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Egimotors RANGER 1000 2025 Owner's Manual

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Egimotors
2025 Owner's Manual
RANGER 1000
QUADRICYCLE
Owner's manual part Number - OM25QRNG1000
Read this manual carefully. It contains important safety
information. This is an adult vehicle only.
Operation is prohibited for those under 18 years of age.
WARNING

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  • Page 1 Egimotors 2025 Owner’s Manual RANGER 1000 QUADRICYCLE Owner’s manual part Number - OM25QRNG1000 Read this manual carefully. It contains important safety information. This is an adult vehicle only. Operation is prohibited for those under 18 years of age. WARNING...
  • Page 2 This Owner Manual refers to EGIMOTORS QUADRICICLES (To be filled in by your Dealer) This Owner’s Manual must always remain inside you Quadricycle (Legal requirement) A digital/printable copy is available on www.egimotors.com Year ________________________________________________________ Model Type___________________________________________________ Code number (spare parts use only) _______________________________...
  • Page 3 If after reading this manual, you still have some questions please do not hesitate to contact your dealer that will be available to help you. Be sure to visit us online at www.Egimotors.it for the latest news and for product and Safety information.
  • Page 4 The original instruction is in English. Other languages are provided as translation of the original Instruction see the EGIMOTORS website for more details and procedure.

  • Page 5: Table Of Contents

    INTRODUCTION ..............7 CERTIFICATE OF PRE-DELIVERY INSPECTION ....10 SAFETY ................14 FEATURES AND CONTROLS ..........37 OPERATION ............... 75 EMISSION CONTROL SYSTEMS .......... 83 MAINTENANCE ..............84 SPECIFICATIONS .............. 128 PRODUCTS ............... 131 TROUBLESHOOTING............133 WARRANTY ..............137 MAINTENANCE LOG ............142...

  • Page 7: Introduction

    INTRODUCTION INTRODUCTION IMPORTANT INFORMATION WARNING Failure to follow the warnings contained in this manual can result in severe injury or death. This vehicle is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles. A collision or rollover can occur quickly, even during routine maneuvers, if you fail to take proper precautions.

  • Page 8: Safety Symbols And Signal Words

    INTRODUCTION SAFETY SYMBOLS AND SIGNAL WORDS The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. DANGER DANGER indicates a hazardous situation which, if not avoided, WILL result in death or serious injury.

  • Page 9: Vehicle Identification Numbers

    Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a EGIMOTORS key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost.

  • Page 10: Certificate Of Pre-Delivery Inspection

    CERTIFICATE OF PRE-DELIVERY CERTIFICATE OF PRE-DELIVERY INSPECTION Quadricycle Certificate of Pre-Delivery Year ______ Model______________________________ VIN___________________________________________ Engine Serial Number ____________________________ Key Number ____________ Km / Hours______________ Registration Plate Number_________________________ ASSEMBLY / SERVICE / INSPECTION • - SEALED BATTERY – Apply dielectric grease to terminal bolts and install cable. Check Voltage and charge if below 12,8 Volts.
  • Page 11 CERTIFICATE OF PRE-DELIVERY Quadricycle Certificate of Pre-Delivery Year ______ Model______________________________ VIN___________________________________________ Engine Serial Number ____________________________ Key Number ____________ Km / Hours______________ Registration Plate Number_________________________ TEST RIDE • - ENGINE – Starting acceleration and smoothness. • - IDLE SPEED – Verify when cold and hot the engine idle properly. •...

  • Page 12: Delivery To Customer

    • - SAFETY TRAINING COURSE SVIA – I have instructed the owner on the authorized SVIA Safety training online course. • - PRE-DELIVERY CERTIFICATION – I certify that pre-delivery inspection and service have been perform on this vehicle in accordance with the instructions issued by EGIMOTORS. DEALERSHIP NAME____________________________#_________ DELIVERED BY_________________________________________...

  • Page 13: Customer Acceptance

    Registration Plate Number_________________________ CUSTOMER ACCEPTANCE • - I have reviewed the EGIMOTORS warranty Policy / Policies • - I have inspected the Quadricycle and it meets my satisfaction. • - I understand the importance of following the Owner’s Manual and instructions.

  • Page 14: Safety

    • Reduce the effectiveness of occupant protection systems, including the seatbelts and the Rollover Protective Structure (ROPS). • Make it illegal to own or operate your vehicle. EGIMOTORS-authorized spark arresters, mufflers, and emissions control components are mandatory for ownership or operation in many areas.
  • Page 15 EGIMOTORS recommends that you supervise younger drivers. Set rules and put limits on how, when, and where they are allowed to use this vehicle. For example,...
  • Page 16 SAFETY PREPARE VEHICLE FOR THE RIDE Before starting off, always perform the Pre-Ride Inspection. Failure to inspect and verify that the vehicle is in safe operating condition increases the risk of an accident, which can lead to serious injury or death. ITEM REMARK REFERENCE...

  • Page 17: Specification

    Improper tire maintenance can lead to loss of control and an accident, which could result in serious injury or death. To reduce your risk of injury: • Maintain EGIMOTORS recommended tire pressure. Check pressure before operating. Even if your vehicle has only been driven a short distance, the tire pressure readings can become higher.
  • Page 18 Whenever riding the Quadricycle, always wear googles. EGIMOTORS recommends wearing approved Personal Protective Equipment (PPE) that have markings indicating they are designed to standards...
  • Page 19 SAFETY Always stay completely inside the vehicle and hold the steering wheel or hand holds. Body parts outside of the vehicle can be struck by passing objects or crushed during a rollover. Do not put any part of your body outside of the vehicle for any reason.

