Massimo T-BOSS 550 Owner's/Operator's Manual
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Massimo T-BOSS 550 Owner's/Operator's Manual

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WARNING：
Read this Manual,
and
any
OWNER'S/OPERATOR'S
Supplements
Carefully
MANUAL
Before
Operating
Vehicle.
US 18.1
Assembly
Operation
Maintenance
THIS VEHICLE IS
NOT
DESIGNED
FOR
USE
ON
RENTAL
TRACKS
OR RACING
T-BOSS 550
（Independent Rear Suspension）
BEFORE OPERATING THIS VEHICLE, THE OWNER AND EACH OPERATOR
MUST HAVE READ AND HAVE AN UNDERSTANDING OF ALL THE
INSTRUCTIONS FOR PROPER ASSEMBLY AND SAFE OPERATION, AS
WELL AS THE INSTRUCTIONS CONCERNING THE ENGINE AND ALL OTHER
PORTIONS OF THE VEHICLE.

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Questions and answers

George Ricks
May 7, 2025

Now and then upon take off from stop, there is a squeeling noise, similar to a belt slipping. No problems at high speed. Cause?

0
1 comments:
Mr. Anderson
May 19, 2025

A squealing noise during takeoff in a Massimo 550 could be caused by issues with the clutch system. If the primary clutch is not engaging or releasing properly or if the belt is slipping due to wear or improper tension, it can cause squealing. The belt may also slip if the clutch components are dirty, worn, or misaligned. Checking and servicing the clutch and belt system may resolve the issue.

This answer is automatically generated

0
Gary Hammer
February 16, 2025

My 550 t boss won't start in the cold. It barks back through the intake, every time it should fire.

0
1 comments:
Mr. Anderson
February 16, 2025

The Massimo T-BOSS 550 has difficulty starting in extremely cold weather. The possible reasons mentioned include:

1. Weak Starter – The starter may not be strong enough to turn the engine over efficiently in cold conditions.
2. Battery Issues – The battery may not have enough cold cranking amps to provide sufficient power in low temperatures.
3. Lack of Battery Maintainer – The battery is not maintained with a charger, which could lead to reduced performance in the cold.
4. Cold Temperatures – The engine struggles to start only in extremely low temperatures, especially in single digits, and the vehicle is not stored in a garage, which could help with temperature regulation.

The backfiring through the intake could be caused by:
1. Cold Fuel Mixture – In cold weather, fuel may not vaporize properly, leading to incomplete combustion and backfiring.
2. Weak Spark or Ignition Timing Issues – A weak battery or cold conditions may cause weak spark ignition, leading to misfires and backfires.
3. Starter Struggles – If the starter is weak, the engine may not crank properly, leading to improper air-fuel mixture ignition.

Using a battery maintainer, storing the vehicle in a warmer place, or checking the starter and battery capacity could help improve cold-weather performance.

This answer is automatically generated

0
John Mauch
July 20, 2025

My T-550 will barely pull itself up a slight hill. It just doesn't seem to have any power. Could it need an adjustment on the drive train? I've looked online for a service/repair manual and can't find one anywhere. Thank you for any assistance.

0
Ronald seaman
July 7, 2025

Where is the VIN number located?

0
David
June 9, 2025

My Massimo T Boss 550 is very hard to shift to any gear, I disconnected the cable from the gearbox and cable movement is smooth. Want to service the transmision but cant find where to refill after i drain it

0
Ricky Smith
May 23, 2025

Just bought a T-Boss 550, what would be consider a overheat temperature? Just want to make sure during break in i keep an eye on the temp.

0
John
May 21, 2025

My Massimo t boss 550 does not move when you put it in high or low it does go in reverse

0
Tom fore
February 25, 2025

Transmission slipping on 550 Massimo atv

0

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Summary of Contents for Massimo T-BOSS 550

  • Page 1 THIS VEHICLE IS DESIGNED RENTAL TRACKS OR RACING T-BOSS 550 （Independent Rear Suspension） BEFORE OPERATING THIS VEHICLE, THE OWNER AND EACH OPERATOR MUST HAVE READ AND HAVE AN UNDERSTANDING OF ALL THE INSTRUCTIONS FOR PROPER ASSEMBLY AND SAFE OPERATION, AS WELL AS THE INSTRUCTIONS CONCERNING THE ENGINE AND ALL OTHER PORTIONS OF THE VEHICLE.
  • Page 2 NOTE: A storage area/toolbox has been provided on the UTV for storage of this manual, and addendums. Please keep this manual and addendums in the glove compartment so that it can be found easily and referenced when needed. WARNING The engine exhaust from this product contains chemicals known, in certain quantities, to cause cancer, birth defects or other reproductive harm.

