Introduction Militia 1000s Introduction

Transcript

Introduction MILITIA 1000S INTRODUCTION Congratulations on your purchase of the MILITIA 1000S. This Owner’s / Operator’s manual will provide you information regarding safe operation, operational instructions, maintenance and care. Fully understanding this manual and following all of the instructions herein will provide the knowledge needed to have safe and enjoyable UTV operation. For questions regarding this UTV, please call (972) 243-4555. IMPORTANT SAFETY MESSAGES ● READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR UTV. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS. ● PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE UTV. ● NEVER OPERATE THE UTV WITHOUT PROPER TRAINING OR INSTRUCTION. ● THIS UTV SHOULD NOT BE RIDDEN BY ANYONE UNDER 16 YEARS OF AGE. 1-1 Introduction MILITIA 1000S IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: 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, bystander or a person inspecting or repairing the machine. A CAUTION indicates special precautions that must be taken to avoid damage to the machine. NOTE: A NOTE provides key information to make procedures easier clearer. 1-2 Introduction MILITIA 1000S IMPORTANT NOTICE This UTV is designed and manufactured for OFF - ROAD use only. It is illegal and unsafe to operate this UTV on any public street, road or highway. This UTV complies with all applicable OFF - ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture. Please check your local riding laws and regulations before operating this UTV. When the temperature is below -4°F (-20°C), park the UTV in a place where the temperature is higher than -4°F (-20°C). Start the UTV after the UTV has warmed up. Please see page 7-3 on the warming up process. Follow the proper parking procedures when the temperature is higher than 100°F (38°C): turn off the engine; make sure the radiator fan is on for 3 minutes before turning off the power switch. Starting the UTV for the first time will take longer because the fuel will need reach the fuel injectors. To start the UTV the first time, hold the ignition key on at 5-second intervals. Allow the starter to rest 15 seconds between each start attempt. 1-3 Introduction MILITIA 1000S NIVERSAL SYMBOLS As a guide to the operation of your vehicle, various universal symbols have been utilized on the instruments and controls. The symbols are shown below with an indication of their meaning. Safety Alert Symbol Lift Cylinder-Retract Diesel Fuel Lift Cylinder-Extend Engine coolant-Temperature Lift Cylinder-Float Parking Brake Hazard Warning Lights Battery Charging Condition Master Lighting Switch Engine Oil-Pressure Audible Warning Device Turn Signal/Hazard Fault indicator light of EPS system Differential Lock 2WD/ 4WD Position light bulb 1-4 Introduction MILITIA 1000S Table of Contents Subject Page Subject Page Introduction 1-1 Starting 8-1 Important manual information 1-2 Seat belt 8-1 Important notice 1-3 Head light switch 8-2 Universal symbols 1-4 Hazard light switch 8-2 Location of parts 1-8 Turn signal light switch 8-2 Illustrated contents 1-9 Brake pedal 8-3 Safe operation 2-1 Gear shift lever 8-3 Safety instructions 2-1 4WD lever 8-4 Operation 2-2 Accelerator pedal 8-5 Children safety instructions 2-2 Stopping 8-5 Driving on a slope 2-2 Fuel gauge 8-5 Driving in harsh conditions 2-3 Coolant temperature gauge 8-5 Driving at high speed 2-3 Winch mount plate 9-1 Instructions for carrier 2-3 Transporting vehicle 9-1 Parking 2-3 Service intervals 9-2 Transportation 2-4 Periodic service 10-1 Maintenance 2-4 How to open the hood and tilt the seat 10-1 Warning and caution labels 3-1 Hood 10-1 Servicing of vehicle 4-1 Operator’s sea 10-1 Specifications table 5-1 Moving the seat forward and backward 10-2 Vehicle limitations 5-3 Adjustment of the steering wheel 10-2 Pre-operation 6-1 Cargo bed 10-2 Operating the engine 7-1 Front and rear shock adjustment 10-3 Starting the engine 7-1 Spring preload 10-3 Cold starting 7-3 Rebound damping force 10-4 Stopping the engine 7-3 Compression damping force 10-4 Warming up 7-3 Jack-up point 10-5 Warm-up transmission oil in the low 7-3 Front end 10-5 Rear end 10-5 temperature range Operating the vehicle 8-1 Visual inspection 10-5 Operating new vehicle 8-1 Checking and Refueling 10-5 Do not operate the vehicle at full 8-1 Checking coolant level 10-6 speed for the first 50 hours Cleaning radiator screen 10-6 Changing lubricating oil for new vehicles 8-1 Checking brake pedal 10-7 1-5 Introduction MILITIA 1000S Checking parking brake 10-8 Every 500 hours 10-18 Checking gauges meter and easy 10-8 Replacing fuel filter 10-18 Every 600 hours 10-18 checker lamps Checking head light turn signal light etc 10-8 Adjusting engine valve clearance 10-18 Checking seat belt and ROPS 10-8 Every 1500 hours 10-18 Checking CV boot 10-8 Checking injection and fuel pump 10-18 Checking tire inflation pressure 10-8 Every 1 year 10-18 Every 50 hours 10-9 Replacing air cleaner primary element 10-178 Greasing 10-9 and secondary element Checking engine start system 10-9 Every 2 years 10-18 Checking wheel bolt torque 10-10 Changing brake fluid 10-8 Cleaning air cleaner primary element 10-10 Flushing Cooling system and changing 10-18 Evacuator valve 10-11 coolant Chick fuel line and fuel filter 10-11 Anti-freeze 10-19 Checking the battery 10-11 Replacing radiator hose 10-20 Battery charging 10-12 Replacing fuel hose 10-20 Adjusting toe-in 10-12 Replacing brake master cylinder (inner 10-20 Cleaning muffler 10-13 parts) Every 200 hour 10-13 Replacing front brake seal 10-20 Changing engine oil 10-13 Replacing rear brake cylinder seal 10-20 Replacing engine oil filter 10-14 Replacing intake air line 10-20 Replacing engine oil 10-14 Every 4 years 10-20 Checking brake pedal 10-15 Replacing brake hose 10-20 Checking the brake pedal free travel 10-15 Replacing mini-blade fuses 10-20 Checking the brake pedal stroke 10-15 Replacing procedure 10-21 Checking brake hose and lines 10-15 Replacing light bulb 10-21 Checking brake light switch 10-15 Storage 10-21 Checking radiator hose and clamp 10-16 Vehicle storage 10-21 Precaution at overheating 10-16 Removing the vehicle from storage 10-22 Checking intake air line 10-16 Electric power steering system 11-1 Every 300 hours 10-16 Troubleshooting 12-1 Checking tire 10-16 Engine troubleshooting 12-1 Every 400 hours 10-17 Check malf code meaning by reading 12-2 Changing transmission fluid 10-17 the below table Changing front and rear axle case oil 10-17 Battery troubleshooting 12-3 Machine troubleshooting 12-4 1-6 Introduction MILITIA 1000S Options 13-1 Emissions warranty 14-1 1-7 Introduction MILITIA 1000S LOCATION OF PARTS ① Roll-over protective structure. ② Front hood ③ Hazard/Turn signal light (if equipped) ④ Headlights ⑤ Winch mount plate 1-8 Introduction MILITIA 1000S ILLUSTRATED CONTENTS ① Steering wheel ② Brake pedal ③ Accelerator Pedal ④ Cup holder ⑤ Gear indicator ⑥ Tachometer ⑦ Speedometer ⑧ DC socket ⑨ Gear shift lever (Range) ⑩ Parking brake lever 1-9 Introduction MILITIA 1000S ① Cargo bed ② Tail lamp ③ Muffler ④ Rear trailer hitch bracket ⑤ Handgrip ⑥ Fuel tank cap 1-10 Safe Operation All operators, including experienced UTV drivers or You should always wear protective equipment, passengers, such as helmet, boots, eye protection, ear should carefully read and fully understand this Users Manual, and operate strictly as the manual states in order to achieve the best protection, and glove setc. 4. Only a qualified driver with driving license performance and avoid accidents. Everyone who should operate this UTV. Never operate after uses your UTV should be trained on how to operate drinking alcohol, using drugs or controlled the UTV and be required to read this manual before substances, or while fatigued. operation. 5. Always perform the pre-operation checks as following: 1. Safety Instructions: 5) Check seat belts for wear or damage, if necessary, replace it. 1. 2. 3. Only start and operate the vehicle after you 6) Check brakes, throttle, brake pedal and have finished reading this manual. other mechanical parts for proper operation. Pay close attention to the warning and caution If you discover any irregularities, replace labels on the UTV. related parts as necessary. Periodically Understand completely and learn to use the check the fittings and fasteners. safety devices (roll-over protective structure, 7) seat belts), and never change the original level. safety devices. If the safety devices are damaged, consult your local dealer Check engine oil level and engine coolant 8) for Check that the UTV is equipped to handle the surroundings. replacement. Always use seat belts. 9) Check and keep vehicle clean. Sludge, grease and debris can cause a fire and severe injury. 6. Passenger quantity and loading: 1) Only the driver and one passenger inside cab. It is suggested that children under age of 5 not be allowed as a passenger. 2) Single-row vehicle’s loading limit is 660lbs(300KG). Reduce the loading weight according to road conditions. Never exceed the weight limits for operation. ①Roll-over protective structure； ②Seat belts； 7. Do not wear loose articles of clothing during operation, as these can be drawn into moving parts on the vehicle and could cause a severe injury to occur. 2-1 Never allow unauthorized persons to repair this UTV. This may affect vehicle performance and cause injury. Safe Operation 2. Operation 11. Always pay close attention to your surroundings, and check for streets, trail 1. Start the engine only in an open ventilated intersections or other obstacles. area. Carbon monoxide is colorless, odorless 12. Always use signals in advance of turns. and is emitted from the engine and can cause 13. Do not allow entrance or exit of the vehicle death in areas with poor ventilation. 2. while it is moving. Never start the vehicle or operate the gear 14. Keep the floorboard free of debris that can selector unless seated in the driver’s seat. 3. 4. obstruct the ability to use the brake pedal. Never start the engine until the select lever is 15. Position your hands on the steering wheel. placed in “N” position and the brake is in the Always keep your hands and feet inside brake position. passenger area of the vehicle. Never try to The driver and passenger shall always wear stand while operating the vehicle. their seatbelt while the vehicle is being 16. Do not tow passengers, or attempt to jump the operated. 5. vehicle. Operators of the UTV should not wear 3. Children safety instructions earphones. 