Trail Rover SCOUT 500TX User Manual Download

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For technical assistance, call 877-722-4097

DESIGNED FOR OFF ROAD USE ONLY

It is against the law to operate on public roads

Read and Follow Safety Instructions

Always wear a helmet

SCOUT 500TX

Troubleshooting

Front Wheel

Shakes, Swings or

Jumps

Steering and

Suspension

Tires out of balance or alignment

Bearing and wheel damage

Swing arms loose or damaged

Excess play in steering

Steering system bolts loose

Balance and Align

Repair or Replace wheel

Repair or Replace

Tighten

Difficulty Steering

Steering

Low air pressure in tires

Swing arm dragging or blocked

Tires out of balance or alignment

Steering Assembly is blocked

Add air

Repair or Replace

Balance and Align

Remove Blockage

Brake Troubleshooting

Excessive Pedal

Travel or Sinking

when Brake is

Engaged

Brake Assembly or

Master Cylinder

Brake fluid level is low

Loose connections/leaks from damaged lines

Space between pad and drum too wide

Brake pads and/or drums worn

Master cylinder damaged or leaks oil

Piston rod is damaged or leaks oil

Air in Brake Line

Brake pads/drums too hot

Check, Add Brake Fluid

Check Connections or Replace

Adjust

Replace

Repair or Replace

Release Air

Allow to cool

Jerks or Pulls when

Brake is Engaged

Brake Assembly or

Master Cylinder

Oil on pads and/or drums

Space between brake pad and drum not even

Brake fluid pump blocked or leaking fluid

Air pressure in tires on right & left not even

Front wheels out of alignment

Vehicle frame is damaged – Right and left

wheelbase is different

Blockage in brake fluid line

Brake pads and drums don’t connect evenly

Loose connections/bolts in suspension

Vehicle out of balance

Tread wear is not even on all tires

Clean or Replace

Adjust

Repair or Replace

Equalize Air Pressure in Tires

Align Properly

Repair, Adjust or Replace

Remove Blockage

Repair or Replace

Check, Repair and Tighten

Verify, repair and adjust

Replace tires, Align, & Balance

Brakes Stick

Brake Assembly

Hydraulic brake pump stuck or blocked

Not enough tension in piston spring

Parking brake not properly adjusted

Blockage in parking brake line

Blocked brake clip

Brake pads worn

Brake Lines are flat preventing flow

Repair main pump

Adjust or Replace

Adjust

Remove Blockage/Replace

Lubricate or Replace

Replace

Summary of Contents for SCOUT 500TX

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

Page 2: ... of Any Kind Bushings Filters of Any Kind Acts of Nature Light Bulbs Required Routine Maintenance Lubricants Steering Wheel Coolant or Fluids of Any Kind Travel Charges Brake Pads Brake Shoes Brake Rotors and Brake Discs Any part not purchased with TrailRover Seals Gaskets Belts Cables Hoses of any kind Physical damage caused by corrosion fire or explosion not caused by defective materials or work...

Page 3: ...s about the operation or maintenance of your TrailRover UTV please call us at 877 722 4097 to speak to a factory trained technical service representative Read this manual carefully You should pay special attention to sections labeled Warning and Caution Failure to follow Warning instructions could result in severe injury or death to the operator a bystander or a person inspecting or repairing your...

Page 4: ...smaller hills before operating on steeper hills Do not modify your TrailRover through improper installation or use of accessories Never attempt wheelies jumps or other stunts Always follow proper procedures for climbing hills as described in this manual Check the terrain carefully before climbing any hill Never climb hills with excessively loose or slippery surfaces Never make sudden gear changes ...

Page 5: ...rate on public roads Read and Follow Safety Instructions Always wear a helmet 1 Engine hood 2 Turn Indicator 3 Headlight 4 Brush Guard 5 Tire 6 Seats 7 Safety Belt 8 Side board 9 Fuel Cap 10 Rear Fender 11 Cargo Bay 12 Safety Bar 13 Head Rest 14 Cover 15 Steering Wheel 16 Canopy Frame SCOUT 500TX Overview ...

Page 6: ...is against the law to operate on public roads 6 Read and Follow Safety Instructions Always wear a helmet 1 CTV case 2 Gear Case Oil Intake 3 Flange of transmission shaft 4 Generator 5 Carburetor 6 Starter 7 Idle speed control 8 Spark Plug 9 Oil intake SCOUT 500TX Engine Overview ...