  • Page 3: Table Of Contents

    CONTENTS 1. INTRODUCTION · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·1.1 2. UNDERSTANDING WARNING · · · · · · · · · · · · · · · · ·2.1 3.
  • Page 4 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 1. INTRODUCTION Introduction Congratulations on the purchase of your Utility Vehicle (UTV). We take pride in offering you this product engineered and manufactured to the highest performance and quality standards. We are sure that you will enjoy superior levels of performance, reliability, riding comfort, and safety.

  • Page 5: Introduction

    T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 1. INTRODUCTION Important Safety Notice ●This vehicle is designed and manufactured for off-road use. ●Check the laws and regulations in force before choosing where to operate this vehicle. It is illegal to operate this vehicle on public lands where vehicles its size are prohibited.
  • Page 6 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 1. INTRODUCTION A UTV CAN BE HAZARDOUS TO OPERATE. A UTV handles differently from other vehicles including motorcycles, ATVs and cars. A collision rollover can occur quickly, even during routine maneuvers such as turning and driving on hills or over obstacles, if you fail to take proper precautions.
  • Page 7 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 1. INTRODUCTION maintenance procedures and schedules described in this manual.  Always keep both hands, arms, feet, and legs inside the vehicle at all times during operation. Keep your feet on the floorboard. Never hold onto the enclosure except when using the handgrip inside the enclosure.
  • Page 8 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 1. INTRODUCTION 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.

  • Page 9: Understanding Warning

    T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 2. UNDERSTANDING WARNINGS ATTENTION: This is an ADULT VEHICLE ONLY! Not a toy! READ AND UNDERSTAND WARNINGS AND OWNER’S MANUAL BERORE OPERATION. KNOW YOUR VEHICLE BEFORE YOU BEGING RIDING! Read this manual thoroughly referring to the various areas which are being discussed on your machine.
  • Page 10 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 2. UNDERSTANDING WARNINGS SAFETY ALERT WARNINGS identify special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life. Read all WARNINGS in this manual care fully. Follow their instructions to remain safe. The following precautionary signal words are used throughout this manual to convey the following messages: This is the safety alert symbol.

  • Page 11: Safety Warning

    T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 3. SAFETY WARNING NOTE： Warning decals have been placed on the vehicle for your protection. Read and follow the instructions on each decal carefully. In the event any decal becomes illegible or comes off, contact your dealer for a replacement.
  • Page 12 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 3. SAFETY WARNING NOTE：Maximum tire pressure:Front :24psi(170kPa) Rear : 22psi(150kPa) 3- 2...
  • Page 13 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 3. SAFETY WARNING 3- 3...
  • Page 14 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 3. SAFETY WARNING 3- 4...
  • Page 15 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 3. SAFETY WARNING 3- 5...
  • Page 16 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 3. SAFETY WARNING 3- 6...
  • Page 17 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 3. SAFETY WARNING 3- 7...

  • Page 18: Daily Pre-Ride Inspection

    T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 4. DAILY PRE-RIDE INSPECTION WARNING You must inspect your UTV each time before riding to ensure it is in proper working order. If proper inspection is not done, severe injury or death could result. Use the following checklist to verify your machine is in proper working order each time you ride.
  • Page 19 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 4. DAILY PRE-RIDE INSPECTION released. Have an authorized dealer repair as necessary for proper operation. 5, Headlight / Taillight / Brake light— check operation of all indicator lights and switches. 6, Engine stop switch— check for proper function. 7, Wheels—...

