Massimo 700UTV-5, Owner'S Manual

Page 1: ...MASSIMO ALLIGATOR 700 4 MSU 700 4 Owner s Manual ...

Page 2: ...afety information It provides information about special techniques and skills necessary to ride your UTV It also includes basic maintenance and inspection procedures If you have any questions regarding the operation or maintenance of your UTV please consult the dealer AN IMPORTANT SAFETY MESSAGE READ THIS MANUAL TOGETHER WITH TIPS FOR THE UTV RIDER CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR UT...

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Page 4: ...ator 700 4 and MSU 700 4 series UTV s have three kind of appearances with the same methods for using inspection and maintenance With the details of using inspection and maintenance the instruction is suitable for all 700 4 series UTV s ...

Page 5: ...wing notations The Safety Alert Symbol means ATTENTION YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the machine operator a bystander or a person inspecting or repairing the machine A CAUTION indicates special precautions that must be taken to avoid damage to the machine A NOTE provides key information to make procedures easier or clearer ...

Page 6: ...he temperature is higher than 20 4 F After the UTV has warmed up the UTV can be started Please check page 6 2 on the warming up process When the temperature is higher than 38 100 F and when you park the UTV after it run at high speed please turn off the flameout switch firstly while make the radiator fan still work for 3 minute then turn off the power switch to save the battery When you park the U...

Page 7: ...Accelerator pedal 4 12 Brake pedal 4 13 Parking brake lever 4 14 Drive select lever 4 15 Fuel tank cap 4 15 Front Seats 4 16 Rear Seats 4 17 Seat Belt For Front Seats 4 17 Seat Belt For Reat Seats 4 18 Glove compartment 4 20 Cargo bed 4 20 Front and rear shock absorber adjustment 4 23 Trailer hitch bracket 4 25 Auxiliary DC jack 4 26 5 PRE OPERATION CHECKS 5 1 Front and rear brakes 5 2 Fuel 5 4 En...

Page 8: ...your vehicle 7 6 Braking 7 7 Going uphill 7 8 Going downhill 7 10 Crossing through shallow water 7 12 Riding over rough terrain 7 15 Riding in brush or wooded areas 7 16 Encountering obstacles on the trail 7 17 8 PERIODIC MAINTENANCE AND ADJUSTMENT 8 1 Periodic maintenance chart for The emission control system 8 4 General maintenance and lubrication chart 8 5 Hood 8 7 Console 8 9 Engine oil and oi...

Page 9: ... 36 Brake pedal and accelerator pedal lubrication 8 37 Rear knuckle upper and lower pivot lubrication 8 37 Steering shaft lubrication 8 38 Wheel removal 8 39 Wheel installation 8 39 Battery 8 40 Battery maintenance 8 42 Fuse replacement 8 43 Replacing a headlight bulb 8 45 Headlight beam adjustment 8 48 Tail brake light bulb replacement 8 48 Troubleshooting 8 50 Check and solution to Common Proble...

Page 10: ...1 1 LOCATION OF THE WARNING AND SPECIFICATION LABELS ...

Page 11: ...ls on your vehicle They contain important information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or comes off a replacement label is available from your dealer ...

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Page 16: ...avoid operating the vehicle on any paved surfaces including sidewalks driveways parking lots and streets Never operate this vehicle on any public street road or highway even a dirt or gravel one Never operate this vehicle without wearing an approved motorcycle helmet that fits properly You should also wear eye protection goggles or a face shield gloves over the ankle boots long sleeved shirt or ja...

Page 17: ...e steering wheel A sudden jolt could wrench the steering wheel around and your thumbs or fingers could be injured if they are in the way of the steering wheel spokes Always go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when driving the vehicle Never operate on excessively rough slippery or loose terrain until you have learned and...

Page 18: ...deeper than the floorboards on this model Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings Always be sure there are no obstacles or people behind you when you operate in reverse When it is safe to proceed in reverse go slowly Do not brake abruptly when carrying loads in the carg...

Page 19: ... of sparks open flames or other sources of ignition such as the pilot light of water heaters and clothes dryers When transporting the vehicle in anot her vehicle be sure it is kept in an upright position Otherwise fuel may leak out of the carburetor or fuel tank WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries HOW TO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot ...

Page 20: ... or running the engine in a closed area WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time HOW TO AVOID THE HAZARD Always operate your vehicle in an area with adequate ventilation ...

Page 21: ...ir intake duct 5 Spark plug 6 V belt case 7 Driver seat belt 8 Driver seat 9 Passenger seat belt 10 Cargo bed release levers 11 Rear shock absorber assembly adjusting ring 12 Cargo bed 13 Tail brake lights 14 Spark arrester 15 Fuel tank cap 16 Passenger seat 17 Oil filter cartridge 18 Engine oil dipstick 19 Battery 20 Fuses 21 Coolant reservoir 22 Radiator cap ...

Page 22: ... On Command four wheel drive and differential lock switches 28 Multi function meter unit 29 Auxiliary DC jack 30 Drive select lever 31 Parking brake lever 32 Accelerator pedal NOTE The vehicle you have purchased may differ slightly from those in the figures of this manual ...

Page 23: ...when ordering spare parts from a dealer or for reference in case the vehicle is stolen 1 KEY IDENTIFICATION NUMBER 2 VEHICLE IDENTIFICATION NUMBER 3 MODEL LABEL INFORMATION Key Identification Number The key identification number is stamped on the key as shown in the following illustration This number can be used for ordering a new key 1 Key identification number ...

Page 24: ...3 4 Vehicle identification number The Vehicle identification number is stamped into the frame 1 Vehicle identification number NOTE The vehicle identification number is used to identify your vehicle ...

Page 25: ...ctrical circuits are supplied with power and the headlights and taillights come on when the light switch is on OFF All electrical circuits are switched off The key can be removed in this position START The electric starter is engaged by turning and holding the key in this position Release the key when the engine starts ...

Page 26: ...arting instructions prior to starting the engine See pages 6 1 6 3 for details Indicator and warning lights 1 High range indicator light H 2 Parking brake indicator light P 3 Low range indicator light L 4 Four wheel locked showing light 5 Neutral indicator light N 6 Reverse indicator light R 7 On Command four wheel drive differential gear lock indicator 8 Coolant temperature warning light 9 Far li...

Page 27: ...n High range indicator light H This indicator light comes on when the drive select lever is in the H position Neutral indicator light N This indicator light comes on when the drive select lever is in the N position Reverse indicator light R This indicator light comes on when the drive select lever is in the R reverse position Furthermore this indicator light flashes when the engine is being raced ...

