Bad Boy Onslaught 550 EFI 4X4 EPS, Owner'S Manual

Page 1: ...READ THIS MANUAL CAREFULLY It contains important safety information OWNER S MANUAL This vehicle should not be operated by those under 16 years of age 647524 550 EFI 4X4 550 EFI 4X4 EPS ...

Page 2: ...with an engine size greater than 90 cc Take the training course before your operate ATV ask your dealer for information This ATV is designed for one person only CALIFORNIA Proposition 65 Warning WARNING Motor vehicles may contain fuels oils and fluids battery posts terminals and related accessories which contain lead and lead compounds and other chemicals identified by the State of California to p...

Page 3: ... LIABILITY FOR ERRORS IN THIS MANUAL and SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDENTAL AND CONSEQUENTIAL DAMAGES resulting from the use of the information and material in this manual NAME ADDRESS TELEPHONE PURCHASE DATE mm dd yyyy ATV MODEL FRAME NO ENGINE NUMBER KEY NUMBER ...

Page 4: ...ot carry a passenger IMPORTANT MANNUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH Particularly important information is distinguished in this manual by the following notations This is safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injur...

Page 5: ...CK SWITCH TIRES COOLANT STEERING LOCK SPEEDOMETER SPARK PLUG AIR CLEANER ENGINE OIL AND OIL FILTER DIFFERENTIAL GEAR OIL FINAL GEAR OIL SEAT STORAGE COMPARTMENT BATTERY AND FUSE REPLACING A HEADLIGHT BULB REPLACING THE TAIL BRAKE LIGHT BULB AUXILIARY DC JACK PRECAUTION OF ATV RIDING PERIODIC MAINTENANCE CLEANING AND STORAGE TROUBLESHOOTING MAINTENANCE RECORD CONSUMER INFORMATION 2016 MY EMISSIONS ...

Page 6: ...al 1060 lbs 481 kg Type 4 Stroke Engine Installation and arrangement Vertical below center incline Fuel Used Above 92 unleaded Cycle Cooling 4 stroke Water cooled Cylinder Bore Ø 92 mm Stroke 75 6 mm Number Arrangement Single Cylinder Displacement 502 6 cc Compression Ratio 9 9 1 Max HP 14 4 5500 kw rpm Max Torque 31 2 3600 Nm rpm Ignition Transistorized Ignition Starting System Electrical starter...

Page 7: ...peed change Speedometer 0 300 km hr Horn 93 112 dB A Fuel capacity 18 0 3 l Lubrication System Forced circulation splashing Engine oil Engine oil SAE 10 W 40 Capacity 4 08 qts 3 86 L Gear lubrication Spec SAE 90 Differential 15 2 oz 450 ml Final gear 15 2 oz 450 ml Spark Plug NGK CR7E Battery 12 18 V AH Lamps Front Lamps HI LO 60 watt 2 60 watt 2 Rear Lamps 5 watt 1 Brake Lamps 21 watt 1 ...

Page 8: ... number for future reference Number is located front right hand side of chassis as shown in 1 2 Engine number is located front of the engine as shown in 2 3 Manufacturer s DATA PLATE The manufacturer s data plate is located front right hand side of chassis as shown in 3 3 1 2 ...

Page 9: ...8 LOCATION OF THE WARNING AND SPECIFICATION LABELS 1 3 4 2 7 4 8 6 9 14 5 18 17 ...

Page 10: ...on your ATV These labels contain important information for safe and proper operation Never remove any labels from your ATV If a label becomes difficult to read or comes off request a replacement label from your dealer 1 2 12 16 11 13 15 10 19 ...

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Page 14: ...ate an ATV on any public street road or highway even dirt or gravel one Never operate an ATV without wearing an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots a long sleeved shirt or a jacket and long pants Never consume alcohol or drugs before or while operating this ATV Never operate at speeds too fast for your skills or the ...

Page 15: ... manual Dismount on the uphill side or to a side if pointed straight uphill Turn the ATV around and remount following the procedure described in this manual Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as large rocks or fallen trees Always follow proper procedures when operating over obstacles as described in this manual Always be car...

Page 16: ...Carbon Monoxide Poisoning Do not run engine indoors Even if you try to ventilate engine exhaust with fans or open windows and doors carbon monoxide can rapidly reach dangerous levels Do not run engine in poorly ventilated or partially enclosed areas such as barns garages or carports Do not run engine outdoors where engine exhaust can be drawn into a building through opening such as window and door...