  • Page 20: Operation Warning

    T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 5. OPERATION WARNINGS WARNING POTENTIAL HAZARD Improper handling of gasoline. WHAT CAN HAPPEN Gasoline can catch fire and you could be burned. HOW TO AVOID THE HAZARD Always turn off the engine when refueling. Do not refuel right after the engine has been running and is still very hot.
  • Page 21 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 5. OPERATION WARNINGS WARNING POTENTIAL HAZARD When transporting the vehicle in another vehicle, be sure it is kept in an upright position. Otherwise, fuel may leak out of the carburetor or fuel tank. WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries.
  • Page 22 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 5. OPERATION WARNINGS WARNING POTENTIAL HAZARD Malfunction of the accelerator pedal. WHAT CAN HAPPEN The accelerator pedal could be hard to operate, making it difficult to speed up or slow down when you need to. This could cause an accident.
  • Page 23 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 5. OPERATION WARNINGS WARNING POTENTIAL HAZARD Try to stop the tipping vehicle with your arm or leg. WHAT CAN HAPPEN You could be severely injured. You could suffer a crushed hand, arm, leg, or foot, HOW TO AVOID THE HAZARD You must keep your arms and legs inside the vehicle until it has stopped moving.
  • Page 24 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 5. OPERATION WARNINGS WARNING POTENTIAL HAZARD Overloading the cargo bed WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated maximum load limit for this cargo bed. Cargo should be properly distributed and securely attached.
  • Page 25 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 5. OPERATION WARNINGS WARNING POTENTIAL HAZARD Driving with improperly operating brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride. Do not operate the vehicle if you find any problem with the brakes.
  • Page 26 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 5. OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating vehicle without being familiar with all controls. WHAT CAN HAPPEN Loss of control, which could cause an accident or injury. HOW TO AVOID THE HAZARD Read the Owner’s Manual carefully. If there is a control or function you do not understand, ask our authorized dealer.
  • Page 27 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 5. OPERATION WARNINGS WARNING POTENTIAL HAZARD Servicing an engine while it is running. WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body, causing injury. Electrical components can cause shocks or can start fires. HOW TO AVOID THE HAZARD Turn off the engine when performing maintenance unless otherwise specified.
  • Page 28 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 5. OPERATION WARNINGS WARNING POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the sponge material. WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode. HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the sponge material.
  • Page 29 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 5. OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing: ● Make sure the brakes operate smoothly and that the brake pedal position is correct.
  • Page 30 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 5. OPERATION WARNINGS WARNING POTENTIAL HAZARD Failure to handle batteries or battery electrolyte carefully. WHAT CAN HAPPEN You could be poisoned. You could be severely burned by the sulfuric acid in battery electrolyte. Batteries produce explosive gases.
  • Page 31 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 5. OPERATION WARNINGS WARNING POTENTIAL HAZARD A headlight bulb is hot when it is on and immediately after it is turned off. WHAT CAN HAPPEN You can be burned, or a fire could start if the bulb touches something flammable.
  • Page 32 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 5. OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating/ riding this UTV without wearing an approved helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating/ riding without an approved helmet increases your chances of a severe head injury or death in the event of an accident. Operating/ riding without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident.
  • Page 33 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 5. OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this UTV at excessive speeds. WHAT CAN HAPPEN Increases your chances of losing control of the UTV, which can result in an accident. HOW TO AVOID THE HAZARD Always travel at a speed which is proper for the terrain, visibility and operating conditions;...
  • Page 34 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 5. OPERATION WARNINGS WARNING POTENTIAL HAZARD Removing hands from steering wheel or feet from footrests during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the UTV or could cause you to lose your balance and fall off the UTV. HOW TO AVOID THE HAZARD Always keep both hands on the steering wheel and both feet on the footrests of your UTV during operation.
  • Page 35 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 5. OPERATION WARNINGS WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn.
  • Page 36 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 5. OPERATION WARNINGS WARNING POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN UTV could go out of control, causing a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the Owner’s Manual.
  • Page 37 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 5. OPERATION WARNINGS WARNING POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause UTV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in the Owner’s Manual.
  • Page 38 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 5. OPERATION WARNINGS WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN Could result in UTV overturning. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill.
  • Page 39 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 5. OPERATION WARNINGS WARNING POTENTIAL HAZARD Skidding or sliding, WHAT CAN HAPPEN You may lose control of the UTV. You may also regain traction unexpectedly, which may cause the UTV to overturn. HOW TO AVOID THE HAZARD On slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance or skidding or sliding out of control.
  • Page 40 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 5. OPERATION WARNINGS WARNING POTENTIAL HAZARD Improperly operating in reverse, WHAT CAN HAPPEN You could hit an obstacle or person behind you, resulting in severe injury. HOW TO AVOID THE HAZARD When you select reverse gear, make sure there are no obstacles or people behind you.
  • Page 41 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 5. OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this UTV with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident.
  • Page 42 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 5. OPERATION WARNINGS WARNING After a rollover or an accident, have a qualified service dealer check the complete machine including, but not limited to, brakes, throttle and steering for possible damage. WARNING Safe operation of this rider active vehicle requires good judgment and physical skills.