Page 28: ...il the vehicle starts moving When the on command differential gear lock switch is set to LOCK the indicator will flash until the differential gear is locked Coolant temperature warning light When the coolant temperature reaches a specified level this light comes on to warn that the coolant temperature is too hot If the light comes on during operation stop the engine as soon as it is safe to do so ...

Page 29: ...lock Hour fault code reset button The multi function meter unit is equipped with the following Speedometer which shows the riding speed Odometer which shows the total distance traveled Two trip meters which show the distance traveled since they were last set to zero Clock Hour meter which shows the total time the key has been turned to ON Fault code meter To display the faults of Electronic Fuel I...

Page 30: ...ull tank of fuel This information will enable you to plan future fuel stops NOTE Holding in the TRIP ODO button and then turning the key to ON switches the display between mph and km h Clock Mode Pushing the button switches the display between the clock mode CLOCK and the hour meter mode HOUR in the following order CLOCK HOUR CLOCK To Set the Clock 1 Set into the clock mode 2 Press the watch butto...

Page 31: ...ee attachment for faults code page 11 1 When the fault code is confirmed and has been repaired you just need to press the button meter will go back to clock mode Fuel meter The fuel meter will indicate the fuel volume As the fuel is running out the indicator will turn green into red Vice versa 1 Fuel level warning indicator 2 Fuel meter ...

Page 32: ...to turn on the high beam and the taillights Set the switch to OFF to turn off all the lights 1CAUTION Do not use the headlights with the engine turned off for an extended period of time The battery may discharge to the point that the starter motor will not operate properly If this should happen remove the battery and recharge it ...

Page 33: ...ear lock switch 4WD LOCK Select the appropriate drive according to terrain and the conditions Two wheel drive 2WD Power is sup plied to the rear wheels only Four wheel drive 4WD Power is supplied to the rear and front wheels Four wheel drive with the differential gear locked 4WD LOCK Power is supplied to the rear and front wheels when the differential gear is locked DIFF LOCK Unlike the 4WD mode a...

Page 34: ...tract the operator and increase the risk of losing control and an accident HOW TO AVOID THE HAZARD Always stop the vehicle before chang ing from 2WD to 4WD or from 4WDto 4WD LOCK or vice versa On Command four wheel drive switch 2WD 4WD 1 Select lever 2 On Command four wheel drive switch 2WD 4WD To change from 2WD to 4WD stop the vehicle and then set the switch to 4WD When the vehicle is in 4WD the...

Page 35: ...r lock indicator in the multifunction meter unit display To release the differential gear lock stop the vehicle and set the switch to 4WD WARNING POTENTIAL HAZARD Riding too fast while the vehicle is in 4WD LOCK WHAT CAN HAPPEN All wheels turn at the same speed when the differential is locked so it takes more effort to turn the vehicle The amount of effort required is greater the faster you go You...

Page 36: ...ntial gear lock to engage Riding before the differential gear lock is properly engaged e g when the indica tor and indicator light are flashing will cause the engine speed to be limited until engagement is complete Accelerator pedal Press the accelerator pedal down to increa se engine speed Spring pressure returns the pedal to the rest position when released Always check that the accelerator pedal...

Page 37: ...e accelerator pedal could de hard to operate making it difficult to speed up or slow down when you need to This could cause an accident HOW TO AVOID THE HAZARD Check the operation of the accelerator pedal before you start the engine If it does not work smoothly check for the cause Correct the problem before operating the vehicle Consult a dealer if you can t find or solve the problem yourself Brak...

Page 38: ... up completely To release the parking brake pull up on the lever press the release button and then push the lever all the way down Spring pressure helps return the lever to the released position Be sure to fully release the parking brake before starting out Failure to do so may result in poor performance and premature wearing of the rear brake and V belt 1 Parking brake lever 2 Release button ...

Page 39: ...er is used to shift you vehicle into the low high neutral and reverse positions Refer to pages 6 5 6 7 for the drive select lever operation 1 Drive select lever Fuel tank cap Remove the fuel tank cap by turning it counterclockwise 1 Fuel tank cap ...

Page 40: ...eat lock lever 2 To install a seat insert the projection on the rear of the seat into the seat holders and push down on the seat at the front WARNING POTENTIAL HAZARD A loose seat WHAT CAN HAPPEN The operator could lose control or the operator or passenger could fall if the seat is loose during operation HOW TO AVOID THE HAZARD Make sure the seat is securely latched ...

Page 41: ...eed to pull it up from back and then push it back Seat Belt For Front Seats This vehicle is equipped with three point seat belts for both the operator and passenger Always wear the seat belt while riding in the vehicle 1 Seat belt 2 2 Latch plate 2 3 Buckle 2 ...

Page 42: ...of running To wear the seat belt properly do the following 1 Hold the latch plate as you pull the belt across your lap and chest Make sure the belt is not twisted and is not caught on any portion of the vehicle your clothing or any equipment you are carrying 2 Push the latch plate into the buckle until it clicks Pull up on the latch plate to make sure it is secure 1 Buckle 2 Latch plate ...

Page 43: ...it is loose pull the belt out all the way and then let it retract 5 To release the buckle firmly press the release button 1 Buckle 2 Release button WARNING POTENTIAL HAZARD Not wearing the seat belt Wearing the seat belt improperly WHAT CAN HAPPEN There is increased risk of being killed or seriously injured in an accident HOW TO AVOID THE HAZARD Always wear your seat belt when riding in the vehicl...

Page 44: ...ct from damage do not put metal products like tools or sharply edged products directly in the glove compartment If they must be stored wrap them in appropria te cushion material a Unlock b Open Cargo bed 1 Cargo bed 2 Tailgate 3 Cargo hook 4 ...

Page 45: ...tion and then hook the latches Lifting and lowering the cargo bed 1 Cargo bed release lever To lift Push down the cargo bed release lever on the left or right side of the vehicle and then slowly lift up the cargo bed until it stops To lower Lower the cargo bed slowly to its original po sition and be sure the it is locked into place Maximum load limit 150kg 330lb ...

Page 46: ...m the vehicle Keep hands and fingers away from the pinch points between the bed and the frame WARNING POTENTIAL HAZARD Overloading the cargo bed WHAT CAN HAPPEN Could cause changes in vehicle handl ing which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated maximum load limit for this cargo bed Cargo should be properly distributed and securely attached Reduce speed when car...

Page 47: ...rgo only Front and rear shock absorber adjustment The spring preload can be adjusted to suit the operating conditions You can reduce preload for a softer ride or increase preload if frequent bottoming occurs 1CAUTION Frequent or severe bottoming can cause increased wear or damage to the vehicle Adjust the spring preload as follows To increase the spring preload turn the adjusting ring in direction...

