1. Manuals
  2. Brands
  3. Egimotors Manuals
  4. Offroad Vehicle
  5. Sportsman Touring 570 XE 2025
  6. Owner's manual

Egimotors Sportsman Touring 570 XE 2025 Owner's Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Egimotors
2025 Owner's Manual
Sportsman 570 XE
Touring
QUADRICYCLE
Owner's manual part Number - OM25QSPT570E
Read this manual carefully. It contains important safety
information. This is an adult Quadricycle only.
Operation is prohibited for those under 18 years of age.
WARNING

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Sportsman Touring 570 XE 2025 and is the answer not in the manual?

Questions and answers

Related Manuals for Egimotors Sportsman Touring 570 XE 2025

Summary of Contents for Egimotors Sportsman Touring 570 XE 2025

  • Page 1 Egimotors 2025 Owner’s Manual Sportsman 570 XE Touring QUADRICYCLE Owner’s manual part Number - OM25QSPT570E Read this manual carefully. It contains important safety information. This is an adult Quadricycle only. Operation is prohibited for those under 18 years of age.
  • Page 2 This Owner Manual refers to EGIMOTORS QUADRICYCLES (To be filled in by your Dealer) This Owner’s Manual should always remain inside your quadricycle. 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: Safety Symbols And Signal Words

    SAFETY SYMBOLS AND SIGNAL WORDS The following signal words and symbols appear throughout this manual and on your Quadricycle. 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 6: Table Of Contents

    INTRODUCTION ..............7 CERTIFICATE OF PRE-DELIVERY INSPECTION ...... 9 SAFETY ................13 FEATURES AND CONTROLS ..........30 OPERATION ............... 73 WINCH GUIDE (IF EQUIPPED) ..........94 EMISSION CONTROL SYSTEMS ........104 MAINTENANCE ..............106 SPECIFICATIONS .............. 176 PRODUCTS ............... 179 TROUBLESHOOTING ............

  • Page 7: Introduction

    INTRODUCTION INTRODUCTION IMPORTANT WARNING ABOUT THIS MANUAL WARNING Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. A Quadricycle is not a toy and can be hazardous to operate. This Quadricycle handles differently than other Quadricycles, such as motorcycles and cars.

  • Page 8: Replacement Keys

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

  • Page 9: Certificate Of Pre-Delivery Inspection

    CERTIFICATION 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 10 CERTIFICATE OF PRE-DELIVERY STAMP 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 11: 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 Quadricycle in accordance with the instructions issued by EGIMOTORS. DEALERSHIP NAME____________________________#_________ DELIVERED BY_________________________________________...

  • Page 12: 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 13: Safety

    Quadricycle in your area. Failure to follow the warnings in this manual can result in serious injury or death. This EGIMOTORS Quadricycle is not a toy and can be hazardous to operate. A collision or rollover can occur quickly, even during routine maneuvers, if you fail to take proper precautions.

  • Page 14: Safe Riding Gear

    HELMET Wearing a helmet can prevent a severe head injury. Whenever riding this EGIMOTORS Quadricycle, always wear a helmet that meets or exceeds established safety standards. Clasp the buckle and pull each strap tight to ensure the helmet is properly secured to the head.

  • Page 15: Eye Protection

    EYE PROTECTION Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding this EGIMOTORS Quadricycle, always wear shatterproof goggles or use a shatterproof helmet face shield. EGIMOTORS recommends wearing approved Personal Protective Equipment (PPE) bearing markings CE. Make sure protective eye wear is kept clean.

  • Page 16: Safety Warnings

    SAFETY SAFETY WARNINGS WARNING Failure to operate this Quadricycle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual. See the operation section of this owner’s manual for proper operating procedures.

  • Page 17: Using Alcohol Or Drugs

    SAFETY USING ALCOHOL OR DRUGS Never consume alcohol or drugs before or while operating this Quadricycle. Operating this Quadricycle after consuming alcohol or drugs could adversely affect operator judgment, reaction time, balance and perception. CARRYING MORE THAN ONE PASSENGER ON A 2-UP QUADRICYCLE Carrying more than one passenger on a 2-up Quadricycle greatly reduces the operator's...
  • Page 18 SAFETY HANDLING GASOLINE 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. • Never carry fuel or other flammable liquids on this Quadricycle. Failure to follow this instruction could lead to serious burn injuries or death.

  • Page 19: Operating On Pavement

    SAFETY FORESTRY APPLICATION AND CROP SPRAYING This Quadricycle does not have a Falling Objects Protective Structure (FOPS). Do not use the Quadricycle in forestry application situations where the risk of falling objects may be present. This Quadricycle is not equipped for protection against hazardous substances. It does not offer any protection against substances which are harmful to health.
  • Page 20 SAFETY TURNING IMPROPERLY CAUTION Turning improperly could cause loss of traction, loss of control, accident or rollover. Always follow proper procedures for turning as described in this owner’s manual. Avoid sharp turns. Never turn while applying heavy throttle. Never make abrupt steering maneuvers.

  • Page 21: Stalling While Climbing A Hill

    SAFETY STALLING WHILE CLIMBING A HILL Stalling, rolling backwards or improperly dismounting while climbing a hill could cause a rollover. • Always maintain a steady speed when climbing a hill. • Always engage ADC mode (if equipped) before ascending or descending a hill.

  • Page 22: Operating On Steep Hills

    SAFETY OPERATING ON STEEP HILLS Operating on excessively steep hills could cause an overturn. Never operate on hills too steep for the Quadricycle or for your abilities. Never operate this Quadricycle on hills steeper than 15 degrees. OPERATING ON SLIPPERY TERRAIN Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control,...

  • Page 23: Improper Tire Maintenance

    SAFETY IMPROPER TIRE MAINTENANCE Operating this Quadricycle with improper tires or with improper or uneven tire pressure could cause loss of control or accident. Always use the size and type of tires specified your Quadricycle. Always maintain proper tire pressure as described in the owner's manual and on safety labels.

  • Page 24: Skidding Or Sliding

    SAFETY SKIDDING OR SLIDING Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or rollover. Do not operate on excessively slippery surfaces. Always slow down and use additional caution when operating on slippery surfaces.
  • Page 25 SAFETY IMPROPER CARGO LOADING Overloading the Quadricycle or carrying cargo improperly may cause changes in stability and handling, which could cause loss of control or an accident. • Always follow the instructions in this owner’s manual for carrying cargo. • Never exceed the stated load capacity for this Quadricycle. •...

  • Page 26: Hot Exhaust Systems

    SAFETY HOT EXHAUST SYSTEMS WARNING Exhaust system components are very hot during and after use of the Quadricycle. Hot components can cause burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system. Use caution when traveling through tall grass, especially dry grass and when traveling through muddy conditions.

