making sharp turns on rough terrain. Do not attempt to turn around or make abrupt maneuvers on slopes.
Page 89: Braking
Braking could wrench the steering wheel Braking ability is affected by the type of around, and your thumbs or fingers terrain. In most cases, gradually could be injured if they are in the way application of the brakes is more of the steering wheel spokes.
Page 90 Choose carefully which hills you attempt increases your chance of rollover. to climb. Avoid hills with slippery Practice first on gentle slopes before surfaces or ones where you will not be attempting steeper hills. Always able to see far enough ahead of you. check the terrain carefully before ! WARNING attempting any hill.
Page 91: Going Downhill
If you start to lose traction or Going downhill momentum when climbing, and you Check the terrain carefully before going decide you will be unable to continue, down a hill. When possible, choose a use the brakes to come to a stop. Do path that lets you drive your vehicle not attempt to turn the vehicle around.
Page 92 On most slopes, this will let you use ! WARNING engine braking to help you go downhill POTENTIAL HAZARD slowly. Go as slowly as possible. If you Going down a hill improperly. are starting to go too fast, apply the WHAT CAN HAPPEN brakes gently.
Page 93: Crossing Through Shallow
Crossing through shallow ! WARNING WATER POTENTIAL HAZARD Operating this vehicle through deep If you must cross shallow, slow or fast-flowing water. moving water up to the depth of the WHAT CAN HAPPEN vehicle’s floorboards, choose your Loss of control, which could result in path carefully to avoid sharp drop-offs, an accident including overturn, large rocks, or slippery surfaces that...
Page 94 CAUTION: ! WARNING After riding your vehicle in water, be POTENTIAL HAZARD sure to drain the trapped water by Failure to use extra care when removing the check hose at the operating this vehicle on unfamiliar bottom of the air filter case , the drive terrain.
Page 95: Encountering Obstacles On The Trail
Riding in brush or wooded areas When operating in areas with brush or trees, watch carefully on both sides and above the vehicle for obstacles such as branches that the vehicle might hit, causing an accident, or for brush that might enter the vehicle as you pass and strike the driver or passenger.
Page 96 inspect the area thoroughly. Look ! WARNING from both your approach side and the POTENTIAL HAZARD exit side. If you believe you can Improperly operating over obstacles continue safely, decide the path that WHAT CAN HAPPEN will allow you to a right angle as Could cause loss of control or a possible to minimize vehicle tipping.
Page 97: Periodic Maintenance And Adjustment
PERIODIC MAINTENANCE ! WARNING AND ADJUSTMENT POTENTIAL HAZARD Servicing an engine while it is Periodic inspection, adjustment and running. lubrication will keep your vehicle in the WHAT CAN HAPPEN safest and most efficient condition Moving parts can catch clothing or possible.
Page 98: Periodic Maintenance/Lubrication
Periodic maintenance/lubrication NOTE : For vehicles not equipped with an odometer or hour meter, follow the month maintenance intervals. ● For vehicles equipped with an odometer or an hour meter, follow the km(mi) or hours maintenance ● intervals. However, keep in mind that if the vehicle isn’t used for a long period of time, the month maintenance intervals should be followed.
Page 99 INTIAL EVERY Whichever month ITEM ROUTINE Comes first 1,200 2,400 2,400 4,800 → (mi) (200) (750) (1,500) (1,500) (3,000) hours Check operation/brake pad wear/fluid leakage. ● ○ ○ ○ ○ ○ Front brake* Correct if necessary. Replace pads if worn to the limit. ●...
Page 100: Hood
HOOD To open Unhook the hood latches, and then slowly tilt the hood up until it stops. 1. Hood To close Lower the hood slowly to its original position, and then hook the hood latches. 1. Latch (x2) Secure projections ① on the underside of the hood into slots ②...
Page 101: Console
CAUTION: Console Make sure that all cables and wires ● To install are in place when closing the hood. 1. Place the console in its original Do not drive the vehicle with the ● position. hood open, unlatched, or removed. 2.
Page 102: Changing Oil
Gear Case Oil Type Hypoid gear oil Viscosity SAE 80 (weight) Shaft drive oil of original （1） Suggested oil manufacturer or equivalent Changing Oil Changing the oil with the gear case at （2） normal operating temperature to assure complete and rapid draining. 1、Park the UTV on level ground.
Page 103: Rear Knuckle Upper And Lower Pivot Lubrication
Rear knuckle upper and lower Steering shaft lubrication pivot lubrication Lubricate the pivot points. Lubricate the knuckle upper and lower pivots with a grease gun. Recommended lubricant: Lithium-soap-based grease (all purpose grease) Recommended lubricant: Lithium-soap-based grease - 100 -...
Page 104: Wheel Removal
Wheel removal Wheel installation 1. Loosen the wheel nuts. 1 、 Install the wheel and the nuts. Elevate the vehicle and place a NOTE: suitable stand under the frame. The arrow mark on the tire must point 3. Remove the nuts from the wheel. ●...
