Applestone APU06E, Owner'S Manual

Page 1: ...OWNER S MANUAL APU06E APU06EL EFI 4 4 WD READ THIS MANUAL CAREFULLY It contains important safety information ...

Page 2: ...and manufactured for OFF ROAD use only Driving on public streets roads or highways is illegal Always wear helmet and other protective equipment Do not operate this vehicle after consuming Alcohol or Drugs Gasoline is flammable when refueling Pis shut off engine to avoid sparks and open flame Read owner s manual carefully before riding Keep owner s manual with vehicle Operator and passengers must f...

Page 3: ...mation about the general care and maintenance of your UTV Most importantly carefully read the following pages regarding safety warnings and active riding skills and precautions Children and adults differ in skills physical abilities and judgment Some children may not be able to operate an UTV safely Parents should always supervise their child s use of the UTV at all times Parents should permit con...

Page 4: ...ns or explanations without notice If you have any other questions regarding our UTV s operation or maintenance any authorized dealer can readily answer them Enjoy your UTV And if you respect your UTV respect the environment the local and state laws and act responsibly You will gain the respect of others Product and specifications are subject to change without notice ...

Page 5: ...ngine and Vehicle Identification Number Location 10 LOCATION OF THE WARNING AND SPECIFICATION LABELS 11 SAFETY INFORMATION 16 DESCRIPTION AND VEHICLE IDENTIFICATION 22 CONTROL FUNCTIONS 24 Indicators Display 29 Auxiliary DC jack Cigarette lighter 34 Accelerator pedal 35 Brake pedal 36 Parking brake leve 37 Drive select lever 38 Seat belts 39 Glove compartment 41 ...

Page 6: ...PERATION CHECKS 53 OPERATION 59 Engine break in 62 Parking on a slope 64 Accessories and loading 65 DRIVING YOUR VEHICLE 68 PERIODIC MAINTENANCE AND ADJUSTMENT 79 Periodic maintenance lubrication 80 Engine use and maintenance 92 Troubleshooting charts 102 MAINTENANCE CHART 104 CLEANING AND STORAGE 109 SPECIFICATIONS 113 ATTACHMENT 118 Electrical schematic 128 ...

Page 7: ...ty information Your UTV can provide many years of service and pleasure if you take responsibility for your own safety and understand the challenges you can meet while riding There is much that you can do to protect yourself when you ride You ll find many helpful recommendations throughout this manual The following are a few that we consider most important Follow the age recommendation The minimum ...

Page 8: ...does not have turn signals and other features required for use on public roads If you need to cross a paved or public road get off and walk your UTV across Take time to learn practice Even if you have ridden other UTVs take time to become familiar with your skills and get accustomed to the UTV is size and weight Because many accidents involve inexperienced or untrained riders we urge all riders to...

Page 9: ...its is another major cause of UTV accidents Never ride beyond your personal abilities or faster than conditions warrant Remember that alcohol drugs fatigue and inattention can significantly reduce your ability to make good judgments and ride safely Don t drink and ride Alcohol and riding don t mix Even one drink can reduce your ability to respond to changing conditions and your reaction time gets ...

Page 10: ...help avoid problems inspect your UTV before every ride and perform all recommended maintenance Your UTV comes with a hangtag and several labels containing important safety information Anyone who rides the vehicle should read and understand this information before riding The labels should be considered permanent parts of the vehicle If a label comes off or becomes hard to read contact your dealer f...

Page 11: ... increase the speed 2 when crossing the vehicles parked in front of to be very careful Because the driver of the vehicle may be invisible to you and the door opened the forward block in your way 3 Brake Lining may Motorcycle rinsing wetting lose their role so when cleaning End after walking ago should check all brake system ...

Page 12: ...tanding of the features and operation of this vehicle It also includes basic maintenance and inspection procedures If you have any questions regarding the operation or maintenance of your vehicle please consult an dealer WARNING Please read this manual carefully before operating this vehicle Do not attempt to operate this vehicle until you have attained adequate knowledge of its controls and opera...

Page 13: ... subject to change without notice WARNING Failure to follow WARNING instructions could result in severe injury or death to the vehicle operator a bystander or a person inspecting or repairing the vehicle CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the vehicle NOTE A NOTE provides key information to make procedures easier or WARNING The Safety Alert Symbol ...

Page 14: ...treet road or highway Such use is prohibited by law Check the laws and regulations in force before choosing where to operate this vehicle It is illegal to operate this vehicle on public lands where vehicles its size are prohibited This vehicle complies with almost all state off highway noise level and spark arrester laws and regulations ...