  • Page 27: Equipment Modifications

    SAFETY EQUIPMENT MODIFICATIONS Your EGIMOTORS Quadricycle is designed to provide safe operation when used as directed. Modifications to your Quadricycle may negatively impact Quadricycle stability. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power.

  • Page 28: Safety Labels And Locations

    If an informational or graphic label becomes illegible or comes off, contact your EGIMOTORS dealer to purchase a replacement. Replacement safety labels are provided by EGIMOTORS at no charge. The part number is printed on the label. SPORTSMAN TOURING 570 ①...
  • Page 29 SAFETY OVERRIDE ALERT WARNING Improper use of override button can lead to loss of control resulting in severe injury or death. Do not activate override while throttle is engaged. Always apply throttle gradually while in reverse. Part Number: 7181544 4X4 (AWD) ALERT WARNING Do not push switch to engage 4X4 (AWD) if the rear wheels are spinning.

  • Page 30: Features And Controls

    FEATURES AND CONTROLS FEATURES AND CONTROLS OVERVIEW NOTICE Image is for reference only. Your model might differ slightly. ① ⑦ Brake Lever Thumb Warmer Switch (if equipped) ② Left Hand Controls ⑧ AWD Momentary Switch ③ Drive Mode Switch (if equipped) ⑨...

  • Page 31: Ignition Switch

    FEATURES AND CONTROLS IGNITION SWITCH WARNING Do not attach a large key fob or key ring to the main switch. It may contact the gas tank cap when turning, causing an interruption to the electrical system and an unexpected engine shut-down during operation. This could result in serious injury or death.

  • Page 32: Left-Hand Controls

    FEATURES AND CONTROLS LEFT-HAND CONTROLS ① ④ Light Switch Turn Signal Switch ② ⑤ Engine Stop Switch Horn Switch ③ ⑥ Hazard Switch Override Switch...

  • Page 33: Engine Stop Switch

    FEATURES AND CONTROLS ENGINE STOP SWITCH NOTICE The engine will not start or run when the switch is in the OFF position. Push the stop switch down to stop the engine quickly. Pull the stop switch up to the RUN position before attempting to start the engine. Both the main switch and the engine stop switch will shut off all electrical power to the Quadricycle, including lights.

  • Page 34: Mode / Reverse Override Switch

    FEATURES AND CONTROLS MODE / REVERSE OVERRIDE SWITCH This Quadricycle is equipped with a reverse speed limiter system. To gain additional wheel speed while backing, release the throttle and depress the override switch. WARNING Pressing the override switch while the throttle is open can cause loss of control, which may result in serious injury or death.

  • Page 35: Right-Hand Controls

    Never start or operate an QUADRICYCLE that has a sticking or improperly operating throttle. Immediately contact your EGIMOTORS dealer or other qualified person for service if throttle problems arise. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation.

  • Page 36: Performance Mode

    FEATURES AND CONTROLS AWD MOMENTARY SWITCH The All Wheel Drive (AWD) system is controlled by the AWD Momentary Switch ② . Use this switch to engage TURF mode, 2x4, AWD, or ADC. For more information see further pages. DRIVE MODE SWITCH (IF EQUIPPED) The Drive Mode Switch has three positions: •...

  • Page 37: Brake Lever

    When squeezed, the lever should feel firm. Any sponginess would indicate a possible fluid leak or low master cylinder fluid level, which must be corrected before riding. Contact your EGIMOTORS dealer or other qualified service facility for proper diagnosis and repairs.

  • Page 38: Master Cylinder/Brake Fluid

    FEATURES AND CONTROLS MASTER CYLINDER/BRAKE FLUID WARNING An over-full master cylinder may cause brake drag or brake lock-up, which could result in an accident. Maintain brake fluid at the recommended level. Do not overfill. Check the brake fluid in the master cylinder before each ride.
  • Page 39 FEATURES AND CONTROLS WARNING Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of brake failure, which could result in an accident.

  • Page 40: Auxiliary Foot Brake

    FEATURES AND CONTROLS AUXILIARY FOOT BRAKE WARNING Never back down a hill. Applying the auxiliary brake when backing down a hill may cause rear tip over, which could result in serious injury or death. Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward.

  • Page 41: Brake Fluid Level

    FEATURES AND CONTROLS BRAKE FLUID LEVEL Check the brake fluid level frequently for the auxiliary brake system. The reservoir is located on the frame and can be accessed through the front right wheel well. Maintain the fluid level between the maximum and minimum marks. Use DOT 4 brake fluid only.

  • Page 42: Automatic Transmission Gear Selector

    FEATURES AND CONTROLS AUTOMATIC TRANSMISSION GEAR SELECTOR The transmission gear selector is located on the right side of the Quadricycle. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park To shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear.

  • Page 43: Front Storage Compartment

    FEATURES AND CONTROLS FRONT STORAGE COMPARTMENT If your model is equipped with a front storage compartment, unlock the latches ① on each side to open the storage compartment.

  • Page 44: Instrument Cluster

    FEATURES AND CONTROLS INSTRUMENT CLUSTER OVERVIEW NOTICE Features and telltales vary by model. DISPLAY AREA FUNCTION H = High Gear ① Gear Indicator L = 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 45: Indicator Lamps

    DISPLAY AREA FUNCTION A flashing wrench symbol alerts the operator that the ⑤ Service Indicator preset service interval has been reached. Your EGIMOTORS dealer can provide scheduled maintenance. The clock displays time in a 12-hour or 24-hour ⑥ Clock format.
  • Page 46 FEATURES AND CONTROLS INDICATOR ICON FUNCTION Brake Failure This lamp illuminates when the Brake System detects a stuck brake while the throttle lever is engaged. This lamp also illuminates when the brake fluid level in the rear brake circuit is too low. Stop the Quadricycle, check the brake functionality, and verify the brake fluid in the reservoirs.
  • Page 47 FEATURES AND CONTROLS DISPLAY AREA 1 Pressing MODE button will change the information displayed in ① Area 1 DISPLAY AREA 1 FUNCTION The Quadricycle’s speed will be displayed in mph, Speed or km/h. The Quadricycle’s current engine temperature will Engine Temperature be displayed.
  • Page 48 FEATURES AND CONTROLS DISPLAY AREA 2 Toggle the Up/Down buttons to change the information displayed in ② Area 2 DISPLAY AREA 2 FUNCTION The Quadricycle’s odometer reading will be displayed. Odometer Engine Temperature The Quadricycle Engine Temperature will be displayed. Trip 1 The Quadricycle Trip 1 mileage will be displayed.

  • Page 49: Options Menu

    FEATURES AND CONTROLS OPTIONS MENU From the options menu you can view diagnostic codes, access the advanced menu, set the clock, and much more. For a full list of available options, see below. To enter the Options Menu, press and hold the MODE button.

