Chironex Motoports SPARTAN 500, Owner'S Manual

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

Page 2: ...es I Introduction 3 II Technical parameters 6 III Parts Breakdown 9 IV Safety Instructions 13 V Operating the Spartan UTV 15 VI Breaking in Period 21 VII Maintenance and Repair 22 VIII Troubleshooting 26 IX Torque specifications 39 X Fuel Oil Fluid Specifications 41 XI Circuit Diagrams 42 ...

Page 3: ... and capabilities of the unit This manual has been prepared to instruct you in the safe and responsible operation of your Spartan Utility Vehicle Read and abide by all safety alert information about this vehicle If you do not understand any part of this manual contact your local dealer for additional information and clarification As the operator of this piece of equipment you are in complete contr...

Page 4: ...s mounted in a highly styled and protective full length body Two passengers can ride comfortably in this vehicle protected from splashing water and mud The Brush Guard Bar mounted to the vehicle s frame provides protection against low hanging limbs and briars The Brush Guard Bar also provides a mounting system for optional windshields canopy tops and weather enclosures It also serves as a mounting...

Page 5: ... and equipment specially designed to repair Chironex products Record your Chironex Spartan Utility Vehicle serial number here for quick reference Model Number ___________________________ Serial Number ____________________________ Your Chironex dealer wants you to be satisfied with your new vehicle If you do not understand any part of this manual or you re not satisfied with the service received pl...

Page 6: ... h 9 m 4 Gas mileage 10 km L 5 Load capacity 300Kg III Engine Type Single cylinder 4 stroke liquid cooled Valve train 4 valve top camshaft single shaft Induction Carburetor Bore and stroke mm 87 5 x 82 Engine displacement 493 cc Compression ratio 10 2 1 Maximum power kw r min 24 6500 Maximum torque N m r min 38 8 5500 Minimum fuel consumption rate g Kw h 340 Idle speed r min 1300 100 Starting Elec...

Page 7: ...2 16 87 R Gear 3 828 2 69 11 02 Coolant antifreeze with rust prevention Dimension 610 x 568 x 519 Net weight 70 kg Final Drive shaft Shaft rotation clockwise from the back of engine IV Chassis 1 Differential Tapered arc gear transmission Transmission rate 33 9 2 Drive type Shaft 2WD 4WD Differential LOCK Normal drive Rear wheel drive 3 Suspension Front suspension Independent double wishbone with p...

Page 8: ...eering angle right 37 5 Maximum steering angle left 37 5 7 Brakes Front brakes Dual hydraulic disk Rear brakes Dual hydraulic disk Parking brake Mechanical disk rear axle 8 Electric Dump box Dumping angle 49 9 Winch Rated Single Line Pull 3000 lbs V Electrical components 1 Pipeline voltage 12V 2 Alternator power rating 325W 3 Battery 12V 36A h 4 Starter motor 12V DC motor ...

Page 9: ... Rights reserved 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 ...

Page 10: ...ll Rights reserved 10 Engine Parts Breakdown 1 Carburetor 2 Starter 3 Water temperature sensor 4 Starting handle 5 Left cover 6 Rear shaft flange 7 Front shaft flange 8 Oil filter 9 Thermostat 10 CVT case 11 CVT inlet 12 CVT inlet 13 Plug ...

Page 11: ...All Rights reserved 11 VIN number Rear suspension on the frame above right rear wheel Oil Intake Oil Dipstick Oil drain plug bottom of engine WARNING ENGINE OIL LEVEL SHOULD BE BETWEEN UPPER AND LOWER MARKINGS ELSE YOU RISK ENGINE DAMAGE ...

Page 12: ...mix different types of brake fluids Always maintain brake fluid level to ensure proper functioning of the brakes WARNING Do not unscrew radiator cap when engine is hot contents are at a high temperature and pressure WARNING Use TC DOT approved gear oil in the front and rear differentials Fill up to just below intake Filling too much will result in leakage and too little burn damage to the differen...