  • Page 20: Driving Guidelines

    SAFETY DRIVING GUIDELINES Drive responsibly. This vehicle is not a toy and can be hazardous to operate. This vehicle has higher ground clearance and other features to handle rugged terrain. It can be overturned in situations where some other vehicles may not. Abrupt maneuvers or aggressive driving, even on flat, open areas, can cause loss of control, rollovers, severe injury or death.
  • Page 21 Watching someone else go over a jump or go airborne does not mean you can safely do so. EGIMOTORS cannot determine whether any jump you may encounter is appropriate for this vehicle. Any jump, even a small one, could be poorly maintained, designed, or not suitable for this vehicle and may cause serious injury or death.
  • Page 22 SAFETY Recovering from stalling on a hill If the vehicle loses forward speed, apply the brakes gradually and stop. Do not attempt to turn the vehicle around. Instead, shift to reverse and allow the vehicle to slowly roll straight downhill. Apply light brake pressure to control speed. Overtopping a hill Slow down when you reach the crest of a hill.
  • Page 23 If you cannot safely transport the vehicle on your own, contact a recovery and towing service. After any crash, rollover, or other accident, have a EGIMOTORS dealer inspect the vehicle for possible damage, including seat belts, ROPS, brakes, suspension, and steering systems.
  • Page 24 SAFETY Be prepared in case your vehicle becomes damaged or disabled, especially in remote areas. Consider in advance how to get help and stay safe until it arrives whenever you ride. There is a recovery tow loop at the front and back of the vehicle to attach a winch or strap.
  • Page 25 SAFETY All engine exhaust contains carbon monoxide, a deadly gas. Breathing carbon monoxide can cause headaches, dizziness, drowsiness, nausea, confusion, and eventually death. Carbon monoxide is a colorless, odorless, tasteless gas which may be present even if you do not see or smell any engine exhaust.

  • Page 26: Loading And Unloading

    SAFETY LOADING AND UNLOADING The weight distribution of the cargo loaded onto the trailer is important and will have an impact on how the vehicle handles on the road. Ensure the weight of the cargo is distributed properly and the trailer is not rear, front, or side heavy. Always use a spotter if you are uncomfortable loading the vehicle on your own.
  • Page 27 SAFETY WARNING Cargo and other loose vehicle parts may fly off while transporting this vehicle. Secure or remove all cargo, and inspect the unit for loose parts prior to transport. If transporting the vehicle in a non-enclosed trailer, then the vehicle must FACE FORWARD, or roof must be removed.
  • Page 28 SAFETY TOWING A RANGER Towing this vehicle is not recommended. Always transport the vehicle on a trailer or flatbed with all four wheels off the ground. If towing a disabled vehicle is unavoidable, place the disabled vehicle’s transmission in neutral. Tow the shortest distance possible. Do not operate faster than 16 km/h.

  • Page 29: Hot Exhaust Systems

    SAFETY HOT EXHAUST SYSTEMS WARNING Exhaust system components are very hot during and after use of the vehicle. Hot components can cause burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.
  • Page 30 SAFETY FUEL WARNING Gasoline and gasoline vapor is highly flammable and explosive. Refuel outdoors or in a well-ventilated area free of any source of flame or sparks, including pilot lights from water heaters, furnaces, or clothes dryers. To avoid fires and explosions, follow these precautions when refueling. Do not smoke.

  • Page 31: Handling Gasoline

    SAFETY WARNING Gasoline can expand while inside the tank. To avoid fires and explosions, do not overfill the tank. Allow room for gasoline to expand inside the tank by leaving the tank neck empty. Use only 87 octane (or higher) unleaded fuel (minimum pump octane number of 87 R+M/2) Do not use any fuel lower than 87 octane.

  • Page 32: Safety Labels And Locations

    If any label becomes illegible or comes off, contact your EGIMOTORS dealer to purchase a replacement. Replacement safety labels are provided by EGIMOTORS at no charge.
  • Page 33 SAFETY WARNING Read the owner’s manual. Never allow anyone under 18 years of age to operate this vehicle. Never use alcohol or drugs before or while driving or riding. This vehicle is approved for on-road operation. Wear approved helmet, goggles, and protective clothing. Always wear seat belts. Always use the cab nets or doors.
  • Page 34 INTAKE ALERT The Intake Alert Caution label is located on the air intake. WARNING Use a EGIMOTORS approved air filter. The use of a non-EGIMOTORS approved air filter may cause engine damage. Before installing filter ensure there is no dirt or debris in the clean side of the intake tube.

  • Page 35: Safety Alert

    SAFETY SHIFT ALERT The Shift Alert is located on the console. WARNING To avoid transmission damage, shift only when vehicle is stationary and at idle. APPLY BRAKE TO START. When this vehicle is not in operation, or unattended, place shift in the park position.

  • Page 36: Jacking Points

    SAFETY JACKING POINTS WARNING Make sure the vehicle is in park with the parking brake set (if applicable). Use wheel chocks to prevent the vehicle from rolling when the vehicle is raised on a jack. Make sure to use appropriate jack stands, and never work under or around a vehicle that is unsupported.