  • Page 50: Electronic Power Steering (Eps)

    FEATURES AND CONTROLS ELECTRONIC POWER STEERING (EPS) Electronic power steering (EPS), if equipped, engages when the ignition key is turned to the ON position. EPS remains engaged whether the Quadricycle is moving or idle. See the Instrument Cluster section for EPS Warning Indicator information.

  • Page 51: Diagnostic Code

    FEATURES AND CONTROLS DIAGNOSTIC CODE Diagnostic Code Screen will show available MIL that has come on during that ignition cycle. To access the Diagnostic Code Screen, do the following: 1. Press and hold the MODE button to enter the Options Menu. “OPTIONS”...
  • Page 52 FEATURES AND CONTROLS NOTICE When the gauge is displaying a fault code, the warning telltale (check engine or EPS) will blink to indicate which controller set the fault code. 3. To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu.

  • Page 53: Enter Pin

    2. Select “ADVANCED MENU” by pressing the MODE button. 3. Enter PIN. NOTICE If PIN is lost or displaced please contact your EGIMOTORS dealer for assistance. 4. To exit the Advanced Menu the user can select Exit Menu function from...
  • Page 54 FEATURES AND CONTROLS REQUIRE PIN TO START (IF EQUIPPED) 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 “ADVANCED MENU” by pressing the MODE button. 3.
  • Page 55 FEATURES AND CONTROLS START PIN DELAY 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 “ADVANCED MENU” by pressing the MODE button. 3.
  • Page 56 FEATURES AND CONTROLS CHANGE PIN 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 “ADVANCED MENU” by pressing the MODE button. 3.

  • Page 57: 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 58: Unit Selection Temperature

    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 59 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.

  • Page 60: Back Light Color

    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 61: 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 62: Service Hours

    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 63 FEATURES AND CONTROLS PIN ACTIVATED SECURITY SYSTEM (P.A.S.S.) (IF EQUIPPED) — INSTRUMENT CLUSTER The optional PIN Activated Security System (P.A.S.S.) is designed to prevent unauthorized use. When enabled, the Quadricycle cannot be operated until a valid passcode has been entered. To enable/disable P.A.S.S., follow the procedures below.
  • Page 64 FEATURES AND CONTROLS NOTICE If the battery becomes low while the P.A.S.S. system is enabled, the gauge may show “New Quadricycle Detected” after the battery has been recharged/replaced. Leave the key in the ON position to allow system reconfirmation. DISABLE P.A.S.S. 1.

  • Page 65: All Wheel Drive System

    FEATURES AND CONTROLS ALL WHEEL DRIVE SYSTEM The All Wheel Drive (AWD) system is controlled by the AWD Momentary ① Switch Engage AWD before getting into conditions where front wheel drive may be needed. If the rear wheels are spinning, release the throttle before switching to AWD mode.
  • Page 66 FEATURES AND CONTROLS An unlocked Differential gives a better drivability of your Quadricycle especially when turning by allowing the inside wheel to rotate slower than the outside wheel when turning. If you need to make sharp turns on hard surface or grass without damages this is the right option to use.

  • Page 67: Awd Mode

    FEATURES AND CONTROLS AWD MODE To engage AWD mode, push the momentary switch to the right twice. AWD will engage when engine speed slows to below 2800 RPM. The gauge will display “AWD.” There is no limit to the length of time the Quadricycle may remain in AWD.

  • Page 68: Auxiliary Outlet

    FEATURES AND CONTROLS AUXILIARY OUTLET A 12-volt accessory outlet is located on the pod. Use the outlet to power an auxiliary light or other optional accessories or lights. FUEL CAP This Quadricycle is equipped with a digital fuel gauge that will indicate a low fuel condition.
  • Page 69 FEATURES AND CONTROLS BATTERY CHARGE PORT ① Your Quadricycle is equipped with a battery charge port . The battery charge port allows you to quickly and easily connect a battery charger or maintainer to your Quadricycle’s battery. NOTICE Image is for reference only. Your model might differ slightly.
  • Page 70 FEATURES AND CONTROLS HITCHES See the Specifications section for hitch weight capacities. WARNING Do not operate a combination Tractor-machine or Tractor-trailer unless all instructions have been followed. See the Hauling Cargo section for details. WARNING Whenever the Tractor is towing, always stay clear of the area between the Tractor and the towed object.
  • Page 71 FEATURES AND CONTROLS HITCH REMOVAL / INSTALLATION ① ② 1. To remove the hitch, remove the cotter pin and hitch pin ② Remove the hitch, then reinstall the hitch pin and secure the cotter ① ① 2. To install the hitch, remove the cotter pin from the hitch pin and ②...
  • Page 72 FEATURES AND CONTROLS DEFA ENGINE HEATER (X2 MODELS) (IF EQUIPPED) WARNING Before using the DEFA engine heater, make sure the area around the heater is clean and free of debris. WARNING Only connect the DEFA engine heater to a grounded socket. Only a DEFA connection cable must be used for the DEFA WarmUp...

  • Page 73: Operation

    OPERATION OPERATION SAFE OPERATION PRACTICES WARNING Failure to operate the Quadricycle 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 74: Trail Etiquette

    Quadricycle in your area. Respect the environment in which you ride your Quadricycle. Find out where the designated riding areas are by contacting your EGIMOTORS dealer, a local riding club, or local officials. Help keep our trails open for recreational Quadricycle use. As an off-road enthusiast, you represent the sport and can set a good example (or a poor example) for others to follow.

  • Page 75: Engine And Drivetrain Break-In

    OPERATION QUADRICYCLE BREAK-IN PERIOD The break-in period for your new EGIMOTORS Quadricycle is the first 25 hours of operation, or the time it takes to use the first two tanks full of gasoline. No single action on your part is as important as a proper break-in period. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components.

  • Page 76: Brake System Break-In

    OPERATION BRAKE SYSTEM BREAK-IN Apply only moderate braking force for the first 50 stops. Aggressive or overly forceful braking when the brake system is new could damage brake pads and rotors. Perform the following steps on a new Quadricycle or anytime brake pads are replaced on the Quadricycle: 1.

  • Page 77: Pre-Ride Checklist

    OPERATION PRE-RIDE CHECKLIST Failure to inspect and verify that the QUADRICYCLE is in safe operating condition before operating increases the risk of an accident. Always inspect the QUADRICYCLE before each use to make sure it's in safe operating condition. ITEM REMARKS Ensure proper operation.

  • Page 78: New Operator Driving Procedures

    OPERATION DRIVING PROCEDURES NEW OPERATOR DRIVING PROCEDURES 1. Complete a certified safety training course. 2. Wear protective riding gear. See the Safe Riding Gear section. 3. Perform the pre-ride inspection. 4. Place the transmission in PARK. 5. Lock the temporary brake lock.
  • Page 79 OPERATION TURNING THE QUADRICYCLE Both rear wheels drive equally at all times. This means that the outside wheel must travel a greater distance than the inside wheel when turning, and the inside tire must slip traction slightly. 1. Slow down. 2.