Page 15: ... or to trace your vehicle in the event of loss These numbers are required by the authorized UTV dealer to complete warranty claims properly No warranty will be allowed by if the engine identification number EIN or vehicle identification number VIN is removed or mutilated in any way We strongly recommend that you take note of all the serial number on you vehicle and supply them to your insurance co...

Page 16: ...ne and Vehicle Identification Number Location TYPICAL 1 EIN Engine Identification Number on left side under of the crankcase 2 VIN Vehicle Identification Number on right side under of the frame 3 ENGINE NUMBER ...

Page 17: ... 11 LOCATION OF THE WARNING AND SPECIFICATION LABELS ...

Page 18: ... on you 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 1 3 ...

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Page 22: ...y the driver and one passenger Never carry passengers in the cargo bed Always be sure the driver and passenger are wearing seat belts Never give a ride to a passenger who is too small to reach and hold the handgrip on the enclosure Always 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 ...

Page 23: ...lways follow the inspection and maintenance procedures and schedules described in this manual Always keep both hands arms feet and legs in side the vehicle at all times during operation Keep your feet on the floorboard Never hold onto the enclosure except when using the handgrip inside the enclosure Otherwise your hand could be injured if it is caught between the enclosure and an obstacle outside ...

Page 24: ...t excessive speed Practice turning at slow speeds before attempting to turn at faster speeds Do not attempt turns on steep inclines Never operate the vehicle on hills that are too steep for it or for your abilities Go straight up and down hills where possible Maximum slope angle 15 Never operate on hills that are slippery or ones where you will not be able to see far enough ahead of you Never go o...

Page 25: ...ays 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 cargo bed Always use the size and type of tires specified in this manual Always maintain proper tire pressure as described in this manual Never exceed the stated load capacity Cargo should be as far forward in the bed a...

Page 26: ...icinity of sparks open flames and clothes dryers When transporting the vehicle in another vehicle be sure it is kept in an upright position or other sources of ignition such as the pilot lights of water heaters Otherwise fuel may leak out of the 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 of gaso...

Page 27: ... 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 28: ...22 DESCRIPTION AND VEHICLE IDENTIFICATION 1 2 3 4 5 6 7 8 10 14 11 13 12 9 15 16 17 18 19 20 ...

Page 29: ...er 8 Driver seat 9 Air filter element engine and air intake duct 10 Cargo bed push rod switch 11 Rear shock absorber assembly adjusting ring 12 Tail brake lights 13 Engine exhaust pipe 14 Cargo bed 15 Cargo bed push rod 16 Refueling mouth 17 Passenger seat 18 Fuses 19 Compensation water kettle 20 Batter 21 2WD 4WD switch 22 Switch combination 23 Indicators Display 24 MP3 switch 25 Auxiliary DC jac...

Page 30: ...ched off The key can be removed in this position D All electrical circuits are switched off Y All electrical circuits are supplied with power and the headlights and taillights come on when the light switch is on Q The electric starter is engaged by turning and holding the key in this position Release the key when the engine starts ...

Page 31: ... each operation of the electric starter to let it cool Do not turn the key to the Q position with the engine running or damage to the electric starter can result See starting instructions prior to starting the engine Switches combination 1 Horn switch 2 Winch switch Release wire rope Contraction wire rope 3 Dangerous warning lights switch 1 2 3 ...

Page 32: ...26 Switches combination 1 Direction indicator 2 Headlamp Switch 3 Lighting Switch 4 Wiper Switch ...

Page 33: ...p up the button 4WD push the button 2 On Command differential gear lock switch 4WD LOCK 4WD push the button LOCK Pop up the button This vehicle is equipped with an On Command four wheel drive switch 2WD 4WD and a differential gear lock switch 4WD LOCK Select the appropriate drive according to terrain and conditions 1 2 ...

Page 34: ...cargo box 1 The switch is automatic hold the switch upward the cargo box will be up stop the holding the cargo box will be stopped 2 hold the switch downward the cargo box will be down stop the holding the cargo box will be stopped ...

Page 35: ...29 Indicators Display ...

Page 36: ... and be switched betweens the figure of speed will display and update synchronous while switching between KM H and MPH in unit of pedometer Press the button of Time Set the user can set the hour and minute Then adjust hours or minute by ascending or descending by continuing press button of mode of Set Reset user can clean the record to zero for particular period of working mileage and time by pres...