Page 17: ... oil leakage Correct if necessary Differential gear oil Check ATV for oil leakage Correct if necessary Coolant Check coolant level in reservoir and add recommended coolant to specified level if necessary Check cooling system for leakage Correct if necessary Front brake Check operation if soft or spongy have the dealer bleed hydraulic system Check brake pads for wear and replace if necessary Check ...

Page 18: ...levers Make sure that operation is smooth Lubricate pedal pivoting point if necessary Axle boots Check for cracks or damage and replace if necessary Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Instruments light and switches Check operation and correct if necessary ...

Page 19: ...itch 2 High Low beam Switch 3 Four Wheel Brake Lever 4 Starter Switch 5 Override 6 Ignition Switch 7 Speedometer Display 8 Auxiliary DC jack 9 2WD 4WD LOCK Switch 10 Throttle 11 Fuel Tank Cap 12 L H N R Lever 13 Parking Brake ...

Page 20: ...un Turn Signal Switch Right Left hand direction Horn Sounded by pushing This vehicle is equipped with a safety protection system to start the engine must be brake applied Remove the function of over ride 1 Set the shift gear at R then press over ride button press and hold the button 2 When pressure on the button is released reverse gear speed will be limited again 3 FOUR WHEEL BRAKE LEVER WITH PAR...

Page 21: ...be between the minimum and maximum level markings Before each trip check the brake actuating system The gap between the end of the brake lever and the handlebar should be approximately 12 mm 0 5 inch Inform your local dealer of any deviations Irregularities of brakes such as leaks and poor performance should be dealt with by an authorized dealer NOTE The brake fluid level must be above the MIN mar...

Page 22: ...ver from N to H L or R L shift is used for rough surfaces Shifting H to L and any gear direction the vehicle must be at a complete stand still 3 For reverse with the brake on push the knob in and move the shift lever from N to R CAUTION Operating the shift lever when vehicle is moving can be hazardous This is strictly prohibited Always wait until the vehicle stops completely do not operate the ATV...

Page 23: ...ive to four wheel drive and vice versa The ATV handles differently in two wheel drive than in four wheel drive in some circumstances Changing from the two wheel drive to four wheel drive or vice versa while moving may cause the ATV to unexpectedly handle differently This could distract the operator and increase the risk of losing control and causing an accident This ATV is equipped with a switch t...

Page 24: ...speed you are traveling This ATV is equipped with a switch allowing you to lock the differential gear when in four wheel drive Select the appropriate switch position according to the terrain and the conditions 4WD four wheel drive Power is supplied to the rear and front wheels LOCK four wheel drive with the differential gear locked Power is supplied to the rear and front wheels and the differentia...

Page 25: ...is moving is extremely dangerous and you may lose control of the vehicle The gear box mechanism can be damaged if the lever is moved while the ATV is in motion Always stop the ATV completely before shifting between 2WD 4WD and LOCK 7 TIRES Check tire pressure regularly to make sure it is at the recommended specifications Also check for wear and damage Tire pressure Use the low pressure tire gauge ...

Page 26: ...n the tire tread depth decreases to 12 in 3 mm due to wear replace the tire Tire information This ATV is equipped with tubeless tires with valves WARNING Use of improper tires on this ATV may cause loss of control increasing your risk of an accident After extensive tests only the tires listed below have been approved for this model by the vehicle manufacturer Model 550 EFI 4x4 550 EFI 4x4 EPS Fron...

Page 27: ...ark remove the coolant reservoir cap add coolant or distilled water to the maximum level mark and install the reservoir cap CAUTION If coolant is not available use distilled water or soft tap water instead Do not use hard water since it is harmful to the engine If water has been used instead of coolant replace it with coolant as soon as possible otherwise the cooling system will not be protected a...

Page 28: ...N Mix antifreeze with distilled water only However if distilled water is not available soft water may be used for refilling Do not use hard water since it is harmful to the engine 11 Pour the recommended coolant into the radiator until it is full Antifreeze water mixture ratio 1 1 Recommended antifreeze High quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Co...