Page 48: ...4 24 1 Spring preload adjusting ring 2 Position indicator NOTE A special wrench can be obtained at a dealer to make this adjustment Standard position B A Minimum soft E Maximum hard 1 Special wrench ...

Page 49: ...lead to an accident HOW TO AVOID THE HAZARD Always adjust the shock absorbers on the left and right side to the same setting Trailer hitch bracket This vehicle is equipped with a 5 cm 2 in receiver bracket for a standard trailer hitch Trailer towing equipment can be obtained at a dealer See pages 6 11 6 13 for precaut ion information 1 Trailer hitch bracket ...

Page 50: ...ghts radios etc The auxiliary DC jack should only be used when the engine is running 1 Auxiliary DC jack cap 1 Set the light switch to OFF 2 Start the engine See pages 6 1 6 3 3 Open the auxiliary DC jack cap and then insert the accessory power plug into the jack 1 Auxiliary DC jack Maximum rated capacity for the auxiliary DC jack DC 12V 120W 10 A ...

Page 51: ...um capacity This may overload the circuit and cause the fuse to blow If accessories are used without the engine running or with the headlights turned on the battery will lose its charge and engine starting may become difficult Do not use an automotive cigarette lighter or other access with a plug that gets hot because the jack can be damaged ...

Page 52: ...r Check coolant level Fill with coolant if necessary 5 6 8 15 8 16 Final gear oil Differential gear oil Check for leakage 5 7 Accelerator pedal Check for proper accelerator pedal operation 5 8 5 10 Seat belts Check for proper operation and belt wear 5 10 Steering Check for proper operation 5 8 5 10 Fittings and fasteners Check all fittings and fasteners 5 11 Lights and switches Check for proper op...

Page 53: ... the inspection and maintenance procedures and schedules described in the Owner s Manual Front and rear brakes Brake pedal Check for correct brake pedal free play If the brake pedal free play is incorrect have a dealer adjust it See pages 8 35 8 36 Check the operation of the brake pedal It should move smoothly and there should be a firm feeling when the brakes are applied If not have the vehicle i...

Page 54: ...operly If the brakes do not provide proper braking performance inspect the brake system See pages 8 32 8 36 WARNING POTENTIAL HAZARD Driving with improperly operating brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride Do not operate the vehicle if you find any problem with the brakes If a ...

Page 55: ...h a pump octane number R M 2 of 86 or higher or research octane number of 91 or hither If knocking or pinging occurs use a different brand of gasoline or premium unleaded fuel Unleaded fuel will give you longer spark plug life and reduced maintenance cost Gasohol The UTV uses an electric fuel injection system and its emissions completely meet the requirements of relevant rule of the United States ...

Page 56: ...e up any spilled fuel immediately Be sure the fuel tank cap is closed securely Engine oil Make sure the engine oil is at the specified level Add oil as necessary See pages 8 10 8 13 1CAUTION In order to prevent clutch slippage since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specification of CD or oils of a higher quality than specifie...

Page 57: ...the coolant every two years See pages 8 18 8 19 for details 1CAUTION Hard water or salt water is harmful to the engine You may use soft water if you cannot get distilled water Coolant reservoir capacity up to the maximum level mark 0 35L 0 31lmp qt 0 37US qt WARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot WHAT CAN HAPPEN You could be burned by hot flui...

Page 58: ... and additive rating GL 5 or GL 6 rated hypoid gear oils may also be used Differential gear oil Make sure the differential gear oil is at the specified level Add oil as necessary See pages 8 16 8 17 for details Recommended oil SAE 80 API GL 5 Hypoid gear oil Throttle Pedal Check to see that the accelerator pedal operates correctly It must operate smoothly and fully spring back to the idle position...

Page 59: ...ar 2 Apply the brakes Start the engine Allow it to warm up thoroughly 3 Measure the distance the throttle pedal moves before the engine begins to pick up speed Freeplay should 1 16 to 1 8 inches 1 5 3mm WARNING Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation Never start ...

Page 60: ...ing Wheel Inspection Check the steering wheel for specified freeplay and smooth operation 1 Position the vehicle on level ground 2 Lightly turn the steering wheel left and right 3 There should be 0 8 1 0 20 25 mm of freeplay If there is excessive freeplay or strange noises or the steering feels rough or catchy have the steering system inspected by an authorized dealer Seat belts Make sure that bot...

Page 61: ...asteners Always check the tightness of chassis fittings and fasteners before a ride Take the vehicle to a dealer or refer to the Service Manual for correct tightening torque Lights Check the headlights and tail brake lights to make sure they are in working condition Repair as necessary for proper operation Switches Check the operation of all switches Have a dealer repair as necessary for proper op...

Page 62: ...fac turing corporation of America for this model Other tire combinations are not recommended Type Size Front 25 8 12 6PR Rear 25 10 12 6PR 2 The tires should be set to the recommended pressure Recommended tire pressure Front 70kpa 0 7 kgf cm2 10psi Rear 70kpa 0 7 kgf cm2 10psi Check and adjust tire pressures when the tires are cold Tire pressures must be equal on both sides 3 Tire pressure below t...

Page 63: ...he tire pressure gauge NOTE The tire pressure gauge is included as stan dard equipment Make two measurements of the tire pressure and use the second reading Dust or dirt in the gauge could cause the first reading to be incorrect Set pressure with tires cold Set tire pressures to the following specifica tions Recommended pressure Minimum Maximum Front 70kpa 0 70kgf cm 2 10pai 63kpa 0 64kgf cm 2 9pa...

Page 64: ...5 13 1 Tire pressure gauge Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire a Tire wear limit ...

Page 65: ...k your dealer Starting The Engine In Low Temperatures WARNING POTENTIAL HAZARD Freezing control cables in cold weather WHAT CAN HAPPEN You could be unable to control the vehicle which could lead to an accident or collision HOW TO AVOID THE HAZARD When riding in cold weather always make sure all control cables work smoothly before you begin riding 1 Check the throttle cable parking cable and the re...

Page 66: ...hould come on If the neutral indicator light does not come on ask a dealer to inspect the electric circuit The engine can be started in any gear if the brake is applied However it is recommended to shift into neutral N before starting the engine 4 With your foot off the accelerator pedal start the engine by turning the key to START NOTE If the engine fails to start release the key and then try sta...

Page 67: ...r 12V the idle speed will be normal If the idle speed is still high please contact your dealer Warming Up To get maximum engine life always warm up the engine before driving Never accelerate hard with a cold engine To see whether or not the engine is warm check if it responds to the throttle normally 1 Release the brakes and press the accelerator pedal gradually 2 If the rotation rate of the engin...