  • Page 37: Features And Controls

    FEATURES AND CONTROLS FEATURES AND CONTROLS COMPONENT LOCATIONS ① Console ⑧ Tailgate ② Radiator ⑨ Hip Bar ③ Bumper ⑩ Cargo Box ④ Headlight ⑪ Fuel Cap ⑤ Taillights ⑫ ROPS Cab Frame ⑥ CV Boot/Rear Caliper ⑬ Fuse Block (underneath seat) ⑭...
  • Page 38 FEATURES AND CONTROLS CONSOLE ① Turn Signal Lever ⑦ Storage Compartment ② Instrument Cluster ⑧ 12V Auxiliary Outlet ③ Gear Selector (Shifter) ⑨ Battery Trickle-Charging Outlet ④ Park Brake Lever ⑩ 12V Auxiliary Outlet ⑤ Heater Control Panel (if equipped) ⑪...

  • Page 39: Steering Wheel

    FEATURES AND CONTROLS STEERING WHEEL The steering wheel can be tilted upward or downward for rider preference. Lift and hold the steering wheel adjustment Lever ① while moving the steering wheel upward or downward. Release the lever when the steering wheel is at the desired position.

  • Page 40: Using Low Gear

    FEATURES AND CONTROLS Maintaining shift linkage adjustment is important to assure proper transmission function. Your EGIMOTORS dealer can assist in resolving any shifting problems. NOTICE Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission could result. Always shift when the vehicle is stationary and the engine is at idle.

  • Page 41: Ignition Switch

    FEATURES AND CONTROLS SWITCHES Not all switches are present on every model. IGNITION SWITCH The ignition switch is a four-position, key-operated switch. The key can be removed from the switch when it is in the OFF position. Ignition Switch Label The engine is off.

  • Page 42: Turn Signal Lever

    FEATURES AND CONTROLS TURN SIGNAL LEVER Before turning, activate a turn signal to alert others of your intentions. Check turn signal lamps before each ride. Move the lever upward ① to signal a right turn. The right signal lamps and indicator will flash.

  • Page 43: Horn Switch

    FEATURES AND CONTROLS HIGH BEAM HEADLIGHTS Key ignition switch to SYSTEM ON position. Push the headlight switch towards the driver to switch from the low beam headlights to high beam headlights. Pull the headlight switch again to switch from high beam headlights to low beam headlights.

  • Page 44: All-Wheel Drive (Awd) System

    FEATURES AND CONTROLS ALL WHEEL DRIVE (AWD) SYSTEM The All Wheel Drive system is controlled by the AWD switch. The switch has three positions, AWD (4x4), 2WD (2x4) and Turf Mode (1x4). When in AWD, the demand drive unit will automatically engage any time the rear wheels lose traction.

  • Page 45: Engaging Awd

    FEATURES AND CONTROLS ENGAGING AWD The AWD switch may be turned on or off while the vehicle is moving. Initially, the vehicle's electronic system will not enable the AWD until the engine RPM is below 3100. Once enabled, the AWD remains enabled until the AWD switch is turned off.
  • Page 46 FEATURES AND CONTROLS LOCKING/UNLOCKING THE REAR DIFFERENTIAL NOTICE Damage to the differential can occur if it is engaged while the vehicle is traveling at high speeds or while the rear wheels are spinning. Slow the vehicle to nearly stopped before engaging the differential. Locking the differential in slippery or low traction conditions helps improve traction.

  • Page 47: Auxiliary Outlet

    WEEKS, EGIMOTORS recommends using a BatteryMINDer® 2012 AGM - 2 AMP charger, which can be ordered through your dealer. EGIMOTORS provides a charging accessory with your vehicle that allows easy connection to the battery through the Battery Trickle-Charging Outlet, located on the dash. While charging, place the charger outside of the vehicle and protect it from moisture.

  • Page 48: Foot Pedals

    FEATURES AND CONTROLS FOOT PEDALS BRAKE PEDAL Depress the brake pedal ① to slow or stop the vehicle. Apply the brakes while starting the engine. When the brake pedal is depressed, the brake light comes on. Check the brake light before each ride. 1.

  • Page 49: Park Brake Lever

    FEATURES AND CONTROLS PARK BRAKE LEVER Always apply the service brakes before engaging or releasing the park brake. To help prevent the vehicle from rolling, set the park brake when parking the vehicle. When the park brake is set and the park brake indicator is illuminated, engine speed is limited.

  • Page 50: Seat Belts

    FEATURES AND CONTROLS SEATS CAUTION Prolonged sun exposure can cause excessive heating of the steering wheel and seats. Use caution when handling hot surfaces to avoid burns. NOTE These seats are designed for this quadricycle model. Replacement with different seats is not possible. Before operating the vehicle, always push down on all seat backs to ensure the latches are secure.

  • Page 51: Seat Belt Inspection

    FEATURES AND CONTROLS WARNING Falling from a moving vehicle could result in serious injury or death. Always fasten your seat belt securely before operating or riding in the vehicle. To wear the seat belt properly, follow this procedure: ① 1. For 3-point belts, pull the seat belt latch downward and across your chest toward the buckle at the inner edge of the seat.

  • Page 52: Seat Adjustments

    FEATURES AND CONTROLS If your model is equipped with a storage console and cup holders located between the front seats, lift the console lid to access the storage compartment. Pull the rear edge of a seat upward to release the latch pins from the grommets. Roll the seat forward to access the under-seat area.

