SSR Motorsports BISON 500U Owner's/Operator's Manual
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SSR Motorsports BISON 500U Owner's/Operator's Manual

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OWNER'S/OPERATOR'S
WARNING：
Read this Manual, and any Supplements Carefully Before
Operating Vehicle.
Assembly
Operation
Maintenance
THIS VEHICLE IS NOT DESIGNED FOR USE ON RENTAL
TRACKS OR RACING
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.
MANUAL
BISON 500U

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  • Page 1 Operation Maintenance THIS VEHICLE IS NOT DESIGNED FOR USE ON RENTAL TRACKS OR RACING BISON 500U  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. Please keep this manual in the storage box so that it can be found easily and referenced when needed.

  • Page 4: Table Of Contents

    CONTENTS 1. INTRODUCTION · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·1.1 2. UNDERSTANDING WARNINGS · · · · · · · · · · · · · · · · ·2.1 3.

  • Page 5: Introduction

    OWNER’S/OPERATOR’S MANUAL 1. INTRODUCTION Introduction Congratulations on the purchase of your Utility Task 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 6 OWNER’S/OPERATOR’S MANUAL 1. INTRODUCTION Important Safety 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 local laws and regulations before choosing where to operate this vehicle.
  • Page 7 OWNER’S/OPERATOR’S MANUAL 1. INTRODUCTION A UTV CAN BE HAZARDOUS TO OPERATE. A UTV handles differently from other vehicles including motorcycles, ATVs and cars. A 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 8 OWNER’S/OPERATOR’S MANUAL 1. INTRODUCTION safe operating condition. Always follow the inspection and 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 9 OWNER’S/OPERATOR’S MANUAL 1. INTRODUCTION Avoid crossing the side of a steep hill if possible.  Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual.

  • Page 10: Understanding Warnings

    OWNER’S/OPERATOR’S MANUAL 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 11 OWNER’S/OPERATOR’S MANUAL 2. UNDERSTANDING WARNINGS SAFETY ALERT WARNINGS identify special instructions or procedures which, if not followed correctly, could result in personal injury, or loss of life. Read all WARNINGS in this manual carefully. 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 12: Safety Warning

    OWNER’S/OPERATOR’S MANUAL 3. SAFETY WARNINGS NOTE： Warning decals have been placed on the vehicle for your protection. Read and follow the instructions on each of these decals carefully. In the event any decal becomes illegible or comes off, contact your dealer for a replacement.
  • Page 13 OWNER’S/OPERATOR’S MANUAL 3. SAFETY WARNINGS 3- 2...
  • Page 14 OWNER’S/OPERATOR’S MANUAL 3. SAFETY WARNINGS 6&7 3- 3...
  • Page 15 OWNER’S/OPERATOR’S MANUAL 3. SAFETY WARNINGS 3- 4...
  • Page 16 OWNER’S/OPERATOR’S MANUAL 3. SAFETY WARNINGS 3- 5...
  • Page 17 OWNER’S/OPERATOR’S MANUAL 3. SAFETY WARNINGS 3- 6...

  • Page 18: Daily Pre-Ride Inspection

    OWNER’S/OPERATOR’S MANUAL 4. DAILY PRE-RIDE INSPECTION WARNING You must inspect your UTV each time before driving to ensure it is in proper working order. If a proper inspection is not done, injury or death could result. Use the following checklist to verify your machine is in proper working order each time you drive.
  • Page 19 OWNER’S/OPERATOR’S MANUAL 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.

  • Page 20: Operation Warning

    OWNER’S/OPERATOR’S MANUAL 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. This could cause an accident. HOW TO AVOID THE HAZARD Check the operation of the accelerator pedal before you start the engine.
  • Page 21 OWNER’S/OPERATOR’S MANUAL 5. OPERATION WARNINGS 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. HOW TO AVOID THE HAZARD Before closing the bed, be sure others are standing away from the vehicle.
  • Page 22 OWNER’S/OPERATOR’S MANUAL 5. OPERATION WARNINGS 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 before every ride. Do not operate the vehicle if you find any problem with the brakes.
  • Page 23 OWNER’S/OPERATOR’S MANUAL 5. OPERATION WARNINGS Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident. HOW TO AVOID THE HAZARD Never modify this vehicle through improper installation or use of accessories.
  • Page 24 OWNER’S/OPERATOR’S MANUAL 5. OPERATION WARNINGS 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 & operating conditions, and your experience.
  • Page 25 OWNER’S/OPERATOR’S MANUAL 5. OPERATION WARNINGS time to react. Could result in the UTV overturning or losing control. HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the UTV. WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery...
  • Page 26 OWNER’S/OPERATOR’S MANUAL 5. OPERATION WARNINGS overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Use extreme caution when riding over large obstacles, such as large rocks or fallen trees. If you cannot avoid obstacles, always follow proper procedures as described in this Owner’s Manual.
  • Page 27 OWNER’S/OPERATOR’S MANUAL 5. OPERATION WARNINGS increases the risk of an accident. HOW TO AVOID THE HAZARD Always use the size and type of tires specified in the Owner’s Manual for this vehicle. Always maintain proper tire pressure as described in this Owner’s Manual.
  • Page 28 OWNER’S/OPERATOR’S MANUAL 6. V.I.N. #, ENGINE SERIAL NUMBER, AND KEY Record these numbers in the graphical position 1. Frame VIN (On the right side of the square tube under the cargo bed) 2. Engine Serial Number (Left side of engine crankcase) 6- 1...