6. Use the proper trailer hitch to haul cargo, Always watch children when they are around the otherwise, serious injury or death can happen. vehicle. Children like to imitate adults and this could lead to an accident. Do not leave children alone beside the vehicle. Keep children from the operating area of the vehicle. Turn off the engine and remove the key when children are in the operating area. Never carry children in the cargo area. This is very ①Trailer Hitch dangerous to children. Children under age of 5 7. Do not accelerate quickly when starting the should not be allowed in this vehicle. engine, especially driving on rough terrain as Never allow children to touch or climb on the this can cause injury or death. Press the vehicle, even if they are under adult supervision. accelerator pedal slowly. Always check for people or obstacles behind the 8. Drive at slow speeds before braking. vehicle before shifting the vehicle into reverse. 9. When the differential is unlocked (DIFF.LOCK Avoid a collision with an obstacle or person. is off) the front/rear wheels can turn at different Park the vehicle on a firm, flat area. If parking on a speeds to assist in the stability of the vehicle. slope, you should use hand lever parking brake 10. Never drive over terrain such as a ditch, a hole, then remove the key. dams, excessive mud, or the vehicle can get stuck because of the vehicles weight. 4. Driving on a slope 2-2 Safe Operation Be cautious when riding on a slope, as this is the Driving at high speed main reason for loss of control, and overturn, 1. leading to severe injury or even death. 1. 2. 3. 4. 1. 6. Pay attention to the difference of braking Reduce weight when riding on a slope or rough performances between two and four-wheel terrain. drive. Slow down when turning. Turning at high Avoid the sudden application of the brakes speeds, may result in overturn or even death. when you go uphill or downhill. Be more careful 2. Turn on your headlights at high speeds. when vehicle turns on a slope. 3. Drive only when the vehicle speed can be controlled. If you start to lose momentum or need to park when climbing, use the hand lever brake to 5. wheels. Drive in a straight line on a slope at a lowspeed. Check the condition of the front and rear 4. Do not use DIFF.LOCK when driving at high come to a stop. Release the brake and begin speeds. This may cause loss of control of the to coast down the hill. vehicle. If do not believe you can operate the UTV 5. When driving at high speeds, sudden turning of safely in reverse do not attempt to ascend the the steering wheel will reduce vehicle stability. slope any further. Never sharply turn the steering wheel at high Riding in mud, a ditch, and on slopes will speeds. increase the risk of an overturn. Be more cautious when operating in 4WD, vehicle 7. Instructions for carrier traction will increase and it is easy to misjudge 7. for vehicle’s ability to climb a grade. 1. Never carry a passenger in the cargo area. Drive gradually and slowly when climbing. 2. Evenly distribute the cargo to maintain proper Avoid suddenly changes of vehicle speed or stability. Avoid overloading the carrier. Cargo direction. should be securely attached. 3. road conditions or on steep inclines. 5. Driving in harsh conditions 4. 1. 2. 3. 4. Reduce loaded weight when driving on poor Only the driver should be in the seat when Vehicle can be operated during the day or operating the hydraulic dump mechanism (if under good light conditions. applicable).Once lowered, lock the cargo bed and in place before operating the vehicle. Don’t put passengers should wear helmet and protective your hands or your body under the cargo bed equipment. when the carrier is lifted (if applicable). Avoid The Driver should slow down according to road driving before securing and locking the cargo conditions, terrain, visibility conditions. bed. Under all conditions, both operator Be cautious when driving over a ditch, stone 8. Parking roads or hidden obstacles. Avoid operating in any unknown depth of water. （water depth should not exceed axle height）. 2-3 Safe Operation 1. 2. Set the gear shift to the “N” position and pull 3. kept away from sparks. The battery produces the braking brake to the top position to park the hydrogen and oxygen during charging and this vehicle. could accelerate the risk of explosion. Avoid stopping the vehicle on a slope. If 4. stopping on a slope make sure the vehicle is stationary before exiting. Read and follow the instructions before replacing the battery. 5. During maintenance, first aid kits and fire extinguishers should be placed at your fingertips. 6. During maintenance, you should disconnect the battery cables. ① Parking brake lever. ② Pull to “PARK” 9. Transportation 1. Avoid dragging the vehicle behind another vehicle. Use a trailer or truck to transport the vehicle. 2. When loading or unloading, pay attention to ① 7. Battery Do not open the radiator cap before coolant has cooled down. When the coolant is cold, your surroundings and others in the area. open slowly and let the coolant pressure reduce, and then open radiator cap. Check for 8. Maintenance the coolant level in the coolant reservoir. If necessary, add coolant. Stop the vehicle and park it on level ground. Pull the parking brake and remove all cargo. Place the 8. equipment, only by professionals. shift lever in the “N” position, stop the engine and 9. remove the key. 1. Keep the specified tire pressure to ensure driving safety. When working next to the engine, exhaust, or 10. Elevate the vehicle and place a suitable stand radiator, work only after it has cooled down. 2. Tires should be mounted on rims with special Wait for the engine to stop running and cool under the frame when removing the wheels.Be down before checking the coolant level. sure tore-tighten the wheel nuts to the Otherwise, you could be burned by hot fluid or specified torque. steam. No smoking when adding electrolyte or refueling. The fuel tank and battery should be 2-4 Warning Labels Warning and caution labels （1） （2） （3） （4） （5） （6） （7） （8） （9） 3-1 Warning Labels （10） （11） (12） (13) (14) (15) 3-2 Warning Labels (16) 3-3 Vehicle Identification Number SERVICING OF VEHICLE Your dealer is interested in your new vehicle and has the desire to help you get the most value from it. After reading this manual thoroughly, you will find you can do some of the regular maintenance by yourself. However, when in need of parts or major service,be sure to see your dealer. For service, contact the dealership from which you purchased your vehicle or your ① Vehicle serial number. local dealer. When in need of parts, be prepared to give your dealer both the vehicle and engine serial numbers. Locate the serial numbers now and record them in the space provided. Type Serial No. Vehicle ① Engine serial number Engine Product Identification Number Date of Purchase Name of Dealer 4-1 Specifications SPECIFICATION TABLE Model Engine Specification Make HS2V91MY-1 Type 2 cylinders, 4-cycle, gasoline, SOHC, water Displacement(s) Horsepower cc 976CC Kw(HP) Rated revolution Low idling revolution Fuel Capacity 48.85（65.51） rpm 7500 rpm 1350 to 1500 L 28 Transmission CVT Wheels, Drive system 4, Rear 2WD or 4WD Differential lock Electric control: switch Gear selection Hi-Lo range forward, Neutral, Reverse Brakes Front/Rear Wet disk brake Parking brake Rear wheel, hand lever Steering Suspension Dimensions Electronic power Front Independent, Dual A-arm type Rear Independent, Dual A-arm type Length mm(in.) 2880 (113.4) Wide mm (in.) 1760（69.3） Height mm (in.) 1900（74.8） Front tread centers mm (in.) 1385 (54.5) Rear tread centers mm (in.) 1350 (53.1) Wheelbase mm (in.) 2160（85） Ground Clearance front axle rear axle Turning diameter mm (in.) m (ft) 330（13.77） 320（13） 9.4（30.8） Max. rolling weight (Towing Capacity) kg (lbs.) 800（1764） Payload capacity kg (lbs.) 159（350） Weight kg (lbs.) 690(50.8) 5-1 Specifications Model Cargo bed Width mm (in.) 1290（27.16） Length mm (in.) 690（27.2） Depth mm (in.) 190（7.5） Volume (1 row/2 row) Bed height (unloaded) Cargo bed capacity Sound level, operator ear Tire Specification 3 m (cu.ft.) 0.24（8.47） mm (in.) 927（36.5） kg (lbs.) 159（350） db (A) 85 Front 25×8-12/12×6(min); 27×9-14/14×7(max) 6PR Rear 25×10-12/12×8(min); 27×11-14/14× 9(max) 6PR Body color Various NOTE:  The values in “Ground clearance” and “Weight” are those of the machine equipped with the tires in the table above.  The company reserves the right to change the specifications without notice. TRAVELING SPEEDS Range gear shift lever km/h (mph) Low 79（49） High 115（72） Reverse 40（25） 5-2 Specifications VEHICLE LIMITATIONS The Vehicle has been thoroughly tested for proper performance with implements sold or approved by manufacturer. Use with implements which are not sold or approved and which exceed the maximum specifications listed below, or which are otherwise unfit for use, vehicle may result in vehicle malfunction or failures with a possibility of the vehicle damage, property damage and injury to the operator or others. Any malfunctions or failures of the vehicle resulting from use with improper implements are not covered by the warranty. Max. Cargo loading weight Cargo Bed Capacity=159kg(350lb) Max. rolling weight Cargo Load Capacity=190kg(419lb) 800kg (1764 lbs.) *(operator+one passenger+opt+acc )weight Max. tongue weight 58 kg (128 lbs.) 1. Above mentioned specifications are based on level ground condition. 5-3 Pre-Operation DAILY CHECK To better prevent troubles,it is important to know the condition of the vehicle, before operating.Check it before starting. CAUTION： To avoid personal injury： Be sure to check and service the vehicle on a level surface with the engineoff, the parking brake “ON”, andimplements lowered to the ground if equipped. Check items -Visually inspect the exterior of the vehicle -Check engine oil level -Check transmission oil level -Check brake fluid level -Check coolant level -Clean radiator screen (When used in dusty areas) -Check brake pedal -Check parking brake -Check indicators,gauges and meters -Check lights -Check seat belts and roll-over protective structures. -Check front and rear CV joint boots. -Check tire inflation pressure. -Check backup beeper (if equipped). -Refuel (See "PRE-OPERATION CHECK" in "PERIODIC SERVICE" section.) -Check danger,warning and caution labels (See "DANGER,WARNING AND CAUTION LABELS＂in＂SAFE OPERATION＂section.) 6-1 Operating the Engine STARTING THE ENGINE CAUTION： To avoid personal injury：  1.Make sure the parking brake is set. Read "SAFE OPERATION" in front of this manual.  