Page 68: ...e accelerator pedal 2 Apply the brakes then shift by moving the drive select lever along the shift guide NOTE Make sure that the drive select lever is completely shifted into position 1 Drive select lever 3 Release the brakes and press the accelerator pedal gradually Shifting Neutral to Reverse 1 Stop the vehicle Keep your foot off the accelerator pedal 2 Apply the brake pedal 3 Shift from neutral...

Page 69: ...go back and gearshifts can be removed to reverse position 1 Position pin 2 Cadle 3 Adjnst 1 Drive select lever NOTE When in reverse the reverse indicator light should be on If the light does not come on ask a dealer to inspect the reverse indicator light electrical circuit Due to the synchronizing mechanism in the engine the light may not come on until the vehicle starts moving 4 Check behind for ...

Page 70: ...person behind you resulting in serious injury HOW TO AVOID THE HAZARD When you shift into reverse make sure there are no obstacles or people behind you When it is safe to proceed go slowly Parking a When parking stop the engine and shift the drive select lever into the neutral position b Push the brake pedal down and pull the parking brake to top position to park the vehicle 1 Parking handbar ...

Page 71: ...l or other incline WHAT CAN HAPPEN The vehicle could roll out of control increasing the chance of an accident HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines If you must park on an incline apply the parking brake and block the front and rear wheels with rocks or other objects Do not park the vehicle at all on hills that are so steep you could not walk up them easily ...

Page 72: ...es to use the first three 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 Perform the following procedures carefully Excessive heat build up during the first three hours of operation will damage close fitted engine pa...

Page 73: ...rolonged full throttle operation or any condition which might result in excessive engine heating must be avoided However momentary 2 3 seconds maximum full throttle operation under load does not harm the engine Each full throttle acceleration sequence should be followed with a substantial rest period for the engine by cruising at lower r min so the engine can rid itself of the temporary build up o...

Page 74: ...during the break in period as recommended Pull only light loads Avoid aggressive acceleration and high speed operation during the break in period Accessories and loading Accessories Accessories can affect the handing and control of your vehicle Keep the following in mind when considering an accessory or operating a vehicle which has accessories Choose only accessories designed for your vehicle You...

Page 75: ... it does without accessories Loading Cargo or a trailer can change the stability and handling of a vehicle You must use common sense and good judgment when carrying cargo or towing a trailer Keep the following points in mind Never exceed the weight limits shown An overloaded vehicle can be unstable MAXIMUM LOADING LIMIT Vehicle loading limit total weight of cargo operator passengers and accessorie...

Page 76: ...he scale with the tongue at hitch height Adjust the load in the trailer if necessary to reduce the weight on hitch If you are carrying cargo and towing a trailer include the tongue weight in the maximum vehicle load limit Load cargo in the cargo bed as close to the center of the vehicle as possible and tie it down using the cargo hooks equipped on the cargo bed Tie down cargo securely in the trail...

Page 77: ...ded weight affects the stability and handling of the vehicle WARNING POTENTIAL HAZARD Overloading this vehicle or carrying or towing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this vehicle Cargo should be properly distributed and securely attached Reduce speed when carryi...

Page 78: ... Please also read all caution and warning labels on your vehicle This vehicle is designed for the operator and one passenger The driver and passenger must always wear a seat belt Never carry passengers in the cargo bed WARNING POTENTIAL HAZARD Not wearing the seat belt Wearing the seat belt improperly WHAT CAN HAPPEN There is increased risk of being killed or seriously injured in an accident HOW T...

Page 79: ...e cargo bed HOW TO AVOID THE HAZARD Never carry a passenger in the cargo bed The cargo bed is designed to carry cargo only The total weight of operator passenger accessories cargo trailer tongue weight and the vehicle itself must not exceed 998Kg 2 200 lb See Loading on page 6 11 Carrying a passenger and cargo can affect vehicle handling ...

Page 80: ...istributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking Always follow the instructions in your Owner s Manual for carrying cargo or pulling a trailer The driver and passenger must always wear a seat belt and an approved motorcycle helmet Also wear eye protection and protective clothing including over the ankle boots gloves a long sl...

Page 81: ...ases your chances of a severe head injury or death in the event of an accident Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket lo...

Page 82: ...before attempting more difficult maneuvers Perform the Pre Operation Checks on pages 5 1 5 11 Set the parking brake shift to neutral and follow the instructions on page 6 1 to start the engine Once it has warmed up and you have turned the choke off you are ready to begin driving your vehicle With the engine idling shift the drive select lever into low or high Then release the parking brake Press t...

Page 83: ...go out of control if you attempt sharp high speed turns You should also be careful making sharp turns on rough terrain Do not attempt to turn around or make abrupt maneuvers on slope Position your hands on the steering wheel so that your thumbs and fingers do not wrap around the wheel This is particularly important when driving in rough terrain The front wheels will move right and left as they res...

Page 84: ...ver open the throttle suddenly 3 Back slowly 4 Apply the brakes lightly for stopping 5 Avoid making sharp turns Before shifting into reverse gear always check for obstacles or people behind the vehicle When it s safe to proceed back slowly BRAKING Braking ability is affected by the type of terrain In most cases gradually application of the brakes is more effective than abrupt braking particularly ...

Page 85: ...f a hill which increases your chance of rollover Practice first on gentle slopes before attempting steeper hills Always check the terrain carefully before attempting any hill Use common sense and remember that some hills are too steep for you to climb Choose carefully which hills you attempt to climb Avoid hills with slippery surfaces or ones where you will not be able to see far enough ahead of y...

Page 86: ...face of a hill Go straight up the hill Practice on smaller hills before attempting large hills Before climbing the hill first be sure you are operating in low range 4WD or if necessary with 4WD Diff Lock To climb a hill you need traction momentum and steady throttle Travel fast enough to keep your momentum going but not so fast that you cannot react to changes in the terrain as you climb Slow down...

Page 87: ...he engine brake if necessary to slow your descent Release the brake and begin to coast down the hill Use engine braking as much as possible gently applying the brakes when necessary GOING DOWNHILL Check the terrain carefully before going down a hill When possible choose a path that lets you drive your vehicle straight downhill Avoid sharp angles that could allow the vehicle to pitch or roll over C...

Page 88: ...n low range 4WD On most slopes this will let you use engine braking to help you go downhill slowly Go as slowly as possible If you are starting to go too fast apply the brakes gently Avoid sudden application of the brakes which could cause the vehicle to start sliding If you are sliding or skidding try to steer in the direction the vehicle is sliding to help you regain control If you must turn on ...