  • Page 29: Control And Functions

    OWNER’S/OPERATOR’S MANUAL 7. CONTROL AND PARTS FUNCTIONS Dashboard 1. Hood release lever 2. TFT Meter 3. Ignition Switch 4. Horn Switch 5. Accessory Socket HOOD RELEASE LEVER: Pull the lever upward to open the hood. IGNITION SWITCH: The ignition switch has 4 positions: Steering lock→OFF→ON→START 7- 1...
  • Page 30 OWNER’S/OPERATOR’S MANUAL 7. CONTROL AND PARTS FUNCTIONS ACCESSORY SOCKET The accessory socket (1) is attached to the right side of the dashboard. You can use the accessory socket to power a trouble light, spotlight, CB radio, or cell phone etc. CAUTION Do not plug in any heat-generating accessories such as an automobile cigarette lighter because it will damage the socket.
  • Page 31 OWNER’S/OPERATOR’S MANUAL 7. CONTROL AND PARTS FUNCTIONS Rocker switches [Middle] 1． Hazard Light Switch: Turns on all the turn signals. 2． Front Axle Drive Mode Switch: ① 2WD: Only the rear wheels are driven. ② 4WD: The front wheel & rear wheels get power for better traction.
  • Page 32 OWNER’S/OPERATOR’S MANUAL 7. CONTROL AND PARTS FUNCTIONS Rocker switches [Left] 1. Turn Signal Switch: Turns on the left/right turn signals. 2. Headlight Switch: ① Turns off the daytime running lights and headlights. ② Turns on the daytime running lights. ③ Turns on the daytime running lights and the headlights.
  • Page 33 OWNER’S/OPERATOR’S MANUAL 7. CONTROL AND PARTS FUNCTIONS LCD Meter 1. Left Turn Indicator 13. Neutral indicator 2. EFI fault indicator 14. Reverse indicator 3. Function button “SET” 15. Engine RPM 4. Parking indicator 16. Gear indicator 5. Low fuel level warning indicator 17. Speed 6.
  • Page 34 OWNER’S/OPERATOR’S MANUAL 7. CONTROL AND PARTS FUNCTIONS Driving mode 4WD-FRONT DIFFERENTIAL LOCK REAR DIFFERENTIAL LOCK Key function: Short Press Button SET: Adjust backlight brightness Short Press Button SEL: Trip A, Trip B switch Long Press Button SEL: Trip A or Trip B reset Long Press Button SET&SEL: Clock setting mode Clock setting mode: short press SEL：adjust the flashing position...
  • Page 35 OWNER’S/OPERATOR’S MANUAL 7. CONTROL AND PARTS FUNCTIONS DTC number DTC Descriptor P0107 Map Open/GND P0108 Map Short V P0112 IAT Short GND P0117 Toil Short GND P0118 Toil Short V|Open P0122 TPS Open|GND P0123 TPS Short V P0131 O2 Short GND P0132 O2 Short V P0038...
  • Page 36 OWNER’S/OPERATOR’S MANUAL 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 37 OWNER’S/OPERATOR’S MANUAL 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 38 OWNER’S/OPERATOR’S MANUAL 7. CONTROL AND PARTS FUNCTIONS AUTOMATIC TRANSMISSION GEAR SELECTOR OPERATION The transmission gear selector is located on the right side of the steering wheel. The transmission selector lever has four positions: high gear, low gear, neutral, and reverse. CAUTION To change gears, stop the vehicle and with the engine idling, move the lever to the desired gear.
  • Page 39 OWNER’S/OPERATOR’S MANUAL 7. CONTROL AND PARTS FUNCTIONS FUEL TANK CAP 1.Fuel tank cap Remove the fuel tank cap by turning it counterclockwise. 7- 11...
  • Page 40 OWNER’S/OPERATOR’S MANUAL 7. CONTROL AND PARTS FUNCTIONS SEATS 1. Driver seat 2. Passenger seat To remove the seat, lift the front of the seat, and then slide the seat up and forward. To install the seat, insert the projections on the rear of the seat into the seat holders and push down on the seat at the front.
  • Page 41 OWNER’S/OPERATOR’S MANUAL 7. CONTROL AND PARTS FUNCTIONS SEAT BELTS This vehicle is equipped with three-point seat belts for both the operator and passenger. Always wear your seat belt while riding in the vehicle. 1. Buckle 2. Latch plate 1. Buckle 2.
  • Page 42 OWNER’S/OPERATOR’S MANUAL 7. CONTROL AND PARTS FUNCTIONS TRAILER HITCH BRACKET 1.Trailer hitch. 2.Trailer hitch mount. FUEL AND OIL SYSTEM WARNING Gasoline is highly flammable and explosive under certain conditions.  Always exercise extreme caution whenever handling gasoline.  Always refuel with the engine stopped and outdoors or in a well-ventilated area.