  • Page 53: Electronic Power Steering

    EPS has shut down. Turn the key off and on to reset the unit. If the light remains on after starting the engine, the EPS system is inoperative. See your EGIMOTORS dealer, or other qualified person, as soon as possible for repair. Continued operation could result in permanent damage to the EPS unit and increased steering effort.

  • Page 54: Rollover Protective Structure (Rops)

    Use the strap adjusters to tighten any loose straps. Promptly replace worn or damaged cab nets and latches with new cab nets and latches. Your EGIMOTORS dealer or qualified technician can assist. SECURING THE NET 1.

  • Page 55: Trailer Hitch

    FEATURES AND CONTROLS TRAILER HITCH This vehicle is equipped with a receiver hitch bracket for a trailer hitch and trailer towing equipment (for off road use only). NOTICE To avoid injury and property damage, always heed the warnings and towing capacities outlined in the specification table.
  • Page 56 FEATURES AND CONTROLS HITCH REMOVAL / INSTALLATION ① 1. To remove the hitch (if equipped), remove the cotter pin and hitch pin ① Remove the hitch, then reinstall the hitch pin and secure the cotter pin ① 2. To install the hitch, remove the cotter pin from the hitch pin and remove ②...

  • Page 57: Instrument Cluster

    FEATURES AND CONTROLS INSTRUMENT CLUSTER OVERVIEW NOTICE Features and telltales vary by model. DISPLAY AREA FUNCTION H = High Gear L ① Gear Indicator = Low Gear N = Neutral R = Reverse Gear P = Park – = Gear Signal Error (or shifter between gears) This area displays odometer, trip meter, trip meter 2, ②...

  • Page 58: Indicator Lamps

    A flashing wrench symbol alerts the operator that ⑧ Service Indicator the preset service interval has been reached. Your EGIMOTORS dealer can provide scheduled maintenance. The clock displays time in a 12-hour or 24-hour ⑨ Clock format.
  • Page 59 FEATURES AND CONTROLS INDICATOR ICON FUNCTION Neutral This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position. This lamp is a reminder to the operator to Helmet/Seat ensure all riders are wearing helmets and Belt seat belts before operating.

  • Page 60: Display Area

    FEATURES AND CONTROLS DISPLAY AREA 1 Pressing the MODE button will change the information displayed in Area 1 ①. DISPLAY AREA 1 FUNCTION The vehicle’s speed will be displayed in mph, or km/h. Speed The vehicle’s current engine temperature will be Engine Temperature displayed.
  • Page 61 FEATURES AND CONTROLS DISPLAY AREA 2 Toggle the Up/Down buttons to change the information displayed in Area 2 ② . DISPLAY AREA 2 FUNCTION The vehicle’s odometer reading will be displayed. Odometer Engine Temperature The vehicle Engine Temperature will be displayed. Trip 1 The vehicle Trip 1 mileage will be displayed.

  • Page 62: Options Menu

    FEATURES AND CONTROLS OPTIONS MENU Press and hold the MODE button to enter the Options Menu. OPTIONS MENU NOTES Diagnostic Codes Only displays if fault codes are present or stored Units - Distance Select MPH or KPH Select between °F and °C Units - Temp Clock Select between 12H or 24H, and set...

  • Page 63: Unit Selection Distance

    FEATURES AND CONTROLS UNIT SELECTION DISTANCE 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Units-Distance” from the Options Menu by pressing the MODE button.
  • Page 64 FEATURES AND CONTROLS UNIT SELECTION TEMPERATURE 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Units - Temp” from the Options Menu by pressing the MODE button. Reference the image shown above: ①...
  • Page 65 FEATURES AND CONTROLS CLOCK 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Clock” from the Options Menu by pressing the MODE button. Reference the image shown above: ①...
  • Page 66 FEATURES AND CONTROLS BACK LIGHT COLOR 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Backlight Color” from the Options Menu by pressing the MODE button.

  • Page 67: Back Light Level

    FEATURES AND CONTROLS BACK LIGHT LEVEL 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Backlight Level” from the Options Menu by pressing the MODE button.
  • Page 68 FEATURES AND CONTROLS SERVICE HOURS 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Service Hours” from the Options Menu by pressing the MODE button. Reference the image shown above: ①...

  • Page 69: Diagnostic Code

    FEATURES AND CONTROLS DIAGNOSTIC CODE NOTICE Diagnostic Code Screen will show available MIL that has come on during that ignition cycle. 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item.
  • Page 70 FEATURES AND CONTROLS DIAGNOSTIC DISPLAY CODE DEFINITIONS Open Load:There is a break in the wires that lead to the item listed in the chart (injector, fuel pump, etc.), or the item has failed. Short-to-Ground:The wire is shorted to ground between the electronic control unit and the item listed in the chart.
  • Page 71 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION Injector 1 (MAG) Driver Circuit (SDI Part Load) Open/Grounded Driver Circuit Short to Driver Circuit Grounded Injector 2 (PTO) Driver Circuit (SDI Part Load) Open/Grounded Driver Circuit Short to Driver Circuit Grounded Ignition Coil Primary Driver Circuit Short to 1268 Driver 1 (MAG)
  • Page 72 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION Driver Circuit Starter Enable Circuit 1321 Open/Grounded Driver Circuit Short to 1321 Driver Circuit 1321 Grounded Chassis Relay Driver Circuit 520208 Open/Grounded Driver Circuit Short to 520208 Driver Circuit 520208 Grounded All Wheel Drive Driver Circuit 520207 Control...
  • Page 73 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION EPS MODELS ONLY Vehicle Speed Sensor Data Valid But Above Normal Operational Range - Most Severe Level Data Erratic, Intermittent Or Incorrect Abnormal Rate Of Change Received Network Data In Error System Power Data Valid But Above Normal Operational Range - Most Severe...
  • Page 74 FEATURES AND CONTROLS DIAGNOSTIC CODES COMPONENT CONDITION EPS MODELS ONLY Steering Torque Condition Exists 520223 Partial Failure Steering Torque Full Condition Exists 520224 Failure EPAS Inverter Data Valid But Above Temperature Normal Operational 520225 Range - Most Severe Level Data Valid But Above Normal Operating 520225 Range - Moderately...