Page 37: ... the temperature is above 102 stop engine immediately Check coolant lever and add if low see authorized dealer if temperature indicator stay on and overflow tank is full of coolant 2 quantity of fuel indicator light When the last segment clears a low fuel warning is activated the fuel gauge will blink refuel immediately otherwise the vechile will be stopped and can not start again ...

Page 38: ...ne If the lamp is on while the engine working it indicates that the system failed When some electric jet parts are found fault check engine indicator lamp will also be ON the vehicle still can keep running the driving performance is getting worse which reminds the driver should send the vehicle to repair 4 2WD 4WD indicator 2WD 4WD 4WD LOCK ...

Page 39: ...r 6 Direction Indicator Turn Left Turn Right 7 Parking Indicator Means the vechile is in the parking before start driving remind the driver to release the park brake and move the lever downward then start driving 8 Headlight Indicator Means headlight is in the working ...

Page 40: ...er and then insert the accessory power plug into the jack 4 When the auxiliary DC jack is not being used put back the Cigarette lighter Maximum rated capacity for the auxiliary DC jack DC 12V 120W 10A CAUTION Do not use accessories requiring move than the above maximum capacity This may overload the circuit and cause the fuse to blow If accessories are used without the engine running or with the h...

Page 41: ... accelerator pedal fully returns to the idle position as soon as it is released WARNING POTENTLAL HAZARD Malfunction of the accelerator pedal WHAT CAN HAPPEN The accelerator pedal could be hard to operate making it difficult to speed up or slow down then 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 d...

Page 42: ...36 Brake pedal Press the brake pedal to slow or stop the vehicle 1 Brake pedal ...

Page 43: ...rake lever Pull the parking lever up so that the unit can engage park brake To release the unit press button in the front end of parking lever then push the parking lever to the bottom CAUTION Never use parking brake lever then the vehicle don t stop fully Adjust the parking cable if necessary Be sure to fully release the parking brake lever before starting the vehicle Parking brake lever Release ...

Page 44: ...ine must shift the gear to the N first otherwise can not start the engine If the gear not in the N position press the brake pedal also can start the engine CAUTION When parking the vehicle the gear must be shifted into N position When shift the gear especially for the R gear must press the brake pedal first then shifting after Vehicles completely stopped Unlock button Drive select lever ...

Page 45: ...ght 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 secur 1 Buckle 2 Latch plate 3 Put the lap portion of the belt low on your hips Push down on the buckle end of the belt as you pull up on the shoulder part so the belt is snug across your hips 4 Position the shoulder ...

Page 46: ...NTIAL 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 vehicle Be sure the seat belt is close fitting across your hips and chest and is latched securely ...

Page 47: ...ucts directly in the glove compartment If they must be stored wrap them in appropriate cushion material a Unlock b Open Trailer hitch bracket This vehicle is equipped with a 5cm 2in receiver bracket for a standard trailer hitch Trailer towing equipment can be obtained at an dealer 1 Trailer hitch bracket a b 1 ...

Page 48: ...rt or jacket whenever you drive Although complete protection is not possible wearing proper gear can reduce the chance of injury then you drive The following suggestions will help you choose the proper driving gear Helmets and eyes protection Your helmet is your most important piece of driving gear because it offers the beat protection against head injuries A helmet should fit your head comfortabl...

Page 49: ...your driving skills is an on going process Even if you have driven other UTVs take time to become familiar with hoe this UTV in a safe area to build your skills Do not drive in rough WARNING Operating this without wearing an approved motorcycle helmet eye protection and protective clothing could increase your chances of head or eye injury possibly death in the event of severe accident Always wear ...

Page 50: ...ended that is not one under the age of 16 be permitted this UTV without adult supervision No Alcohol or Drugs Alcohol drugs and driving don t mix Even a small amount of alcohol can impair your ability to operate a UTV safely Likewise drugs even if WARNING Operating UTV without proper instruction could increase your risk of an accident which could lead to serious injury or death WARNING A child dri...

Page 51: ...ly but because having a breakdown or even a flat tine can be a major inconvenience If your UTV has overturned or has been involved in a collision do not drive it until your UTV has been inspected by your dealer There maybe damages or other problems you can not see WARNING Operating this UTV after consuming alcohol or drugs can seriously affect your judgment cause you to react more slowly affect yo...

Page 52: ... Check for leaks Tires Use a gauge to check the air pressure Adjust if needed Also look for signs of damages or excessive wear Nut Bolts Check the wheels to see that the axle nuts are tightened use a wrench to make sure all accessible nuts bolts and fasteners are tight WARNING mproperly maintaining this UTV or failing to correct a problem before driving can cause a crash in which you can be seriou...