Page 29: ...reen Battery charge indicator N Neutral Gear Green Engine coolant Temperature Red R Reverse Gear Green Engine check Yellow EFI model 1 Engine oil indicator Red if this light turns on check the oil level if oil level is good please contact your local dealer for inspection 2 Temperature indicator Red if the light is on with the engine running it implies that there is a cooling system problem Please ...

Page 30: ...layed in 2nd row 2 Digital tachometer displays up to 19 900 RPM 3 Tachometer signal is picked up from either the ECU or the ignition coil MAX RPM Maximum Tachometer 1 MAX RPM is displayed on 2nd row 2 Displays highest tachometer reading achieved after last RESET operation SPEED Speed Meter 1 Speedometer display is on 1st row of the screen 2 Displays speedometer reading up to 300 0 Km H or 187 5 MP...

Page 31: ...the TIME screen for TYPE II then press the MODE and SET buttons simultaneously for 3 seconds to set the time 2 When the digit is blinking press the SET button to reach the desired number then press the MODE button to move to the next digit 3 After setting the time press the MODE and SET buttons simultaneously to save the time and go back to the ODO screen 4 During setting if the digits are not cha...

Page 32: ...ngine could be operating improperly Do not attempt to diagnose such problems yourself Instead have your dealer check the ATV 2 Check the spark plug for electrode erosion and excessive carbon or other deposits and replace it if necessary Specified spark plug NGK CR7E 3 Measure the spark plug gap with a wire thickness gauge and if necessary adjust the gap to specification Spark plug gap 0 7 0 8 mm T...

Page 33: ...l NOTE The sponge material should be wet but not dripping 13 ENGINE OIL AND OIL FILTER The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter replaced at the intervals specified in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the ATV on a level surface and remove the side access cover 2 Check the engine...

Page 34: ...used oil 4 Remove the engine oil drain bolt and its gasket to drain the oil from the crankcase NOTE Dispose of lubricant in accordance with local regulations Skip the steps 5 7 if the oil filter cartridge is not being replaced 5 Remove the left internal fender 6 Remove the oil filter cartridge with an oil filter wrench 7 Apply a thin coat of engine oil to the O ring of new oil filter 8 Install the...

Page 35: ...differential gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart To check the differential gear oil level 1 Place the ATV on a level surface 2 Remove the differential gear oil filler bolt and its gasket and then check the oil level in the differential gear case The oil level should be at the brim of the filler h...

Page 36: ...GEAR OIL The final gear case must be checked for oil leakage before each ride If any leakage is found have a dealer check and repair the ATV In addition the final gear oil level must be checked and the oil changed as follow at the intervals specified in the periodic maintenance and lubrication chart To check the final gear oil level 1 Place the ATV on a level surface 2 Remove the final gear oil fi...

Page 37: ... quarts 0 35 L 6 Check the oil filler bolt gasket for damage and replace it if necessary 7 Install the oil filler bolt and its gasket and then tighten the bolt to the specified torque Tighten torque 32 36 Nm or 24 ft lb 330kgf cm 8 Check the final gear case for oil leakage If oil is leaking check for the cause 16 SEAT To remove the seat 1 Open the lock by turning the key 2 Pull up on the seat at t...

Page 38: ... checked and tightened if necessary WARNING Battery electrolyte is poisonous and dangerous as it contains sulfuric acid which can cause severe burns Avoid contact with skin eyes or clothing Always shield your eyes when working near batteries Batteries produce explosive gases Keep sparks flame cigarettes or other sources of ignition away Ventilate when charging or using in an enclosed space KEEP OU...

Page 39: ...ll be stored for more than two months check it at least once a month and fully charge it if necessary CAUTION Always keep the battery charged Storing a discharged battery can cause permanent battery damage To install the battery 1 Place the battery in its compartment 2 Connect the positive battery lead first then connect the negative battery lead by installing their bolts CAUTION When installing t...

Page 40: ...e main switch when checking or replacing a fuse 2 Remove the blown fuse and then install a new fuse of the specified amperage WARNING Always use a fuse of the specified rating and never use a substitute object in place of the proper fuse An improper fuse or a substitute object can cause damage to the electrical system which could lead to a fire 3 Turn the key ON and turn on the electrical circuits...

Page 41: ...ife will be adversely affected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner 5 Adjust the headlight beam if necessary Adjusting a headlight beam 6 CAUTION It is advisable to have a dealer make this adjustment To raise a headlight beam turn the headlight beam adjusting screw in clockwise To lower a headlight beam turn the adjust...