  • Page 80: Driving On Slippery Surfaces

    OPERATION DRIVING ON SLIPPERY SURFACES WARNING Skidding or sliding can cause loss of control or rollover (if tires regain traction unexpectedly). When operating on slippery surfaces such as ice or loose gravel, reduce speed and use extra caution to reduce the chance of skidding or sliding out of control.

  • Page 81: Driving Uphill

    OPERATION DRIVING UPHILL Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn. Whenever traveling uphill, follow these precautions: 1. Always engage ADC before ascending or descending a hill. 2. Drive straight uphill. 3.

  • Page 82: Driving Downhill

    OPERATION DRIVING DOWNHILL When driving downhill, follow these precautions: 1. Always check the terrain carefully before descending a hill. 2. Always engage AWD or ADC mode (if equipped) before ascending or descending a hill. 3. Avoid steep hills. Maximum incline is 15° 4.

  • Page 83: Driving On A Sidehill (Sidehilling)

    OPERATION DRIVING ON A SIDEHILL (SIDEHILLING) Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary. If crossing a sidehill is unavoidable, follow these precautions: 1.

  • Page 84: Turning Around On A Hill (K-Turn)

    OPERATION TURNING AROUND ON A HILL (K-TURN) If the Quadricycle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 1. Stop and lock the temporary brake lock while keeping body weight uphill. 2.

  • Page 85: Driving Through Water

    If the Quadricycle tips or overturns in water, or if the engine stops during or after operating in water, service is required before starting the engine. Your EGIMOTORS dealer can provide this service. If it's impossible to bring the Quadricycle in before starting the engine, perform the service outlined in the Quadricycle Immersion section of this manual, and take the Quadricycle in for service at the first opportunity.

  • Page 86: Driving Over Obstacles

    OPERATION DRIVING OVER OBSTACLES Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches. 3.

  • Page 87: Driving In Reverse

    OPERATION DRIVING IN REVERSE Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the Quadricycle. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles. 6.

  • Page 88: Starting The Engine

    OPERATION BOARDING AND DISMOUNTING THE QUADRICYCLE BOARDING If boarding from the left side of the Quadricycle, grasp the left handlebar grip with your left hand. Step onto the footrest and place your right foot and leg across the seat. Sit astride the Quadricycle. If boarding from the right side of the Quadricycle, grasp the right handlebar grip with your right hand.

  • Page 89: Cold Weather Operation

    OPERATION NOTICE Immediately after starting the engine, allow the Quadricycle to warm up by avoiding heavy engine loads and high RPM. Operating the Quadricycle with heavy engine loads before the engine has warmed up may cause engine damage. COLD WEATHER OPERATION If the Quadricycle is used year-round, check the oil level frequently.

  • Page 90: Parking On An Incline

    OPERATION PARKING THE QUADRICYCLE 1. Stop the Quadricycle on a level surface. When parking inside a garage or other structure, be sure that the structure is well ventilated and that the Quadricycle is not close to any source of flame or sparks, including any appliance with pilot lights.

  • Page 91: Hauling Cargo

    OPERATION HAULING CARGO CARGO WARNING WARNING Overloading the Quadricycle or carrying or towing cargo improperly can alter Quadricycle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo: REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO.

  • Page 92: Towing Loads

    OPERATION HAULING CARGO GUIDELINES When hauling cargo, adhere to the following: 1. Never exceed the weight capacities specified for your QUADRICYCLE on warning labels and in the specifications section of this manual. 2. Always load a cargo box with the load as far forward as possible. Make sure the cargo box dump latch is securely latched before loading and operating.
  • Page 93 Using an improper hitch or exceeding the maximum tongue weight capacity can result in serious damage to the Quadricycle. Never install a hitch longer than 13 cm. Never install automotive accessories on your EGIMOTORS QUADRICYCLE. Always install EGIMOTORS-approved (or equivalent) accessories designed for QUADRICYCLE use.

  • Page 94: Winch Guide (If Equipped)

    WINCH GUIDE (IF EQUIPPED) WINCH GUIDE (IF EQUIPPED) WINCH SAFETY These safety warnings and instructions apply if your Quadricycle came equipped with a winch or if you choose to add an accessory winch to your Quadricycle. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.
  • Page 95 WINCH GUIDE (IF EQUIPPED) 12. If winching at an angle is unavoidable, follow these precautions: a. Look at the winch drum occasionally. Never let the winch cable “stack” or accumulate at one end of the winch drum. Too much winch cable at one end of the winch drum can damage the winch and the winch cable.

  • Page 96: Winch Operation

    WINCH GUIDE (IF EQUIPPED) WINCH OPERATION Read the Winch Safety Precautions in the preceding pages before using your winch. Consider practicing the operation and use of your winch before you actually need to use it in the field. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.
  • Page 97 Replace the winch cable at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure. For your safety, always replace EGIMOTORS winch parts (including the cable) with genuine EGIMOTORS replacement parts available at your authorized...
  • Page 98 WINCH GUIDE (IF EQUIPPED) • If possible, keep the winch cable aligned with the centerline of the winching Quadricycle. This will help the spooling of the winch cable and reduce the load on the fairlead. • If freeing a stuck Quadricycle by attaching to a tree, use an item such as a tow strap to avoid damaging the tree during winch operation.
  • Page 99 WINCH GUIDE (IF EQUIPPED) c. On a long pull, it may be necessary to stop winching so that the damper can be repositioned to the new mid-point of the winch cable. Always release the tension on the winch cable before repositioning the damper.
  • Page 100 WINCH GUIDE (IF EQUIPPED) 13. Extensive winching will run down the battery on the winching Quadricycle. Let the winching Quadricycle’s engine run while operating the winch to prevent the battery from running low if winching for long periods. 14. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again.

  • Page 101: Winch Cable Care

    Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY. For your safety, always replace EGIMOTORS winch parts (including the cable) with genuine EGIMOTORS replacement parts available at your authorized EGIMOTORS dealer, or other qualified person.

  • Page 102: Shock Loading

    WINCH GUIDE (IF EQUIPPED) SHOCK LOADING WARNING Your winch cable is very strong but it is NOT designed for dynamic, or “shock” loading. Shock loading may tension a winch cable beyond its strength and cause the cable to break. The end of a broken winch cable under such high loading can cause SEVERE INJURY or DEATH to you and other bystanders.

  • Page 103: Winch Maintenance And Service Safety

    3. Never work on your winch without first disconnecting the battery connections to prevent accidental activation of the winch. 4. For your safety, always replace EGIMOTORS winch parts (including the cable) with genuine EGIMOTORS replacement parts available at your authorized EGIMOTORS dealer, or other qualified person.