  • Page 43: Starting The Engine

    OWNER’S/OPERATOR’S MANUAL 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 44 OWNER’S/OPERATOR’S MANUAL 8. STARTING THE ENGINE Jump-starting Jump-starting the vehicle should be avoided. The battery should be removed and charged instead. However, if the vehicle must be jump started, proceed as follows. 1. Turn the key to “OFF”. 2. Connect the positive end of a full charged 12V battery to the positive end of the battery in the vehicle using a jumper cable.
  • Page 45 OWNER’S/OPERATOR’S MANUAL 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 the new engine will result in more efficient performance and longer life for the engine.

  • Page 46: Riding Gear

    OWNER’S/OPERATOR’S MANUAL 10. RIDING GEAR Always wear clothing suited to the type of riding you are doing. UTV riding requires special protective clothing which will make you feel more comfortable and reduce chances of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding. Select an approved off-road motorcycle-type helmet that fits properly to prevent a severe head injury.
  • Page 47 OWNER’S/OPERATOR’S MANUAL 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 48: Carrying Loads

    OWNER’S/OPERATOR’S MANUAL 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 49 OWNER’S/OPERATOR’S MANUAL 11. CARRYING LOADS  Avoid making sharp turns unless at very slow speeds.  Avoid hills and rough terrain. Choose terrain carefully. Added weight affects the stability and handling of the vehicle. WARNING POTENTIAL HAZARD Overloading this vehicle, carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident.
  • Page 50 OWNER’S/OPERATOR’S MANUAL 11. CARRYING LOADS Lifting and Lowering the Cargo Bed 1.Cargo bed release lever To lift: Push the cargo bed button on the dashboard upward to lift the cargo bed until it stops. To lower: Push the cargo bed button on the dashboard downward to lower the cargo bed until it stops.
  • Page 51 OWNER’S/OPERATOR’S MANUAL 11. CARRYING LOADS 11-4...
  • Page 52 OWNER’S/OPERATOR’S MANUAL 12. CVT SYSTEM WARNING The CVT system rotates at high speeds. Creating large amounts of force on the clutch components. Do not modify any components of the CVT system. Any modification will damage the system; and cause the system to be out of balance. The CVT housing must be securely in place during operation.

  • Page 53: Exhaust System

    OWNER’S/OPERATOR’S MANUAL 13. EXHAUST SYSTEM SYSTEM REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED! CAUTION Exhaust system components are very hot during and after use of the UTV.  Do not touch exhaust system components. Serious burns can result.  Be especially careful when traveling through tall grass. The potential for fire exists.
  • Page 54 OWNER’S/OPERATOR’S MANUAL 13. EXHAUST SYSTEM WARNING When cleaning the spark arrestor, you must follow the safeguards listed below to avoid serious injury.  Do not perform this operation immediately after the engine has been run because the exhaust system becomes very hot. Keep combustible materials away from the exhaust system, ...
  • Page 55 OWNER’S/OPERATOR’S MANUAL 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 56 OWNER’S/OPERATOR’S MANUAL 14. BATTERY Battery Installation and Connections WARNING To avoid the possibility of explosion, always connect the battery cables in the order specified. Red (positive) cable first; black (negative) cable last. An exploding battery can cause serious injury or death. WARNING Battery terminals and connections should be kept free of corrosion.
  • Page 57 OWNER’S/OPERATOR’S MANUAL 14. BATTERY CAUTION Your UTV is equipped with a 30Ah Battery. This may not be sufficient to provide power for optional equipment. When installing optional equipment please upgrade your battery, as necessary. See your dealer for more information. 14-3...