Page 42: ...running and light switch is set to OFF When the auxiliary DC jack is being used the electric current should not exceed 5 A 1 Set the light switch to OFF 2 Turn the accessory off 3 Start the engine 4 Open the auxiliary DC jack cap and then insert the accessory power plug into the jack 5 Turn the accessory on 6 When the auxiliary DC jack is not being used cover it with the cap CAUTION Do not use acc...

Page 43: ...different types of terrain Do not operate this ATV at speeds too fast for your skills or the conditions as this increases your chances of losing control of the ATV and having an accident Always travel a speed that is proper for the terrain visibility and operating conditions and your experience Beginning and inexperienced operator should complete the certified training course They should then regu...

Page 44: ... helmet and other personal protective equipment can reduce the severity of injuries in an accident WARNING Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident Wear eye protection when operating your ATV to reduce the risk of a serious accident or injury Eye protection such as a face shield or goggles may reduce the ris...

Page 45: ...ehicle handling unexpectedly Make sure the load does not interfere with your control or ability to see where you are going Tie down cargo in the trailer securely Make sure cargo in the trailer cannot move around A shifting load can cause an accident Reduce speed and allow more room to stop A heavier vehicle takes longer to stop Avoid hills and rough terrain Choose terrain carefully Use extreme cau...

Page 46: ...ons could lead to an accident Exhaust system WARNING Dry grass or brush or other combustible material accumulated around the engine area could catch fire Do not operate idle or park the ATV in dry grass or other dry ground cover Keep the engine area free of dry grass brush or other combustible material Someone touching the exhaust system during or after operation could be burned Do not touch the h...

Page 47: ...d control of the ATV and may cause the ATV to go out of control Always avoid paved surfaces including sidewalks driveways parking lots and streets Do not ride on any public road street or highway Riding on public roads can result in collisions with other vehicles In many states it is illegal to operate ATVs on public streets roads and highways WARNING Never operate this ATV on any public street ro...

Page 48: ...lt terrain Shift to the park position and follow the instruction to start the engine Once it has warmed up you are ready to begin riding your ATV With the engine idling shift the drive select lever into the low gear position or high gear position Apply the throttle slowly and smoothly If the throttle is applied too abruptly the front wheels may lift off the ground resulting in a loss of directiona...

Page 49: ...then practice the procedure again If the riding surface is slippery or loose it may help to position more of your weight over the front wheels by moving forward on the seat Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves Improper riding procedures such as abrupt throttle changes excessive braking incorrect body movement or too much speed ...

Page 50: ...ible ride straight up hills Slow down when you reach the crest of the hill if you cannot see clearly what is on the other side there could be another person an obstacle or a sharp drop off Use common sense and remember that some hills are too steep for you to climb or descend If you are climbing a hill and you find that you have not properly judged your ability to make it to the top you should tur...

Page 51: ... riding your ATV downhill shift your weight as far to the rear and uphill side of the ATV as possible Move back on the seat and sit with your arms straight Engine compression will do most of the braking for you For maximum engine compression braking effect select the low gear position and change to 4WD before beginning to descend the hill Use caution while descending a hill with loose or slippery ...

Page 52: ...nting the front wheels slightly uphill When riding on slopes be sure not to make sharp turns either up or down hill If your ATV does begin to tip over gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance gradually steer again in the direction you wish to travel CROSSING THROUGH SHALLOW WATER WARNING Operating this vehicle through deep or fas...

Page 53: ...ING WARNING Skidding or sliding improperly may cause you to lose control of this ATV You may also regain traction unexpectedly which may cause the ATV to overturn Learn to safety control skidding or sliding by practicing at low speeds and on level smooth terrain ON extremely slippery surfaces such as ice go slowly and be very cautions in order to reduce the chance of skidding or sliding out of con...

Page 54: ...TV around if you still have forward speed If not stop dismount on the uphill side of the ATV and physically turn the ATV around If the ATV starts to slip backwards DO NOT USE THE REAR BRAKE IF THE ATV IS IN 2WD The ATV may tip over on top of you Dismount the ATV on the uphill side If your ATV is traversing a sloping surface Be sure to ride with your weight positioned towards the uphill side of the...

