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Chironex Motoports SPARTAN 500 Owner's Manual

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SPARTAN 500 OWNERS MANUAL
CHIRONEX MOTORSPORTS INC.
- 1 -
© Copyright Chironex Motorsports Inc. All Rights reserved.

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Summary of Contents for Chironex Motoports SPARTAN 500

  • Page 1 SPARTAN 500 OWNERS MANUAL CHIRONEX MOTORSPORTS INC. - 1 - © Copyright Chironex Motorsports Inc. All Rights reserved.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Topic Pages Introduction Technical parameters Parts Breakdown Safety Instructions Operating the Spartan UTV Breaking-in Period Maintenance and Repair Troubleshooting VIII Torque specifications Fuel/ Oil / Fluid Specifications Circuit Diagrams - 2 - © Copyright Chironex Motorsports Inc. All Rights reserved.

  • Page 3: I Introduction

    I. Introduction Chironex welcomes you to its growing family of new Spartan series Utility Vehicle owners. The Spartan has been designed for the Canadian outdoors with careful attention paid to every detail. Proper set-up, maintenance and safe operating practices will help you get years of satisfactory use from this vehicle.
  • Page 4 Getting Acquainted with your Utility Vehicle This off-road utility vehicle is a very unique vehicle designed exclusively for off-road use. It is not designed, properly equipped, or licensed to be safely operated on public streets and highways. This vehicle is designed to carry two people and a limited amount of gear or cargo comfortably and safely over rough terrain.
  • Page 5 If you are still unsatisfied, seek out the owner or general manager of the dealership. For further assistance Initial breaking-in period for the Spartan 500 4x4 is 1000km, during which extra care must be taken (see Section VI). Upon expiration of this period, continue to carry out the necessary maintenance procedures.

  • Page 6: Ii Technical Parameters

    II、Technical parameters Common technical data (III) Engine 1 Weight parameters (kg) Type: Single cylinder, 4-stroke, liquid cooled Dry Weight: 500 Valve train: 4 valve, top camshaft, single shaft Induction: Carburetor 2 Dimensions (mm) Bore and stroke (mm): 87.5 x 82 Length/ Width: 2690×1270 Engine displacement: 493 cc...
  • Page 7 Engine oil pump type： TOTOR (IV)、Chassis Oil filter: Full-flow mechanical w/ paper element 1. Differential： Fuel Capacity: 20 L Tapered arc gear transmission Carburetion type: Vacuum slide Transmission rate： 33/9 Air filter: Sponge element 2. Drive type：Shaft, 2WD/4WD/Differential LOCK Fuel type: RQ-93 or better Normal drive: Rear wheel drive.
  • Page 8 6. Steering system：Rack-and-pinion steering 8. Electric Dump box： Steering wheel turns, lock to lock: 2.5 Dumping angle: 49° Total steering angle: 75°. 9. Winch: Maximum steering angle, right: 37.5°. Rated Single Line Pull: 3000 lbs. Maximum steering angle, left: 37.5°. 7.

  • Page 9: Iii Parts Breakdown

    1. Safety belt 2. Frame 3. Steering wheel 4. Rear view mirror 5. Engine hood 6. Indicator 7. Bumper 8. Headlight 9. Winch 10. Wheel 11. Seat 12. Side cover 13. Rear mudguard 14. Cargo bed 15. Headrest bar 16. Head rest III Parts Breakdown - 9 - ©...
  • Page 10 Carburetor Starter Water temperature sensor Starting handle Left cover Rear shaft flange Front shaft flange Oil filter Thermostat 10. CVT case 11. CVT inlet 12. CVT inlet Plug Engine Parts Breakdown - 10 - © Copyright Chironex Motorsports Inc. All Rights reserved.
  • Page 11 VIN number Rear suspension （on the frame above right rear wheel） Oil drain plug（bottom of engine） WARNING：ENGINE OIL LEVEL SHOULD BE BETWEEN UPPER AND LOWER MARKINGS. ELSE YOU RISK ENGINE DAMAGE. Oil Intake Oil Dipstick - 11 - © Copyright Chironex Motorsports Inc. All Rights reserved.
  • Page 12 WARNING： Do not unscrew radiator cap when engine is hot; contents are at a high temperature and pressure. Fuel tank intake（left side） Coolant, Brake fluid intake WARNING：Use only TC / DOT approved brake fluid. Do not mix different types of brake fluids. Always maintain brake fluid level to ensure proper functioning of the brakes.