  • Page 75: Operation

    OPERATION OPERATION VEHICLE BREAK-IN IMPORTANT INFORMATION WARNING Failure to operate the vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual.

  • Page 76: Brake Burnishing

    OPERATION BRAKE BURNISHING It is recommended that a burnishing procedure be performed on new vehicles or after installation of new brake pads or rotors. This helps to conform the pads to the rotor surface and achieve optimum braking performance. Test drive the machine and gradually accelerate to more than 30km/h. Apply light to moderate pressure to the brake pedal to slow the vehicle to roughly 5 mph.

  • Page 77: Cold Weather Operation

    OPERATION • When hauling or towing heavy cargo • When consistently operating at speeds less than 56 km/h in hard- pulling terrain, such as mud, rocks or sand/dune environments. OPERATING GUIDELINES BOARDING AND EXITING THE VEHICLE • Never try to climb onto or exit the vehicle while it is moving. •...

  • Page 78: Fuel Recommendation

    Octane (R+M/2) rated gasoline. Using lower octane gasoline could result in engine damage. Ethanol Content EGIMOTORS recommends gasoline containing up to 10% ethanol (E10). Higher levels of ethanol (ex. E15 and E85) may result in engine damage. Seasonal Blends EGIMOTORS recommends using gasoline that is purchased during the season the vehicle is being used, especially summer vs.

  • Page 79: Driving In Reverse

    OPERATION DRIVING IN REVERSE WARNING Before shifting into reverse, use extra care to make sure the area is clear of people or obstacles. When it’s safe to proceed, back slowly. Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2.

  • Page 80: Hauling Cargo

    OPERATION HAULING CARGO WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo: Never exceed the stated load capacity for this vehicle. REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO.

  • Page 81: Towing Loads

    OPERATION Your vehicle has been designed to carry or tow specific capacities. Reduce speed and allow a greater distance for braking when carrying cargo. Loads should be centered on the vehicle and carried as low as possible in the box. For stability on rough or hilly terrain, reduce both speed and cargo. Exercise caution if the cargo load extends over the side of the box.

  • Page 82: Dumping The Cargo Box

    OPERATION DUMPING THE CARGO BOX To dump the cargo box, do the following: 1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Apply the brakes. 3.

  • Page 83: Emission Control Systems

    Do not modify the engine, intake or exhaust components, as doing so may affect compliance with governmental noise level requirements. SPARK ARRESTER Your EGIMOTORS vehicle has a spark arrester that was designed for on-road and off-road operation. It is required that this spark arrester remain installed and functional when the vehicle is operated.

  • Page 84: Maintenance

    OVERVIEW Any qualified repair shop or person may maintain, replace or repair the emission control devices or systems on your vehicle. An authorized EGIMOTORS dealer can perform any service that may be necessary for your vehicle. EGIMOTORS also recommends EGIMOTORS parts for emissions-related service, however equivalent parts can be used.
  • Page 85 MAINTENANCE Vehicles subjected to severe use must be serviced at 50% of the stated interval. Examples of Severe Use: Frequent immersion in mud, water, or sand, constant high RPM use, prolonged low-speed heavy load operation, extended idle, and short trip cold weather operation. INITIAL BREAK-IN SERVICE FIRST 25 HOURS / 800 KM Initial fluid level inspection;...
  • Page 86 MAINTENANCE Vehicles subjected to severe use must be serviced at 50% of the stated interval. Examples of Severe Use: Frequent immersion in mud, water, or sand, constant high RPM use, prolonged low-speed heavy load operation, extended idle, and short trip cold weather operation.
  • Page 87 Transmission Fluid Wiring Inspect for wear, routing, and retention. * It is recommended to have an authorized EGIMOTORS dealer perform these services. Vehicles subjected to severe use must be serviced at 50% of the stated interval. Examples of Severe Use: Frequent immersion in mud, water, or sand, constant high RPM use, prolonged low-speed heavy load operation, extended idle, and short trip cold weather operation.

  • Page 88: Lubrication Recommendations

    MAINTENANCE ELEVATING THE VEHICLE FOR SERVICE WARNING Improperly jacking or supporting the vehicle can result in the vehicle falling or tipping, which can lead to serious injury or death. When elevating vehicle: • Move vehicle to a firm level surface. •...

  • Page 89: Greasing Points

    MAINTENANCE GREASING POINTS Prop Shaft Greasing Point ① Rear Suspension Greasing Points ②...