  • Page 43: And Engine Serial Number

    T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 6. V.I.N. AND ENGINE SERIAL NUMBER 6- 1...
  • Page 44 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 6. V.I.N. AND ENGINE SERIAL NUMBER Record these numbers from your UTV in the spaces provided. 1. Frame VIN (Rear right of the frame tube) 2. Engine Serial Number (Left side of engine crankcase) The vehicle frame and engine serial numbers are important for model identification when registering your vehicle, obtaining insurance or whenever replacement parts are required.

  • Page 45: Control And Functions

    T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 7. CONTROL AND PARTS FUNCTIONS ELECTRICAL SWITCHES Switch On Panel 1. Switch 2WD / 4WD and Front Diff Lock 6. Rear Diff Lock Switch 2. Turn Signal Lamp Switch Switch（Optional） Emergency 3. Horn Switch（Optional） 8.Tractor Switch 4.
  • Page 46 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 7. CONTROL AND PARTS FUNCTIONS NOTE: When switch on 2WD / 4WD, the mechanics in the front gear box maybe still engaged / disengaged, the mechanics would finally disengaged / engaged when rides on a hard surface or rides in reverse.
  • Page 47 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 7. CONTROL AND PARTS FUNCTIONS visibility such as fog, rain and darkness. 6. Rear Diff Lock Switch When in 2WD, the switch can change rear diff lock or rear diff unlocked. When in 4WD, the switch can not work, the vehicle will stay rear diff lock.
  • Page 48 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 7. CONTROL AND PARTS FUNCTIONS LCD METER 1. Turn Left Indicator Light 10. Dome Lamp Indicator 2. Position Lamp Indicator 11. Coolant Temperature Meter 3. High Beam Indicator Light 12. 2WD/4WD/DIFF Lock Indicator 4. Parking Brake Indicate Lamp 13.
  • Page 49 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 7. CONTROL AND PARTS FUNCTIONS ACCELERATOR PEDAL WARNING Before starting the engine, check the accelerator pedal to be sure it is operating smoothly. Make sure the accelerator pedal fully returns to the idle position as soon as it is released.
  • Page 50 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 7. CONTROL AND PARTS FUNCTIONS BRAKE PEDAL 1.Brake pedal Press the brake pedal to slow or stop the vehicle. WARNING Never operate the UTV with a spongy feeling brake pedal. Operating the UTV with a spongy brake pedal can result in loss of braking. Loss of braking could cause an accident.
  • Page 51 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 7. CONTROL AND PARTS FUNCTIONS AUTOMATIC TRANSMISSION GEAR SELECTOR OPERATION The transmission gear selector is located at the right side of the steering wheel. The transmission selector lever has four positions: reverse; neutral; high forward; and low forward NOTE: To extend belt life, use low forward gear in heavy pulling situations and in situations where you are operating below 7mph(11km/h) for extended periods of time.
  • Page 52 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 7. CONTROL AND PARTS FUNCTIONS FUEL TANK CAP 1.Fuel tank cap Remove the fuel tank cap by turning it counterclockwise. SEATS 1.Drive seat 2.Passenger seat To remove a seat, lift the rear of the seat, and then slide the seat up and backward. To install a seat, push down on the seat at the front and insert the projections on the rear of the seat into the seat holders.
  • Page 53 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 7. CONTROL AND PARTS FUNCTIONS SEAT BELTS 1.Seat belt (×2) 2.Latch plate (×2) 3.Buckle (×2) This vehicle is equipped with three-point seat belts for both the operator and passenger. Always wear the seat belt while riding in the vehicle. 1.
  • Page 54 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 7. CONTROL AND PARTS FUNCTIONS To Wear The Seat Belt Properly, do the following: 1. Hold the latch plate as you pull the belt across your lap and chest. Make sure the belt is not twisted and is not caught on any portion of the vehicle, your clothing, or any equipment you are carrying.
  • Page 55 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 7. CONTROL AND PARTS FUNCTIONS CARGO BED 1.Cargo bed 2.Tailgate 3.Cargo hook (×4) Opening And Closing The Tailgate 1.Tailgate 2. handle To open Pull the handle, and then lower the tailgate. To close Place the tailgate in the original position, and be sure that it is locked into place.
  • Page 56 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 7. CONTROL AND PARTS FUNCTIONS To lower Lower the cargo bed slowly to its original position and be sure that it is locked into place. WARNING POTENTIAL HAZARD Pinch points. WHAT CAN HAPPEN You or someone else could be pinched between the cargo bed and the frame when the bed is being lowered.
  • Page 57 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 7. CONTROL AND PARTS FUNCTIONS WARNING POTENTIAL HAZARD Carrying a passenger/ passengers in the cargo bed WHAT CAN HAPPEN The passenger(s) could fall, be thrown out, or be struck by objects in the cargo bed. HOW TO AVOID THE HAZARD Never carry a passenger/ passengers in the cargo bed.
  • Page 58 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 7. CONTROL AND PARTS FUNCTIONS To Close Put the hood in place, push up it and then tighten the screws. WARNING If the screws loose, or the front hood installation is not in place, the front hood will come off during operation, striking the driver or passenger and causing serious personal injury.
  • Page 59 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 7. CONTROL AND PARTS FUNCTIONS Never remove the pressure cap when the engine is warm or hot. Escaping steam can cause severe burns. The engine must be cool before removing the pressure cap. Radiator Coolant Level Inspection NOTE:This procedure is only required if the cooling system been...
  • Page 60 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 7. CONTROL AND PARTS FUNCTIONS with soap and water and change clothing.  Never start the engine or let it run in an enclosed area. Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time.
  • Page 61 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 7. CONTROL AND PARTS FUNCTIONS 4. Put dipstick into the oil tank (don’t screw in it), remove it and read the oil level. 5. Remove dipstick and check to see that the oil level is between the full and add marks(2).