Read the danger,warning and caution labels located on the vehicle.  To avoid the danger of exhaust fume poisoning, do not operate the engine in closed buildings without proper ventilation.  Start the engine only from operator’s seat. Never start the engine while standing on ground.  Make it a rule to set gear shift lever to “NEUTRAL” position before starting the engine. ① Parking brake lever ② Pull to “PARK” NOTE： The parking brake warning lamp(P) comes on while parking brake is applied and goes off when it is released. IMPORTANT:  Do not use starting fluid or ether.  To protect the battery and the starter, make sure that the starter is not continuously turned for more than 5 seconds.  ①Parking brake warning lamp 7-1 Operating the Engine 2.Set gear shift lever to the “NEUTRAL”position. 1. Insert the key into the key switch and turn it to START.(Starts the engine.) OFF (Stops the engine) ON (Engine runs or headlights on) ◆ Display and Warning Lights 1. When the key is turned to “START”, lamps(1 engine oil pressure) should come on. If trouble codes occur at any location with the engine ①Gear shiftlever. (H) High Range (L)Low Range running, the warning lamp corresponding to that location comes on. 2. The parking brake warning lamp(2 parking brake) comes on while parking brake is (N) “Neutral” position applied and goes off when it is released. (R)“REVERSE” 3.Push the accelerator pedal down slowly. IMPORTANT Relying on the engine warning lights is never enough. Never fail to conduct daily checks ① Accelerator pedal carefully by referring to Pre Operation Check ② Accelerator pedal depressed “ in “PERIODIC SERVICE” section. 3. Turn the key to the “START” position and release when the engine starts. IMPORTANT:  Because of safety devices, the engine will not start except when the gear shift lever is placed in the “NEUTRAL” position and the brake is depressed. 7-2 Operating the Engine ■Cold Starting When the ambient temperature is below 15℃( 5℉), and the engine is very cold. If the engine fails to start after 5 seconds, turn off the key for 30 seconds and start again. STOPPING THE ENGINE 1. After slowing the engine to idle, turn the key to “OFF”. 2. Remove the key. WARMING UP CAUTION： To avoid personal injury:  Be sure to set the parking brake during warm-up.Be sure to set the shift lever to the “NEUTRAL” position during warmup.  Allow the engine to warm up for 5 minutes without applying any load. This is to allow oil to reach every engine part. If a load is applied to the engine without warm-up engine damage may occur. ■ Warm-Up Transmission Oil in the Low Temperature Range IMPORTANT:  Do not operate the vehicle under full load until it is sufficiently warmed up. 7-3 Operating the Vehicle OPERATING NEW VEHICLE and are not mated to each other. Small pieces of How a new vehicle is handled and maintained metal grit may develop during the operation of determines the life of vehicle. the vehicle; and this may wear out or damage A new vehicle just off the factory production line the parts. Therefore, change the lubricating oil a has been tested, however the various parts are little earlier than would ordinarily be required. For not mated to each other, so the operator should further details of change interval hours, see pay more attention to the vehicle operation for “MAINTENANCE” section. the first 50 hours. Drive at a slower speed and avoid excessive work or operation until the various parts become “broken-in”. How you break in the vehicle greatly affects the life of your vehicle. Therefore, to obtain the maximum STARTING 1.Fasten the seat belts during operation. ■Seat Belt performance and the longest life of the vehicle, it is very important to properly break-in your WARNING vehicle. For better handling of a new vehicle, the To avoid personal injury: following precautions should be observed.  Seat belts reduce injury. Always wear your seat belts. The lap-style seat belts ■Do not operate the vehicle at full speed for may not provide adequate protection for the first 50 hours.  small children. Pay special attention Do not start quickly nor apply the brakes when carrying a child passenger. suddenly.  In winter, operate the vehicle after fully warming up the engine.  Do not run the engine at speeds faster than prescribed.  On rough roads, slow down to suitable speeds. Do not operate the vehicle at fast speed. The above precautions are not limited to new vehicles, but to all vehicles. It CAUTION： To avoid personal injury:  Always use the seat belts when operating and riding the vehicle. Adjust the seat belts for proper fit and connect the buckle. This seat belt is an auto-locking retractable type. should be especially observed for new vehicles. ■Changing Lubricating Oil for New Vehicles The lubricating oil is especially important for a new vehicle. Various parts are not “broken-in” 8-1 Operating the Vehicle 1. Tail lights (lamps at the rear of the vehicle) 2. The instrument panel illuminates. ■Hazard Light Switch [If equipped] Press the top half of the hazard light switch, the hazard lights flash along with the indicator on the instrument panel. Press the bottom half of the hazard light switch to turn off the hazard lights. ① Seat belt Note: 2.Selecting light switch position.  ■Head Light Switch the key switch is in the “ON” or “OFF” Turn on the key switch and toggle the head light position. switch to the “ON” position. Keeping the switch “ON” causes the battery Toggle the head light switch to the “OFF” position to turn off the head light. The hazard light switch will operate when voltage to run down. ■Turn Signal Light Switch [If equipped] To indicate a right turn, push on the lower half of the turn toggle switch. To indicate a left turn, push on the upper half of the turn toggle switch. When the left or right signal is activated, the indicated turning light will flash and the other will ① Head light switch stay on. ② Head lights “OFF” The indicator lamp at the instrument panel also ③Low Beam On flashes indicating the direction of the turn. ④ High Beam On ⑤4WD button NOTE: ⑥ 2WD button  The turn signal light switch only operates NOTE： when the key switch is in the “ON” position. Turning the head light switch to the “ON” position If the hazard light switch is pressed to the causes “ON” position while the turn signal is the following lamps to light activated, the indicated turning light will flash simultaneously. 8-2 Operating the Vehicle and other will stay on.  Be sure to return switch to center position after turning. ① Brake pedal ① Head light 4.Selecting the Correct Gear. ②Front turn signal lamp; ■Gear ShiftLever 3.Checking the brake pedal. ■Brake Pedal CAUTION: CAUTION: To avoid personal injury: To avoid personal injury:  If the operator suddenly brakes, an accident may occur due to loss of control or the shifting forward of heavy  when ascending or descending a slope.  When driving on icy, wet or loose surface, make sure the vehicle is correctly loaded to avoid skidding or loss of steering control. Reduce the vehicle speed.  board. Depress the pedal to slow or stop the Operate in reverse at slow speeds to maintain control. 1. The gear shift lever can only be shifted when the vehicle is completely stopped and speed. The brake pedal is the left pedal on the foot Before ascending or descending a slope, shift to the “L” range to control the loads.  Avoid changing range gear shift lever the brake pedal is pressed. 2. To avoid transmission and shift linkage damage, completely stop the vehicle using vehicle. the brake pedal before shifting gears. 3. Select proper gear depending on the type of job. 4. Before exiting the vehicle, shift the gear shift lever to the “NEUTRAL” position and set parking brake. 8-3 Operating the Vehicle  to avoid skidding and loss of steering control. Reduce the speed and engage the 4-wheel drive.  An accident may occur if the brakes are applied suddenly while towing heavy loads. The load can shift forward causing loss of control.  The braking characteristics are different between two and four wheel drive. Be ① Range gear shift lever aware of the differences and practice the (L)LOW Range differences at slower speeds first. (H)HIGH Range (N)NEUTRAL” POSITION (R)“REVERSE” NOTE:  When gear shift lever is hard to engage, do not force the lever. Set the parking brake, slightly depress the accelerator pedal and release it to neutral position, then shift the lever.  When the lever is hard to disengage, do not IMPORTANT: force the lever. 5. Release the parking brake and start slowly. Depress the brake pedal fully, then shift the To release the parking brake, depress the brake lever. pedal, push release button and push down on AN accident could occur through improper the parking brake lever. Make sure that indicator use of the gear shift lever in the Instrument panel goes off. ■4WD Lever CAUTION: To avoid personal injury:  When traveling at higher speeds. Use only 2WD. When driving on icy, wet or loose surfaces, make sure the vehicle is correctly loaded 8-4 Operating the Vehicle ① Parking brake lever ② “RELEASE” ■Accelerator Pedal The Accelerator pedal is used to increase the engine and vehicle speed. Push down on it for higher speed. ① Coolant temperature gauge ② Fuel gauge ■Fuel Gauge Park the vehicle on a flat place. Turn the key switch to “On”, the fuel gauge will indicate the fuel level. Be careful not to fully empty the fuel tank. ① Accelerator pedal Otherwise air may enter the fuel system. STOPPING ■STOPPING 1. Release the Accelerator pedal 2. Step on the brake pedal. CHECKS DURING DRIVING ■Immediately Stop the Engine if：  The engine suddenly slows down or accelerates.  Unusual noises are suddenly heard.  Exhaust fumes suddenly become very Fuel gauge ■Coolant Temperature Gauge CAUTION: white. While driving, check the following items to see if To avoid personal injury: all parts are functioning normally.  Do not remove radiator cap until the coolant temperature is well below its boiling point. Then loosen cap slightly to relieve pressure before removing cap completely. 8-5 Operating the Vehicle 1. With the key switch “ON” the temperature gauge indicates the temperature of the coolant. White Zone for “cold” and Red zone for “hot”. 2. If the indicator reaches the Red zone, the engine coolant is overheated. Check the vehicle by referring to the “TROUBLESHOOTING” section. ① Hour meter The hour meter indicates in five digits the hours the vehicle has been used; the last digit indicates 1/10 of an hour. The speedometer indicates the traveling speed. ① Speedometer 8-6 Maintenance and Adjustment WINCH MOUNT PLATE Always read and follow the instructions in the winch owner’s manual before attempting to install or use a winch. ① Winch mount plate ■Transporting The Vehicle Pay attention to the following points when transporting the vehicle. 