Page 89: ...ter test your brakes If necessary apply the brakes several times to let friction dry out the linings WARNING POTENTIAL HAZARD Operating this vehicle through deep or fast flowing water WHAT CAN HAPPEN Loss of control which could result in an accident including overturn which could increase the risk of drowning HOW TO AVOID THE HAZARD Never operate this vehicle in fast flowing water or in water deep...

Page 90: ...your dealer before starting the engine If it s impossible to take your vehicle to a dealer before starting it follow the steps outlined below 1 Move the vehicle to dry land 2 Check the air box If water is present dry the air box and replace the filter with a new filter 3 Remove the spark plugs 4 Turn the engine over several times 5 Dry the spark plugs and reinstall them or install new plugs 6 Atte...

Page 91: ...before reassemble 9 check the gearshift release the water inside Wash it if it is necessary CAUTION Make sure all motion parts coated with grease after wash and reassemble 1 Air filter case check hose 1 V belt cooling duct check hose ...

Page 92: ...ry loss of control and damage to the vehicle could occur WARNING POTENTIAL HAZARD Failure to use extra care when operating this vehicle on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the vehicle overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar ter...

Page 93: ...ides and above the vehicle for obstacles such as branches that the vehicle might hit causing an accident or for brush that might enter the vehicle as you pass and strike the driver or passenger Never hold onto the enclosure so your hand is outside the vehicle Hold only onto the handgrip inside the enclosure ...

Page 94: ...ping Go only fast enough to maintain your momentum but still give yourself plenty of time to react to changes in conditions If there is any question about your ability to maneuver safely over the obstacle you should turn around if the ground is flat and you have the room or back up until you find a less difficult path WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Cou...

Page 95: ...pection adjustment and lubrication are explained on the following pages WARNING POTENTIAL HAZARD Servicing an engine while it is running WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body causing injury Electrical components can cause shocks or can start fires HOW TO AVOID THE HAZARD Turn off the engine when performing maintenance unless otherwise specified Have a dealer perform ...

Page 96: ...our own preventive maintenance and minor repairs The tools provided in the Owner s tool kit are sufficient for this purpose except that a torque wrench is also necessary to properly tighten nuts and bolts NOTE If you do not have a torque wrench available during a service operation requiring one take your vehicle to dealer to check the torque settings and adjust them as necessa ry ...

Page 97: ...ng which in some situations could lead to an accident HOW TO AVOID THE HAZARD Never modify this vehicle through improper installation or use of accessories All parts and accessories added to this vehicle should be genuine or equivalent components designed for use on this vehicle and should be installed and used according to instructions If you have questions consult an authorized vehicle dealer ...

Page 98: ...pecial tools data and technical skills ITEM ROUTINE Whichever Comes first INITIAL EVERY Month 1 3 6 6 12 Km mi 320 200 1 200 750 2 400 1 500 2 400 1 500 4 800 3 000 hours 20 75 150 150 300 Valves Check valve clearance Adjust if necessary Fuel line Check fuel hose for cracks or damage Replace if necessary Spark plug Check condition Adjust gap and clean Replace if necessary Exhaust system Check for ...

Page 99: ...cartridge Replace Final gear oil Check oil lever oil leakage Replace Differential gear oil Accelerator pedal Check operation and free play V belt Check operation Check for wear cracks or damage Wheels Check balance damage runout Replace if necessary Front brake Check operation brake pad wear fluid leakage se e page 8 6 COrrect if necessary Replace pads if worn to the limit Rear brake Check operati...

Page 100: ... lithium soap based grease Steering system Check operation and for looseness Replace if damaged Check toe in Adjust if necessary Engine mount Check for cracks or damage Check bolt tightness Front and rear axle boots Check operation Replace if damaged NOTE Recommended brake fluld DOT4 Brake fluid replacement When disassembling the master cylinder or caliper replace the brake fluid Normality check t...

Page 101: ...8 7 Hood To open Unhook the hood latches and then slowly tilt the hood up until it stops 1 Latch 2 1 Hood ...

Page 102: ...side of the hood into slots on the back of the instrument panel Secure slots on the side of the hood around projections on the frame 1 Projection 2 2 Slot 2 3 Slot 2 4 Projection 2 CAUTION Make sure that all cables and wires are in place when closing the hood Do not drive the vehicle with the hood open unlatched or removed ...

Page 103: ...lever boot will come loose 1 Console To install 1 Place the console in its original position 2 Install the parking brake lever boot 3 Install the seats CAUTION When installing the console be sure not to pinch the cables or wires Make sure that the groove at the bottom of the parking brake lever boot and the drive select lever boot fits securely around the edge of the hole in the console ...

Page 104: ...l be sure to warm up the engine suff iciently and then wait at least ten minutes until the oil settles for an accurate reading 4 Remove the engine oil filler cap and wipe off the dipstick with a clean rag 5 Insert the dipstick in the oil filler hole without screwing it in and then remove it again to check the oil level NOTE The engine oil should be between the minimum and maximum level marks 1 Max...

Page 105: ...ine to collect the used oil and then remove the engine oil filler cap 3 Remove the engine oil drain bolt to drain the oil from the crankcase 1 Engine oil drain bolt NOTE Skip steps 4 6 if the oil filter cartridge is not being replaced 4 Remove the oil filter cartridge with an oil filter wrench 1 Oil filter cartridge 2 Oil filter wrench NOTE An oil filter wrench is available at a nearby dealer ...

Page 106: ... tighten it to the specified torque with a torque wrench Tightening torque Oil filter cartridge 17Nm 1 7m kgf 12 ft lbf 1 Oil filler cartridge 2 Torque wrench 7 Install the engine oil drain bolt and then tighten it to the specified torque Tightening torque Engine oil drain bolt 30Nm 3 0m kgf 22 ft lbf 8 Add the specified amount of recomm ended engine oil and then install the engine oil filler cap ...

Page 107: ...ves Do not use oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign material enters the crankcase 9 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause 10 Turn the ...

Page 108: ...E The oil level should be at the brim of the filler hole 3 If the oil is below the brim of the filler hole add sufficient oil of the recommended type to raise it to the correct level CAUTION 1 Be sure no foreign material enters the final gear case 2 Please clean the sensor every 500km period 4 Install the oil filler bolt and then tighten it to the specified torque Tightening torque Final gear oil ...

Page 109: ...Tightening torque Final gear oil drain bolt 20 Nm 2 0 m kgf 14 ft lbf 5 Add the recommended final gear oil up to the brim of the filler hole Recommended oil SAE 80 API GL 4Hypoid gear oil Oil quantity 0 25 L 0 22 lmp qt 0 26 US qt CAUTION Be sure no foreign material enters the final gear case 6 Install the oil filler bolt and then tighten it to the specified torque Tightening torque Final gear oil...