Page 53: ...re the headlight brake light and tail light are working properly Brakes Press the brake pedal several times check for proper brake pedal free play Make sure there is no brake fluid leakage Engine stop When engine is running turn the switch key counterclockwise Make sure engine stops Steering Wheel Check that the wheels turn properly as you turn the steering wheel Cable Check the cable housing for ...

Page 54: ... permission to drive on private property Avoid posted areas and obey no trespassing signs You should never drive your UTV on public streets roads or highways even if they are not paved Drivers of street vehicles may have difficulty seeing and avoiding you which could lead to a collision In many states it is illegal to WARNING Operating this UTV on paced surfaces may seriously affect handling and c...

Page 55: ...r ability to react and control the off highway recreational vehicle WARNING Operating this UTV on paced surfaces may seriously affect handling and control of the UTV and may cause the vehicle to go out of control Never operate the on any paved surfaces including sidewalks Operating this UTV on paced surfaces may seriously affect handling and control of the UTV and may cause the vehicle to go out o...

Page 56: ...rrain or when visibility is limited It s sometimes difficult to see and react obstructions WARNING Removing hand from steering wheel or feet from foot controls during operation can reduce your ability to control the UTV Always keep both hands on the steering wheel and both feet on the foot controls of your UTV during operation WARNING Operating this UTV at excessive speeds increases your changes o...

Page 57: ...Do not operate on excessively rough slippery or loose terrain until you have learned and practiced the skills necessary to control the UTV on such terrain Always be especially cautious on these kinds of terrain Do Not Perform Stunts You should always operate your UTV in a safe and reasonable manner When driving always keep all wheels on the ground WARNING Failure to take extra care when operating ...

Page 58: ... maximum life and performance from your new vehicle The following guidelines explain proper break in procedures 1 After the engine starts the engine is not allowed in high speed in the neutral gearshift 2 Drive vehicle from stop to low speed slowly 3 Avoid braking strongly 4 Do not exceed the vehicle speed on the below schedule Starting and Operating Instructions Before starting the engine be sure...

Page 59: ...ontrollable speed PRE OPERATION CHECKS Before using this vehicle check the following points WARNING POTENTIAL HAZARD Failure to inspect the vehicle before operating Failure to properly maintain the vehicle WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your vehicle each time you use it to make sure the vehicle is in safe operatin...

Page 60: ...o not provide proper braking performance inspect the brake system 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 problem cannot be corrected by the adjustm...

Page 61: ...arts such as the valves and piston rings as well as to the exhaust system Gasohol There are two types of gasohol gasohol containing ethanol and that containing methanol Gasohol containing ethanol can be used if ethanol content does not exceed 10 Gasohol containing methanol is not recommended by because it may cause fuel system damage or vehicle performance problems ...

Page 62: ...en the release button is pushed firmly Wash off any dirt or mud which could affect operation Have an dealer repair as necessary for proper operation WARNING POTENTIAL HAZARD Improper care when refueling WHAT CAN HAPPEN Fuel can spill which can cause a fire and severe injury Fuel expands when it heats up If the fuel tank is overfilled fuel could spill out due to heat from the engine or the sun HOW ...

Page 63: ... 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 an dealer repair as necessary for proper operation Tires WARNING POTENTIAL HAZARD Operating this vehicle with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of ...

Page 64: ...a 0 45kgf cm2 6 5Psi Higher pressures may cause the tire to burst Inflate the tires very slowly and carefully Fast inflation could cause the tire to burst How to measure tire pressure Use the tire pressure gauge NOTE The tire pressure gauge is included as standard equipment Make two measurements of the tire pressure and use the second reading Dust or dirt in the gauge could cause the first reading...

Page 65: ...re a Tire wear limit OPERATION WARNING POTENTIAL HAZARD Operating vehicle without being familiar with all controls WHAT CAN HAPPEN Loss of control which could cause an accident or injury HOW TO AVOID THE HAZARD Read the Owner s Manual carefully If there is a control or function you do not understand ask your dealer ...

Page 66: ... vehicle and the 4 Connect the negative lead of the jumper cable to the negative terminal of the negative lead to an unpainted metal surface of the vehicle 1 Jumper cable positive lead 2 Jumper cable negative lead WARNING Do nor connect the negative lead of the jumper cable to the negative terminal of the battery in the vehicle Be especially careful not to touch the positive lead of the jumper cab...