  • Page 90: Engine Oil

    Maintenance Chart. OIL RECOMMENDATIONS EGIMOTORS recommends the use of PS-4 5W-50 4-Cycle Oil or a similar oil. Refer to the Specifications section for capacities. Oil may need to be changed more frequently if PS-4 engine oil is not used. Follow the manufacturer's recommendations for ambient temperature operation.

  • Page 91: Oil Check

    MAINTENANCE OIL CHECK The oil dipstick is located on the engine. Access the dipstick through the right rear wheel well. To check the oil, do the following: 1. Position vehicle on a level surface and place the transmission in PARK. 2.

  • Page 92: Engine Oil And Filter Replacement

    MAINTENANCE ENGINE OIL AND FILTER REPLACEMENT Always change engine oil and filter at the intervals outlined in the Periodic Maintenance Chart. Always change the oil filter whenever changing the engine oil. The engine oil dipstick is located on the right front side of the engine. The engine oil fill cap is located on top of the valve cover.
  • Page 93 MAINTENANCE 8. Using a clean dry cloth, clean the filter sealing surface on the engine crankcase. 9. Lubricate the O-ring on the new oil filter with a film of fresh engine oil. Check to make sure the O-ring is in good condition. Install it to specification.

  • Page 94: Gearcase Specification Chart

    MAINTENANCE GEARCASES GEARCASE SPECIFICATION CHART DRAIN PLUG/ FILL PLUG LEVEL CHECK GEARCASE LUBRICANT CAPACITY TORQUE PLUG TORQUE AGL Gearcase Transmission 14–19 N·m 14–19 N·m 1200 mL Lubricant & (Main Transmission Gearcase) Fluid Demand Drive 300 — 350 11–14 N·m 15 N·m Demand Drive Unit (Front Fluid...

  • Page 95: Transmission Oil Change

    MAINTENANCE TRANSMISSION OIL CHANGE The drain plug is located on the bottom of the gearcase. Access the drain plug through the hole in the skid plate. ① 1. Remove the fill plug 2. Place a drain pan under the ② drain plug 3.
  • Page 96 MAINTENANCE DEMAND DRIVE OIL CHANGE 1. Support the vehicle securely with a jackstand. 2. Remove the front tire on the passenger's side for ease of access (optional). 3. Remove the fill plug. ② 4. Place a drain pan under the drain plug on the bottom right-hand side.

  • Page 97: Spark Plug Recommendations

    Refer to the Specifications section for the recommended spark plug type for your vehicle. Always torque spark plugs to specification. NOTICE Using non-recommended spark plugs can result in serious engine damage. Always use EGIMOTORS-recommended spark plugs or their equivalent. SPARK PLUG GAP/TORQUE ELECTRODE GAP NEW OR USED PLUG TORQUE 12 N·m...

  • Page 98: Cooling System

    ADDING OR CHANGING COOLANT EGIMOTORS recommends the use of Antifreeze 50/50 Premix. This antifreeze is already premixed and ready to use. Do not dilute with water. To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every five (5) years and fresh Antifreeze 50/50 Premix added.

  • Page 99: Radiator Coolant Level

    But if the overflow bottle has run dry, the level in the radiator should also be inspected. 5. Reinstall the pressure cap. Use of a non-standard pressure cap will not allow the recovery system to function properly. Your EGIMOTORS dealer can provide the correct replacement part.

  • Page 100: Overflow Bottle Coolant Level

    MAINTENANCE OVERFLOW BOTTLE COOLANT LEVEL Always check and change the coolant at the intervals outlined in the EGIMOTORS Maintenance Schedule. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool). 1. Position the vehicle on a level surface.

  • Page 101: Belt Removal

    See your EGIMOTORS dealer or other qualified service person as outlined in the owner's manual. This PVT system is intended for use on EGIMOTORS products only. Do not install it in any other product. Always make sure the PVT housing is securely in place during operation.
  • Page 102 MAINTENANCE To remove the belt, do the following: ① 1. Remove the eight fasteners that retain the outer clutch cover. NOTE Removal of left rear wheel or left rear shock is NOT necessary for belt replacement. 2. To remove the clutch cover, pull the cover (starting at the bottom), lift up over the suspension, and then out of the vehicle.

  • Page 103: Belt Inspection

    MAINTENANCE 4. Insert clutch spreader tool into threaded hole on driven clutch as shown and turn clockwise to spread clutch. NOTE Clutch spreader tool part number 2883577 is found in vehicle tool kit. 5. Walk the belt out of the driven clutch and drive clutch. Remove the belt from the vehicle.

  • Page 104: Belt Installation

    MAINTENANCE BELT INSTALLATION NOTE Be sure to install belt in the same direction as it was removed. 1. With the clutch spreader tool installed, loop the belt over the drive clutch and over the driven clutch. 2. Rotate the driven clutch and walk the belt into the clutch. 3.
  • Page 105 6. Allow the engine RPM to settle to idle speed. Apply the brakes. Shift the transmission to the lowest available range. 7. Test for belt slippage. If the belt slips, repeat the process. 8. Your vehicle requires service as soon as possible. Your EGIMOTORS dealer can assist.

  • Page 106: Vehicle Immersion

    6. Take the vehicle in for service as soon as possible, whether you succeed in starting it or not. Your EGIMOTORS dealer can provide the required service. 7. If water has been ingested into the PVT follow the procedure for drying.