Page 110: ... filler bolt 2 Correct oil level 3 Differential gear oil CAUTION Be sure no foreign material enters the differential gear case 3 Install the differential gear oil filler bolt and then tighten it to the specified torque Tightening torque Differential gear oil filler bolt 23Nm 2 3 m kgf 17 ft lbf Changing the differential gear oil 1 Place the vehicle on a level surface 2 Place a container under the ...

Page 111: ...gear case with the recommended oil Recommended oil SAE 80 API GL 5 Hypoid gear oil Oil quantity 0 32 L 0 28 lmp qt 0 34 US qt CAUTION Be sure no foreign material enters the differential gear case 6 Install the differential gear oil filler bolt and then tighten it to the specified torque Tightening torque Differential gear oil filler bolt 23Nm 2 3m kgf 17 ft lbf 7 Check for oil leakage If oil leaka...

Page 112: ...n the engine is cold as the coolant level varies with engine temperature NOTE The coolant should be between the minimum and maximum level marks 1 Coolant reservoir cap 2 Maximum level mark 3 Minimum level mark 4 If the coolant is at or below the minimum level mark remove the reservoir cap add coolant to the maximum level mark install the reservoir cap and then close the hood Coolant reservoir capa...

Page 113: ...ng water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant have a dealer check the antifreeze content of the coolant as soon as possible The radiator fan is automatically switched on or off according to the coolant temperature in the radiator If your vehicle overheats see page 8 45 for details Axle boots Check the protective boots for holes or tear...

Page 114: ...rk plug inspection Removal 1 Lift the cargo bed up See pages 4 20 4 22 for cargo bed lifting and lowering procedures 2 Remove the spark plug cap 1 Spark plug cap 3 Use the spark plug wrench in the tool kit to remove the spark plug as shown ...

Page 115: ...m to light tan for a vehicle that is being ridden normally Do not attempt to diagnose such problems yourself Instead take the vehicle to a dealer You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode erosion becomes excessive or if carbon and other deposits are excessive you should replace the spark...

Page 116: ...hen wipe off any grime from the spark plug threads 3 Install the spark plug and tighten it to the specified torque Tightening torque Spark plug 17 5 Nm 1 75 m kgf 12 7 ft lbf NOTE If a torque wrench is not available when you are installing the spark plug a good estimate of the correct torque is 1 4 to 1 2 turn past finger tight Have the spark plug tightened to the specified torque as soon as possi...

Page 117: ...er case If dust or water collects in this hose empty the hose and clean the air filter element and air filter case 1 Air filter check hose Remove the seats See pages 4 16 4 17 for seat removal and installation procedures Remove the console See page 8 9 for console removal and installation proced ures ...

Page 118: ...case cover by unho oking the holders 1 Holder 4 2 Air filter case cover 4 Remove the air filter element 5 Remove the sponge material from its frame 1 Air filter element 1 Air filter frame 2 Sponge material 3 Element retaining plate ...

Page 119: ...cess solvent out of the sponge material and let it dry CAUTION Do not twist the sponge material when squeezing it 8 Inspect the sponge material and replace it if damaged 9 Thoroughly apply foam air filter oil or other quality liquid foam air filter oil not spray type to the sponge material NOTE The sponge material should be wet but not dripping 10 Pull the sponge material over its frame 11 Install...

Page 120: ...r filter case for obstructions Check the air filter element rubber joint to the carburetor and manifold fittings securely to avoid the possibility of unfiltered air entering the engine CAUTION Never operate the engine with the air filter element removed This will allow unfiltered air to enter causing rapid engine wear and possible engine damage Additionally operation without the air filter element...

Page 121: ...it 1 V belt cooling duct check hose V belt case drain plug The V belt case drain plug is located under the driver seat See pages 4 16 4 17 for seat removal and installation procedures After riding in water deep enough to allow water to enter the V belt case remove the drain plug to drain any water from the case NOTE If water drains from the V belt case after removing the drain plug have a dealer i...

Page 122: ...ffler are cool before cleaning the spark arrester 1 Remove the bolts 1 Bolt 3 2 Remove the tailpipe by pulling it out of the muffler 3 Tap the tailpipe lightly and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe ...

Page 123: ...9 5 Nm 0 95 m kgf 6 9 ft lbf WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester Hot exhaust system WHAT CAN HAPPEN Could injure the eyes Could cause burns Could cause carbon monoxide poisoning possibly leading to death Could start a fire HOW TO AVOID THE HAZARD When cleaning the spark arrester Always let the exhaust system cool prior to touching exhaust components Do not start the en...

Page 124: ...ake pad is provided with wear indicator grooves which allow you to check the brake pad wear without having to disassemble the brake To check the brake pad wear check the wear indicator grooves If a brake pad has worn to the point that the wear indicator grooves have almost disappeared have a dealer replace the brake pads as a set 1 Brake pad wear indicator groove NOTE The wheels need to be removed...

Page 125: ... a dealer replace the brake pads as a set 1 Brake pad wear indicator groove Checking the brake fluid level 1 Minimum level mark Insufficient brake fluid may let air enter the brake system possibly causing the brakes to become ineffective Before riding check that the brake fluid is above the minimum level mark and replenish if necessary A low brake fluid level may indicate worn brake pads and or br...

Page 126: ...ction and lead to poor braking performance Be careful that water does not enter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock Brake fluid may deteriorate painted surfaces or plastic parts Always clean up spilled fluid immediately Have a dealer inspect the brake system if the brake fluid level goes down Brake flui...

Page 127: ... Have a dealer check the brake system if necessary 1 Brake pedal WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the brake pedal position is correct Make sure the brakes do not drag All air must be bled ...

Page 128: ... and installation procedures 3 Remove the console See page 8 9 for console removal and installation procedures 4 Check the parking brake lever free play The maximum free play is equal to one click of the parking brake lever If necessary adjust the free play as follows 1 Parking brake lever free play NOTE The parking brake lever must be released when checking and adjusting the parking brake lever f...

Page 129: ...rake pedal is properly adjusted when the brake light comes on just before braking takes effect If necessary adjust the brake light switch as follows 1 Open the hood See pages 8 7 8 8 for hood opening and closing procedures 2 Turn the adjusting nut while holding the brake light switch in place To make the brake light switch in place To make the brake light come on earlier turn the adjusting nut in ...