Page 67: ...he engine before starting off Never accelerate hard with a cold engine To see whether or not the engine is warm check if it responds to the throttle normally with the starter choke turned off Shifting Neutral to Reverse 1 Stop the vehicle Keep your foot off the accelerator pedal 2 Apply the brake pedal 3 Shift from neutral to reverse or vice versa by moving the drive select lever along the shift g...

Page 68: ...k in There is never a more important period in the life of your vehicle than the period between zero and 20 hours For this reason we ask that you carefully read the following material Because the engine is brand new you must not put an excessive load on it for the first several hours of running During the first 20 hours the various parts in the engine wear and polish them selves to the correct ope...

Page 69: ...od consult an dealer 0 10 hours Avoid continuous operation above half throttle Allow a cooling off period of five to ten minutes after every hour of operation Vary the speed of the vehicle from time to time Do not operate it at one set throttle position 10 20 hours Avoid prolonged operation above 3 4 throttle Rev the vehicle freely but do not use full throttle at any time After break in The vehicl...

Page 70: ...ID 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 no hills that are so steep you could not walk up them easily 1 Bring the vehicle to a stop by applying the brakes 2 Stop the engine 3 With the brakes applied set the parking brake ...

Page 71: ...ity or suitability of them Choose a genuine accessory or one that is equivalent in design and quality Accessories should be rigidly and securely mounted An accessory which can shift position or come off while you are operating could affect your ability to control the vehicle Do not mount an accessory where it could interfere with your ability to control the vehicle Examples include but are not lim...

Page 72: ...hroom scale Put the tongue of the loaded trailer on the scale with the tongue at hitch height Adjust the load in the trailer 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 The down cargo securely in...

Page 73: ... Avoid hills and rough terrain Choose terrain carefully Added 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 ...

Page 74: ...n 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 TO AVOID THE HAZARD Always we...

Page 75: ... HAZARD Overloading this vehicle orcarrying or towing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle hand ling 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 carrying cargo or pulling a trailer Allow greater distance for braking Always follow...

Page 76: ... approved motorcycle helmet eye protection and protective clothing WHAT CAN HAPPEN Operating without an approved motorcycle helmet increases 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 moto...

Page 77: ... This is particularly important when driving in rough terrain The front wheels will move right and left as they respond to the terrain and this movement will be felt in the 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 Braking Braking ability is affected by the type of terrain In m...

Page 78: ...ossing the side of 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 Maximum slope angle 15 Choose carefully which hills you attempt to climb Avoid hills with slippery surfaces or ones where you will ...

Page 79: ...he brake and begin to coast down the hill Use engine braking as much as possible gently applying the brakes when necessary WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn move easily on extremely steep hills than on lever surfaces or small hills HOW TO AVOID THE HAZARD Never operate your vehicle on hills too steep for it or your abilities Neve...

Page 80: ...no faster than you will be able to react to obstacles that may appear WARNING POTENTIAL HAZARD Going down a hill improperly WHAT CAN HAPPEN Could cause loss of control or cause the vehicle to overturn HOW TO AVOID THE HAZARD Always check the terrain carefully before you start down any hill Never go down a hill at high speed Avoid going down a hill at an angle that would cause the vehicle to lean s...

Page 81: ...e starts to tip gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance gradually steer again in the direction you want to go CrossingthroughshallowWATER If you must cross shallow slow moving water up to the depth of the vehicle s floorboards choose your path carefully to avoid sharp drop offs large rocks or slippery surfaces that could cause t...

Page 82: ... lead to a rollover or accident Avoid jumping the vehicle as injury loss of control and damage to the vehicle could occur 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 w...

Page 83: ...nside the enclosure Encountering obstacles on the trail If you cannot go around an obstacle such as a fallen tree trunk or a ditch stop the vehicle where it is safe to do so 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 overtu...

Page 84: ...act 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 have the room or back up until you find a less difficult path WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or a collision Could cause the vehicle to overturn HOW TO AVOID THE HAZARD...

Page 85: ...ubrication are explained in 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 an dealer perform service if you are not ...

Page 86: ...hicles equipped with an odometer or an hour meter follow the km mi or hours maintenance intervals However keep in mind that if the vehicle isn t used for a long period of time the month maintenance intervals should be followed Items marked with an asterisk should be performed by a dealer as they require special tools data and technical skills ...

Page 87: ...ngine and air intake duct Clean Replace if necessary Every 20 40 hours More often in wet or dusty areas Crankcase breather system Check breather hose for cracks or damage Replace if necessary Exhaust system Check for leakage Tighten if necessary Replace gasket s if necessary Spark arrester Clean Fuel line Check fuel hose for cracks or damage Replace if necessary Engine oil Replace warm engine befo...