  • Page 13: Iv Safety Instructions

    IV、Safety Instructions: 10. Check whether the winch and dump box are in good working order 1. Check for leaks of engine oil, coolant, fuel, lubricant. 11. Check fuel level. 2. Check the levels of engine oil, brake fluid and coolant. If necessary, add more.
  • Page 14 Warning： (1) Driver must be of legal age to operate the UTV. (2) Fasten the safety belt before riding the UTV. (3) Driver should be adequately insured. (4) Driver should operate UTV at speeds of 35—45km/h. Speeding will cause an accident.
  • Page 15 “OFF”（close）position： All circuits are turned off (2)Ignition switch except for the emergency light, electric fan and Ignition switch has four positions： cigarette lighter. “ON”（open）position： All circuits except starter and ignition are connected, keeps an engine running “START”（start）position： Connects starter and ignition circuit to start engine;...
  • Page 16 1、Temperature Gauge 2.3.、L/R Indicators 4、Fuel Gauge 5、High beam 6、Odometer 7、Speedometer 8、2WD/ 4WD （ ） Temperature Gauge: Displays the temperature of engine coolant. (4) Lights （ ） 2, 3 Indicators: Left or Right indicator blinks corresponding to turning signal switched on. Both indicators blink if hazard light is switched （...
  • Page 17 flashers in case of emergency. Use the turn signal button to switch on left and right signal lights corresponding to the left and (6) Accelerator and brake pedals right arrows marked. To turn off both signal lights keep The accelerator pedal (left) and brake pedal (right) are button in the center position.
  • Page 18 (9) Winch Keep the winch button pressed in the “ ” position to extend the winch cable to the required length. To retract IN” keep the button pressed in the “ position. WARNING：After parking the vehicle, pull up the hand brake lever.
  • Page 19 (11)Windshield and wiper (optional) Turn knob in clockwise direction to the preferred “Low” or “High” setting. To switch off the wiper, turn knob in anti- clockwise direction to the “Off” position. (12)Reverse speed over ride button (installation optional) Under normal circumstances do not use the reverse over ride. Use the over ride only when you are stuck or need to reverse in rough terrain.
  • Page 20 VI、Breaking-in period The operating quality and longevity of the UTV depends on taking proper care during the breaking-in period. During the initial 1600 km of driving the various components of the UTV should be allowed to wear into each other. Adhere to the speed limit, keep total UTV payload to a minimum and carry out periodic maintenance as per the guidelines in this manual.
  • Page 21 During the breaking -in period, it is necessary to monitor engine coolant temperature to avoid running engine at low temperatures for long periods or at high temperatures without coolant. This will accelerate abrasion and cause damage to the engine cylinder. 4.
  • Page 22 Part/ Component Maintenance Item Troubleshooting Change engine oil and oil filter Adjust idling speed: 1300 + 100 r/m, listen for any abnormal 1 Engine Check coolant level noises coming from the engine, clean air filter core Front and rear brakes Brake fluid level;...
  • Page 23 Part/ Component Maintenance Item Troubleshooting Change engine oil and oil filter Adjust idling speed: 1300 + 100 r/m, listen for any abnormal Engine Check coolant level noises coming from the enginem clean air filter core 2 Steering assembly Steering play Tighten all bolts and nuts of steering assembly Brake fluid level;...
  • Page 24 MILEAGE First 1000 km Every 3000 km Every 6000 km MAINTENANCE ITEM PERIOD of OPERATION First 3 months Every 3 months Check Check Brake Hose Change once every 3 years Brake Fluid Change once every 18 months Brake Check Check Steering assembly Check Check...
  • Page 25 MILEAGE First 1000 km Every 3000 km Every 6000 km MAINTENANCE ITEM PERIOD of OPERATION First 3 months Every 3 months F/R Differentials, reverse gear (including gear oil) Check Check Battery Check Check Steering assembly Check Check Transmission assembly Check Check Lights/ Instruments Check...