Page 130: ...uter covering of control cables becomes damaged Cables can also become frayed or kinked Operation of controls could be restricted which could cause an accident or injury HOW TO AVOID THE HAZARD Inspect cables frequently Replace damaged cables Lubricate the inner cables and the cable ends If the cables do not operate smoothly ask a dealer to replace them Recommended lubricant Engine oil ...

Page 131: ...Lubricate the pivoting parts Recommended lubricant Lithium soap based grease all purpose grease Rear knuckle upper and lower pivot lubrication Lubricate the knuckle upper and lower pivots with a grease gun Recommended lubricant Lithium soap based grease ...

Page 132: ...ate the pivot points Recommended lubricant Lithium soap based grease all purpose grease Lubrication of Drive Shaft Bearing Block 1 Bearing block Lubricate the bearing block Recommended lubricant Lithium soap based grease all purpose grease ...

Page 133: ...the nuts from the wheel Remove the wheel 1 Nut 4 Wheel installation 1 Install the wheel and the nuts NOTE The arrow mark on the tire must point toward the rotating direction of the wheel Tapered nuts are used for both the front and rear wheels Install the nut with its tapered side towards the wheel 1 Arrow mark ...

Page 134: ...pped with a sealed type battery Therefore it is not necessary to check the electrolyte or add distilled water in the battery If the battery seems to have discharged consult a dealer CAUTION Do not try to remove the sealing caps of the battery cells You may damage the battery Wheel nut torque Front 55Nm 5 5 m kgf 40 ft lbf Rear 55Nm 5 5 m kgf 40 ft lbf ...

Page 135: ... with skin eyes or clothing Always shield eyes when working near batteries Keep out of reach of children Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Get prompt medical attention EYES Flush with water for 15 minutes and get prompt medical attention Keep batteries away from sparks flames cigarettes or ot...

Page 136: ...ttery before reinstallation CAUTION A special battery charger constant voltage ampere or constant voltage is required for recharging a sealed type battery Using a conventional battery charger may shorten the battery life 2 Always make sure the connections are correct when putting the battery back in the vehicle 1 Negative battery lead 2 Positive battery lead ...

Page 137: ...t up and pulling it out 1 Battery compartment cover 2 Turn the key to OFF and turn off the electrical circuit in question CAUTION To prevent accidental short circuiting turn off the main switch when checking or replacing a fuse 3 Remove the blown fuse and then install a new fuse of the specified amperage 1 Main fuse 2 Spare main fuse 3 Headlight fuse 4 Ignition fuse 5 Auxiliary DC jack fuse 6 Four...

Page 138: ...ical circuit in question to check if the device operates 5 If the fuse immediately blows again have a dealer check the electrical system 6 Install the battery compartment cover 7 Close the hood WARNING POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire HOW TO AVOID THE HAZARD A ways use a fuse of the specifi...

Page 139: ... 8 for hood opening and closing procedures 2 Remove the cover at the rear of the headlight by pulling it off 1 Cover at the rear of the headlight 3 Remove the headlight bulb holder cover by pulling it off 1 Headlight bulb holder cover 4 Remove the headlight bulb holder by pushing it in and turning it counterclock wise ...

Page 140: ...t bulb is hot when it is on and immediately after it is turned off WHAT CAN HAPPEN You can be burned or a fire could start if the bulb touches something flammable HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it 6 Insert a new headlight bulb into the bulb holder by pushing it in ...

Page 141: ...ffected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner 7 Install the bulb holder by pushing it is and turning it clockwise 8 Install the bulb holder cover and the cover at the rear of the headlight CAUTION Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly 9 Close the hood 10 Ad...

Page 142: ...ction To lower the beam turn the adjusting screw in direction 1 Headlight beam adjusting screw Tail brake light bulb replacement If a tail brake light bulb burns out replace it as follows 1 Remove panel A if replacing the left tail brake bulb or panel B if replacing the right tail brake bulb by removing the quick fasteners and bolts 1 Panel A ...

Page 143: ...older 3 Push the defective bulb in and turn it counterclockwise to remove it from the bulb holder 4 Push a new bulb in and turn it clockwise to install in the bulb holder 5 Install the bulb holder together with the bulb by turning it clockwise 6 Install the panel by installing the quick fasteners and bolts and then tighten the bolts to the specified torque ...

Page 144: ... dealer The skilled technicians at a dealer ship have the tools experience and know how to properly service your vehicle Imitation parts may look like parts but they are often inferior Consequently they have a shorter service life and can lead to expensive repair bills WARNING POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame WHAT CAN HAPPEN Fuel can ignite or explode c...

Page 145: ...ce parts and impact fittings S N Problems Solutions 1 Covers are cracked up when go acrossing the field 1 Covers are cracked up when go acrossing the field 2 Change for new plastic covers 3 Re paste the stickers and re rivet the warning lables 2 Vehicle s bottem protect tion plate is damaged by prominence on ground 1 Check if the reduction gear box and differential in front and rear bridge are dam...

Page 146: ... in calipers are over worn or contaminated by stuffs which can reduce friction 3 Check if there is any leakage in brake system s oil lines or conjunctions 4 Check if the post rod in brake master cylinder is deformed 5 Check if there is any air go into the oil lines and drain the air with special equipment 6 Check if the remain oil in master cylinders of front and rear brake is still above the lowe...

Page 147: ... damper rubber sleeves connecting front suspension rock and frame are damaged Table 3 Check and Solution of Common Problems in Electrical System S N Problems Solutions 1 Lamps don t work 1 check if the headlight switch functions well 2 Check if the wires are broken 3 Check if the lamps or bulbs are broken 2 Vehicle cannot go into 4 drive mode 1 Check if the control switch on meter board works well...

Page 148: ...e switch is broken 2 Check if the wire is broken 3 Check if the ECU in electrical injection system is broken Table 4 Check and Solution of Common Problems in Running System S N Problems Solutions 1 Swing clearance of stee ring wheel is too big 1 Check the fix screws connecting steering rod to steering stem and knuckle to find out if they are loose or broken 2 Check the bulds on the ends of steerin...

Page 149: ...ke seriously in running 1 Check the bearing in rear bridge bearing seat to find out if they are broken 2 Check the sliding bearing connecting rear bridge and rocks to find out if they are worn or loose 3 Check the inner splines of rear wheel hubs and outer splines of rear wheel axles to find out if they are worn or broken 4 Check the lock screws of rear wheels and axles to find out if they are loo...

Page 150: ...sorbers lose their damping force in their travel 6 Front bridge makes noise in running 1 Check if the spline of intermediate driving shaft is broken 2 Check if the splines in left right drive shafts of front rear bridges are broken 3 Check if the gears in rear bridge reduction gear box and differential are over worn 4 Check the dust cover of constant velocity universal joint in right left drive sh...