Page 88: ...on and free play Wheels Check balance damage runout Repair if necessary Wheel bearings Check bearing assemblies for looseness damage Replace if damaged Front and rear Suspension Check operation and for leakage Correct if necessary Steering system Check operation and for looseness Replace if damage Check toe in Adjust if necessary Drive shaft universal joint Lubricate with lithium soap based grease...

Page 89: ...e hoses every four years or if cracked or damaged When disassembling the master cylinder or caliper replace the brake fluid Normally check the brake fluid level and add fluid as required On the inner parts of the master cylinder and caliper replace the oil seals every two years ...

Page 90: ...ain pan under the oil drain plug 1 3 Remove the oil filler cap 2 and the drain plug 1 oil drain plug 2 oil filler cap Gearbox Oil Level The oil should be level with the bottom of the oil level bole Refill as required until gearbox oil level flows through oil level hole Type Hypoid gear oil Viscosity weight SAE 85w 90 Suggested oil Shaft drive oil of original manufacturer or equivalent ...

Page 91: ...brication Lubricate the knuckle upper and lower pivots with a grease gun Recommended lubricant Lithium soap based grease Steering shaft lubrication Lubricate the pivot points Recommended lubricant Lithium soap based grease all purpose grease ...

Page 92: ... the nuts from the wheel 4 Remove the wheel 1 Nut x4 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 93: ...ed 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 dealer CAUTION Do not try to remove the sealing caps of the battery calls You may damage the battery WARNING POTENTIAL HAZARD Failure to handle batteries or battery electrolyte carefully WHAT CAN HAPPEN You could be poisoned You could be sever...

Page 94: ... for 15 minutes and get prompt medical attention Keep batteries away from sparks flames Ventilate when charging or using in a closed space Battery maintenance 1 When the vehicle is not used for a month or longer remove the battery and store it in a cool dark place Completely recharge the battery before reinstallation CAUTION The carburetor was set at the factory after many tests If the settings ar...

Page 95: ... battery explosion and or serious damage to the electrical system may occur If a fuse blows All of the electrical circuits on your UTV have fuses to protect them from damage caused by excess current flow short circuit or overload If something electrical on your UTV stops working the first thing you should check for is a blown fuse 1 Check all the fuses before looking elsewhere for another possible...

Page 96: ...g a fuse 3 Remove the blown fuse and then install a new fuse of the specified amperage Troubleshooting Although vehicles receive a rigid inspection before shipment from the factory trouble may occur during operation Any problem in the fuel compression or ignition systems can cause poor starting and loss of power The troubleshooting chart describes a quick easy procedure for making check If your ve...

Page 97: ...king the fuel system while smoking or near an open flame WHAT CAN HAPPEN Fuel can ignite or explode causing severe injury or property damage HOW TO AVOID THE HAZARD Do not smoke when checking the fuel system Make sure there are no open flames or sparks in the area including pilot lights from water heaters or furnaces ...

Page 98: ...any protective measure To Avoid the injury and engine damage should take some proective measures when making assembly or using the engine ratation parts No maintenance or use the engine in a closed room No repair the engine in the roadside it could cause a fair Do not make modification on the engine or its parts it will resault in the human injury engine damage and warranty terminated exhaust gas ...

Page 99: ...from the cooling system otherwise it will cause the engine overheated and high pressure of cooling system a Lubricants capacity New machine 2 2L Engine overhaul 2 2L Replace the oil filter 2 0L Replace the engine oil 1 9L b Use high quality ethylene glycol base antifreeze and mixed with distilled water Never mix alcohol base anti freeze and different brands of anti freeze The ratio of antifreeze s...

Page 100: ...rrectly 5 Turn off the accelerator completely press the start switch Attention If fail to start turn off the start switch few seconds then start again not more than 5 seconds 6 Turn off the throttle shift the gear into H L and R after the vehicle completely stopped Warning When shift must stop the car and turn off the throttle otherwise will damage the machine and cause the accident Warning Keep t...

Page 101: ...2 3 mins in the idling condition 3 Turn off the electric switch Engine Maintenance Daily maintenance 1 Clean the oil mud and dust 2 Check the fastening external parts tighten the bolts nuts and screws 3 Check the oil leakage air leakage and compression pressure whether is in the normal condition 4 If the lubricants level is under MIN scale should add the oil and enusre the oil level reaches in the...

