Trail Rover SCOUT 500TX User Manual
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Trail Rover SCOUT 500TX User Manual

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SCOUT 500TX
DESIGNED FOR OFF ROAD USE ONLY
1
Read and Follow Safety Instructions
It is against the law to operate on public roads
Always wear a helmet
For technical assistance, call 877-722-4097

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Summary of Contents for Trail Rover SCOUT 500TX

  • Page 1 SCOUT 500TX DESIGNED FOR OFF ROAD USE ONLY Read and Follow Safety Instructions It is against the law to operate on public roads Always wear a helmet For technical assistance, call 877-722-4097...
  • Page 2 Warranty Summary The owner must properly use, maintain and care for their TrailRover™ as explained in the Owner’s Manual. Owner must maintain all records of service performed on their UTV. Only an authorized dealer or approved service enter can perform warranty repairs. Periodic service and inspections are considered regular maintenance and are not reimbursable.
  • Page 3 Table of Contents Safety Information .................................. 3, 4 Overview of Vehicle and Components ..........................5 - 10 Break-In Period Instructions ..............................11 Pre-Driving Inspections ................................12 Operation Instructions ..............................13 - 18 Maintenance & Repair ...............................19 - 21 Troubleshooting .................................22 - 27 Technical Specifications ..............................28 - 34 Warranty .....................................35 - 37 Congratulations on the purchase of your new TrailRover™...

  • Page 4: Important Safety Information

    UTV on such terrain. Always be especially cautious on this kind or terrain. • Never operate your Trail Rover™ on any public road or highway. Your TrailRover™ is not designed for use on public roads. • Never operate your TrailRover™ without wearing an approved motorcycle helmet that fits properly. You should also wear eye protection (goggles of face shield), gloves, boots, a long sleeved shirt or a jacket and long pants.
  • Page 5 SCOUT 500TX Overview 1.Engine hood 2. Turn Indicator 4.Brush Guard 5.Tire 3.Headlight 6.Seats 7.Safety Belt 8.Side board 9. Fuel Cap 10.Rear Fender 11. Cargo Bay 12. Safety Bar 13. Head Rest 14. Cover 15.Steering Wheel 16.Canopy Frame DESIGNED FOR OFF ROAD USE ONLY...
  • Page 6 SCOUT 500TX Engine Overview 1.CTV case 2. Gear Case Oil Intake 3. Flange of transmission shaft 4.Generator 5.Carburetor 6.Starter 7. Idle speed control 8. Spark Plug 9.Oil intake DESIGNED FOR OFF ROAD USE ONLY Read and Follow Safety Instructions It is against the law to operate on public roads...

  • Page 7: Add Oil

    SCOUT 500TX Engine Overview Vehicle Identification Number Engine Number Overflow Add Oil Oil Intake Engine oil dipstick Caution: Oil level must remain at appropriate levels at all times to prevent engine damage. Engine damage cause by failure to maintain correct levels is not covered under the warranty.