Page 7: ...Safety Instructions Always wear a helmet Vehicle Identification Number Engine Number Oil Intake Engine oil dipstick Caution Oil level must remain at appropriate levels at all times to prevent engine damage Engine damage cause by failure to maintain correct levels is not covered under the warranty SCOUT 500TX Engine Overview Overflow Add Oil ...

Page 8: ... will cause engine damage If fuel contains Ethanol it cannot contain more than 10 Fuel stabilizers must be added to the gasoline following the manufacturer s instructions on the fuel stabilizer label Engine damage caused by low octane fuel is not covered under the warranty Engine damage caused by fuel with high ethanol levels is not covered under the warranty Warning To prevent the risk of serious...

Page 9: ...view Check Oil Level in Differential Here Warning Check oil level in the differential frequently Damage will occur if lubricating oil is not changed as recommended if oil level is too low or too high Check Lubrication Levels in Transmission Here Warning Check oil level in the transmission box frequently Damage will occur if lubricating oil is not changed as recommended if oil level is too low or t...

Page 10: ...NLY It is against the law to operate on public roads 10 Read and Follow Safety Instructions Always wear a helmet Fuse box Relay under driver s seat Relay Display 1 Horn relay 2 Low beam relay 3 High beam relay 4 Flash relay Fuse Display SCOUT 500TX Engine Overview 2 1 3 4 ...

Page 11: ... oil Never substitute or mix oil brands Mixing brands or using a non recommended oil may cause serious engine damage which is not covered under the warranty Engine and Drive Train Break in 1 Fill the fuel tank with gasoline Always exercise extreme caution whenever handling gasoline Never allow a child to handle gasoline 2 Check the oil level Add the recommended oil as needed to maintain the oil le...

Page 12: ... a training course before operating your TrailRover 2 Do not ride at night or when visibility is poor rain fog dusk Your vehicle doesn t have lights that are designed for driving poor weather or dark conditions 3 Engine exhaust fumes are poisonous Never start the engine or let it run in an enclosed area Never allow a child to handle gasoline 4 Never install accessories not approved by our company ...

Page 13: ...se of the choke pulled half way out may be necessary If the engine is over choked when warm depress the throttle lever fully while cranking to aid in starting Release the throttle lever immediately after the engine starts If the engine does not start and all conditions are favorable change the spark plug and try again Stopping the Engine 1 Release the throttle pedal completely and brake to a compl...

Page 14: ...d in a safe place WE DO NOT HAVE DUPLICATE KEYS AVAILABLE Ignition Switch The ignition switch has four positions OFF Everything but brake light is off ACC Auxiliary components Lights Mp3 and horn only ON ON All circuits except engine are on Engine will operate in ON position START With transmission in NEUTRAL parking brake engaged and foot on brake pedal turn the key to START and release the key w...

Page 15: ... Operation 1 Engine Temperature Gauge 2 Left Turn Signal and Hazard Light Indicator 3 Gear Display Back light for current gear L Low Speed H High Speed N Neutral R Reverse 4 Speedometer 5 Right Turn Signal and Hazard Light Indicator 6 Fuel Gauge 7 Brake Fluid Alarm Low brake fluid levels Add brake fluid immediately 8 High Beam Headlight Indicator 9 Odometer Mileage Indicator Dashboard Controls ...

Page 16: ...adlights on Parking lights and dashboard controls remain on With pressed all the way down press up to turnhight beam ligts on Press down to turn high beam lights off Press down to turn hazard lights on Press down or to turn on the corresponding turn signal lights Step down the brake pedal to turn he brake lights on Pressing the BRAKE will stop your TrailRover With the gear set to Low High or Rever...

Page 17: ...s DOWN on TRAILER switch to return the cargo box to its original position MAKE SURE THE AUXILIARY SWITCH IS IN THE OFF POSITION WHEN NOT IN USE LEAVING THE SWITCH IN THE ON POSITION WILL DRAIN THE BATTERY SCOUT 500TX Operation Pull the parking brake UP to help prevent movement when parked to prevent sliding Press the button on the parking brake to disengage the parking brake Caution Do not leave t...