  • Page 58: Troubleshooting

    OWNER’S/OPERATOR’S MANUAL 15. TROUBLESHOOTING LOW BATTERY VOLTAGE Possible Cause Solutions See ”8. STARTING THE ENGINE” Starting a faulty engine for and check the fuel/ air/ ignition/ a long time. compression system. Leaving the ignition switch When stopping the engine, turn (key) on when parking the off the ignition switch (key) at UTV.
  • Page 59 OWNER’S/OPERATOR’S MANUAL 15. TROUBLESHOOTING NOTE: The following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection, adjustment, and replacement of parts. Adjustment and replacement must be done by your dealer.
  • Page 60 OWNER’S/OPERATOR’S MANUAL 15. 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 Improper plug gap Faulty main switch Worn electrodes Faulty brake switch Wire between terminals broken...
  • Page 61 OWNER’S/OPERATOR’S MANUAL 15. TROUBLESHOOTING POOR MEDIUM AND HIGH-SPEED PERFORMANCE Air cleaner Improper fuel pressure Clogged air cleaner element Clogged main nozzle Fuel tank Low fuel pressure due to the fuel pump clogged POOR SPEED PERFORMANCE Ignition system Compression system Dirty spark plug Worn cylinder Improper heat range Worn or seized piston rings...
  • Page 62 OWNER’S/OPERATOR’S MANUAL 15. TROUBLESHOOTING OVER HEATING Fuel system Ignition system Improper spark plug gap ECU setting incorrect Improper spark plug heat Improper fuel level adjustment range Clogged air cleaner element Faulty igniter unit Compression system Engine oil Heavy carbon deposit build- Incorrect engine oil level Improper engine oil quality Improperly adjusted valve...
  • Page 63 OWNER’S/OPERATOR’S MANUAL 15. TROUBLESHOOTING Compression spring Damage Gears Damage CLUTCH SLIPPING Clutch weight spring Incorrect Primary Clutch Position Worn/loose Incorrect engine mount Clutch shoe (see 12. CVT system) Worn/damaged Primary sliding sheave Seized POOR STARTING PERFORMANCE V-belt Primary sliding sheave Slipping/oily V-belt Improper operation Damage...

  • Page 64: Specifications

    OWNER’S/OPERATOR’S MANUAL 16. SPECIFICATIONS Dimensions & Capacities L × W × H 3070mm×1622mm×2060mm Seat height 460mm Wheelbase 1930mm Ground Clearance 230mm Fuel capacity 30L (7.93 Gal.) Engine Oil Capacity 2.7 L Dry Weight 669 kg (1475 lbs.) Load Capacity 350 kg (772 lbs.) (Combined Rider&...
  • Page 65 OWNER’S/OPERATOR’S MANUAL 16. SPECIFICATIONS Engine Engine Type XY192MR 4Stroke, Single Cylinder, SOHC Bore x Stroke 92mmx75mm Displacement 498.6cc Starter System Electric Starter Engine Cooling Liquid -Cooled Lubrication System Wet Sump Ignitions Spark Plug Type K6RTC or BKR5E-11 Electrical Equipment Battery 12V 30AH Head light （Low beam）...
  • Page 66 OWNER’S/OPERATOR’S MANUAL 17. WIRING DIAGRAM 17-1...
  • Page 67 OWNER’S/OPERATOR’S MANUAL 17. WIRING DIAGRAM Battery Battery 17-2...
  • Page 68 OWNER’S/OPERATOR’S MANUAL 17. WIRING DIAGRAM Battery Battery Head Head Light Light Head Head Light Light Turn Turn signal signal Light(F,L) Light(F,L) Turn Turn signal signal Light(F,R) Light(F,R) Turn Turn signal signal Light(F,L) Light(F,L) Turn Turn signal signal Light(F,R) Light(F,R) Parking Switch Belt Switch 17-3...
  • Page 69 OWNER’S/OPERATOR’S MANUAL 17. WIRING DIAGRAM Battery Battery Water Water temperature temperature sensor sensor REC/REG REC/REG Spark Spark Plug Plug 17-4...