Page 102: ...p 2 Loosen bolt 4 take down the filter assy 5 Take out the filter element 6 Fill a wash pan of a proper size with a cleaning solvent Immerse the filter element 6 in cleaning solvent and wash it Press the filter element 6 to remove the excess solvent Damaged element must be replaced Assemble the the air filter combination 6 and put it into the body 1 Plastic cover 2 Air filter cover 3 Clamp 4 Bolt ...

Page 103: ... NGK Clean the surface of the spark plug gas ket and its mating surface and then wipe off any grime from the spark plug threads Measure the electrode gap with a wire thickness gauge and if necessary adjust the gap to specification Spark plug gap 0 8 0 9 mm 0 031 0 035 in Install the spark plug and tighten it to the specified torque Tightening torque Spark plug 17 5 Nm 1 75m kgf 12 7ft lbf ...

Page 104: ...n oil dip rod 5 drain bolt 3 and washer 2 with solvent Install washer 2 and drain bolt 3 Fill engine oil the oil level should be on the oil dip rod 5 upper limit Start the engine and alow it to run for several minutes at idling speed then turn off the engine Make sure no oil leakage 1 Left Crankcase 2 Washer 3 Bolt 4 Cover 5 Oil dip rod 6 Oil filter ...

Page 105: ... out the air otherwise will cause the engine high temperature or water spalashing Check the valve clearance adjust the clearance if necessary Check and adjust the valve clearance as following Remove cover plate recoil starter Remove the inspection cap on left crankcase Remove 2 valve adjusting cover Turn the crankshaft until the line of T D C on rotor is aligned with mark of inspection hole on lef...

Page 106: ...re it slightly contacts the feeler gauge tighten bolt and nut Take out the feeler gauge measure the clearance if the clearance is incorrect repeat the above steps until the proper clearance is obtained 2 valve adjusting cover Inspection cap Recoil starter Cover plate a exhaust valve b intake valve 1 valve adjusting cover 2 valve 3 rocker arm 4 valve adjusting bolt 5 nut ...

Page 107: ... any cracks or damages are found replace drive belt with a new one Start the engine check the running voice and exhaust pipe condition If anything different must find the reason and solve it inspect the idling speed according to the specification Otherwise must be adjusted ...

Page 108: ...uel Restart the engine No compression There is compression Compression normal Wipe clean with dry cloth Attach spark plug cap and ground to chassis Wet Dry Use the electric starter Spark is weak Spark is good No spark Ignition system is normal Adjust the spark plug gap or replace the spark plug Ask an dealer to inspect Ask an dealer to inspect Ask an dealer to inspect Check the connections rechatg...

Page 109: ...radiator still hot WHAT CAN HAPPEN You can 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 110: ...p water can be temporarily used provided that it is changed to the recommended coolant as soon as possible MAINTENANCE CHART The maintenance is very important if you are not familiar with safe service practices and adjustment procedures see your authorized dealer ...

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Page 115: ...he spark plug and all filler caps are properly installed 2 If the engine case is excessively greasy apply degreaser with a paint brush Do not apply degreaser to the wheel axles 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job CAUTION Excessive water pressure may cause water seepage and deterioration of wheel bearings brakes transmission seals and electri...

Page 116: ... cover pliable and glossy 7 Automotive type wax may be applied to all painted and chrome plated surfaces Avoid combination cleaner waxes Many contain abrasives 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 abilit...

Page 117: ... fuel system Specified amount 1 oz of stabilizer to each gallon of fuel or 7 5 cc of stabilizer to each liter of fuel NOTE Use of fuel stabilizer and conditioner eliminates the need to drain the fuel system Consult an dealer if the fuel system needs to be drained instead 2 Remove the spark plug pour about one tablespoon of SAE 10W30 or 20W40 motor oil in the spark plug Ground the spark plug wire a...

Page 118: ...xposed metal surfaces with a light film of oil Do not apply oil to any rubber parts or the seat covers 7 Remove the battery 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 30 of move than 30 90 NOTE Make any necessary repairs before storing the vehicle ...

Page 119: ...n 3 900 mm 153 5 in 3500 mm 137 8 in 1480 mm 58 3 in 1800 mm 70 9 in 2580 mm 101 6 in 260 mm 10 2 in 3 900 mm 153 5 in Basic weight With oil and full fuel tank 540 0 kg 1 190 lb 640kg 1 410 lb Engine Engine type Cylinder arrangement Displacement Bore stroke Compression ratio Starting system Lubrication system Liquid cooled 4 stroke SOHC Forward inclined single cylinder 594 cm3 96 82 0 mm 3 78 3 23...