Page 13: ... 5 Check steering play 6 Check engine support frame bolts transmission system and running system 7 After starting engine listen for any abnormal noises and confirm whether all meter readings are normal 8 Check brake pedal movement and functionality of brakes including the hand brake 9 Check whether the lights steering light brake light warning light running lights headlight low and high beams are ...

Page 14: ...limit speed to 20 km h when turning 6 Do not over load the dump box If cargo height exceeds height of dump box it must be fastened down This will prevent cargo from falling forward and hurting the driver 7 The antifreeze in radiator is only suitable for use in temperatures above 35 C Please use antifreeze with the appropriate temperature rating for temperatures below 35 C 8 Do not use the hand bra...

Page 15: ...osition Connects starter and ignition circuit to start engine automatically returns to ON position after engine starts LOCK lock position The steering wheel is locked at this position and the key can be pulled out 3 Instruments Note You only can start the engine when gear is in N position The engine can not be started up when gear is in H L or R positions WARNING Ignition key can not be turned to ...

Page 16: ... Displays the total distance travelled 7 Speedometer Display the current speed 8 2WD 4WD and differential lock Single axle indicator being lit corresponds to 2WD In 4WD mode both axles indicator are lit When an X in displayed it indicates 4WD with the front differential locked L H N R Gear Indicator Displays the currently operational gear corresponding to Low High Neutral and Rear 4 Lights Press l...

Page 17: ...enter position 5 Horn Press button located at the center of the steering wheel to blow horn 6 Accelerator and brake pedals The accelerator pedal left and brake pedal right are located at the floor board on the driver side of the UTV Step on the brake pedal before switching into L H R gear as required then step on the accelerator pedal to move 7 Hand brake Parking brake Remember to pull up the hand...

Page 18: ...WD 4WD LOCK To select normal rear wheel drive switch button to 2WD position this mode is for on road driving Switch to 4WD position to select all wheel drive use this mode for off roading If the UTV gets stuck or you are driving in extreme terrain and or weather conditions switch to LOCK position this locks the front differential WARNING After parking the vehicle pull up the hand brake lever Push ...

Page 19: ...ride only when you are stuck or need to reverse in rough terrain WARNING Do not change from 2WD to 4WD when the UTV is in motion Selected gear is displayed on the dash At times the gear is selected only after stepping on the accelerator In order to prevent damage to the transmission step lightly on the accelerator pedal momentarily to ensure that the gear is in the right position NOTE Using the 4W...

Page 20: ...s 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 1 Maximum permissible speed Mileage Maximum permissible speed 800Km 40Km h 800 1600Km 50Km h 1600Km 60Km h Avoid full throttle starts sudden acceleration or deceleration during the breaking in period ...

Page 21: ... Check if all nuts and bolts are properly tightened including those of transmission components 5 First maintenance of vehicle After the first 1000km it is necessary to carry out a complete maintenance For maintenance instructions refer to the Maintenance and repair section in this manual VII Maintenance and repair WARNING It is important to carry out a complete maintenance after driving the UTV fo...

Page 22: ... Transmission box Gear shifting Belt abrasion 5 Gear box Change gear oil 6 Front rear differential Change gear oil 7 Tires Tire pressure and tread depth Front tie in 3 3 mm 8 Transmission assembly Bolts on front and rear differentials Bolts flange nuts on transmission shaft Tighten bolts and nuts 9 Lights Headlight brake light Signal light Dashboard lights Running lights Bulbs Switches Buttons 19 ...

Page 23: ...mm 4 Gear box Gear Oil Noise Gear oil level should be within specified limit 5 Front rear differential Gear Oil Noise Gear oil level should be upto the intake 6 Tires Tire pressure tread depth abrasion Front tire pressure 250 kPa Rear tire pressure 300 kPa Tread depth greater than 1 6 mm 7 Lights Headlight brake light Signal light Dashboard lights Running lights Bulbs Switches Buttons 8 Battery Ba...