Page 18: ...ower Supply Cigarette Lighter The cigarette lighter can be used as a charger or to power small electronic devices Caution Please check your device to ensure compatibility with the 12V DC power supply Mp3 and USB Adapter With the ignition switch turned to the ON or ACC position also press the button in the middle of MP3 player to listen to music on your Mp3 player There is a USB interface under the...

Page 19: ...n Stepless shift performance and belt abrasion Tires Tire pressure and thread depth Tire pressure F tire 21PSI R tire 28PSI Check front tie in 2 5mm Transmission Make sure the bolts flange nuts on transmission shaft and the bolts on main drive are tightened Lights Illumination and signal Check all bulbs signal switches fuses and buttons Battery Check fluids in cell if applicable If applicable add ...

Page 20: ...ring organization Flexible with no blockage Each linking drag pole ball head and locking nut are tightened Brake Brake fluid is at the correct level brake pedal is smooth brakes work when pressed Tire Air pressure thread no signs of damage Tire pressure Front tires 21PSI Rear tires 28PSI Thread depth no less than 1 6mm Lights Lamp covers bulbs signals and horn Lamps signals auxiliary switches and ...

Page 21: ...hs DO NOT MIX FLUIDS Brake Check Steering Check Accelerator drag wire Check Brake pedal Check Carburetor Check Tire Check Spark plug Check before every ride Engine oil Change Air filter filter core Clean Change every 30 000 miles Valve clearance Shift drive belt Fuel line Check Change once every three years Front and rear absorber Main drive reverse gear device including gear oil Check Battery Che...

Page 22: ...Loose spark plug Cylinder cover Cylinder body or Crankcase leaks air Piston ring or cylinder body damaged Piston ring blocked or broken Blockage in exhaust or muffler Carburetor settings incorrect Tighten spark plug Clean make sure bolts are tight when reinstalled Replace piston loop or cylinder body Clean or Replace Clean to remove blockage Adjust carburetor Transmission Not in Neutral Surpassing...

Page 23: ...r corrosion Debris on radiator or fan damaged Damaged lines block coolant flow Water pump damaged Blockage in radiator Coolant boils engine overheats after sudden stops at high speed Clean Repair or replace lines add cooling liquid Clean an replace fluid Use only distilled water in coolant Clean or replace Repair or replace lines Repair or replace Repair or replace Reduce speed gradually Avoid sud...

Page 24: ...age in muffler Adjust Carburetor Repair Remove Blockage Transmission Troubleshooting Speed does not increase when Accelerator Engaged Transmission Shift belt slips Too much tension in accelerator spring Accelerator blocked Not enough tension in accelerator spring Replace Reduce Tension Remove Blockage Increase Tension Steering and Suspension Troubleshooting Leans While Moving Tires and Cargo Bay A...

Page 25: ...Brake Line Brake pads drums too hot Check Add Brake Fluid Check Connections or Replace Adjust Replace Repair or Replace Repair or Replace Release Air Allow to cool Jerks or Pulls when Brake is Engaged Brake Assembly or Master Cylinder Oil on pads and or drums Space between brake pad and drum not even Brake fluid pump blocked or leaking fluid Air pressure in tires on right left not even Front wheel...

Page 26: ...n wiring Replace Repair Turn Signals Do Not Work Electrical Damaged relay Damaged bulb Fuse blown Short in wiring Replace Replace Replace Repair Starter Does Not Rotate When Start ing Electrical Battery not charged Starter damaged Damaged relay Damaged ignition switch Charge or Replace Repair or Replace Replace Repair or Replace Shutdown of all Electrical Systems Electrical Battery not charged Mas...

Page 27: ... properly there may be some air in pipe To release the air pull out the small circulating pipe keep adding coolant from intake of radiator Connect back the pipe when the coolant spilled out from the pipe Then fill up the radiator till it is full Cap the radiator and tighten the hoop on the pipe Warning Avoid the risk of serious burns and injury Never remove the radiator cap or attempt to remove th...

Page 28: ... Item Quantity Thread diameter mm Torque Nm 1 Nuts cylinder head 4 M8 22 2 Spark plug 1 M12 18 3 Adjustment nuts valve clearance 2 M6 14 4 Fixed bolts camshaft chain wheel 1 M10 60 5 Bolts chain adjustment 1 M8 8 6 Fixed nuts crankcase combination 9 M6 10 7 Fixed nuts left crankcase cover 11 M6 10 8 Nuts machine flywheel 1 M16 1 80 9 Fixed nuts drive belt wheel 1 M14 1 25 60 10 Fixed nuts clutch 1...