  • Page 26: Viii Troubleshooting

    VIII、Troubleshooting （I）Engine Trouble Indication Solution Problem Cause(s) 1. Lack of compression in cylinder Change Starting trouble Cylinder is worn out Change Piston is worn out Leaks Change gasket Air intake valve worn out/ Cylinder head damage Repair/ Change Plug is loose Tighten Change battery or starter Starter motor cranks too slow...
  • Page 27 （I）Engine failure Problem Indication Cause(s) Solution Uneven or no idle speed 1. Mechanical fault Incorrect valve clearance Adjust Valve housing Repair/ Change Intake manifold Change Improper fuel level in float bowl Adjust Carburetor jet block Clean Fuel pipe Change Idle Adjustment screw setting is wrong Adjust 2.
  • Page 28 （I）Engine failure Problem Indication Cause(s) Solution Blue exhaust smoke Mechanical fault Excess engine oil Drain the excess engine oil Piston ring worn out Change Valve pipe worn out Change Cylinder wall damage Change Valve rod worn out Change Valve gasket damage Change Lack of power 1.
  • Page 29 （I）Engine failure Problem Indication Cause(s) Solution Engine overheating 1. Fuel system fault Octane number is lower than specified Use the right fuel Fuel passage blocked Clean the fuel pipe Fuel pump fault Change Fuel level in floater bowl is low Adjust the height of floater 2.
  • Page 30 （I）Engine failure Problem Indication Cause(s) Solution Noise from piston Noise from engine Piston worn out Change Cylinder worn out Change Carbon deposit on spark plug Clean Piston pin or pin hole worn out Change Piston ring or ring notch worn out Change Noise from chain circulation Chain elongated...
  • Page 31 （I）Engine failure Problem Indication Cause(s) Solution Engine lacks power Clutch skiding Fuel system fault Octane number is too low Use the right fuel Fuel passage blocked Clean fuel pipe Transmission system Clutch shoe worn out Change Clutch spring is weak Change Fly wheel worn out Change...
  • Page 32 （I）Engine failure Problem Indication Cause(s) Solution Not stable in high and middle Carburetor malfunction speed Carburetor jet block Clean Main air channel block Clean Needle valve block Clean Throttle defect Adjust Fuel filter block Clean/ Change Height of floater incorrect Adjust Starting pin not closed Adjust...
  • Page 33 （II）Transmission failure Problem Indication Cause(s) Solution Vehicle not moving Transmission Shift belt slips Change Speed adjusting plate abrasion Change Speed adjusting plate jam Repair/ Change Spring Repair/ Change Transmission not staying in gear/ difficult to shift gears Gear box or shifter Speed changing drum groove worn out Change Right and left gear changing rods bent...
  • Page 34 （III）Running system, suspension and steering failure Problem Indication Cause(s) Solution Steering assembly, running Left and right absorber has been Tire worn out abnormally system, suspension damaged, weak Adjust/ Change Tyre not balanced or wheel hub is distorted Change Front wheel alignment wrong Check/ Adjust Vehicle overload Check load...
  • Page 35 （III）Running system, suspension and steering failure Problem Indication Cause(s) Solution Steering assembly, running Steering is heavy system Low air pressure in tire Change air pressure Ball head of left and right swing arm and drag pole is blocked Change Steering block Repair/ Change Mesh clearance is too small Adjust...
  • Page 36 （IV）Brake system failure Problem Indication Cause(s) Solution Vehicle frame damage, left and right Braking leads to leaning Brake system suspension wheelbase is different Repair/ Adjust Brake line Repair/ Adjust Brake disks not in contact Repair Suspension parts loose Check, repair and fasten Brake clip block Brake system Brake pump...
  • Page 37 （V）Lights, Instruments, Circuit Failure Problem Indication Cause(s) Solution Front headlight does not illuminate Lighting system Switch damage Repair/ Change Battery damage Change Bulb defective Change Only one front headlight does not illuminate Lighting system Bulb defective Change Lead or grounding defect Repair circuit Steering light does not illuminate...
  • Page 38 （V）Lights, Instruments, Circuit Failure Problem Indication Cause(s) Solution Lights not working (not including headlight) Light circuit Switch damage Change Bulb defective Change Wiring damage, loose contact Repair Fuse blown Change Ground wire loose contact Repair Instruments not working Instrument or wiring Fuse blown Change Wiring damage, loose contact...

  • Page 39: Ix Torque Specifications

    IX、Torque specifications Engine Thread Thread diameter Torque diameter Torque Item (mm) (Nm) Item (mm) (Nm) 25 Bolt on ignition switch 1 M10x1.25 1 Reverse gear sensor 1 M10x1.25 26 Bolts on crankcase 14 M6 2 Spark plug 1 M12x1.25 3 M8 3 Water temperature sensor 1 R/c1/8 27 Bolt on sector gear...
  • Page 40 ： FRONT, REAR SUSPENSION Thread diameter Torque Thread Torque Item (mm) (Nm) Item diameter (mm) (Nm) Bolts on front steering joint and 21 Hand brake bolt 2 M8x20 shock absorbers 4 M12x50 22 Bumper bolt 2 M10x20 2 Bolts on F/R brake disks 18 M10x50 23 Axle bolt 2 M8x25...
  • Page 41 Torque Specification (Nm) Other screws (8.8 grade) X、Fuel and Lubricating oil specification Category Specification Capacity Remark Fuel RQ-90 or higher grade lead-free 27 L Fuel tank capacity 1900 ml (change oil) 2000 ml (change filter) Engine Oil, Gear Oil (Gear box) SAE15W - 40/SF or SC 2200 ml (repair engine) Front Differential Oil...
  • Page 42 2WD AND 4WD TRANSFER CIRCUIT - 42 - © Copyright Chironex Motorsports Inc. All Rights reserved.
  • Page 43 SPARTAN 500 CIRCUIT DIAGRAM - 43 - © Copyright Chironex Motorsports Inc. All Rights reserved.
  • Page 44 - 44 - © Copyright Chironex Motorsports Inc. All Rights reserved.
  • Page 45 _________________________________________________________________________ © Copyright 2007-2008 Chironex Motorsports Inc. All Rights reserved...

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