  • Page 107: Filter Systems

    MAINTENANCE FILTER SYSTEMS AIR FILTER REPLACEMENT Inspect the air filter at the intervals outlined in the EGIMOTORS Maintenance Schedule. In extremely dusty conditions, air filter replacement will be required more often. 1. Tilt the rear cargo box to access the airbox.

  • Page 108: Spark Arrester

    MAINTENANCE SPARK ARRESTER WARNING Never operate the vehicle without the spark arrester. Remove any combustible materials from the area. Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death in a very short time.

  • Page 109: Brake Fluid

    MAINTENANCE BRAKES The front and rear brakes are hydraulic disc type brakes. Press down on the brake pedal to engage the brakes. BRAKE FLUID Inspect the brake system routinely. Inspect the level of the brake fluid before each operation. WARNING After opening a bottle of brake fluid, always discard any unused portion.

  • Page 110: Brake Inspection

    MAINTENANCE BRAKE INSPECTION WARNING Do not apply WD-40®or any petroleum product to brake discs. These types of products are flammable and may also reduce the friction between the brake pad and caliper. WARNING Brake components get hot with prolonged use and can cause burns. Wear protective gloves when inspecting the brakes.

  • Page 111: Front Suspension Adjustment

    MAINTENANCE FRONT SUSPENSION ADJUSTMENT NOTICE See ELEVATING THE VEHICLE FOR SERVICE for information on how to safely raise the vehicle. The front suspension can be adjusted to provide a stiffer suspension, if necessary. 1. Support the vehicle securely with a jack stand. 2.

  • Page 112: Steering Wheel Inspection

    Improper tire inflation or the use of non-standard size or type of tires may adversely affect vehicle handling, which could result in vehicle damage or personal injury. Always maintain proper tire pressure. Always use EGIMOTORS approved size and type of tires for this vehicle when replacing tires. WARNING Tires age, even if they have not been used or have only been used occasionally.

  • Page 113: Axle And Wheel Nut Torque Specifications

    MAINTENANCE AXLE AND WHEEL NUT TORQUE SPECIFICATIONS Inspect the following items occasionally for tightness, and if they've been loosened for maintenance service. Do not lubricate the stud or the lug nut. Lug Nut (Aluminum 160 Nm Front and Rear Wheels) Lug Nut (Steel Wheels) 81 Nm...

  • Page 114: Headlight Bulb Replacement

    MAINTENANCE LIGHTS Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Do not operate this vehicle at night or in low light conditions until the headlight is replaced.

  • Page 115: Headlight Adjustment

    MAINTENANCE HEADLIGHT ADJUSTMENT The headlight beams are adjustable. 1. Ensure the tire pressure of all tires is at recommended levels. 2. Place the vehicle on a level surface with the headlight approximately ① 7.6m from a wall. ITEM DESCRIPTION ① Measure Distance = 20.0 cm ②...
  • Page 116 MAINTENANCE ④ 6. If a headlight needs adjustment, locate the adjustment screw at the back of the headlight. Loosen the screw, adjust the headlight, then tighten the screw. 7. Adjust the beam to desired position. Repeat the procedure to adjust the other headlight.

  • Page 117: Brake Lights

    MAINTENANCE LIGHTS Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Do not operate this vehicle at night or in low light conditions until the headlight is replaced. Always make sure lights are adjusted properly for best visibility.
  • Page 118 MAINTENANCE FUSES The fuse box is located under the front seat ① . If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse.
  • Page 119 MAINTENANCE FUSE SIZE FEATURE SUPPORTED Trailer Access Display Heater (if equipped) 7.5A Heater Cont (if equipped) Horn...
  • Page 120 MAINTENANCE BATTERY WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil.

  • Page 121: Battery Maintenance And Charging

    If you do not drive the vehicle for more than TWO WEEKS, EGIMOTORS recommends using a BatteryMINDer® 2012 AGM - 2 AMP charger (PN 2830438), which can be ordered through your dealer.

  • Page 122: Battery Removal

    MAINTENANCE STATE OF VOLTAGE (DC) ACTION CHARGE TIME* CHARGE 100% 12.8-13.0 volts None, check None required monthly 75%-100% 12.6-12.8 volts May need slight 3-6 hours charge, if no charge given, check in 2 weeks 50%-75% 12.3-12.6 volts Needs charge 5-11 hours 25%-50% 12.0-12.3 volts Needs charge...

  • Page 123: Battery Installation

    MAINTENANCE BATTERY INSTALLATION 1. Ensure that the battery is fully charged. 2. Place the battery in the battery holder. 3. Coat the terminals with dielectric grease or petroleum jelly. 4. Connect and tighten the red (positive) cable first. Torque the cable connector nut to 4.5 Nm 5.

  • Page 124: Cleaning And Storage

    Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle. The best and safest way to clean your EGIMOTORS vehicle is with a garden hose and a pail of mild soap and water.
  • Page 125 Replacement safety labels are provided by EGIMOTORS at no charge. POLISHING THE VEHICLE EGIMOTORS recommends the use of common household aerosol furniture polish for polishing the finish on your EGIMOTORS vehicle. Follow the instructions on the container. POLISHING TIPS • Avoid the use of automotive products, some of which can scratch the finish of your vehicle.

  • Page 126: Storage Tips

    Make any necessary repairs and clean the vehicle as recommended. STABILIZE THE FUEL 1. Fill the fuel tank. 2. Add EGIMOTORS Carbon Clean Fuel Treatment or EGIMOTORS Fuel Stabilizer or equivalent fuel treatments or stabilizers. Follow the instructions on the container for the recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.