Page 29: ...ixed screws steering unit M10 30 4 50 N m Across rod nuts 4 60 N m Nuts across rod joint M12 2 70 N m Bolts steering bar M8 25 2 25 N m Screws fixed steering plate M10 20 2 50 N m Screws front brake bottom plate M10 2 8 50 N m Bolts lower swing arm M12 80 4 55 N m Nuts lower swing bottom head M12 2 90 N m Bolts lower swing bottom head M10 35 4 55 N m Bolts front absorber cross bar M12 60 2 95 N m ...

Page 30: ...t on cam of reverse gear M16 1 160N m Fixed screws reverse gear unit M10 4 50N m Fixed Screws main driver M8 28N m Nuts tire M12 16 55N m Screws frame M12 95 M12 70 6 2 110N m Engine drain bolt 45N m Rear axle drain bolt 55N m Bolts exhaust pipe M8 2 15N m Screws carburetor M6 2 10N m Bolts rear brake plate M8 8 23N m Screw dump bed M12 65 2 60N m Screws uplift pump M10 50 1 50N m Screws steering ...

Page 31: ...olts fuel tank M8 20 3 28N m Bolts transmission M8 25 8 30N m X Specifications fuel lubricating oil and brake Fluid Category Specification Capacity Remark Fuel Premium Unleaded 91 Octane or Higher 27L Lubricating oil transmission box 80w 90 0 25L Lubricating oil Engine SAE15W 40 1 35L Lubricating oil Differential 18 hyperbola gear oil 0 8L Lubricating oil reverse gear box 18 hyperbola gear oil 0 1...

Page 32: ...ake performance No load When V 20km h 2 5 When V 30km h 5 4 When V 40km h 9 5 When V 50km h 14 6 0 50Km h accelerating time S 15 Time of start running the used time from stop to run 200m distance S 18s Accelerating time the used time run 200m at 30km h S 14s Oil consumption in Liters for 60 miles 6 at 24 mph Exhaust Reach Euro II exhaust standard Limit load of cargo Box 300Kg Engine Specs Type VM1...

Page 33: ...0 32 1500 Lubricating type Pressure and splash lubricating type Engine oil pump type trochoid Water pump type centrifugal Carburetor type Y28V5 Magneto electric machine type TCI exterior spring flywheel magneto electric Power supply voltage 12V Spark plug type DR8EA NGK Clutch type dry type automatic centrifugal type Automatic shift ratio 2 20 0 88 1 Chasis Clutch and transmission tapered plate be...

Page 34: ...steering wheel 70 The maximum left turning angle of left wheel 35 The maximum right turning angle of right wheel 35 Brakes Front and rear dual pipeline hydraulic pressure brake system front and rear wheel brake drums Parking brake equipped with mechanical transmission rear wheel brakes Cargo Box Roll Bar Reinforced Roof and Winch Roll bar reinforced roof structure and self saving winch to pull veh...

Page 35: ...CTURER S suggested retail for the parts and labor charges deemed appropriate for the repair The owner is responsible for providing the receipt for the parts and services provided in order to receive reimbursement LABOR WARRANTY Labor is described as the work completed by an authorized technician on components covered under the labor warranty MANUFACTURER will be responsible for Pre Approved labor ...

Page 36: ...te of Delivery Date of Purchase Thorough Description of Name of Customer Problem NOTE MOST OF THE ABOVE INFORMATION IS PROVIDED ON THE ORIGINAL INVOICE 3 In all situations a repair is considered the appropriate course of action unless it is deemed irreparable If the UTV cannot be repaired in the field and must be returned to the factory approval must be obtained from Customer Care Manager Cost for...

Page 37: ...y each TrailRover UTV TrailRover would not be taken upon to go by any other warranty There are no additional warranties express or implied which extend beyond the terms of the warranty The liability of the Manufacturer under this limited warranty if any is solely limited to remedying of defects in material and workmanship by an authorized dealer at its place of business during normal business hour...

Page 38: ...hnical assistance call 877 722 4097 DESIGNED FOR OFF ROAD USE ONLY It is against the law to operate on public roads 38 Read and Follow Safety Instructions Always wear a helmet SCOUT 500TX Warranty Information ...

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