  • Page 62: Starting The Engine

    T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 8. STARTING THE ENGINE Procedure for Starting a Cold Engine WARNING Never run an engine in an enclosed area. Carbon monoxide exhaust gas is poisonous and can cause severe injury or death. Always start engines outdoors. WARNING POTENTIAL HAZARD Freezing control cables in cold weather.
  • Page 63 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 8. STARTING THE ENGINE NOTE: If the engine fails to start, release the key, and then try starting again. Wait a few seconds before the next attempt. Each cranking should be as short as possible to preserve battery energy. Do not crank the engine more than 5 seconds on each attempt.
  • Page 64 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 8. STARTING THE ENGINE cable from the vehicle and charged battery, and then disconnect the positive lead of the jumper cable from the charged battery and the battery in the vehicle. 7. Close the hood. WARNING If the hood latches are hooked improperly, or the latches and their attachments can not work properly, the front hood can come off during operation, striking the driver or passenger and causing serious personal...

  • Page 65: Vehicle Break-In Period

    T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 9. VEHICLE BREAK-IN PERIOD The break-in period for your new UTV is defined as the first 50 hours of operation. No single action on your part is as important as a proper break in period. Careful treatment of new engine will result in more efficient performance and longer life for the engine.

  • Page 66: Riding Gear

    T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 10. RIDING GEAR SAFE RIDING GEAR Always wear clothing suite to the type of riding you are doing. UTV riding requires special protective clothing which will make you fell more comfortable and reduce chances of injury. 1.
  • Page 67 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 10. RIDING GEAR WARNING POTENTIAL HAZARD Operating this vehicle without wearing an approved motorcycle helmet, eye protection, and protective clothing. WHAT CAN HAPPEN Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident.

  • Page 68: Carrying Loads

    T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 11. CARRYING LOADS CARRYING LOADS Cargo or a trailer can change the stability and handling of a vehicle. You must use common sense and good judgment when carrying cargo or towing a trailer. Keep the following points in mind: ...
  • Page 69 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 11. CARRYING LOADS  Make sure the load does not interfere with controls or your ability to see where you are going.  Drive more slowly than you would without a load. The more weight you carry, the slower you should go. Although conditions vary, it is good practice not to exceed low range whenever you are carrying heavier loads or when towing a trailer.
  • Page 70 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 11. CARRYING LOADS WARNING POTENTIAL HAZARD Overloading this vehicle or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle 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.
  • Page 71 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 12. DRIVING YOUR VEHICLE GETTING TO KNOW YOUR VEHICLE This off-highway utility vehicle will handle and maneuver differently from an ordinary passenger car or other vehicle. Before you begin to use your vehicle, be sure you have read this Owner’s Manual completely and understand the operation of the controls.
  • Page 72 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 12. DRIVING YOUR VEHICLE LEARNING TO OPERATE YOUR VEHICLE You should become familiar with the performance characteristics of the vehicle in a large, flat area that is free of obstacles and other vehicles. Practice control of the accelerator pedal, brakes, steering, and drive select lever.
  • Page 73 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 12. DRIVING YOUR VEHICLE BRAKING Braking ability is affected by the type of terrain. In most cases, gradually application of the brakes is more effective than abrupt braking, particularly on loose surfaces like gravel. Always allow for greater braking distance on rough, loose, or slippery surfaces.
  • Page 74 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 12. DRIVING YOUR VEHICLE Never operate your vehicle on hills too steep for it or your abilities. Never operate vehicles on hills steeper than 20％. Do not drive across the face of a hill. Go straight up the hill. Practice on smaller hills before attempting large hills.
  • Page 75 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 12. DRIVING YOUR VEHICLE 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 check the terrain carefully before you start down any hill. Never go down a hill at high speed.