  • Page 104: Emission Control Systems

    SPARK ARRESTER Your EGIMOTORS Quadricycle 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 Quadricycle is operated.

  • Page 105: European Vibration And Noise

    EMISSION CONTROL SYSTEMS EUROPEAN VIBRATION AND NOISE The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is measured per EN 15997.

  • Page 106: Periodic Maintenance

    Any qualified repair shop or person may maintain, replace or repair the emission control devices or systems on your Quadricycle. An authorized EGIMOTORS dealer can perform any service that may be necessary for your Quadricycle. EGIMOTORS also recommends EGIMOTORS parts for emissions-related service, however equivalent parts can be used.
  • Page 107 MAINTENANCE EGIMOTORS MAINTENANCE SCHEDULE The intervals shown are based on Quadricycles operated under normal conditions. Each interval is given in hours and kilometers. Items should be serviced at whichever interval comes first. Continue to reference the following maintenance schedules at the given intervals as hours and kilometers increase on the Quadricycle.
  • Page 108 MAINTENANCE Quadricycles 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 109 Check fluid. Wiring Inspect for wear, routing, and retention. * Have an authorized EGIMOTORS dealer or other qualified person perform these services. Quadricycles 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 110 MAINTENANCE ELEVATING THE QUADRICYCLE FOR SERVICE Some service procedures require elevation of the Quadricycle. Always position the Quadricycle on a firm, level surface before elevating. Do not position a jack or jack stand under any components other than the frame. Use an appropriate lift or floor jack.

  • Page 111: Lubrication Guide

    MAINTENANCE LUBRICATION GUIDE Check and lubricate all components at the intervals outlined in the EGIMOTORS Maintenance Schedule. Items not listed in the chart should be lubricated at the General Lubrication interval. The a-arms and lower control arms are lubricated at the factory, and no additional lubrication will be needed.

  • Page 112: Oil Recommendations

    EGIMOTORS recommends the use of EGIMOTORS PS-4 Full Synthetic 5W-50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if EGIMOTORS oil is not used. Always use 5W-50 oil. Follow the manufacturer's recommendations for ambient temperature operation.
  • Page 113 MAINTENANCE 3. Clean the area around the dipstick. 4. With the engine off, remove the dipstick. Wipe it dry with a clean cloth. 5. Install the dipstick and tighten it all of the way to ensure an accurate measurement. 6. Remove the dipstick and check the oil level. The oil level should be between the full and add lines on the dipstick.

  • Page 114: Oil And Oil Filter Change

    OIL AND OIL FILTER CHANGE IMPORTANT Always change the oil filter when you change the engine oil. The engine oil and oil filter should be changed in accordance with the EGIMOTORS Maintenance Schedule. See the Lubrication Guide section for fluid recommendations and capacities.
  • Page 115 MAINTENANCE 1. Position the Quadricycle on a level surface. Put the transmission in PARK (P) and lock the temporary brake lock. ① 2. Clean the area around the drain plug 3. Put a drain pan below the drain plug. ① ②...
  • Page 116 7. Put a drain pan below the oil filter 8. To access the oil filter, remove the seat and right side panel. 9. Use an Oil Filter Wrench (available from your EGIMOTORS dealer) to turn the oil filter counter-clockwise to remove it.
  • Page 117 MAINTENANCE ④ 14. Remove the engine access panel on the right side of the Quadricycle. 15. Clean the area around the dipstick. 16. Remove the dipstick. Use a funnel to slowly add the recommended oil to bring the oil level between the full and add lines on the dipstick. Do NOT overfill.

  • Page 118: Transmission Fluid

    Images are for reference only. Your model might differ slightly. The transmission fluid should be checked and changed in accordance with the EGIMOTORS Maintenance Schedule. See the Lubrication Guide section for fluid recommendations and capacities. Maintain the fluid level at the bottom of the fill plug hole.

  • Page 119: Fluid Change

    MAINTENANCE 6. Install the fill plug and torque to specification. TORQUE Transmission Drain / Fill Plug: 16 N·m 7. Clean any residual fluid off of the Quadricycle and inspect for leaks. 8. Install the rear left wheel. FLUID CHANGE 1. Position the Quadricycle on a level surface. Put the transmission in PARK (P) and lock the temporary brake lock.
  • Page 120 MAINTENANCE 6. Remove the drain plug and allow the fluid to drain completely. Discard the used fluid properly. 7. Clean any dirt or debris on the drain plug. Inspect the o-ring and replace if necessary. 8. Install the drain plug and torque to specification. TORQUE Transmission Drain / Fill Plug: 16 N·m...
  • Page 121 MAINTENANCE 11. Remove the fill plug. 12. Use a funnel to slowly add the proper amount of the recommended fluid. The fluid level should reach the bottom of the fill hole threads. FLUID CAPACITY Recommended Lubricant: Capacity: 948 mL 13. Clean any dirt or debris on the fill plug. Inspect the o-ring and replace if necessary.

  • Page 122: Front Gearcase (Demand Drive) Fluid

    FRONT GEARCASE (DEMAND DRIVE) FLUID The front gearcase fluid should be checked and changed in accordance with the EGIMOTORS Maintenance Schedule. See the Lubrication Guide section for fluid recommendations and capacities. Change the front gearcase fluid every 25 hours if the ADC unit is exposed to extreme use.
  • Page 123 MAINTENANCE FLUID CHECK 1. Position the Quadricycle on a level surface. Put the transmission in PARK (P) and lock the temporary brake lock. ① 2. Clean the area around the fill plug 3. Remove the fill plug and check the fluid level. The fluid level is correct if fluid is visible at the fill hole threads.
  • Page 124 MAINTENANCE FLUID CHANGE 1. Position the Quadricycle on a level surface. Put the transmission in PARK (P) and lock the temporary brake lock. ② 2. Clean the area around the drain plug 3. Put a drain pan below the drain plug. 4.

  • Page 125: Power Steering Unit

    MAINTENANCE 9. Use a funnel to slowly add the proper amount of the recommended fluid. The fluid level should reach the bottom of the fill hole threads. FLUID CAPACITY Recommended Lubricant: Demand Drive Fluid Capacity: 265 mL 10. Clean any dirt or debris on the fill plug. Inspect the o-ring and replace if necessary.

  • Page 126: Recovery Bottle Coolant

    EGIMOTORS recommends the use of EGIMOTORS Antifreeze 50/50 Premix. This antifreeze is already premixed and ready to use. Do not dilute with water. See the EGIMOTORS Products section for the part numbers. RECOVERY BOTTLE COOLANT The recovery bottle is located under the front cab and can be accessed through the front right wheel well.

