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Summary of Contents for TrailMaster Challenger 200UTV
- Page 1 TrailMaster Challenger 200UTV Set up instruction Version: 4.0 2023/05/14 !This set up instruction is for authorized or trained mechanic use only.! Pictures used in the instruction are for reference only...
- Page 2 CHALLENGER 200UTV P. D. I 1. Check the components after opening the box. 1.1 Battery (pic.1): type YTX12-BS (12V10Ah), includes one battery, one battery liquid, two bolts and nuts for installation. 1.2 Steering wheel (1 pc) 1.3 Owner’s manual (1pc)
- Page 3 CHALLENGER 200UTV P. D. I 1.4.1 Bag 1: Hub cover 4pcs, zip tie 10 1.4.2 Bag 2: battery box (1pc), battery strap (1pc), bolt M8X55 (4pc), bolt M8X60 (2pc), bolt M8X30 (8 pc), bolt M6X16 (6pc), bolt M6X30 (2 pc), screw M6X16 (6 pc), bolt M6X12 (3 pc), washer∮6 (6 pc), cotter...
- Page 4 CHALLENGER 200UTV P. D. I 1.6 Rear roll cage bar 1pc 1.7 Front roll cage bar 1pc 1.8 Front light cover (lights are pre-installed) 1pc 1.9 Top headlights mounting bar 1pc...
- Page 5 CHALLENGER 200UTV P. D. I 1.10 Front wheel left and right 1of each 1.11 Front wheel left and right 1of each 1.12 Rear shock 1pc...
- Page 6 CHALLENGER 200UTV P. D. I 1.13 canopy top 1pc, side net door left and right 1 of each, bar cushions 1.14 Top headlight mounting parts 1 set 1.15 Side mirror 1 set (The mirror in the box can be different!)
- Page 7 CHALLENGER 200UTV P. D. I 1.16 Front metal bumper 1pc 1.17 Windshield 1pc (already installed) 1.18 Front lights mounting bar 1pc...
- Page 8 CHALLENGER 200UTV P. D. I 2. Assembly： 2.1 Assemble the rear shocks: take down the bolts from the shocks; lift the rear swing arm to let the top of shock into the fixing seats of frame, use 37-44NM torque to fix the shocks attached the frame. (Note: 1NM = 0.74 lb ft):...
- Page 9 CHALLENGER 200UTV P. D. I 2.3 Assemble the front shocks: Take down the bolt on the shocks, attach the shock to the front lower suspension arm, and fix the bolt with 37-44NM torque: 2.4 Assemble the front wheel: Take down the tire bolts on the hub, set up the front wheel on the right position of hub, fix the tire bolts with 37-44NM torque, put on the hub cover.
- Page 10 CHALLENGER 200UTV P. D. I 2.5 Front bumper mounting bracket assembly: assemble the front bumper mounting bracket on the UTV frame using GB5789 M6x16 bolts, PLEASE DO NOT TIGHT THE BOLTS AT THIS STEP. 2.6 Set up the top headlights wire: open the right side of front hood cover...
- Page 11 CHALLENGER 200UTV P. D. I 2.7 Install the front light cover: attach the front light cover on the frame and install it on the frame with M6X16 bolts and M6 nuts. 2.8 Plug the headlight and turn lights’ wire: plug the wires with the connecting sockets;...
- Page 12 CHALLENGER 200UTV P. D. I the nut 2.11 Install the front roll cage bar: put the front roll cage bar into the mount posts on the frame, put in the M8x60 bolt, R-washer, windshield bracket and tighten the M8 nut to fix.
- Page 13 CHALLENGER 200UTV P. D. I 2.12 Install the rear roll cage bar: put the rear roll cage bar onto the mount posts of the frame, fix it using M8x55 bolt, R-washer and M8 nut. 2.13 Joint the front and rear roll cage: joint the roll cages and connect them with M8x30 bolt and M8 nut.
- Page 14 CHALLENGER 200UTV P. D. I 2.15 Install the seat back head rest (No this step with new sport seat!) 2.16 Install the canopy top: put the foam padding on the top roll cage, install the canopy top and tighten it.
- Page 15 CHALLENGER 200UTV P. D. I 2.18 Install the side net doors 2.19 Install the battery, battery cover: put the battery liquid into the battery body, close the battery cover. Put the cushion plate into the battery mount box. Connect the battery wires to the battery poles “+ to +; - to –”, cover them.
- Page 16 CHALLENGER 200UTV P. D. I 2.20 Install the side mirrors: install the side mirrors on the windshield brackets (see. 2.11), fix them with a M10 self-locking nut, and adjust the mirrors. (The mirror in the box can be different!) 2.21 Install the top light mount bar, top lights and windshield (Only for X model): 2.21.1 Install the top light mounting piece onto the top light mounting bar,...
- Page 17 CHALLENGER 200UTV P. D. I 2.21.5 Mount the top part of the windshield onto the windshield top brackets using M8X30 bolt and M8 nut 2.21.6 Connect the top light wiring with the top lights 2.22 Install the front metal bumper, insert the bar end caps...
- Page 18 CHALLENGER 200UTV P. D. I Before driving please make sure that all of the hardware on the UTV are tightened; please read the user manual of TrailMaster Challenger 200UTV carefully, you will be given with important safety information and advices.
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How to adjust brakes
how do you adjust brakes on challenger 200u