  • Page 76: Riding

    T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 12. DRIVING YOUR VEHICLE arm or leg. You could be severely injured. You could suffer a crushed hand, arm, leg, or foot, if part of your body is caught underneath the vehicle. CROSSING THROUGH SHALLOW WATER If you must cross shallow, slow moving water up to 200mm (8 in) depth, choose your path carefully to avoid sharp drop-offs, large rocks, or slippery surfaces that could cause the vehicle to overturn.
  • Page 77 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 12. DRIVING YOUR VEHICLE 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.
  • Page 78 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 12. DRIVING YOUR VEHICLE 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. Use extreme caution when operating over large obstacles, such as large rocks or fallen trees.

  • Page 79: Cvt System

    T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 13. CVT SYSTEM WARNING The CVT system rotates at high speeds. Creating large amounts of force on clutch components. Do not modify any components of the CVT system. Any modification will damage the system; cause the system to be out of balance, The CVT housing must be securely in place during operation, Failure to comply with this warning can result in severe injury or death.
  • Page 80 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 13. CVT SYSTEM CVT SYSTEM On UTV, the approximate gear ratio difference between high and low range is 1:1.67..This difference in gearing affects the operation of the CVT, especially at speeds less than 7 MPH, due to the system’s dependence on engine speed.

  • Page 81: Battery

    T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 14. BATTERY WARNING Whenever removing the battery, disconnect the negative (black) cable first. When reinstalling the battery, connect the negative (black) cable last or an explosive situation could result causing serious injury or death. WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing.
  • Page 82 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 14. BATTERY An exploding battery can cause serious injury or death. WARNING Battery terminals and connections should be kept free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean rags.

  • Page 83: Exhaust System

    OWNER’S/OPERATOR’S MANUAL T-Boss550 18.1 15. EXHAUST SYSTEM SYSTEM REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED! CAUTION: Exhaust system components are very hot during and after use of UTV.  Do not touch exhaust system components. Serious burns can result.  Be especially careful when traveling through tall grass. The potential for fire exists Catalyst There is catalyst inside the muffler on all U.S.