1. Use a suitable truck or trailer. Apply the parking brake and place chocks against the front and rear tires. 2. Tie the vehicle to the sides of the trailer or truck using suitable tie-downs. 9-1 Maintenance and Adjustment CAUTION: To avoid personal injury and vehicle damage:  Be sure you have sufficient knowledge, experience, the proper replacement parts and tools before you attempt any vehicle maintenance task.  If you don’t have the knowledge and equipment which are necessary to perform the maintenance task, consult your local dealer.  Have your local dealer perform inspection items which are marked *4 in the chart below. SERVICE INTERVALS IMPORTANT:  The jobs indicated by ◎ must be done after the first 50 hours of operation. *1 Air cleaner should be cleaned more often in dusty conditions than in normal conditions. *2 Every year or every 6 times of cleaning. *3 Replace only if necessary. *4 Consult your local dealer for this service. *5 When the battery is used for less than 100 hours per year, check the battery condition by reading the indicator annually.  The items listed below with a * mark are registered as emission related critical parts by the U.S.EPA. As the engine owner, you are responsible for the performance of the required maintenance on the engine according to the below instruction. Please see Warranty Statement for more information. Indication of No. Items 50 100 150 200 250 300 350 400 450 500 550 600 650 700 1 Engine oil Change ◎ ○ ○ ○ 2 Engine oil filter Replace ◎ ○ ○ ○ 3 4 Transmission fluid Engine start system Change ○ Check ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 5 Greasing Apply ○ ○ 6 *Muffler Clean ◎ ○ ○ ○ ○ ○ ○ ○ 7 Spark arrester Clean ○ ○ ○ ○ ○ ○ ○ 8 Wheel bolt torque Check ○ ○ ○ ○ ○ ○ ○ 9 Battery condition Check ○ ○ ○ ○ ○ ○ ○ 10 Ton-in Adjust ○ ○ ○ ○ ○ ○ ○ ◎ 9-2 After 700 hrs Every 200 hrs Every 200 hrs Every 400 hrs Every 50 hrs Every 50 hrs Every 100 hrs Every 100 hrs Every 100 hrs Every 100 hrs Every 100 hrs Maintenance and Adjustment Indication of No. Items 50 11 Fuel filter element Check ○ ○ ○ ○ Replace ○ ○ ○ ○ Check 12 100 150 200 250 300 350 400 450 500 550 600 650 700 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ *Fuel line Replace 13 14 15 16 17 *Air cleaner element Brake pedal Parking brake lever Brake light switch Radiator hose and clamp Clean Replace Check ◎ ○ ○ ○ Adjust ◎ ○ ○ ○ Check ◎ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ Check Replace Check 18 *Intake air line Replace 19 20 Brake hose & pipe Check Tire wear Check ◎ Check ◎ ○ Front axle case Change oil Front axle case Change 22 oil Engine valve Adjust 23 clearance *Fuel injection Check 25 *Injection Check 26 Brake fluid Change 27 28 Remote hydraulic hose Rear brake cylinder seal ○ Replace Front brake seal Replace 30 Cooling system Flush ○ ○ Replace 29 Every 100 hrs Every 100 hrs Every 500 hrs Every 100 hrs Every 1 years Every 100 hrs Every 1 years Every 200 hrs Every 200 hrs Every 200 hrs Every 2 years Every 200 hrs Every 1 years Every 200 hrs Every 4years 21 24 After 700 hrs 9-3 Every 300 hrs Every 400 hrs Every 400 hrs Every 800 hrs Every 1500 hrs Every 3900 hrs Every 2 years Every 2 years Every 2 years Every 2 years Every 2 years Maintenance and Adjustment Indication of No. Items 50 31 Coolant Change 32 Fuel system Bleed 33 Fuse Replace 34 Light bulb Replace 100 150 200 250 300 350 400 450 500 550 600 650 700 After 700 hrs Every 2 years Service as required NOTE: ◆ Engine Oil:（10W/40SL） Oil used in the engine should have an American Petroleum Institute (API) service classification and Proper SAE Engine Oil according to the ambient temperatures as shown above. ◆ Brake fluid: Always use DOT3 GENUINE BRAKE FLUID from a sealed container. 9-4 Periodic Service CAUTION: To avoid personal injury: HOW TO OPEN THE HOOD AND TILT THE SEAT CAUTION To avoid personal injury from contact with moving parts:  Never open operator’s seat while the ① seat engine is running. ■Hood pull open the hood. Seats To remove a seat, Remove bolts M6 with a socket wrench, and then remove the seat. Installation is the reverse of removal. ①switch 1. Driver seat To open the hood, turn the latch to release and ② Hood ① RELEASE ■Operator’s Seat To open the seat, raise the seat to the forward position. 1.Bolt(4×M6) 10-1 2.Passenger seat Periodic Service CAUTION: “vertical or upper” direction and hold. To install the seat, Adjust the four bolts M8evenly 2. Adjust the steering wheel up or down to to ensure the seat moves forward and backward normally. Improper installation can result in seat rail being blocked and the inability to move the seat The proper position. 3. Tighten the adjustment lever to secure the steering wheel in the desired position. back and forth. WARNING POTENTIAL HAZARD Aloose 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 mounted firmly. Cargo Bed Moving the Seat Forward and Backward. The seat can be moved forward and backward to fit the height of different drivers. Pull the handle up and move the seat forward and backward. 1. Cargo bed WARNING according to the driver’s height and driving POTENTIAL HAZARD Overloading the cargo bed. WHAT CAN HAPPEN Could cause changes in vehicle handling 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. habits。 Reduce speed when carrying cargo. Allow 1. Move steering wheel adjustment lever to greater distance for braking. 1. Seat handle Adjustment of The Steering Wheel： You can adjust the height of the steering wheel 10-2 Periodic Service Spring preload WARNING 1. Loosen the locknut. POTENTIAL HAZARD Carrying a passenger in the cargo bed. WHAT CAN HAPPEN The passenger could fall, be thrown out, or be struck by objects in the cargo bed. HOW TO AVOID THE HAZARD Never carry a passenger in the cargo bed. This cargo bed is designed to carry cargo only. 2. Turn the spring preload adjusting nut in direction ⓐ to increase the spring preload and thereby harden the suspension, and in direction ⓑ to decrease the spring preload and 3. thereby soften the suspension. Front and Rear Shock Adjustment WARNING These shock absorber assemblies contain highly pressurized nitrogen gas, read and understand the following information before handling the shock absorber assemblies. · Do not tamper with or attempt to open the cylinder assemblies. ·Do not subject the shock absorber assemblies to an open flame or other high heat source. This may cause the unit to explode due to excessive gas pressure. ·Do not deform or damage the cylinders in any way. Cylinder damage will result in poor damping performance. · Do not dispose of a damaged or worn out shock absorber assembly yourself. Take the shock absorber assembly to a HSUN dealer for any service. The spring preload, rebound damping and compression damping forces of the front and rear shock absorber assemblies can be adjusted to suit the operating conditions. NOTE: Never turn an adjusting mechanism beyond the minimum and maximum settings. 10-3 1. Locknut 2. Spring preload adjusting nut 3. Special wrench ·A special wrench can be obtained at a dealer to make this adjustment. ·The spring preload setting is determined by measuring distance A, shown in the illustration. The shorter distance A is, the lower the spring preload; the longer distance A is, the higher the spring preload with each complete turn of the adjusting nut. Periodic Service Spring Preload Setting(Front) Minimum(soft): 332mm(13.07 in) Maximum(hard): 442mm(17.40in) Spring travel setting(Rear) Minimum(soft): 402mm(15.83in) Maximum(hard): 502mm(19.76 in) 1.Compression damping force adjusting screw NOTE: Always tighten the locknut against the adjusting nut, and then tighten it to the specified torque. WARNING ·Suspension components operation. hot touch the Rebound damping force during Turn the rebound damping force adjusting screw in compression damping force adjusting screw, direction S to increase the rebound damping force the rebound damping force adjusting screw and thereby harden the damping, and in direction F or the oil reservoir with your bare hand or to decrease the rebound damping force and skin thereby soften the damping. cooled. until ·Always Never become suspension components adjust the shock have absorber assemblies on the left and right side to the same setting. Uneven adjustment can cause poor handling and loss of stability, which could lead to an accident. 1. Rebound damping force adjusting screw Compression damping force Turn the compression damping force adjusting screw (use 3.0 Allen wrench) in direction ⓐ to increase the compression damping force and thereby harden the damping, and in direction ⓑ to decrease the compression damping force and thereby soften the damping. 10-4 Periodic Service PRE-OPERATION CHECK JACK STAND POINT For your own safety and maximum service life WARNING of To avoid personal injury, death or vehicle damage:  Do not work under the vehicle unless it is secured by safe stands or the vehicle, make a thorough daily inspection before starting the engine or operating the vehicle. suitable CAUTION blocking. To avoid personal injury: ■Front End  Jack up the front end at the front bumper only. Be sure to check and service the vehicle on a flat surface with the engine off and the parking brake “ON”. ■Visual Inspection Look around and under the vehicle for such items as loose bolts, trash build-up, oil or coolant leaks, broken or worn parts ■Checking and Refueling CAUTION ① Jack To avoid personal injury: ② Front bumper ■Rear End  Do not smoke while refueling.  Be sure to stop the engine before refueling. Jack the rear only after placing a wooden block under the right and left frames tubes for securing 1. Turn the key switch to “ON”, check the amount of fuel by the fuel gauge. the engine and then supporting it. Do not apply jack pressure on the steel plate 2. Fill fuel tank when fuel gauge shows1/4 or less fuel in the tank. directly under the engine. ①Fuel cap ① Jack 10-5 Periodic Service the “FULL” and” LOW” marks of recovery Fuel tank capacity 28L（7.39 U.S.GALS.） tank. 3. evaporation, add coolant only up to the IMPORTANT full level. If oil level is low, do not run the engine. In case of leakage add anti- freeze and water in the specified mixing Checking engine oil level 1. When the coolant level drops due to ratio up to the full level.