Page 105: Battery
Battery This vehicle is equipped with a sealed-type battery. Therefore it is not necessary to check the electrolyte or add distilled water in the battery. If the battery seems to have discharged, consult dealer. CAUTION: 1. Tapered nut Do not try to remove the sealing 2.
Page 106: Battery Maintenance
Battery maintenance acid in battery electrolyte. Batteries produce explosive gases. 1. When the vehicle is not used for a HOW TO AVOID THE HAZARD month or longer, remove the battery Avoid contact with skin, eyes or and store it in a cool, dark place. clothing.
Page 107 ! WARNING short circuit or overload). If something electrical on your UTV Do nor connect the negative lead of stops working, the first thing you should the jumper cable to the negative check for is a blown fuse (1). terminal of the battery in the vehicle. Check all the fuses before looking Be especially careful not to: ●...
Page 108 If a fuse blows Fuse replacement All of the electrical circuits on your UTV The main fuse and the fuse boa are have fuses to protect them from located under the hood. If a fuse is blown, turn off the main switch and damage caused by excess current flow ) install a new fuse of the specified short circuit or overload).
Page 109: Recommended Fuses
Recommended Fuses NOTE : Replacing a fuse with one that has a higher rating greatly increases the chance of damage to the electrical system. Tail/brake light bulb replacement If a tail/brake light bulb burns out, （1）Speed power、rear brake light、headlight and fan power replace it as follows: （2）ECU and speed sensor...
Page 110 1. Panel A 1、Quick fastener (x8) 2、Bolt (x2) 3、Panel A 2. Push the defective bulb in and turn it counterclockwise to remove it from the bulb holder. 3. Push a new bulb in and turn it clockwise to install in the bulb holder. 4.
Page 111: Troubleshooting
quick fasteners and bolts, and then quick, easy procedure for making check. tighten the bolts to the specified If your vehicle requires any repair, take torque. it to dealer. The skilled technicians, at dealership Tightening torque: have the tools, experience, and Panel bolt: know-how to properly service your 6.5 N.m (0.65 m.kgf, 4.7 ft,lbf)
Page 112 ! WARNING POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame. WHAT CAN HAPPEN Fuel can ignite or explode, causing severe injury or property damage. HOW TO AVOID THE HAZARD Do not smoke when checking the fuel system.
Page 113 Troubleshooting charts Starting problems or poor engine performance 1.Fuel Check the Remove the fuel hose Fuel pump There is fuel. No fuel. fuel flow. from the fuel pump. is clogged. Check if there is fuel in the fuel tank. No fuel. Supply fuel.
Page 114: Engine Overheating
Engine overheating ! WARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator still hot. WHAT CAN HAPPEN You can be burned by hot fluid and steam blown out under pressure. HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap. Always use a thick rag over the cap.
Page 115 Ask an dealer Wait until the to inspect engine has cooled. Level is low, and repair the check the cooling system. cooling system for leakage. Check the coolant Wait until the Add coolant. Wait until the level in the engine has cooled. (See NOTE.) engine has cooled.
Page 116: Cleaning And Storage
CLEANING AND greasy, apply degreaser with a paint STORAGE brush. Do not apply degreaser to the CLENANING wheel axles. 3. Rinse the dirt and degreaser off with a Frequent, though cleaning of your garden hose. only enough vehicle will not only enhance its pressure to do the job.
Page 117 4. Once the majority of the dirt has cleaner-waxes. Many contain abrasives been hosed off, wash all surfaces which may scratch the paint or protective with warm water and mild, detergent- finish. When finished, start the engine type soap. An old toothbrush or bottle and let it idle for several minutes.
Page 118: Storage
STORAGE container by loosening the drain bolt; Long term storage 60 days or more of this will help prevent fuel deposits your vehicle will require some from building up. Pour the drained fuel preventive procedures to guard onto the fuel tank. against deterioration.
Page 119 Ground the spark plug wire and metal surfaces with a light film of oil. turn the engine over several times Do not apply oil to any rubber parts or to coat the cylinder wall with oil. the seat covers. 4. Lubricate all control cables. 8.
Page 120: Noise Regulation
NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: ⑴ The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or ⑵...
Page 121: Engine
standards. ENGINE Oil Viscosity SAE 5W30 mineral-based oil is recommended for all seasons. However, during the hottest days of the summer, the XP-S 10W40 mineral oil can be used. NOTE: For improved overall performance and all season applications, use XP-S 5W40 synthetic oil.
Page 122: Oil Level
Oil Level CAUTION: Check level frequently and refill if necessary. Do not overfill. Operating the engine with an improper level may severely damage engine. Wipe off any spillage. With vehicle on a level surface and engine cold, not running, check the oil level as follows: 1.
Page 123 should be near or equal to the upper mark. To add oil, remove the dipstick. Place a funnel into the dipstick tube to avoid spillage. Add a small amount of recommended oil and recheck oil level. Repeat the above procedures until oil level reaches the dipstick’s upper mark.