  • Page 8: Brake Fluid

    SCOUT 500TX Engine Overview Oil drain plug (bottom of engine) Gear Case Intake Caution: To prevent leaking and oil loss, oil drain plug must be screwed in tightly. Engine damage caused by failure to replace oil drain plug properly is not covered under the warranty.
  • Page 9 SCOUT 500TX Engine Overview Check Oil Level in Differential Here Warning: Check oil level in the differential frequently. Damage will occur if lubricating oil is not changed as recommended, if oil level is too low or too high. Check Lubrication Levels in...
  • Page 10 SCOUT 500TX Engine Overview Fuse box, Relay (under driver’s seat) Relay Display 1. Horn relay 2. Low beam relay 3. High beam relay 4. Flash relay Fuse Display DESIGNED FOR OFF ROAD USE ONLY Read and Follow Safety Instructions It is against the law to operate on public roads...
  • Page 11 SCOUT 500TX Operation Warning! Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, 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 12 SCOUT 500TX Operation Pre-Ride Inspection Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it’s in safe operating condition.
  • Page 13 SCOUT 500TX Operation Starting the Engine 1. Sit in the driver’s seat and fasten the seat belt. Place the transmission in neutral. Set the parking brake. 3. Apply the brakes. 4. Do not press the throttle pedal while starting the engine.
  • Page 14 SCOUT 500TX Operation Keys Your new TrailRover™ was delivered with two sets of keys. One set is for the ignition and the other is for the oil box. Spare keys should be stored in a safe place. WE DO NOT HAVE DUPLICATE KEYS AVAILABLE.
  • Page 15 SCOUT 500TX Operation Dashboard Controls 1. Engine Temperature Gauge 2. Left Turn Signal and Hazard Light Indicator 3. Gear Display: Back light for current gear (L) - Low Speed (H) - High Speed (N) - Neutral (R) - Reverse 4. Speedometer 5.
  • Page 16 SCOUT 500TX Operation Auxiliary Switches The ignition switch must be turned to the “ACC” or “ON” position for operation of auxiliary components. Press down halfway to turn on front and rear paking lights and dashboard controls. Press all the way down to turn headlights on. Parking lights and dashboard controls remain on.
  • Page 17 SCOUT 500TX Operation Parking Brake Pull the parking brake “UP” to help prevent movement when parked to prevent sliding. Press the button on the parking brake to disengage the parking brake. Caution: Do not leave the parking brake on in the “UP”...
  • Page 18 SCOUT 500TX Operation Auxiliary Power Supply - Cigarette Lighter The cigarette lighter can be used as a charger or to power small electronic devices. Caution: Please check your device to ensure compatibility with the 12V DC power supply. Windshield Wiper (If Equipped) Turn the switch clockwise once for “low”, twice for “high”.
  • Page 19 SCOUT 500TX Maintenance 600 Mile Service Schedule Routine Service should be scheduled at 600 miles for optimal performance and efficiency. If you detect a problem, do not ride the vehicle until it has been serviced and repaired. Adjust idling speed:1500±10% listen for abnormal...
  • Page 20 SCOUT 500TX Maintenance Routine maintenance and a full system check should be performed before every ride. If you detect a problem, do not ride the vehicle until it has been serviced and repaired. Fuel, engine oil, cooling liquid, and other...
  • Page 21 SCOUT 500TX Maintenance Periodic maintenance schedule performed by mile or month, whichever comes first System 3 Months or 600 Miles Brake soft hoses Check Change once every three years Change every 12 months Brake fluid DO NOT MIX FLUIDS Brake...