  • Page 127: Radiator Coolant

    5. Install 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. 6. Close the radiator cap access cover and front rack.
  • Page 128 MAINTENANCE BRAKES HAND BRAKE CAUTION Brake discs can become extremely hot after operation. Allow the discs to cool before performing maintenance to prevent risk of burns. The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. These brakes are self- adjusting. Under normal operation, the diaphragm extends into the reservoir as fluid level drops.

  • Page 129: Seat Removal

    MAINTENANCE SEAT REMOVAL NOTICE A passenger may ride without the passenger seat installed with the installation of kit 2891377. This kit consists of new handgrips and an additional cover. See your EGIMOTORS dealer or other qualified person for more information.
  • Page 130 MAINTENANCE TOURING MODELS ① 1. Pull up on the passenger seat latch lever 2. Tilt the passenger seat forward and then lift up to remove the seat from the Quadricycle. 3. Lift the rear of the driver seat and slide the seat towards the back of the Quadricycle to remove it.

  • Page 131: Seat Installation

    MAINTENANCE SEAT INSTALLATION TOURING MODELS 1. Align the two openings in the bottom of the driver seat with the two seat base ① brackets 2. Slide the driver seat forward and lower the rear.
  • Page 132 MAINTENANCE 3. Press the rear of the driver seat down firmly to seat the two pins into the ② grommets...
  • Page 133 MAINTENANCE 4. Install the passenger seat onto the Quadricycle by pushing back on the ③ backrest and down on the passenger seat latch lever until you feel and hear a click. WARNING Severe injury or death can result from improper seat installation. Make sure you push the passenger seat latch lever all of the way down so that it latches into place.
  • Page 134 MAINTENANCE SIDE PANEL / FOOTWELL REMOVAL LEFT SIDE PANEL / FOOTWELL 1. Remove the seat. 2. Use the multi-function pliers (included in your Quadricycle’s toolkit) to remove the three push rivets from the side panel / close off panel. 3. Grasp the rear of the side panel. With a firm motion, pull the side panel outward to disengage the side panel / close off panel from the Quadricycle.
  • Page 135 MAINTENANCE 4. Remove the two screws and two push rivets from the footwell. 5. Remove the six screws and nuts from the bottom of the footwell. Pull the footwell downward and outward to remove it.
  • Page 136 MAINTENANCE RIGHT SIDE PANEL / FOOTWELL 1. Remove the seat. 2. Use the multi-function pliers (included in your Quadricycle’s toolkit) to remove the two push rivets from the side panel. 3. Grasp the rear of the side panel. With a firm motion, pull the side panel outward to disengage it from the Quadricycle.
  • Page 137 NOTICE Observe the condition of each push rivet and check for damage. If damaged, EGIMOTORS recommends that you replace the push rivet before installation. 2. Loosely install the two screws and two push rivets into the footwell.
  • Page 138 NOTICE Observe the condition of each push rivet and check for damage. If damaged, EGIMOTORS recommends that you replace the push rivet before installation. 2. Loosely install the two screws and two push rivets into the footwell.

  • Page 139: Tire Tread Depth

    MAINTENANCE TIRES WARNING Operating your QUADRICYCLE with worn tires, improperly inflated tires, non- standard tires or improperly installed tires will affect Quadricycle handling and could cause an accident resulting in serious injury or death. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the Quadricycle.

  • Page 140: Wheel Removal

    MAINTENANCE WHEEL REMOVAL WARNING Do not service axle nuts that have a cotter pin installed. Your authorized dealer can assist. 1. Stop the engine, put the transmission in PARK (P), and lock the temporary brake lock. ① 2. Loosen the wheel nuts slightly.

  • Page 141: Wheel Installation

    MAINTENANCE WHEEL INSTALLATION 1. Stop the engine, put the transmission in PARK (P), and lock the temporary brake lock. 2. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation (if equipped). ①...

  • Page 142: Wheel Nut Torque Specifications

    MAINTENANCE 4. Lower the Quadricycle to the ground. 5. Torque the wheel nuts to specification. WHEEL NUT TORQUE SPECIFICATIONS Check the wheel nut torques occasionally and when they have been loosened for maintenance service. Lug Nut 40 N·m (Aluminum Front and Rear PLUS 70 degrees Wheels) 2-Piece Flange Nut...

  • Page 143: Toe Alignment

    Quadricycle to obtain the recommended 6–12 mm toe out alignment. 5. Repeat the measurement procedure on the other side of the Quadricycle. 6. If you discover improper alignment, see your EGIMOTORS dealer for service.
  • Page 144 MAINTENANCE CAMBER AND CASTER The camber and caster are non-adjustable. AIR FILTER It is recommended that the air filter is replaced annually. When riding in extremely dusty conditions, replacement is required more often. 1. Lift up on the rear of the seat. 2.
  • Page 145 MAINTENANCE ④ 5. Loosen the air filter hose clamp and remove air filter assembly. 6. Inspect the air filter and replace if necessary. If the filter has been soaked with fuel or oil, it must be replaced. 7. Reinstall the air filter on the main filter mount.

  • Page 146: Fuse Replacement

    EGIMOTORS dealer or other qualified service facility. TAILLIGHTS/BRAKE LIGHTS REPLACEMENT The taillight assembly is not serviceable. If the light fails to operate properly, replace the entire taillight assembly, the entire assembly must be replaced by an authorized EGIMOTORS dealer or other qualified service facility.

  • Page 147: Headlight Adjustment

    MAINTENANCE HEADLIGHT ADJUSTMENT To adjust the front headlights, do the following: 1. Place the Quadricycle on a level surface with the headlight approximately 7 m from a wall. NOTICE Rider weight must be included on the seat while performing this procedure. 2.

  • Page 148: Spark Plug Recommendations

    Refer to the specifications section for the recommended spark plug type and gap for your Quadricycle. 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. ENGINE TORQUE SPECIFICATION 12 N·m SPARK PLUG INSPECTION Spark plug condition is indicative of engine operation.
  • Page 149 If your Quadricycle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the Quadricycle in for service before starting the engine. Your EGIMOTORS dealer can provide this service. If it's impossible to take your QUADRICYCLE to a dealer before starting it, follow the steps outlined below.

  • Page 150: Spark Arrestor Service

    MAINTENANCE SPARK ARRESTOR SERVICE WARNING Do not perform clean out immediately after the engine has been run, as the exhaust system becomes very hot. Serious burns could result from contact with exhaust components. To reduce fire hazard, make sure that there are no combustible materials in the area when purging the spark arrestor.

  • Page 151: Pvt System

    • See your EGIMOTORS dealer, or other qualified person, for service and repair assistance. • 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 152 MAINTENANCE The basic operation of the EGIMOTORS PVT system is dependent on engine speed and Quadricycle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of pinch applied to the drive belt. Similarly, if the engine speed decreases, the amount of centrifugal force decreases, reducing the amount of belt pinch.