  • Page 127: Fog The Engine

    6. Reinstall the spark plug caps. 7. If EGIMOTORS fuel system additive is not used, fuel tank, fuel lines, and injectors should be completely drained of gasoline. STORAGE AREA / COVERS Be sure the storage area is well ventilated.

  • Page 128: Specifications

    SPECIFICATIONS SPECIFICATIONS RANGER 1000 QUADRICYCLE Gross Vehicle Weight Capacity 1184 kg (includes weight of operator, passenger, cargo, accessories) Unladen mass in running order 600 kg Fuel Capacity 41 L Engine Oil Capacity 2.4 l Coolant Capacity 4.75 l Overall Length 305 cm Overall Width 158 cm...
  • Page 129 SPECIFICATIONS ECU Controlled 32° +/- 2° @ 5000 Ignition Timing Autolite® 5684 / 0.85 mm Nominal Spark Plug/ Gap Lubrication System Wet Sump Cooling Liquid Front Suspension Dual A-Arm, IFS 25.4 cm Travel Rear Suspension Dual A-Arm, IRS 25.4 cm Travel Ignition System Digital CDI Driving System Type...
  • Page 130 SPECIFICATIONS OUTPUT GEAR RATIOS Front Rear 8,56:1 25,59:1 HIGH 4,03:1 12,05:1 REVERSE 7,67:1 22,90:1 SEAT VIBRATION DRIVER RATIO 98 kg 59 kg...

  • Page 131: Lubricants / Service Products

    PRODUCTS PRODUCTS LUBRICANTS / SERVICE PRODUCTS SIZE (QUANTITY) PRODUCT QUANTITY PART NUMBER 355 mL aerosol 2870791 Fogging Oil 0.95 L 2871517 0.95 L 2876244 1.90 L PS-4 2877490 3.8 L 2876245 0.95 L 2878920 1.90 L 2878922 PS-4 Extreme Duty 3.8 L 2878919 0.95 L...
  • Page 132 PRODUCTS SIZE (QUANTITY) QUANTITY PRODUCT PART NUMBER 355 Ml bottle Carbon Clean 2871326 473 mL 2870652 Fuel Stabilizer 9.5 L 2872280 — DOT 4 Brake Fluid 2872189 Loctite® 565 Thread — 2871956 Sealant BatteryMINDer® 2012 — 2830438 AGM - 2 AMP Charger...

  • Page 133: Troubleshooting

    PVT information. Inspect clutch seals for damage if repeated leaking system occurs. See your EGIMOTORS dealer or other qualified person Clutch malfunction Check for clogged air filter, clogged fuel filter, water in the fuel or Poor engine performance foreign material in fuel tank or fuel lines.

  • Page 134: Engine Turns Over, Fails To Start

    Inspect plug and replace if necessary No spark to spark plug Inspect plug and replace if necessary Water or fuel in crankcase See your EGIMOTORS dealer or other qualified person Low battery voltage Recharge the battery to 12.8 VDC Mechanical failure...

  • Page 135: Engine Pings Or Knocks

    TROUBLESHOOTING ENGINE PINGS OR KNOCKS POSSIBLE CAUSE SOLUTION Poor quality or low octane Replace with recommended fuel fuel Incorrect spark plug Set gap to specs or replace plug gap or heat range ENGINE RUNS IRREGULARLY, STALLS OR MISFIRES POSSIBLE CAUSE SOLUTION Fouled or defective spark Inspect, clean and/or replace spark plug...

  • Page 136: Engine Stops Or Loses Power

    TROUBLESHOOTING ENGINE STOPS OR LOSES POWER POSSIBLE CAUSE SOLUTION Out of fuel Refuel Kinked or plugged fuel vent Inspect and replace line Water is present in fuel Replace with new fuel Fouled or defective spark plug Inspect, clean and/or replace spark plug Worn or defective spark plug Your authorized dealer can assist wires...

  • Page 137: Limited Warranty

    This warranty is transferable to another owner during the warranty period through a EGIMOTORS dealer, but any such transfer will not extend the original term of the warranty. The duration of this warranty may vary by international region based upon local laws and regulations.

  • Page 138: Warranty Coverage And Exclusions

    WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES This EGIMOTORS limited warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling.

  • Page 139: Lubricants And Fluids

    DEFECTIVE MATERIALS, COMPONENTS, OR PRODUCTS. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. EGIMOTORS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE.

  • Page 140: How To Obtain Warranty Service

    IF YOU PURCHASE FROM A PRIVATE PARTY: If you purchase a EGIMOTORS product from a private party, to be kept and used outside of the country in which the product was originally purchased, all warranty coverage will be denied. You must nonetheless register your product under your name and address with a local EGIMOTORS dealer in your country to ensure that you receive safety information and notices regarding your product.

  • Page 141: Exported Products

    IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION. This policy does not apply to products that have received authorization for export from EGIMOTORS. Dealers may not give authorization for export. You should consult an authorized dealer to determine this product's warranty or service coverage if you have any questions.

  • Page 142: Maintenance Log

    MAINTANANCE MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance. MILES (KM) SERVICE PERFORMED / DATE TECHNICIAN OR HOURS COMMENTS...
  • Page 143 For more information visit www.Egimotors.it Egimotors Via Filippo da Desio 49/51 20832 Desio (MB) ITALY info@polarisitalia.com...

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