  • Page 70: Maintenance

    OWNER’S/OPERATOR’S MANUAL 18. MAINTENANCE To keep the vehicle performing optimally, the vehicle should be checked and maintained at certain intervals. The meanings of the capital letters in following table are: I: Inspection, including check, clean, lubricate, refuel, repair or replacing if necessary.
  • Page 71 OWNER’S/OPERATOR’S MANUAL 18. MAINTENANCE If you want to know more about maintenance details, please refer to the following table. Due to the nature of the adjustments marked with a D on the following chart, it is recommended these services be performed by an authorized dealer.
  • Page 72 OWNER’S/OPERATOR’S MANUAL 18. MAINTENANCE Item Hours When Remarks  Brake System Pre-ride Pre-ride Pre-ride inspection item Inspect –adjust, lubricate, replace Accelerator pedal Pre-ride Pre-ride if necessary; pre-ride inspection item Check for leaks at tank cap, lines, Fuel System Pre-ride Pre-ride fuel valve, filter, and throttle body Inspect daily, pre-ride inspection ...
  • Page 73 OWNER’S/OPERATOR’S MANUAL 18. MAINTENANCE Item Hours When Remarks Throttle Cable/ Accelerator Inspect –adjust, lubricate, replace if 20 hrs monthly necessary; pre-ride inspection item pedal Shift linkage 50 hrs 6 months Inspect, adjust Drive belt 50 hrs 6 months Inspect, replace if necessary Check operation and for looseness, worn, damage, binding feeling / Steering system...
  • Page 74 OWNER’S/OPERATOR’S MANUAL 18. MAINTENANCE LUBRICATION RECOMMENDATIONS Item Lube Rec Method Frequency 1.Engine Oil SAE 15W/40SG Add to proper level on dipstick Check level daily  As required, change Maintain level between fill lines. 2.Brake Fluid DOT 3 Only every two years or See “7.
  • Page 75 OWNER’S/OPERATOR’S MANUAL 18. 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 M12X1.25 50Ft.Lbs 69N.m NOTE: All nuts that have a cotter pin installed must be serviced by an authorized Dealer.
  • Page 76 OWNER’S/OPERATOR’S MANUAL 18. 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. Rear Spring Adjustment AIR FILTER SERVICE 1.Lift the seat asst. (See 7. CONTROL AND PARTS FUNCTIONS in this manual for bed lifting and lowering.) ○...
  • Page 77 OWNER’S/OPERATOR’S MANUAL 18. MAINTENANCE Park on level ground. Turn the steering wheel right and left. Check for excessive free play, abnormal noises, or a rough feeling. Have an authorized dealer repair as necessary for proper operation. Lubricate the pivoting parts. Recommended lubricant: Lithium-soap-based grease CAMBER AND CASTER...
  • Page 78 OWNER’S/OPERATOR’S MANUAL 18. MAINTENANCE WARNING If the tie rod is positioned incorrectly or adjusted incorrectly, it will not pivot, may break, and may separate. Severe injury or death can result. BRAKES  Always fill reservoir indicated whenever the cover is loosened or removed to insure proper diaphragm operation.
  • Page 79 OWNER’S/OPERATOR’S MANUAL 18. MAINTENANCE and/or brake system leakage. If the brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage.  The brake fluid reservoir is located under the hood. ...
  • Page 80 OWNER’S/OPERATOR’S MANUAL 18. MAINTENANCE Adjusting Note: The adjustment on the caliper is for wear of the brake pads. To adjust the mechanical parking brake, use the following procedure:  1. With the engine off, loosen the adjustor on the lever. ...
  • Page 81 OWNER’S/OPERATOR’S MANUAL 18. MAINTENANCE NOTE: While adjusting free play, it is important you flip the throttle pedal back and forth. 3. Tighten locknut and slide the boots over cable adjuster. SPARK PLUGS  Insulator ① Inspect: Abnormal color: Replace. Normal color is a medium-to-light tan color.
  • Page 82 OWNER’S/OPERATOR’S MANUAL 18. MAINTENANCE Remove the spark plug by rotating it counterclockwise. Reverse the procedure for spark plug installation. Torque to 22ft.Ibs (30N.m). WARNING Winch Warning: The winch is available as an optional accessory, please contact your dealer for more information. Maximum Winch Specs: 12V/200Amp relay needed.
  • Page 83 OWNER’S/OPERATOR’S MANUAL 18. MAINTENANCE CAUTION: 1. Do not add any chemical additives. 2. Be sure not to use oils labeled "ENERGY CONSERVING I" or higher. Engine oil also lubricates the gear-box and additives could cause abnormal wear. 3. Be sure no foreign material enters the crankcase. 4.
  • Page 84 OWNER’S/OPERATOR’S MANUAL 18. MAINTENANCE 5. Install: ○  Aluminum Washer 10 2 NEW ○  Bolt M10 NOTE : Check the drain plug washer. If damaged, replace it with a new one. 6. Fill Oil:  Crankcase Oil quantity: 2.6L 7.

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