  • Page 153: Pvt Drying

    MAINTENANCE PVT DRYING There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating. 1. Position the Quadricycle on a level surface. 2. Remove the drain plug. Allow the water to drain completely. Reinstall the drain plug.
  • Page 154 MAINTENANCE 4. Remove the three fasteners from the rear passenger foot support bracket. 5. Remove the 10 fasteners securing the outer PVT cover to the inner PVT cover. 6. Using care, pull the outer PVT cover out the side of the Quadricycle.
  • Page 155 MAINTENANCE 7. Remove the three inner PVT cover fasteners. 8. Note the orientation of the drive belt so that it can be installed in the same direction. (included in your Quadricycle’s toolkit) into ① 9. Insert the Clutch Spreader Tool the threaded hole on the driven clutch as shown and turn clockwise to spread the clutch.

  • Page 156: Drive Belt Inspection

    MAINTENANCE DRIVE BELT INSPECTION 1. Inspect belt for hour glassing (extreme circular wear in at least one spot and on both sides of the belt). Hour glassing occurs when the drive train does not move and the drive clutch engages the belt. 2.

  • Page 157: Drive Belt Installation

    MAINTENANCE DRIVE BELT INSTALLATION 1. Clean the inside of the PVT covers thoroughly. WARNING Failure to remove all debris when replacing the belt could result in Quadricycle damage, loss of control, and severe injury or death. IMPORTANT Orient the belt as it was removed or orient the new belt so that you can read the text.
  • Page 158 MAINTENANCE 5. Rotate / spin the driven clutch and belt approximately 5-7 times clockwise to properly seat the belt into the driven clutch. 6. Install the inner PVT air duct cover fasteners. Torque fasteners to specification. TORQUE Inner PVT Cover Fasteners: 5 N·m...
  • Page 159 MAINTENANCE 7. Install the outer PVT cover and 10 fasteners. Torque fasteners to specification. TORQUE Outer PVT Cover Fasteners: 5 N·m 8. Install the rear passenger foot support bracket and three fasteners. Torque fasteners to specification. TORQUE Rear Passenger Foot Support Bracket Fasteners: 10 N·m 9.

  • Page 160: Battery Removal

    MAINTENANCE BATTERY WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury, death, Quadricycle damage, and/or battery damage. When removing the battery, always disconnect the negative (-) black cable first. When reinstalling the battery, always connect the negative (-) black cable last.

  • Page 161: Battery Installation

    MAINTENANCE ② 3. Disconnect the negative (-) black cable first. Then disconnect the ③ positive (+) red cable 4. Carefully lift the battery out of the Quadricycle. BATTERY INSTALLATION WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury, death, Quadricycle damage, and/or battery damage.
  • Page 162 MAINTENANCE TORQUE Battery Terminals 7 N·m 4. Install positive battery boot. 5. Connect and tighten the negative (-) black cable. Torque to specification. 6. Verify the battery cables are properly routed.

  • Page 163: Battery Storage

    ① The EGIMOTORS offered battery trickle charger can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point. See the EGIMOTORS Products chapter for the part number.

  • Page 164: Battery Charging

    Battery Tender can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point. See the Egimotors Products section for the part numbers. BATTERY CHARGING Read all instructions before proceeding with the installation of this battery.

  • Page 165: Battery Charging (Sealed Battery)

    MAINTENANCE BATTERY CHARGING (SEALED BATTERY) Always verify battery condition before and 1-2 hours after the end of charging. CHARGE TIME (USING CONSTANT CURRENT CHARGER @ STANDARD AMPS STATE OF VOLTAGE ACTION SPECIFIED ON TOP OF CHARGE BATTERY) 100% 12.6-12.8 volts Low Maintenance None required Battery: check after...

  • Page 166: Battery Identification

    Different types of batteries require different service procedures. Proper servicing and upkeep of the battery is very important for maintaining long battery life. All EGIMOTORS ORV models include either a Conventional battery or a Low Maintenance battery. Your QUADRICYCLE is equipped with a sealed battery, which requires little maintenance.
  • Page 167 LOW MAINTENANCE BATTERY BEST PRACTICES Some EGIMOTORS ORV models include either a Lead Acid or Absorbed Glass Mat (AGM) Low Maintenance battery. See the Service Manual for procedures on how to charge, maintain, and test a Lead Acid or AGM Low Maintenance battery.
  • Page 168 MAINTENANCE LOW MAINTENANCE BATTERIES CHARGING • EGIMOTORS recommends using a BatteryMINDer® 1.5 AMP (PN 2830404) charger, which can be ordered through your normal parts channel. • Nominal voltage is 12.6–12.8 Volts when fully charged. If the voltage falls below 12.5V, charge it immediately, or the battery runs the risk of sulfation.

  • Page 169: Suspension Settings

    High Tension ③ Low Tension WARNING Uneven adjustment settings may cause poor Quadricycle handling, resulting in severe injury or death. Always adjust both the left and right spring preload settings equally. Your EGIMOTORS dealer, or other qualified technician, can assist.
  • Page 170 Follow the adjustment procedures exactly, or see your EGIMOTORS dealer for service. 1. Remove the upper headlight pod.

  • Page 171: Cleaning And Storage

    Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the Quadricycle. The best way to clean your EGIMOTORS Quadricycle is with a garden hose and a pail of mild soap and water.

  • Page 172: Polishing Tips

    • Throttle and shift cables and controls • Body panels • Seats If warning and safety labels are damaged, contact your EGIMOTORS dealer for free replacement. Grease all zerk fittings immediately after washing. Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system.

  • Page 173: Storage Tips

    Washing the Quadricycle section. 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 174: Battery Maintenance

    STORAGE AREA / COVERS Be sure the storage area is well ventilated. Cover the Quadricycle with a genuine EGIMOTORS cover. Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and...
  • Page 175 MAINTENANCE TRAILERING YOUR QUADRICYCLE Follow these procedures when transporting the Quadricycle. 1. Stop the engine. 2. Place the transmission in PARK. 3. Secure the fuel cap, oil cap, and seat. 4. Remove the key to prevent loss during transporting. 5. Use suitable straps or rope to secure the Quadricycle to the front tow hook ①...