(see flush cooling Park the vehicle on a flat surface, raise the system and changing coolant in EVERY 2 cargo bed, apply the parking brake, and shut YEARS in PERIODIC SERVICE section) off engine. 2. To check the oil level, draw out the dipstick, wipe it clean, replace it, and draw it out again, check to see if the level is too low, add new oil to the prescribed level on the dipstick. 1. Recovery tank 2. FULL 3. LOW IMPORTANT  ①~② Oil level is acceptable within this range ① follow the cautions above and securely Low Oil Level③Oil indicator retighten the cap. ④ Dipstick  ■Checking Coolant Level  Do not remove radiator cap while coolant ■Cleaning radiator screen is hot. When cool, slowly rotate to the first CAUTION stop and allow sufficient time for excess TO avoid personal injury: pressure to escape before removing the  cap completely. 2. If water should leak, consult your local Dealer. TO avoid personal injury 1. Use clean fresh water and anti-freeze to fill the recovery tank. CAUTION  If the radiator cap has to be removed, Be sure to stop the engine before removing the screen Park the vehicle on a flat surface, access the 1. Park the vehicle on a flat surface, panel under the hood, set the parking brake, 2. Remove the radiator cover, and shut off the engine. 3. Detach the screen and remove all foreign Check to see that the coolant level is between 10-6 Periodic Service materials, 1. Park the vehicle on a level ground and open the hood. 2. Check to see that the brake fluid level is up to the LOWER mark. 3. If it is below the “LOWER” mark add brake fluid . ① Radiator screen ② DETACH IMPORTANT  Radiator screen must be cleaned from debris to prevent engine from overheating ■Checking brake fluid level ① Upper Level CAUTION ② LOWER Level ■Checking brake pedal TO avoid personal injury:   is below the minimum mark. TO avoid personal injury: Use only DOT3 from a sealed container.  Other types of brake fluid may ruin  Stop the engine and chock the wheels before checking brake pedal. synthetic resin or rubber installed in brake 1. Inspect the brake pedal for free play and system components and may cause brake smooth operation. failure. Adjust if incorrect free play is found. (see Avoid contamination of the brake fluid checking brake pedal in” EVERY 200 HOURS thoroughly clean before removing the filler in PERIODIC SERVICE cap. Do not open the brake fluid reservoir cap unless absolutely necessary.  CAUTION Never operate the vehicle if the brake fluid Use extreme care when filling the reservoir. If brake fluid spills on the power steering hose, wash it off with water immediately, as brake fluid quickly ruins synthetic resin or rubber hoses. 10-7 section) Periodic Service ① Brake pedal ■Checking seat belt and ROPS ② FREE TRAVEL ■Checking parking brake 3. Always check condition of seat belt and Pull the parking brake lever to apply the brakes ROPS with the key switch in the"ON" position and the operating vehicle. parking brake indicator should come on. 4. attaching hardware before Replace if damaged. To release the brake, push in the button on the tip of the parking brake lever and tilt the lever down. ■Checking CV boot NOTE 1. Make sure the parking brake warning lamp on the display goes off when parking brake lever is down. Check to see if the joint boots are damaged or not. 2. If the boots are cut, gashed or show signs of deterioration, consult your local dealer. ① Parking brake lever ② Release button ① CV Joint boot ② Axle ③ RELEASE④ PULL ■Checking gauges meter and warning lamps 1. Inspect the instrument panel for broken gauges meter and warning lamps. 2. Replace if broken. ■Checking head lights, turn signal lights etc 1. Inspect lights for broken bulbs and lenses ① CV Joint boot ② Drive shaft 2. Replace if broken ■Checking tire inflation pressure Though the tire pressure is factory-set to the ■Checking seat belt and ROPS prescribed level, it naturally drops slowly in the 1. Always check condition of seat belt and ROPS course of time, thus check it everyday and attaching hardware before operating vehicle. inflate as necessary. 2. Replace if damaged. 10-8 Periodic Service tire sizes inflation pressure Front : 27x9-14 140kPa (1.4kgf/cm2, 20psi) Rear:27x11-14 140kPa (1.4kgf/cm2, 20psi) EVERY 50 HOURS ■Greasing Apply a small amount of multi-purpose grease to the following points every 50 hours. If you operated the vehicle in extremely wet and muddy ① Gear shift lever pivot (spray type grease ) conditions lubricate grease fittings more often. ■Checking engine start system CAUTION TO avoid personal injury  Do not allow anyone near the vehicle while testing.  If the vehicle does not pass the test, do not operate the vehicle. ◆Preparation before testing ① Parking brake pivot (spray type grease ) 1. Place gear shift in the “NEUTRAL” position. 2. Set the parking brake and stop the engine. ◆Test gear shift lever safety switch 1. Sit on the operator’s seat. 2. Shift the gear shiftlever to: “L”, “H”, “N” or REVERSE position. 3. Turn the key to “START” position. 4. The engine must not crank. 5. If it cranks consult your local dealer for this service. 10-9 Periodic Service ① Range gear shift lever Torque Lug Nuts to 75to 90 N.m ■Cleaning air cleaner primary element 1. Remove the air cleaner cover and primary element. Clean the primary elements. When dry dust adheres to the element blow compressed air from the inside turning the element. Pressure from compressed air must be under 205kpa. When carbon or oil adheres to the element ①Accelerator pedal ② Free Travel soak the element in detergent for 15 minutes then wash it several times in water rinse with ■Checking wheel bolt torque clean water and dry it naturally. After element is fully dried inspect inside of the element with CAUTION a light and check for damage. Replace the To avoid personal injury  Never operate vehicle with a loose Lug nuts.  Every time the Lug nuts are loosened they should be retightened to the specified torque.  Check all Lug Nuts frequently and keep them tight. Check Lug nuts regularly especially when new. If they are loose tighten them as follows: 10-10 primary element once yearly or after every sixth cleaning, whichever comes first. Periodic Service ① First air cleaner ② Secondary air cleaner ③ Primary element 2. ④ Cover 3. IMPORTANT  The air cleaner uses a dry element never apply oil.  Do not run the engine with filter element removed.  regardless of service period. 4. improperly fitted the evacuator valve will not function and dust will adhere to the element. If the fuel line and clamps are found to be damaged or deteriorated replace them. 5. Check fuel filter if it is clogged by debris or contaminated with water replace it. Be sure to refit the cover with the arrow (on the rear of cover) upright. If the cover is The fuel line is made of rubber and ages IMPORTANT When the fuel line is disconnected for maintenance or repair, close both ends of the fuel line with a piece of clean cloth or paper to ◆Evacuator Valve Open the air cleaner cover once a week under ordinary conditions –or daily when used in a dusty conditions-and remove large particles of dust and dirt. prevent dust and dirt from entering.In addition, particular care must be taken not to allow dust and dirt into the fuel pump entrance.Even a small amount of dust or dirt will cause premature wear and malfunction of the fuel pump and injector components. ◆Check fuel line and fuel filter. CAUTION To avoid personal injury:  Be sure to stop the engine and remove the key when attempting to make the following checks and changes.  Check the fuel lines periodically. The fuel lines are subject to wear and aging fuel may leak out onto the running engine causing a fire.  The fuel line connections should be ① Pipe clamp ② Fuel line ③ Fuel pump ■Checking the battery checked annually or every 100service CAUTION hours whichever comes first. 1. Park the vehicle on a flat surface and raise the To avoid personal injury  cargo bed. Never remove the battery while the engine is running. 10-11 Periodic Service   Keep electrolyte away from eyes, hands 1. To slowly charge the battery, connect the and clothes. If spattered with it, wash it battery positive terminal to the chargers away completely with water immediately positive terminal and the negative to the and get medical attention. negative terminal. Then recharge the Wear eye protection and rubber gloves battery following the instructions on the battery charger. when working around the battery. The factory –installed battery is a non-refillable type.If the battery is weak, charge the battery. If the battery will not take a charge replace the 2. A boost charge from another vehicle or power source is only for emergencies. 3. When exchanging an old battery for a new one use battery of equal specification battery with a new one. shown in table 1. ◆Battery charging 4. CAUTION Battery type Volts To avoid personal injury 12V32Ah 12  When the battery is activated with hydrogen and oxygen gases which can be extremely explosive, keep open sparks and ◆Direction for storage 1. remove the battery from the vehicle,store flames away from the battery at all times, especially when charging the battery.  When disconnecting the cable from the in a dry place out of direct sunlight. 2. The battery will self-discharge while it is stored. Recharge it once every three battery start with the negative terminal months in hot seasons and once every six first; when connecting the cable to the months in cold seasons. battery, start with the positive terminal first.  When storing the vehicle for a long period, Always check battery charge by using a ■Adjusting toe-in voltmeter. Proper toe-in 0 to12 mm (0 to 0.47 in) 1. Park vehicle on flat surface. 2. Turn steering wheel so front wheels are in the straight ahead position. 3. Lock the park brake and stop the engine. 4. Measure distance between tire beads at rear of tire at hub height. 5. ① Battery Front distance should be shorter than rear distance if not adjust tie rod length. 10-12 Periodic Service 5. Return the spark arrester to the muffler body and refasten the bolts. IMPORTANT:  Visually check the muffler for cracks or holes in the body, welds or pipes at regular intervals.  ■Cleaning Muffler between approval spark requires arrester clearance sleeve and exhaust pipe to be no larger than CAUTION 0.023”(0.584 mm). To avoid personal injury:  USDA Before touching any part of an exhaust  Replace the entire muffler if it is damaged.  Do not operate the vehicle with a system, be absolutely sure that it has damaged muffler. sufficient time to cool!  Always wear safety goggles and facemask.  