  • Page 84: Maintenance

    T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 16. MAINTENANCE CAUTION Due to the nature of the adjustments marked with a D on the following chart, it is recommended that service be performed by an authorized dealer.  More often under severe use, such as dirty or wet conditions to purge water or dirt contamination from grease fittings and other critical components.
  • Page 85 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 16. MAINTENANCE Item Hours When Remarks  Brake System Pre-ride Pre-ride Pre-ride inspection item –adjust, Inspect lubricate, Accelerator pedal Pre-ride Pre-ride replace if necessary; pre-ride inspection item Check for leaks at tank cap, Fuel System Pre-ride Pre-ride lines, fuel valve, and filter Inspect daily, pre-ride inspection...
  • Page 86 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 16. MAINTENANCE Item Hours When Remarks  Oil Filter 50 hrs 6 months Inspect-clean Engine breather hose 100 hrs 6 months Inspect –adjust, Inspect lubricate, Throttle Cable/ 20 hrs monthly replace if necessary; pre-ride Accelerator pedal inspection item Coolant strength 100 hrs...
  • Page 87 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 16. MAINTENANCE Item Hours When Remarks Radiator 100 hrs Inspect/clean external surface months Cooling System hoses 50 hrs 6 months Inspect/replace if necessary Spark arrestor 10 hrs monthly Clean out-replace if necessary Clutches (drive and 25 hrs 3 months Inspect, clean driven) Engine mounts...
  • Page 88 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 16. MAINTENANCE 16- 5...
  • Page 89 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 16. MAINTENANCE Item Lube Rec Method Frequency Lubricate the pivoting Every 3 months  5.Steering system Grease and sliding parts or 50 hours  6.Tie rods Grease Grease Semi-annually Locate fittings  7.Shift Linkages Grease Semi-annually and Grease 8.Front Wheel Inspect and replace...
  • Page 90 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 16. MAINTENANCE PERIODIC MAINTENANCE RECORD Use the following chart to record periodic maintenance work： Maintenance Servicing Servicing Dealer Remarks Interval Date Performed Person First 5 Hrs 10 Hrs 15 Hrs 20 Hrs 25 Hrs 50 Hrs 75 Hrs 100 Hrs 16- 7...
  • Page 91 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 16. MAINTENANCE The following items should be checked occasionally for tightness; or if they have been loosened for maintenance service. WHEEL NUT TORQUE SPECIFICATIONS Bolt Size Specification Front M10X1.25 55Ft.Lbs 75N.m Rear M10X1.25 55Ft.Lbs 75N.m Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations.
  • Page 92 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 16. MAINTENANCE REAR SPRING ADJUSTMENT The rear shock absorber spring is adjusted by rotating the adjuster in the direction required to increase or decrease spring tension. Turn the adjuster ○ increase or decrease the spring preload. Standard position: 3 Minimum (Soft) position: 1 Maximum (Hard) position: 5...
  • Page 93 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 16. MAINTENANCE STEERING Steering Inspection The steering assembly of the machine should be checked periodically for loose nuts and bolts, worn tie rod ends, worn boots, and damage. Checking routing of all cables, hoses, and wiring to be sure the steering mechanism is not restricted or limited.
  • Page 94 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 16. MAINTENANCE CAMBER AND CASTER The camber and caster are non-adjustable. TOE ALIGNMENT CHECK WARNING Do not attempt to adjust the tie rod for toe alignment. Severe injury or death can result from improper adjustment. Contact your dealer. He/she has the training and tools to Make these adjustment.
  • Page 95 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 16. MAINTENANCE BRAKES Front brake WARNING Once a bottle of brake fluid is opened, use what is necessary and discard the rest. Do not store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air.
  • Page 96 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 16. MAINTENANCE Checking the brake fluid level Insufficient brake fluid may let air enter the brake system, possibly causing the brakes to become ineffective. Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary.
  • Page 97 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 16. MAINTENANCE Brake pedal and accelerator pedal lubrication Lubricate the pivoting parts. Recommended lubricant: Lithium-soap-based grease (all-purpose grease) PARKING BRAKE Checking Although the parking brake has been adjusted at the factory, the brake should be checked for proper operation. The mechanical brake must be maintained to be fully functional.
  • Page 98 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 16. MAINTENANCE adjusters. 5. Make sure the rear wheels turns freely without dragging. 6. Turn the adjustor (the one on the lever) and apply the lever. While adjusting, it is important you apply the lever back and forth for operation, free play and the locking of the parking position.
  • Page 99 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 16. MAINTENANCE Spark Plug Removal and Replacement WARNING Never attempt to remove a spark plug while the engine is warm. The exhaust system or engine could burn you causing severe injury. Remove the spark plug by rotating counterclockwise. Reverse the procedure for spark plug installation.
  • Page 100 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 16. MAINTENANCE Rear Gearcase Lubrication CAUTION Be sure no foreign material enters the gear case. With the UTV on a level surface, remove fill plug and visually inspect the lubricant level through the fill hole. Lubricant should be kept even with the center of the drill point approximately below the top of the fill hole.
  • Page 101 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 16. MAINTENANCE 5. Check for leaks. Front Gearcase Lubrication CAUTION Be sure no foreign material enters the gear case. With the ATV on a level surface, remove fill plug and visually inspect the lubricant level through the fill hole. Lubricant should be kept even with the center of the drill point approximately below the top of the fill hole.
  • Page 102 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 16. MAINTENANCE 4. Reinstall the fill plug. Tight securely (18.4 ft. lbs/25N.m). 5. Check for leaks. WHEELS AND TIRES WARNING Operating your UTV with worn tires, improperly inflated tires, non-standard tires or improperly installed tire will affect vehicle handling which could cause an accident resulting in serious injury or death.
  • Page 103 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 16. MAINTENANCE 2. Attach the wheel nuts and finger tighten them. 3. Lower the vehicle to the ground. 4. Securely tighten the wheel nuts according to the chart found in ―16.MAINTENANCE/ Wheel Nut Torque‖. Tire Inspection When replacing a tire always use original equipment size and type.
  • Page 104 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 16. MAINTENANCE the semicircle on a new bulb with that in the socket before mounting the bulb. Install rebound clip just removed to fasten the bulb and then plug in wires. 3. Remove position lamp socket out of top cover. Remove the worn bulb by taking a hold of it and pulling it out.
  • Page 105 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 16. MAINTENANCE The best and safest way to clean your UTV is with a garden hose and a pail of mild soap and water. Use a professional type washing mitten, cleaning the upper body first and lower parts last. Rinse with water frequently and dry with a chamois to prevent water spots.
  • Page 106 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 16. MAINTENANCE Storage Area/Covers——Set tire pressure and safely support the UTV with the tires 1-2‖(25-50mm) off the ground. Be sure the storage area is well ventilated. Cover the machine with a UTV cover. NOTE: Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.