Page 24: ...ment Check Check Carburetor Check Check Tire s Check Check Spark plug Check Engine oil Change Change Clean Valve clearance Check V belt Check Check Check Gear oil Gear box Change Change Gear oil F R Differential Change Change Front and rear shock absorber Check MAINTENANCE ITEM MILEAGE PERIOD of OPERATION Change once every 3 years Change once every 18 months Change once every 10000 km Change once ...

Page 25: ...ck Battery Check Check Steering assembly Check Check Transmission assembly Check Check Lights Instruments Check Check Brake line and master cylinder Check Check Engine suspension Check Check Front and rear axle suspension Check MAINTENANCE ITEM MILEAGE PERIOD of OPERATION NOTE Periodic maintenance is to be conducted at the specified mileage or time period of operation whichever comes first ...

Page 26: ...tor cranks too slow Change battery or starter motor Air intake improper Adjust Incorrect valve setting Adjust 2 No spark Dirt Clean Change Water Clean Dry Change Ignition coil Change Connector short open circuit Change Magneto Change CDI Change 3 No fuel in carburetor Fuel tank vent pipe tank block Clean or change Fuel pipe block Clean or change Damage to carburetor needle valve Change Block in fu...

Page 27: ...w setting is wrong Adjust 2 Electrical fault Dirt Clean Change Water Clean Dry Change Ignition coil Change Connectors open short circuit Change Magneto Change CDI Change Poor onroad performance Mechanical fault Valve spring Change Cam shaft worn out Change Spark plug is not clean Clean change Insufficient spark plug gap Adjust Change Improper air circulation Adjust Ignition coil Change Fuel level ...

Page 28: ...el level in float bowl Adjust the height Air filter is not clean Clean Change Intake manifold leak Tighten Change Excess engine oil Drain the excess engine oil 2 Electrical fault Spark plug is not clean Clean Change Insufficient spark plug gap Clean Adjust Ignition coil defect Change CDI defect Change Magneto defect Change 3 Mechanical fault Incorrect valve clearance Adjust Valve spring weak Check...

Page 29: ...s not clean Clean or change filter Cylinder piston piston rings worn out Repair change Leak at air intake connecting face Repair change Block in exhaust pipe Dredge Intake manifold leak Repair change 4 Engine cooling system Block in coolant channel or radiator Clear Air in Cooling system or insufficient coolant Release air refill coolant Water pump fault Change Unsuitable coolant Change Thermostat...

Page 30: ...rculation Chain elongated Change chain sprocket Chain worn out Repair Change Chain adjustor defect Change Noise from clutch Crankshaft spline damage Change crankshaft Clutch spline damage Change clutch Noise from Crankshaft Bearing Change Needle bearing damage Change Gap too big Change Noise from CVT Belt loose or worn out Change Roller or main wheel damage Change Noise from transmission system Ge...

Page 31: ...h or stuck Gear box or Gear change system Operating gear damage Change Shift rod bent Change Shift drum worn out Change Shifter fault Adjust Carburetor malfunction Starting trouble Carburetor jet block Clean Venturi block Clean Leak at valves Tighten Adjust change Starting pin adjustment incorrect Adjust Idle and low speed uneven Slow jet valve block Clean Tighten Valve channel Blocked Clean Air i...

Page 32: ...ust Starting pin not closed Adjust Spill over or fuel level fluctuation Needle valve worn out or damaged Change Valve Spring broken Change Floater defect Adjust Change Valve not clean Clean Engine coolant temperature is low Cooling System Fan temperature sensor defect Change Cold weather Cover the radiator Thermostat defect Change Spark weak Ignition System Faulty starter Change Faulty spark plug ...

Page 33: ...gh Low driven gear groove worn to taper Repair Change Speed changing principal and countershaft worn out Repair Change Sector gear tooth worn out Change Sector gear spring defect Change Vehicle leaning Running system Air pressure difference in left and right tires Adjust air pressue in tire Different loads on left and right side Adjust load Shock absorber setting Adjust Change Misalignment of fron...