The particulate matter contained in the muffler contains chemicals that are harmful to people, animals and marine life.  If you are unable to do this work, have it done by your dealer.  Cleaning spark arrester of muffler. ① Muffler ② Spark arrester ③ Muffler cover Maintenance & cleanout procedure: The screen type spark arrester should be removed, cleaned, and inspected after every 100 hours EVERY 200 HOURS ■Changing Engine Oil of use. 1. To avoid personal injury: exhaust pipe, and fastened with six bolts. 2. CAUTION The spark arrester is located inside of the Loosen the bolts and remove the spark  replacing oil. arrester. 3. Shake loosened particles out of the screen  wire brush. Soak in solvent and again clean Allow engine to cool down sufficiently, oil can be hot and can burn. assembly and lightly clean the screen with 1. Park the vehicle on flat surface and raise the cargo bed. with wire brush if necessary. 4. Be sure to stop the engine before 2. If any breaks in the screen or welds are discovered, the assembly must be replaced. 10-13 To drain the used oil, remove the drain plug at the bottom of the engine and Periodic Service completely drain the oil into an oil pan. dipstick. Make sure that the engine oil 3. After draining, reinstall the drain plug. does not leak through the seal and check 4. Fill with the new oil up to the upper notch on the oil level on the dipstick after running the dipstick. the engine and allowing it to cool. Then (See “LUBRICANTS, FUEL AND COOLANT” in replenish “MAINTENANCE” section.) prescribed level. Oil Filter Replaced the engine oil up to the 1.8L (1.89U.S. qts.) Oil capacity Oil Filter Not Replaced 1.6L (1.68U.S. qts.) ① Bolt; ② Cover ③ “O” seal ring; ④ Engine oil filter IMPORANT:  ①~② Oil level is acceptable within this range use only a genuine filter. ③ Dipstick④ Oil inlet ■Replacing Engine Oil ■Replacing Engine Oil Filter CAUTION CAUTION To avoid personal injury: To avoid personal injury:  Be sure to stop the engine before changing the oil filter.  Allow engine to cool down sufficiently, oil can be hot and can cause severe burns. 1. Park the vehicle on a flat surface and raise the  Be sure to stop the engine before changing oil.  Allow engine to cool down sufficiently, oil can be hot and can burn. 1. Park the vehicle on a flat surface, raise the cargo bed, and apply the parking cargo bed. brake. 2. Remove the oil filter. 3. Put a film of clean engine oil on the rubber seal of the new filter. 4. To prevent serious damage to the engine, After the new filter has been replaced, the engine oil normally reads lower on the 10-14 2. Remove the oil filter / oil drain plug and drain all of the old oil. 3. Put a film of clean oil onto the seal of the new filter. Reinstall the oil filter cover. Periodic Service Reinstall the drain plug. 3. If brake pedal free travel is outside of the 4. Add the prescribed amount of oil to the engine specifications, contact your local dealer for 5. After running the engine for a few minutes, adjusting the brake. stop the engine and check the oil level again. ◆ Checking the brake pedal stroke Add oil to the prescribed level. Oil capacity [Filter exchanged] 1L (1.05U.S. qts.) Pedal stroke Less than 120mm(4.7in.) On the pedal 1. Release the parking brake. 2. Step on the pedal and measure the pedal stroke. If brake pedal stroke is outside of the specifications, contact your local dealer for adjusting the brake. ①~② Oil level is acceptable within this range ③ Dipstick④ dipstick location Checking Brake Pedal CAUTION  Stop the engine and chock the wheels before ① Brake pedal checking brake pedal.  ② “FREE TRAVEL”③ “PEDAL STROKE” If the free travel is outside of the specifications contact your local dealer for adjusting the ■Checking Brake Hoses and Lines brake. 1. ◆Checking the brake pedal free travel Proper brake pedal free travel Check to see that brake hoses and Lines are not swollen, hardened or cracked. 2. 7 to 14mm (0.3 to 0.6 in.)On the pedal Check the brake hose and brake line joints for brake fluid leaks. 3. If there is any abnormality, consult your local dealer for this service. 1. Release the parking brake. 2. Slightly depress the brake pedal and measure free travel at the top of the pedal stroke. ■Checking Brake Light Switch 1. Park the vehicle on a flat surface and raise the cargo bed. 10-15 Periodic Service 2. Turn the key switch to the “ON” position. after about 5 minutes after unloaded 3. Step on the brake pedal to check if the brake idling. 3. light comes on. 4. Keep yourself well away from the vehicle If it does not, check the bulb or brake light for at least 10 minutes or while the steam switch. is blowing out. 4. Check to see if there is no longer any ■Checking Radiator Hose and Clamp danger such as steam or hot radiator fluid, Park the vehicle on a flat surface and raise the get rid of the causes of overheating cargo bed. Check to see if radiator hoses are according to the “TROUBLESHOOTING” properly connected every 200 hours of operation or section in this manual, and then start the six months, whichever comes first. engine again. 1. 2. If hose clamps are loose or water leaks, tighten bands securely. ■Checking Intake Air Line Replace hoses and tighten hose clamps 1. securely, if radiator hoses are swollen, hardened or cracked. Replace hoses and Check to see if the hoses and hose clamps are tight and not damaged. 2. If hoses and clamps are found to be worn hose clamps every 2 years or earlier, if or damaged, replace or repair them at checked and found that hoses are swollen, once. hardened or cracked. ① Radiator hose② Clamp bands ① Hose② Hose clamp ◆Precaution at Overheating EVERY 300 HOURS Take the following actions in the event the coolant ■Checking Tires temperature is, close to, or more than the boiling 1. Check to see if tires are not damaged. point, which is called “Overheating”. 2. If the tires are cracked, bulged, or cut, or 1. 2. Stop the vehicle operation in a safe place and they are worn out, replace or repair them keep the engine unloaded idling. at once. Don’t stop the engine suddenly, but stop it 10-16 Periodic Service ◆Tire Tread Depth Always replace the tires when the tread depth is worn to minimum allowable. ① Drain plug ① 3mm(0.12in) IMPORTANT:  EVERY 400 HOURS after changing the transmission fluid. ■Changing Transmission Fluid  damage to the cargo bed, and apply the parking brake. ■Changing Front and Rear Axle Case Oil Allow engine to cool down sufficiently, oil 1. Park the vehicle on a firm, flat and level surface. 2. To drain the used oil, remove the drain the oil completely into the oil pan. Park the vehicle on a flat surface, raise the 3. cargo bed, and apply the parking brake. 2. prevent Park the vehicle on a flat surface, raise the can be hot and can cause severe burns. 1. to transmission. To avoid personal injury:  Run the engine at medium speed for a few minutes CAUTION  Do not operate the vehicle immediately Fill with the new oil up to the upper notch To drain the used oil, remove the drain plug at on the dipstick. the bottom of the transmission case and drain (See the oil completely into the oil pan. COOLANT” in “MAINTENANCE” section.) 4. 3. After draining, reinstall the drain plug. 4. After running the engine for a few minutes, stop the engine and check the oil level again; add oil to prescribed level. 10-17 “LUBRICANTS, FUEL AND After filling, reinstall the filling plug. Oil capacity 0.6L（0.6U.S.gals.） Periodic Service CAUTION To avoid personal injury:  Do not remove the radiator cap while coolant is hot. When cool, slowly rotate cap to the first stop and allow sufficient time for excess pressure to escape before removing the cap completely. ① Drain plug 1. Stop the engine and let cool down. 2. To drain the coolant, open the radiator drain plug and remove radiator cap. The radiator EVERY 500 HOURS cap must be removed to completely drain ■Replacing Fuel Filter the coolant. 3. Consult your local dealer for this service. After all coolant is drained, close the drain plug. EVERY 600 HOURS 4. ■Adjusting Engine Valve Clearance Fill with clean water and cooling system cleaner. Consult your local dealer for this service. 5. EVERY 1500 HOURS Follow directions on the cooling system cleaner container. ■Checking Injection and Fuel Pump 6. After flushing, fill with clean water and anti- Consult your local dealer for this service. freeze until the coolant level is just below the EVERY 1 YEAR radiator cap. ■Replacing Air Cleaner Primary Element and Secondary Element (See “Cleaning Air Cleaner Primary Element” in “every 100 HOURS” in “PERIODIC SERVICE” section.) Install the radiator cap securely. 7. on the recovery tank. 8. Start and operate the engine for few minutes. 9. EVERY 2 YEARS Fill with fresh water up to the “FULL” mark Stop the engine and let cool. 10. Check coolant level of recovery tank and ■Changing Brake Fluid add coolant if necessary. Consult your local Dealer for this service. (See “Checking Brake Fluid Level” in “DAILY CHECK” in “PERIODIC SERVICE” section. ■ Flushing Cooling System and Changing Coolant 10-18 Coolant capacity 4.0L(4.2U.S.qts.) Periodic Service  Antifreeze is extremely flammable and explosive under certain conditions. Keep fire and children away from antifreeze.  When draining fluids from the engine, place a container underneath the engine body.  Do not pour used coolant onto the ground, down a drain, or into any water source.  ① Recovery tank②“FULL” Also, observe all environmental protection regulations when disposing of antifreeze. ③“ LOW”④Radiator cap If it freezes, coolant can damage the cylinders and radiator. If the ambient temperature falls IMPORTANT: below 0℃(32°F) or before a long-term storage,  Do not start the engine without coolant.  Use clean, fresh water and anti-freeze to fill let out cooling water completely, or mix fresh the radiator and recovery tank.  water with long-life coolant and fill the radiator and recovery tank with the mixture.· When the anti-freeze is mixed with water, 1. the antifreeze mixing ratio must be less than several types. Use ethylene glycol(EG) type 50%.  Long-life coolant (hereafter LLC) comes in for this engine. Securely tighten radiator cap. If the cap is 2. loose or improperly fitted, water may leak Before using LLC-mixed cooling water, fill the radiator with fresh water and empty it out and the engine could overheat. again. Repeat this procedure 2 or 3 times to clean ■Anti-Freeze up the inside. CAUTION To avoid personal injury:  When using antifreeze, put on 3. Mixing the LLC 4. The procedure for the mixing of water and antifreeze differs according to the make of some the antifreeze and the ambient temperature. protection such as rubber gloves. If you Refer to SEA J1034 standard and SAE ingest antifreeze, follow the emergency J814c. instructions on the antifreeze container and seek medical attention.  