  • Page 107: Troubleshooting

    T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 17. TROUBLESHOOTING Issues of Improper Operation Driven Clutch (CVT) Burning Possible Causes Solutions Loading the UTV into a Shift transmission to Low Range during pickup or tall trailer when in loading of the UTV to prevent belt burning high range.
  • Page 108 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 17. TROUBLESHOOTING WARNING This UTV is equipped with EFI system ,If the battery is under 12 Volt, the engine will not start. NOTE: The following trouble shooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting.
  • Page 109 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 17. TROUBLESHOOTING IGNTION SYSTEM Battery Ignition system  Improperly charged battery  Faulty ignitor unit  Faulty battery  Faulty pick up coil  Broken magneto woodruff key Fuse  Burnt out, improper connection Spark plug Switch ...
  • Page 110 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 17. TROUBLESHOOTING POOR SPEED PERFORMANCE Ignition system Compression system  Dirty spark plug  Worn cylinder  Improper heat range  Worn or seized piston ring  Faulty igniter unit  Cylinder head gasket broken  Faulty pick up coil ...
  • Page 111 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 17. TROUBLESHOOTING  Incorrect engine oil level  Improper engine oil quality (High viscosity)  Low engine oil quality Brakes  Dragging brake Cooling system  Inoperative fan motor  Faulty thermostat  Faulty thermo switch ...
  • Page 112 T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 17. TROUBLESHOOTING CLUTCH SLIPPING CVT SYSTEM Clutch weight spring Uncorrect Primaty Clutch Position  Worn/loose  Uncorrect engine mount (see 13. CVT system) Clutch shoe  Worn/ damaged Primary sliding sheave  Seized POORSTARTING FAULTY BRAKE PERFORMANCE POOR BRAKING EFFECT ...

  • Page 113: Tools

    T-Boss550 OWNER’S/OPERATOR’S MANUAL 18.1 18. TOOL 18-1...

  • Page 114: Specification

    OWNER’S/OPERATOR’S MANUAL T-Boss550 18.1 19. SPECIFICATION Dimensions & Capacities L X W X H 2730×1460×1890 mm 107×57×74 in Seat height 860 mm 33.8 in Wheel Base 1855 mm 73 in Outer: 4500 mm 177 in Turn Radius Inner: 3000 mm 118 in Ground Clearance 280 mm...
  • Page 115 OWNER’S/OPERATOR’S MANUAL T-Boss550 18.1 19. SPECIFICATION Engine Engine Type LH188MR-A 4Stroke, Single Cylinder, SOHC Bore x Stroke 87.5mmX82mm Displacement 493cm Starter System Electric Starter Engine Cooling Liquid-Cooled Lubrication System Wet Sump Ignitions Spark Plug Type DPR7EA-9（ NGK） Electrical Equipment Battery 12V 18AH (12V 30Ah FOR EPS MODEL) Head light...
  • Page 116 OWNER’S/OPERATOR’S MANUAL T-Boss550 18.1 19. SPECIFICATION Emission Related Parts List Part Number Part Name Fuel Injector 4016 Fuel Pump EFM1090118P Oxygen Sensor RE94 Throttle Position Sensor 064915 Coolant Temperature CS010 Sensor Air Cleaner Element 4CT-14400-00 Intake Manifold 1BK-13586-00 Intake Air Temperature 28086011 Sensor Manifold Absolute...
  • Page 117 OWNER’S/OPERATOR’S MANUAL T-Boss550 18.1 20. WIRNING DIAGRAM T-Boss 550 20-1...

  • Page 118: Emissions Control - System Warranty

    OWNER’S/OPERATOR’S MANUAL T-Boss550 18.1 Emissions Control – System Warranty 21-1...
  • Page 119 OWNER’S/OPERATOR’S MANUAL T-Boss550 18.1 Emissions Control – System Warranty 21-2...
  • Page 120 OWNER’S/OPERATOR’S MANUAL T-Boss550 18.1 Emissions Control – System Warranty 21-3...
  • Page 121 OWNER’S/OPERATOR’S MANUAL 18.1...

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