Page 34: ... axial radial is too big Change Air pressure in tire is too high or too low Adjust air pressure in tire Front wheel unstable Steering assembly running system Tire or wheel imbalance Balance wheel Change tire Wheel hub bearing has been damaged or adjustment is wrong Change Adjust Left and right swing arm ball head worn or loose Change Drag pole tie in has been worn or loose Change Front wheel align...

Page 35: ...isk or pads not clean Repair Clean dust Brake disk or pads worn Change Brake main pump is damaged or leaks oil Repair Change Brake branch pump is damaged or leaks oil Repair Change Insufficient brake fluid Add Air in brake fluid Remove air Brake disk overheated Repair Change Brake is leaning Brake system suspension Oil stain on brake disks or pads Clean Change Hydraulic pump leaking oil or block R...

Page 36: ...e 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 Repair main pump Brake return spring Change Hand brake adjustment Adjust Hand brake line Lubricate or Change Brake branch clip block Repair or Change Brake disk worn Change Brake line Change IV Brake system failure ...

Page 37: ...g light does not illuminate Steering relay has been damaged Change Individual steering bulb has burned Change Grounding defect Repair Fuse blown Change Switch damage Change Starter does not rotate when starting Starter has been damaged Repair Change Starter relay has been damaged Change Grounding defect Repair Ignition switch has been damaged Change All instruments not working Circuit Main fuse bl...

Page 38: ...adlight 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 Repair Instrument damage Change Sensor damaged Change V Lights Instruments Circuit Failure ...

Page 39: ... 18 CVT cover screws 3 M6 10 19 Fuel pipe bolts 2 M14x1 5 18 20 Fuel pump bolts 3 M6 10 21 Needle valve screw 2 M6 10 22 Bolts on driver gear cover 4 M8 32 23 Bolts on driven gear cover 4 M8 25 24 Gear positioning bolt 1 M14x1 5 18 S Item Qty Thread diameter mm Torque Nm 25 Bolt on ignition switch 1 M10x1 25 55 26 Bolts on crankcase 14 M6 10 3 M8 25 27 Bolt on sector gear 1 M6 12 28 Oil filter bol...

Page 40: ...ke 1 M10 50 16 Bolt on pin of push rod 1 M8x20 23 17 Drive shaft flange nuts 4 M14 100 18 Tire nuts 16 M12 55 19 Rollcage screws 6 2 M12x95 M12x70 60 20 Steering wheel nut 1 M12 70 S Item Qty Thread diameter mm Torque Nm 21 Hand brake bolt 2 M8x20 28 22 Bumper bolt 2 M10x20 50 23 Axle bolt 2 M8x25 30 24 Flange bolt upper 1 M12x90 70 25 Flange bolt lower 2 M12x175 70 26 Front axle gear box bolt 6 M...

Page 41: ...cification Capacity Remark Fuel RQ 90 or higher grade lead free 27 L Fuel tank capacity Engine Oil Gear Oil Gear box SAE15W 40 SF or SC 1900 ml change oil 2000 ml change filter 2200 ml repair engine Front Differential Oil First 0 33 L change 0 28 Rear Differential Oil First 0 33 L change 0 28 Brake fluid GB1083JG3 1 1 L Coolant Distilled water Glycol 1 1 SAE15W 40 SF or SAE80W 90GL 4 ...

Page 42: ... Copyright Chironex Motorsports Inc All Rights reserved 42 2WD AND 4WD TRANSFER CIRCUIT ...

Page 43: ... Copyright Chironex Motorsports Inc All Rights reserved 43 SPARTAN 500 CIRCUIT DIAGRAM ...

Page 44: ... Copyright Chironex Motorsports Inc All Rights reserved 44 ...

Page 45: ..._________________________________________________________________________ Copyright 2007 2008 Chironex Motorsports Inc All Rights reserved ...