  • Page 22: Troubleshooting

    SCOUT 500TX Troubleshooting Engine Troubleshooting Problem System Potential Reason Potential Solution No Fuel - Wrong Fuel Add 91 or higher octane fuel Carburetor switch blocked Remove blockage Air leak in fuel system Adjust carburetor screw Fuel System Blockage to oil box...
  • Page 23 SCOUT 500TX Troubleshooting Pressure or ignition wires damaged Replace Ignition contacts dirty or blocked Clean and remove blockage Wiring Connections Engine Works Dirty or damaged spark plug Clean or replace Abnormally TCI damaged Replace Air valve setting wrong Adjust to recommended setting...
  • Page 24 SCOUT 500TX Troubleshooting No fuel Add Premium Unleaded Fuel Fuel system Oil switch damaged Repair or Replace Blockage in carburetor Remove Blockage Electrical Spark plug wire Repair or Replace Wire Engine Shuts Off Cylinder Locked or Piston locked after heavy braking...
  • Page 25 SCOUT 500TX Troubleshooting Tires out of balance or alignment Balance and Align Front Wheel Bearing and wheel damage Repair or Replace wheel Shakes, Swings or Steering and Swing arms loose or damaged Repair or Replace Jumps Suspension Excess play in steering...
  • Page 26 SCOUT 500TX Troubleshooting Lights Damaged bulb Replace Bulb Voltage to high or low Adjust Voltage Fuse Blown Replace Both Headlights Lighting Damaged headlight relay Replace Not Working Short in wiring Repair Damaged Combination Switch Repair or Replace Battery damaged or needs charging...
  • Page 27 SCOUT 500TX Troubleshooting How to add coolant when radiator is empty: Remove line. Fill the Brake radiator until coolant Fluid runs from the line. Here Securely re-attach the line to prevent leaking.   Coolant Here Correctly fill up the coolant and release the air inside.
  • Page 28 SCOUT 500TX Tech Specs IX、Torque Specifications Sequence Item Quantity Thread diameter mm Torque（Nm） number Nuts - cylinder head Spark plug Adjustment nuts - valve clearance Fixed bolts - camshaft chain wheel Bolts - chain adjustment Fixed nuts - crankcase combination...
  • Page 29 SCOUT 500TX Tech Specs FRONT, REAR SUSPENSION AND OTHER PARTS ITEM SPECIFICATION QNT MOMENT REMARK M10×60 40N·m Screws - engine fix sleeve M10×240 50N·m Screw - engine support 40 N·m Adjusting nuts - engine M10×30 50 N·m Fixed screws - steering unit 60 N·m...
  • Page 30 SCOUT 500TX Tech Specs Nut on steering wheel 80 N·m Rear U bolts 90 N·m Bolts - rear absorber M8-55 25N·m Nut - Engine Cam 140N·m Nut on cam of reverse gear 160N·m Fixed screws - reverse gear unit 50N·m Fixed Screws - main driver 28N·m...
  • Page 31 SCOUT 500TX Tech Specs Bolts - bumper M10×20 50N·m Bolts - fuel tank M8×20 28N·m Bolts - transmission M8×25 30N·m X、Specifications fuel, lubricating oil and brake Fluid Category Specification Capacity Remark Premium Unleaded 91 Fuel Octane or Higher Lubricating oil（transmission box）...
  • Page 32 SCOUT 500TX Tech Specs Weight in Pounds (not including driver) Equipment Total Weight: 1190 Front shaft： 529 Rear shaft: 661 Dimensions 104” Long ×49” Wide × 75” High Wheelbase: 71" Tread： front wheel：1058 rear wheel： 1070 Approach angle(°)：60 Removed angle(°)：85...
  • Page 33 SCOUT 500TX Tech Specs Rated power (kw/r/min)： 13.8/6500 Lowest fuel consuming rate (g/Kw·h)： 340 Idling speed (r/min)： 1500±10% Ignition type: TCI（digital） Start type： Electronic start USE PREMIUM UNLEADED FUEL ONLY Fuel requirement: Minimum Octane Rating: 91 FUEL ADDITIVE REQUIRED IF FUEL CONTAINS MORE THAN 10% ETHANOL SAE 15W—40...
  • Page 34 SCOUT 500TX Tech Specs Front wheel camber： 1°±45: Main pin K.P.I： 13° Main pin castor： 4±1° Front toe-in： 2—5mm Tires Front wheel： Front wheel type 25×8.00 Air pressure：148Kpa (21PSI) Rear wheel： Tire type 25×10.00—12 Air pressure：197Kpa (28PSI) Steering Adopt gear rack type re director, total circle number of steering plate：3.75；...

  • Page 35: Warranty Information

    SCOUT 500TX Warranty Information 18 Month Limited Manufacturer’s Warranty UTV WARRANTY POLICY AND PROCEDURES Important Notice: The following are not actual warranties, but detailed descriptions of our warranty policies and procedures. Certain exclusions and disclaimers may apply to these descriptions. Always read the warranty that comes with each UTV. These policies and procedures are subject to change at any time and without notice.
  • Page 36 SCOUT 500TX Warranty Information OWNER’S RESPONSIBILITIES As the TrailRover™ owner, you are responsible for the performance of required maintenance by an individual who is qualified to perform the service. You must maintain accurate records of maintenance performed on your TrailRover™ including all receipts for maintenance on your TrailRover™.
  • Page 37 SCOUT 500TX Warranty Information LIMITATIONS The TrailRover™ warranty is terminated if the UTV has been subject to alteration, misuse, or abuse. Misuse or abuse is defined as but not limited to: theft, use of UTV in commercial applications, failure to follow maintenance...
  • Page 38 SCOUT 500TX Warranty Information DESIGNED FOR OFF ROAD USE ONLY Read and Follow Safety Instructions It is against the law to operate on public roads Always wear a helmet For technical assistance, call 877-722-4097...

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