Page 120: ...igher 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 80 L 1 58 Imp qt 1 90 US qt 2 00 L 1 76 Imp qt 2 11 US qt 0 10 30 50 70 90 110 130 F 20 10 0 10 20 30 40 5...

Page 121: ...adiator capacity including all routes 2 50 L 2 20 Imp qt 2 64 US qt Fuel Type Fuel tank capacity UNLEADED GASOLINE ONLY 27 0 L 5 9 lmp gal 7 14 US gal Spark plug Type manufacturer Spark plug gap DPR8EA 9 NGK 0 8 0 9 mm 0 031 0 035 in Transmission Primary reduction system Secondary reduction system Final stage system CVT reduction ratio 0 7 2 88 Gear reduction ratio low 3 514 High 5 857 Reverse 3 8...

Page 122: ...disc brake Dual disc brake Foot operation Suspension Front suspension Rear suspension Double wishbone Double wishbone Shock absorber Front shock absorber Rear shock absorber Coil spring oil damper Coil spring oil damper Electrical Ignition system Generator system Battery type Battery capacity ECU A C magneto Colloid free maintenance battery 12VDC 34Ah ...

Page 123: ...117 Model APU06E APU06EL Headlight type Type Bulb voltage wattage quantity Headlight Tail brake light Krypton bulb 12V35W 2 12V5W 21W 2 ...

Page 124: ...YST CO LTD DP2G16 O2 Sensor ZHEJIANG CFMOTO POWERCO LTD 107011 Muffler YONGKANG DUWEI MUFFLER FACTORY APU05E 0802000 CDI ECU ZHEJIANG CFMOTO POWERCO LTD ECU 065 11 Spark Plugs NGK SPARK PLUG SHANGHAI CO LTD DPR7EA 9 NGK Fuel Tank ZHEJIANG APPLESTONE VEHICLE CO LTD APSD Fuel Tank Cap Cover RUIAN CHUANLONG VEHICLE PARTS CO LTD LZ111 110300 Air Cleaner ZHEJIANG CFMOTO POWERCO LTD CF188 110000 fuel li...

Page 125: ...119 二 THE SKETCH MAP OF CRANKCASE WASTE RECYCLING ...

Page 126: ...or company vehicle which ever comes first and continues for 60 months after that date or 10 000 which ever comes first provided there has been no abuse neglector improper maintenance of your vehicle Where a warrantable condition exists the Distributor will repair your vehicle at no cost to you including diagnosis parts and labor If an emission related part on your vehicle is defective the part wil...

Page 127: ...because of your failure to ensure the performance of all scheduled maintenance or lack of maintenance records or receipts You are responsible for presenting your vehicle to an authorized dealer as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days As the vehicle owner you should be aware that you may be denied your warranty covera...

Page 128: ...e to fail to confirm with applicable regulations of the United States Environmental Protection Agency or the California Air Resources Board for the periods specified above Your emission control system warranty covers components whose failure would increase an engine s emission including electronic controls fuel injection system carburetor the ignition system catalytic converter or any other system...

Page 129: ...ency situation The use of replacement parts not equivalent to the original parts may impair the effectiveness of your vehicle s emission control system If such a replacement part is used and an authorized dealer determines it is defective or causes a failure of a warranted part your claim for repair to bring your vehicle into compliance with applicable standards may be denied If an emergency situa...

Page 130: ...te hourly labor rate The owner may reasonably be required to keep receipts and failed parts in order to receive compensation This Emission Control System Warranty is in addition to the standard Limited Warranty EXCLUSIONS AND LIMITATIONS This warranty does not cover the following Failures or malfunctions of the emission control systems caused by abuse alteration accident misuse the use of leaded g...

Page 131: ...cements of parts and other services and adjustments for required maintenance Any vehicle equipped with an odometer or hour meter where the reading is altered so that actual mileage cannot be readily determined Repairs or replacements as a result of Accident Misuse Use of replacement parts or accessories not conforming to the original specifications which adversely affect performance Physical damag...

Page 132: ...emedying of defects in material workmanship by an authorized dealer at its place of business during customary business hours This warranty does not cover in convenience or loss of use of the vehicle or transportation of the vehicle to from the authorized dealer The Distributor is not liable to any person for incidental consequential or special damages of any description whether arising out of expr...

Page 133: ...ted in this warranty are disclaimed Some states do not allow limitations on how long an implied warranty lasts so the above limitations may not apply if it is inconsistent with the controlling state law No dealer is authorized to modify this Emission Control System Warranty If you have any questions regarding your warranty rights and responsibilities you should contact 3500 South DuPont Highway in...

Page 134: ...128 Electrical schematic ...