Page 55: ...ibly leading to death WARNING Brake discs calipers drums and linings can become very hot during use To avoid possible burns let brake components cool before touching them The intervals given in the periodic maintenance charts should be considered as a general guide under normal riding conditions However depending on the weather terrain geographical location and individual use the maintenance inter...

Page 56: ...rake Check operation and correct if necessary Check the brake lever and pedal free play and adjust if necessary I I I I Check brake friction plate wear and replace if necessary I I I I 14 Brake hoses Check for cracks or other damage and replace if necessary I I I Replace Every 4 years 15 Wheels Check run out and for damage and replace if necessary I I I 16 Tires Check tread depth and for damage an...

Page 57: ... Ensure the service book is stamped and signed Failure to do so could invalidate your warranty The maintenance schedule is based on months of use or kilometers traveled Do the scheduled maintenance based on which ever comes first CAUTION Some maintenance items need more frequent service if you are riding in unusually wet sandy or muddy areas or at full throttle Hydraulic brake service Regularly ch...

Page 58: ...s have resulted from improper high pressure detergent applications such as those available in coin operated car washers 4 Once most of the dirt has been hosed off wash all surfaces with warm water and mild detergent type soap An old toothbrush or bottlebrush is handy for hard to reach places 5 Rinse the ATV off immediately with clean water and dry all surfaces with a chamois clean towel or soft ab...

Page 59: ...nder head so that the electrodes are grounded d Turn the engine over several times with the starter e Remove the spark plug cap from the spark plug and then install the spark plug and the spark plug cap 4 Lubricate all control cables and the pivoting points of all levers and pedals 5 Check and if necessary correct the tire air pressure and then block up the ATV so that all of its wheels are off th...

Page 60: ...battery voltage Recharge battery to 12 5 VDC Mechanical failure See your dealer Engine pins or knocks Possible cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine backfires Possible cause Solution Weak spark from spark plugs Inspect clean and or replace...

Page 61: ... plugs Fuel is very high octane Replace with lower octane fuel Incorrect jetting See your dealer Engine stops or loses power Possible cause Solution Out of fuel Refuel Kinked or plugged fuel vent line Inspect and replace Water present in fuel Replace with new fuel Overuse of choke Inspect clean and or replace spark plugs Fouled or defective spark plugs Inspect clean and or replace spark plugs Worn...

Page 62: ...g Dealer stamp 2nd Service Date Odometer reading Dealer stamp 3rd Service Date Odometer reading Dealer stamp 4th Service Date Odometer reading Dealer stamp 5th Service Date Odometer reading Dealer stamp 6th Service Date Odometer reading Dealer stamp 7th Service Date Odometer reading Dealer stamp ...

Page 63: ...stamp 10th Service Date Odometer reading Dealer stamp 11th Service Date Odometer reading Dealer stamp 12th Service Date Odometer reading Dealer stamp 13th Service Date Odometer reading Dealer stamp 14th Service Date Odometer reading Dealer stamp 15th Service Date Odometer reading Dealer stamp ...

Page 64: ...nce in case the ATV is stolen KEY IDENTIFICATION NUMBER ___________________________ VEHICLE IDENTIFICATION FRAME NUMBER ___________________________ KEY IDENTIFICATION NUMBER The key identification number is stamped into the key Record this number in the space provided and uses it for reference when ordering a new key Vehicle identification frame number is stamped into the frame The vehicle identif...

Page 65: ... ignition and the engine computer Also included may be hoses connectors and other emissions related assemblies Where a warrantable condition exists Textron Specialized Vehicles will repair your ATV at no cost to you including diagnosis parts and labor Manufacturer s Warranty Coverage If any emissions related part on your ATV is defective the part will be repaired or replaced by Textron Specialized...

Page 66: ...e limits This warranty begins on the date the ATV is delivered to the first purchaser other than an authorized Textron Specialized Vehicles dealer or the date it is first used as a demonstrator lease or company ATV whichever comes first and continues for the time and mileage listed below Your emission control system may include parts such as the carburetor or fuel injection system ignition system ...

Page 67: ...etail price and labor reimbursement is at a geographically appropriate hourly labor rate for Textron Specialized Vehicles recommended time allowance For reimbursement present the replacement parts and a copy of the paid receipt to Textron Specialized Vehicles The use of replacement parts not equivalent to the original parts may impair the effectiveness of your ATV emissions control systems If such...