Page 124 TYPICAL WARNING 1. Oil drain plug The engine oil can be very Allow enough time for oil to flow out of hot. In order to avoid oil filter. potential burns, do not Unscrew the oil filter cover. remove the engine drain plug or the filter cover if the engine is hot.
Page 125: Engine Coolant
drain plug areas are not leaking. Stop engine. Wait a while to allow oi l to flow down to crankcase then ch eck oil level. Refill as necessary. Dispose of oil as per your local environmental regulations. Engine Coolant Recommended coolant Always use ethylene-glycol antifreeze 1.
Page 126: Coolant Replacement
Remove access panel. If the coolant is added in the coolant reservoir, check the level in the radiator too. Add coolant if necessary. WARNING In order to avoid getting burned, do not remove the radiator cap if the engine is hot.
Page 127 container. Drain the system completely and reinstall the coolant drain plug. 1. Coolant drain plug NOTE: Do not unscrew the coolant drain plug completely. Unscrew the bleeding screw on the top Pinch hose between radiator and of thermostat housing. thermostat housing with a large pincher or an equivalent.
Page 128: Air Filter
and refill if necessary. Run engine at idle with the radiator cap off. Slowly add coolant if necessary. As this point, wait until engine reaches normal operating temperature. Depress the throttle level two or three times; then add coolant if required. Install radiator cap.
Page 129: Drive Belt
reverse order of their removal. Insufficient clearance will cause loss of power and possibly damage the valves. Drive Belt Excessive clearance will cause noise. See and authorized ODES dealer to Spark Arrester check the width and the condition of The muffler must be periodically purged drive belt.
Page 130 Remove the cleanout plug of the 2. Radiator muffler. Inspect radiating fins. They must be Block the end of the muffler with a shop clean, free of mud, dirt, leaves and any rag and start engine. other deposit that would prevent the Momentarily increase engine RPM radiator to cool properly.
Page 131: Gearbox Oil
check the performance of the cooling system. Gearbox Oil Recommended Oil Use XP-S chaincase oil or an equivalent. CAUTION: Do not use unrecommended other types of oil when servicing. Do not mix with other types of oil. 1. Oil level plug Gearbox Oil Level 2.
Page 132 tilt the vehicle toward the right side. When the gearbox is empty, install the drain plug and replace the vehicle on the ground. Refill gearbox, using XP-S chaincase oil or an equivalent. CAUTION: Do not use other unrecommended types of oil when servicing.
Page 133: Maintenance Chart
MAINTENANCE CHART The maintenance is very important, if you are not familiar with safe service practices and adjustment procedures, see your authorized dealer. PERIODIC MAINTENANCE CHART A:ADJUST INITIAL INSPECTION 10 HOURS OR 300 KM OR 300 km C:CLEAN (The initial maintenance is very important and must not to be neglected) I:INSPECT 25 HOURS OR 750 KM L:LUBRICATE...
Page 134 ENGINE Engine oil level (2) EVERY RIDE Customer Engine oil and Customer filter (2) Pre-ride inspection Valve adjustment Dealer item. (3) Every 100 Engine mount Dealer hours, check fasteners coolant Air filter(2) C(4) R(4) Customer strength (4) More Exhaust system Dealer often under Spark arrester...
Page 135 ENGINE MANAGEMENT SYSTEM A:ADJUST INITIAL INSPECTION 10 HOURS OR 300 KM OR 300 km (The initial maintenance is very important and must not to be C:CLEAN neglected) I:INSPECT 25 HOURS OR 750 KM L:LUBRICAT 50 HOURS OR 1500 KM R:REPLACE 100 HOURS OR 3000 KM OR 1 YEAR 200 HOURS OR 6000 KM OR 2 YEAR TO BE PERFOMED BY...
Page 136 BRAKES Brake fluid (front Customer / (2) Pre-ride inspection and rear)(2) Dealer item. Brake pads I(4) Customer (4) More often under severe use such dusty Brake system area, sand, snow, wet (discs, hoses, Customer or muddy conditions. etc.) BODY /FRAME Engine Customer compartment...
Page 137: Specifications
SPECIFICATIONS Model UTV800 Overall length 2850mm Overall width 1610mm Overall height 1880mm Dimensions Seat height 850mm Wheelbase 1900mm Ground clearance 285mm Basic weight With oil and full fuel tank 550kg Wet tank lubrication, oil filters can be Final gear Type...
Page 138 Model UTV800 Frame type Steel tube frame Caster angle 5.0 ° Chassis Trail 26.0mm（1.02in） Tubeless Type 25×8 – 12 Tire Size Front 25×10 – 12 Size Rear Front and rear unified System Dual disc brake Type Front Brakes Single disc brake...
Page 139 Model UTV800 2V91 Engine model Two-cylinder, overhead cam (SOHC), water Type cooling, Cylinder diameter 91 mm Piston stroke 61.5 mm Compression ratio 10.3：1 Displacement 7.97 L Maximum torque 73N.m/5000 RPM Idle speed 1250rpm...

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