When antifreeze comes in contact with the skin or clothing, wash it off immediately.。  IMPORTANT: When the antifreeze is mixed with water, the antifreeze mixing ratio must be less than Do not mix different types of Antifreeze. The mixture can produce a chemical reaction causing harmful substances. 10-19 50%. Periodic Service add water only to keep the antifreeze mixing Freezing point VOL% Anti-freeze ℃ 40 50 ° ratio less than 50%. In case of leakage, add Boiling point ° F ℃ -24 -12 106 222 -37 -34 108 226 antifreeze and water in the specified mixing F ratio before filling into the radiator. ■Replacing Radiator Hose *At 1.013×105Pa(760mmHg) pressure (atmospheric). A higher boiling point is obtained by using a radiator pressure cap which permits the development of pressure within the cooling system. Add only water if the mixture reduces in any amount by evaporation. 2) If the mixture is weak, add the LLC of the same manufacturer and type in the same mixture percentage. *Never add any long-life coolant of different manufacturer.(Different brands may have different additive components, and the engine may fail to perform as specified.) 3. When the LLC is mixed, do not employ any radiator cleaning agents. The LLC contains an anticorrosive agent. If mixed with the cleaning agent, sludge may build up, adversely affecting the engine parts. 4. The vehicle’s genuine long-life coolant has a service life of 2 years. Be sure to change the coolant every 2 years. NOTE:  The above data represents (See “Checking Radiator Hose and Clamp” in “EVERY 200 HOURS” in “PERIODIC SERVICE” section.) ■Replacing Fuel Hose Adding the LLC 1) Replace the hoses and clamps. industry standards that necessitate minimum glycol content in the concentrated antifreeze. When the coolant level drops due to evaporation, Consult your local Dealer for this service. ■ Replacing Brake Master Cylinder (Inner parts) Consult your local dealer for this service. ■Replacing Front Brake Seal Consult your local dealer for this service. ■Replacing Rear Brake Cylinder Seal Consult your local dealer for this service. ■Replacing Intake Air Line Consult your local dealer for this service. EVERY 4 YEARS ■Replacing Brake Hose Consult your local Dealer for this service. ■Replacing Mini Blade Fuses The mini-blade fuses are intended to protect the electrical components. If any of them have blown out, be sure to pinpoint the cause. 10-20 Periodic Service STORAGE ◆Replacing procedure 1) Disconnect the negative cable of the battery. 2) Open the mini-blade fuse box cover. 3) Pull out the mini-blade fuse. To avoid personal injury: 4) Insert a new mini-blade fuse into the mini-  CAUTION Do not clean the vehicle when the engine is running. blade fuse box. 5) Close the mini-blade fuse box cover. 6) Connect the negative battery cable.  To avoid the danger of exhaust fume poisoning, do not operate the engine in a closed building without proper ventilation.  When storing, remove the key from the key switch to avoid unauthorized persons from operating the vehicle and getting injured. VEHICLE STORAGE If you intend to store your vehicle for an extended period of time, follow the procedures outlined below. ① Mini-blade fuse box cover These procedures will insure that the vehicle is ready to operate with minimum preparation when ■Replacing Light Bulb  Head lights it is removed from storage. Take the bulb out of the light body and 1. tighten if necessary. replace it with a new one.  2. Other lights Check the bolts and nuts for looseness,and Apply grease to vehicle areas where bare metal exist and to pivot areas. Detach the lens and replace the bulb 3. Unload the cargo bed. 4. Inflate the tires to a pressure a little higher Light Capacity Head lights 2x35W Tail light 2x5W Brake light 2x21W circulate oil throughout the engine block and Instrument panel light 2W internal moving parts for about 5 minutes. than usual. 5. Change the engine oil and run the engine to With all implements lowered to the ground, coat any exposed rods with grease(if equipped). 10-21 Periodic Service 6. Remove the battery from the vehicle. Store procedures. REMOVING THE VEHICLE FROM STORAGE Keep the vehicle in a dry place where the 1. the battery following the battery storage 7. tires if they are low. vehicle is sheltered from the elements. 2. Cover the vehicle. 8. Check the tire air pressure and inflate the Before installing the battery, be sure it is fully charged. Keep the vehicle indoors in a dry area that is protected from sunlight and excessive heat. 3. Check to see if the fan works. If the vehicle must be stored outdoors, cover 4. Check all fluid levels(engine oil,transmission oil,engine coolant, transmission coolant and it with a waterproof tarpaulin. Put boards under the tires to keep dampness away from tires. any attached implements). 5. Start the engine. Observe all gauges. If all Keep the tries out of direct sunlight and gauges are functioning properly and reading extreme heat. normal, move the vehicle outside. Once outside, park the vehicle and let the engine IMPORTANT:  idle for at least five minutes. Shut the engine When washing the vehicle, be sure to stop off and work around vehicle and make a the engine. visual inspection looking for evidence of oil Allow sufficient time for the engine to cool or water leaks. 6).With the engine fully warm up,release the before washing.  Do not wash with high-pressure equipment. parking brake and test the brakes for proper  Cover the vehicle after the muffler and the adjustment as you move forward. Adjust the engine have cooled down. brake as necessary. 10-22 Electric Power Steering System INTRODUCTION pollution to the environment. However, Our UTV is equipped with Electric Power EPS system does not cause pollution to the Steering System (EPS). To keep reliability of environment. EPS during operation, please correctly use 5) If the engine does not start, the EPS system EPS system according to the following can also work off the battery, and once descriptions and keep up with daily inspections sufficient power is generated, the power and maintenance. steering system is function able. This chapter also provides important you encounter any problems during operation or IMPORTANT INFORMATION FOR SAFETY: maintenance, please consult your local dealer. This UTV is equipped with EPS system, please information to safely use the EPS system. If ADVANTAGES OF EPS SYSTEM: read this chapter carefully before operating the 1) High efficiency. Traditional hydraulic power UTV, and only when you are familiar with and steering systems are connected by master the EPS system methods and mechanical and hydraulic systems and are of precautions. Make inspections of the EPS low efficiencies; usually 60%-70%. However, system at regular intervals to ensure the security EPS system is connected by a mechanical and reliability of your UTV. and electric motor and it has a much higher  efficiency of up to 90%. Please carefully read this chapter before 2) EPS system starts the motor only when it operating or driving and understand the needs to generate power without increasing correct ways to operate and drive the UTV fuel consumption. with the EPS system, and also 3) The power of EPS system is controlled by characteristics, functions and limits of UTV. software, so that the UTV can be operated Do inspections and maintenance on the with power steering at various speeds. 4) EPS system, uses a rigid connection system, EPS system at regular intervals. Correct operation and driving skills will ensure the so the impact of road conditions on steering wheel is greatly decreased. No pollution to security and reliability of UTV.  environment. For the To make sure your EPS system will be useful for a long time please follow the traditional hydraulic power steering system, methods for maintenance in this chapter. the hydraulic circuit has hydraulic hose and fittings inside the system so oil leaks may occur, and hydraulic hoses are recyclable. This system type can produce not  Typical parts of the EPS system In general, EPS system has the following parts: 11-1  Steering torque sensor  Motor to generate power torque Electric Power Steering System  EPS system control unit (ECU）。 and monitors working condition of the EPS  Speed sensor。 system.  Temperature sensor Faults can be displayed by a fault indicator light  Battery voltage sensor and fault indicator of EPS system, so the driver  Mechanical reduction transmission can acknowledge faults of the EPS in time and mechanism(Reducer) take some measures to keep himself/herself  Gear/rack type steering gear safe.  Steering rod joint When a fault occurs on the EPS system, a fault  Ball stud of steering knuckle indicator light will be on. At the same time, the  Steering shaft and universal joint fault indicator of EPS system will display the fault code for maintenance. ■ Construction of EPS 1. Structure chart of EPS ① Fault indicator light of EPS system Fault code diagram ① Steering Wheel ② Reducer ③ Motor ④ Steering transmission shaft ⑤ Universal Joint ⑥ Tie Rod Joint ⑦ Tie Rod ⑧ Steering Knuckle ⑨ Steering Gear The Meter is an important part of the UTV. The Meter works together with the EPS system 11-2 No. Fault code 1 F00001 2 F00002 3 F00006 4 F00005 5 F00003 6 F00011 7 F00010 ECU non-working Fault style 1#fault of steering torque sensor 2#fault of steering torque sensor ECU overheating low voltage battery alarm Dynamic motor without power alarm Fault of speed sensor Fault indicator light of EPS system lit lit lit lit lit lit lit Troubleshooting ENGINE TROUBLESHOOTING If something is wrong with the engine, refer to the table below for the cause and its corrective countermeasure. Trouble Cause    Countermeasure Check the fuel tank and fuel filter。 Check the electric fuel pump. Check the injector. Check the ECU with Motor Scan KF90121. Replace filter electric fuel pump injector and ECU If necessary. Check to see if the fuel tank cover is tight. Use oils of different viscosities, depending on ambient temperatures. Clean battery cables and terminals. Charge the battery. In cold weather (-15℃), always remove the battery from the vehicle, charge and store it indoors. install it on the vehicle only when the vehicle is going to be used。 Check the fuel system. Clean or replace the injector. Replace crankshaft position sensor.    