Page 151: ...d value 3 Check MEUI for failure 3 Power performance is falling 1 Check if there is one cylinder not working 2 Check gasoline nozzle for block 3 Check and clean core of air cleaner 4 Check muffler for partly block and clean spark arrestor 4 Popping in engine 1 Check air cleaner and admission line for leak 2 Check the connection joint of exhaust pipe with engine or muffler for leak 3 Check the grad...

Page 152: ...t loop for mixed with air 7 Engine can not start 1 Check the battery which with low electricity may cause the motor failure 2 Check the starting motor for damage 3 Check if MEUI can work in good condition 4 Check if the ignition loop can work in good condition 5 Check if the spark plug is foulled or burned 6 Check if the ignition signal is in good condition 7 Check if the air cleaner is blocked 8 ...

Page 153: ...ARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap Always use a thick rag over the cap Allow any remaining pressure to escape before completely removing the cap ...

Page 154: ...aser to the wheel axles 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job 1CAUTION Excessive water pressure may cause water seepage and deterioration of wheel bearings brakes transmission seals and electrical devices Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin operated car wa...

Page 155: ...sives which may scratch the paint or protective finish When finished start the engine and let it idle for several minutes WARNING POTENTIAL HAZARD Operation with wet brakes after washing WHAT CAN HAPPEN Wet brakes may have reduced stopping ability increasing the chance of an accident HOW TO AVOID THE HAZARD Test the brakes after washing Apply the brakes several times at slow speeds to let friction...

Page 156: ...o the fuel tank Specified amount 1 oz of stabilizer to each gallon of fuel or 7 5 ml of stabilizer to each liter of fuel NOTE Use of fuel stabilizer and conditioner eliminates the need to drain the fuel system Consult a dealer if the fuel system needs to be drained instead 3 Remove the spark plug pour about one tablespoon of SAE 10W30 or 20W40 motor oil in the spark plug Ground the spark plug wire...

Page 157: ... and charge it Store it in a dry place and recharge it once a month Do not store the battery in an excessively warm or cold place less than 0 32 F or more than 30 86 F NOTE Make any necessary repairs before storing the vehicle ...

Page 158: ...3 in 1 900 mm 74 8 in 818 mm 32 2 in 2 840mm 111 8 in 280 mm 11 0 in 5 000 mm 196 8 in Basic weight With oil and full fuel tank 688 0 kg 1 517 lb Engine Engine type Cylinder arrangement Displacement Bore stroke Compression ratio Starting system Lubrication system Liquid cooled 4 stroke Water cooled Forward inclined single cylinder 686cm 3 100 84mm 9 10 1 Electric starter Wet sump ...

Page 159: ...SG type or higher JASO standard MA CAUTION In order to prevent clutch slippage since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERVING Ⅱ or higher 1 90L 1 67lmp qt 2 01 US qt 2 00L 1 76lmp qt 2 11 US qt ...

Page 160: ...il 0 32L 0 28 lmp qt 0 34 US qt Radiator capacity including all routes 2 50L 2 20 lmp qt 2 64 US qt Air filter Engine Intake duct Wet element Dry element Fuel Type Fuel tank capacity Unleaded gasoline only 30 0L 6 60 lmp gal 7 93 US gal Throtlle valve Type quantity Spark plug Type Spark plug gap DR8EA DPR8EA 9 DPR8EA 9 0 8 0 9 mm 0 031 0 035 in Clutch type Wet centrifugal automatic ...

Page 161: ...smission type Operation Reverse gear Sub transmission ratio low High V belt Shaft drive 41 21 24 18 33 9 9 544 V belt automatic Right hand operation 25 14 1 471 35 17 2 058 28 19 1 473 Chassis Frame type Caster angle Trail Steel tube frame 5 0 26 0mm 1 02 in Tire Type Size front rear Tubeless 25 8 12NHS 25 10 12NHS ...

Page 162: ...ear suspension Double wishbone Double wishbone Shock absorber Front shock absorber Rear shock absorber Coil spring oil damper Coil spring oil damper Wheel travel Front wheel travel Rear wheel travel 185mm 7 3 in 185mm 7 3 in Electrical Ignition system Generator system Battery type Battery capacity DC CDI AC magneto U1L 11 12V3 2 0Ah Headlight type Krypton bulb ...

Page 163: ...t Parking brake indicator light On Command four wheel drive differential gear lock indicator On Command differential gear lock indicator light High range indicator light Low range indicator light LED LED LED LED LED LED LED LED Specified fuses Main fuse Headlight fuse Ignition fuse Auxiliary DC jack fuse Four wheel drive motor fuse Signaling system fuse Backup fuse 30 0A 15 0A 10 0A 10 0A 3 0A 10 ...

Page 164: ...10 7 ...

Page 165: ...T Circuit High Voltage or Open KsDGDM_IAT_ShortHigh 113 275 P0117 Coolant Oil Temperature Sensor Circuit Low Voltage KsDGDM_CoolantShortLow 117 279 P0118 Coolant Oil Temperature Sensor Circuit High Voltage or Open KsDGDM_CoolantShortHigh 118 280 P0122 TPS Circuit Low Voltage or Open KsDGDM_TPS_ShortLow 122 290 P0123 TPS Circuit High Voltage KsDGDM_TPS_ShortHigh 123 291 P0131 O2S 1 Circuit Low Volt...

Page 166: ...age KsDGDM_FPP_CircuitShortHigh 232 562 P0336 CKP Sensor Noisy Signal KsDGDM_CrankNoisySignal 336 822 P0337 CKP Sensor No Signal KsDGDM_CrankNoSignal 337 823 P0351 Cylinder 1 Ignition Coil Malfunction KsDGDM_EST_A_Fault 351 849 P0352 Cylinder 2 Ignition Coil Malfunction KsDGDM_EST_B_Fault 352 850 P0505 Idle Speed Control Error KsDGDM_IdleControl 505 1285 P0562 System Voltage Low KsDGDM_SysVoltLow ...

Page 167: ...ter 2 Circuit Low Voltage KsDGDM_O2_HeaterShortLow 37 55 P0500 VSS No Signal KsDGDM_VSS_NoSignal 500 1280 P0850 Park Neutral Switch Error KsDGDM_ParkNeutralSwitch 850 2128 P0445 CCP short to high KsDGDM_CCP_CircuitShortHigh 445 1093 P0444 CCP short to low open KsDGDM_CCP_CircuitShortLow 444 1092 P0171 BLM Max Adapt Kohler Special KsFDIAG_BLM_MaxAdapt 171 369 P0172 BLM Min Adapt Kohler Special KsFD...