  • Page 176: Specifications

    SPECIFICATIONS SPECIFICATIONS SPORTSMAN TOURING 570 SPORTSMAN TOURING 570 Gross Vehicle Weight Capacity (includes weight 560kg of operator, passenger, cargo, accessories) 375kg Unladen mass in running order Fuel Capacity 25.5 L Engine Oil Capacity 1.9 L Coolant Capacity 2.5 L Demand Drive Fluid Capacity 265 mL Transmission Oil Capacity 948 mL...
  • Page 177 1250 +/- 50 NGK® MR7F Spark Plug Type / Gap 0.076 cm Lubrication System Wet Sump Automatic PVT (EGIMOTORS Variable Driving System Type Transmission) Touring 570: Sealed MacPherson Ride® Strut with 20.8 cm Travel Front Suspension Touring 570 SP: Sealed Dual A-Arm with 22.6 cm...
  • Page 178 SPECIFICATIONS DRIVER’S SEAT VIBRATION TOURING MEAN MEAN WEIGHTED WEIGHTED RATIO AWS: RMS SEAT RMS SEAT DRIVER ACCL. (AWS) ACCL. (AWB) [M/S2] [M/S2] Heavy 0.68 0.85 Light 0.82 0.89...

  • Page 179: Lubricants / Service Products

    PRODUCTS PRODUCTS LUBRICANTS / SERVICE PRODUCTS PRODUCT SIZE PART NUMBER Fogging Oil 340 g aerosol 2870791 0.95 L 2876244 PS-4 3.8 L 2876245 0.95 L 2889395 PS-4 Extreme Duty 3.8 L 2889396 Includes 2 qt of PS-4 engine oil, Oil Change Kit 1 oil filter, and 1 drain plug 2877473 washer...

  • Page 180: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING 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 181 TROUBLESHOOTING DIAGNOSTIC CODES COMPONENT CONDITION Voltage Below Normal, Or Shorted Fuel Level 1 To Low Source Data Valid But Above Normal Fuel Level 1 Operating Range - Moderately Severe Level Engine Intake Manifold Voltage Below Normal, Or Shorted #1 Pressure To Low Source Voltage Above Normal, Or Shorted Engine Intake Manifold...
  • Page 182 TROUBLESHOOTING DIAGNOSTIC CODES COMPONENT CONDITION Voltage Above Normal, Or Battery Potential / Power Input 1 Shorted To High Source Battery Potential / Power Input 1 Voltage Below Normal, Or Shorted To Low Source Data Valid But Below Normal Battery Potential / Power Input 1 Operational Range - Most Severe Level Data Valid But Below Normal...
  • Page 183 TROUBLESHOOTING DIAGNOSTIC CODES COMPONENT CONDITION Calibration Out Of Calibration Abnormal Frequency Or Pulse Crankshaft Position Sensor Width Or Period Data Erratic, Intermittent Or Crankshaft Position Sensor Incorrect Abnormal Frequency Or Pulse Camshaft Position Sensor Width Or Period Injector 1 (Front) (MAG) (SDI Voltage Above Normal, Or Port Injector) Shorted To High Source...
  • Page 184 TROUBLESHOOTING DIAGNOSTIC CODES COMPONENT CONDITION Malfunction Indicator Lamp Voltage Below Normal, Or 1213 Status Shorted To Low Source Ignition Coil Primary Driver 1 Voltage Above Normal, Or 1268 (Front) (MAG) Shorted To High Source Ignition Coil Primary Driver 1 Data Erratic, Intermittent Or 1268 (Front) (MAG) Incorrect...
  • Page 185 TROUBLESHOOTING DIAGNOSTIC CODES COMPONENT CONDITION ECU Power Output Voltage Above Normal, Or Shorted 3598 Supply Voltage #2 To High Source ECU Power Output Voltage Below Normal, Or Shorted 3598 Supply Voltage #2 To Low Source ECU Power Output Voltage Above Normal, Or Shorted 3599 Supply Voltage #3 To High Source...
  • Page 186 TROUBLESHOOTING DIAGNOSTIC CODES COMPONENT CONDITION Voltage Below Normal, Or Throttle Position Sensor 2 520198 Shorted To Low Source Voltage Above Normal, Or Throttle Position Sensor 2 520198 Shorted To High Source Current Below Normal Or Canister Purge Valve 520202 Open Circuit Voltage Above Normal, Or Canister Purge Valve 520202...
  • Page 187 TROUBLESHOOTING DIAGNOSTIC CODES COMPONENT CONDITION Voltage Above Normal, Or All Wheel Drive Control Circuit 520207 Shorted To High Source Voltage Below Normal, Or All Wheel Drive Control Circuit 520207 Shorted To Low Source Voltage Below Normal, Or Chassis Relay 520208 Shorted To Low Source Current Below Normal Chassis Relay...
  • Page 188 TROUBLESHOOTING DIAGNOSTIC CODES COMPONENT CONDITION IC CAN Communication with Condition Exists 520230 EPAS IC CAN Communication with Condition Exists 520230 EPAS EPAS Power Save Condition Condition Exists 520231 Accelerator Position/Brake Condition Exists 520275 Position Interaction Throttle Position Sensor (1 or 2 Data Erratic, Intermittent Or 520276 Indeterminable)
  • Page 189 TROUBLESHOOTING DIAGNOSTIC CODES COMPONENT CONDITION ECU Monitoring Error Condition Exists 520286 ECU Monitoring Error (Level 3) Condition Exists 520287 ECU Monitoring of Injection Condition Exists 520288 Cut Off (Level 1) ECU Monitoring of Injection Condition Exists 520289 Cut Off (Level 2) Throttle Body Control - Requested Throttle Angle Not Condition Exists...
  • Page 190 TROUBLESHOOTING DIAGNOSTIC CODES COMPONENT CONDITION Voltage Below Normal, Or Intercooler Pump Driver Circuit 520496 Shorted To Low Source Voltage Above Normal, Or Intercooler Pump Driver Circuit 520496 Shorted To High Source Current Below Normal Or Intercooler Pump Driver Circuit 520496 Open Circuit Bad Intelligent Device Or Farm Mode Set Speed...

  • Page 191: Drive Belt Wear/Burn

    TROUBLESHOOTING DRIVE BELT WEAR/BURN POSSIBLE CAUSE SOLUTION Driving onto a pickup or tall Use low range during loading. trailer in high range Starting out going up a steep Use low range. incline Driving at low RPM or ground speed 4.8–11.3 km/h Drive at a higher speed or use low range more frequently.

  • Page 192: 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 193: 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 194: 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 195: Limited Warranty

    At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to EGIMOTORS within ten days of purchase. Upon receipt of this registration, EGIMOTORS will record the registration for warranty. No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be your proof of warranty coverage.

  • Page 196: 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 197: 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 198: 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.

  • Page 199: 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 200: Maintenance Log

    MAINTANANCE LOG MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE KM OR TECHNICIAN SERVICE PERFORMED / HOURS COMMENTS...
  • Page 201 MAINTENANCE LOG DATE KM OR TECHNICIAN SERVICE PERFORMED / HOURS COMMENTS...
  • Page 202 For more informations visit www.Egimotors.it Egimotors Via Filippo da Desio 49/51 20832 Desio (MB) ITALY info@polarisitalia.com...

Table of Contents