Clean or replace the air cleaner. Clean or replace the spark plug. Replace the ignition coil.     Shift to lower gear or reduce load. Fill cooling system to the correct level; Check radiator and hoses for loose connections or leaks. Check to see if the fuse is not blown. Check the electric system.  Remove all trash.  Flush cooling system.      No fuel flow  ·Water is in the fuel system Engine is difficult to start or cannot start.   Engine power insufficient is  Insufficient fuel. The injector is clogged. Crankshaft position sensor is Spoiled. The air cleaner is clogged. Spark plug is dirty or spoiled. Ignition coil is spoiled. Check with the diagnostic instrument (Motor Scan KF90121 ). Engine overloaded  Low coolant level.  The motor driven fan does not turn. Dirty radiator core or grille screens. Coolant flow route corroded.        Engine stops suddenly Engine overheats In winter, oil viscosity increases, and Engine revolution is slow. Battery becomes weak and the engine does not turn over quick enough.   If you have any questions, consult your local dealer. 12-1       Troubleshooting Check malf code meaning by reading the below table. Mt05 ECU Malf Code Table:23 Malf code in MT05 Description P0107 MAP Circuit Low Voltage or Open P0108 MAP Circuit High Voltage P0112 IAT Circuit Low Voltage P0113 IAT Circuit High Voltage or Open P0117 Coolant/Oil Temperature Sensor Circuit Low Voltage P0118 Coolant/Oil Temperature Sensor Circuit High Voltage or Open P0122 TPS Circuit Low Voltage or Open P0123 TPS Circuit High Voltage P0131 O2A Circuit Low Voltage P0132 O2A Circuit High Voltage P0031 O2A Heater Circuit High Voltage P0032 O2A Heater Circuit Low Voltage P0201 Injector 1 Circuit Malfunction P0202 Injector 2 Circuit Malfunction P0230 FPR Coil Circuit Low Voltage or Open P0232 FPR Coil Circuit High Voltage P0336 CKP Sensor Noisy Signal P0337 CKP Sensor No Signal P0351 Cylinder 1 Ignition Coil Malfunction P0352 Cylinder 2 Ignition Coil Malfunction P0505 Idle Speed Control Error P0562 System Voltage Low P0563 System Voltage High P0650 MIL Circuit Malfunction P1693 Tachometer Circuit Low Voltage P1694 Tachometer Circuit High Voltage If you have any questions, consult your local dealer. 12-2 Troubleshooting BATTERY TROUBLESHOOTING Trouble Cause  Countermeasure Battery overused until lights are dim.  Preventive measure Battery has  Charge the battery  sufficiently. not Charge the battery properly. been recharged. Starter does not function  Poor terminal  and connection From beginning starter does not function, and Battery life expired  Insufficient  When viewed from the with an insufficient top amount plates, look * Refillable type battery   only of Battery was used with too  new Charge battery  much  Battery life expired. Charge the  battery   corroded and heat up. Poor terminal  connection Regularly check the Charge battery Replace battery. Keep the terminal Clean the terminal clean and tight. and Apply grease and treat with anti- tighten securely. corrosives. Battery electrolyte level  * Refillable type battery only There is a crack or pin holes in the drops rapidly.  Replace battery.  Consult your local electrolytic cells.  Charging system trouble. dealer.  If you have any questions, consult your local dealer.  The factory installed battery is non-refillable type. 12-3 properly properly  Terminals are severely be electrolyte level. Insufficiently  must before initial use Add distilled water charge Battery serviced battery. without recharging. Recharging is impossible. Apply grease and treat with anti-corrosive. Replace and electrolyte. whitish. clean and tight. Insufficiently Battery was used Keep the terminal battery charging  of   tighten securely.  lights soon become dim Clean the terminal Troubleshooting MACHINE TROUBLESHOOTING Trouble Cause  High idling speed of engine  High rotary speed for clutch connection.  Non good adjust for gearshift stay wire. Non agility for Gearshift  Gear abrasion Clarence for the inner and outside gears of transmission are not matching properly Too much clearance in the transmission gears. Gears are not connecting well  Parking brake  Hydraulic brake calipers will not release   Transmission noise  Less vehicle power No good brake or noise    Countermeasure Replace throttle cable; Replace throttle petal Replace the throttle Replace he junior clutch spring; Replace the primary clutch. Put the gearshift rod into the position of “N”. Put the gearshift arm of engine into ”N”. Adjust the stay wire and the bolt. Lock tightly. Replace the gears  Replace the gears  Replace the gears   Replace the gears Adjust the parking brake rod and any cables  Contact the distributor.        Removing the grease for the clutch. Replace CVT transmission belt Replace the clutch.  Check the braking oil level  Contact the dealer.  Contact the dealer   CVT is not engaging properly     Low hydraulic brake fluid Air inside the braking system. Brake discs abrasion Assembling bolt of disc plate loose Assembling bolt for disc brake calipers are loose  If you have any questions, consult your local dealer. 12-4  Lock tightly  Lock tightly OPTIONS Consult your local dealer for further details. 1. Roof； 2. Windshield； 3. Windlass ; 4. Motor Scan KF90121; 5. Rear Trailer Hitch & Pin(2〞)； 6. EPS. 13-1 Massimo Motor Sports LLC. Emission Control System Warranty Statement YOUR WARRANTY RIGHTS AND OBLIGATIONS The U.S. Environmental Protection Agency and Massimo Motor Sports LLC (hereinafter “Massimo”) are pleased to explain the emission control system warranty on your Off-Road vehicle. New off-road motor vehicles must be designed, built and equipped to meet U.S. EPA Federal and California anti-smog standards. Massimo must warrant the emission control system on your vehicle for 5,000 km, or at least 30 months, whichever comes first, provided that there has been no abuse, neglect or improper maintenance of your vehicle. This off-road vehicle was designed to meet the emission standards for 10,000 km, or five years, whichever comes first. Your emission control system warranty covers components whose failure would increase an engine’s emissions of any regulated pollutant Where a warrantable condition exists, Massimo 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 will be repaired or replaced by Massimo. This is your EMISSION CONTROL SYSTEM WARRANTY. NOTICE! Use of this vehicle in any type of competitive event completely and absolutely voids this and all other warranties offered by Massimo. OWNER’S WARRANTY RESPONSIBILITIES As the vehicle owner, you are responsible for the performance of the required maintenance listed in your owner’s manual. Massimo recommends that you retain all receipts covering maintenance on your vehicle, but Massimo cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance. You are responsible for presenting your vehicle to the Massimo 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 Massimo may deny your warranty coverage if your vehicle or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications. If you use your vehicle in any type of competitive event, this warranty is immediately and completely void. If you have any questions regarding your warranty rights and responsibilities, you should contact Massimo Motor Sports LLC, 3101 W Miller RD .,Garland, TX 75041 (Phone: 972-243-4555 or Toll Free: 877-881-6376 or the U.S. Environmental Protection Agency at 2000 Traverwood Drive, Ann Arbor, MI 48105. Massimo Motor Sports LLC warrants that each new off-road vehicle: A. is designed, built and equipped so as to conform at the time of initial retail purchase with all applicable regulations of the United States Environmental Protection Agency, and Massimo Motor Sports LLC. Emission Control System Warranty Statement YOUR WARRANTY RIGHTS AND OBLIGATIONS B. is free from defects in material and workmanship which cause such vehicle to fail to conform to applicable regulations of the United States Environmental Protection Agency for the periods specified above. I. Coverage. Warranty defects shall be remedied during customary business hours at any authorized Massimo dealer located within the United States of America in compliance with the Clean Air Act and applicable regulations of the United States Environmental Protection Agency. Any part or parts replaced under this warranty shall become the property of Massimo. II. Limitations This Emission Control System Warranty shall not cover any of the following: A. Repair or replacement as a result of (1) accident, (2) misuse (3) repairs improperly performed or replacements improperly installed, unless performed by a Massimo authorized dealer, (4) use of improper replacement parts or accessories not conforming to specifications set forth by Massimo, which adversely affect performance and/or (5) Use in competitive racing or related events. B. Inspections, replacement of parts and other services and adjustments required for required maintenance. C. Any vehicle equipped with an odometer or hour meter on which the odometer mileage or hour meter reading has been changed so that actual mileage cannot be readily determined. III. Limited Liability A.The liability of Massimo under this Emission Control System Warranty is limited solely to the remedying of defects in material or workmanship by an authorized Massimo dealer at its place of business during customary business hours. This warranty does not cover inconvenience or loss of use of the vehicle or transportation of the vehicle to or from the Massimo dealer. Massimo shall not be liable for any other expenses, loss or damage, whether direct, indidental, consequential or exemplary arising in connection with the sale or use of or inability to use the vehicle for any purpose. Some states do not allow the exclusion or limitation of any incidental or consequential damages, so the above limitations may not apply to you. B. No express emission control system warranty is given by Massimo except as specifically set forth herein. Any emission control system warranty implied by law, including any warranty of merchantability or fitness for a particular purpose, is limited to the express emission control system warranty terms stated in this warranty. The foregoing statements of warranty are exclusive and in lieu of all other remedies. Some states do not allow limitations on how long an implied warranty lasts, so the above limitations may not apply to you. Massimo Motor Sports LLC. Emission Control System Warranty Statement YOUR WARRANTY RIGHTS AND OBLIGATIONS C. No dealer is authorized to modify this Limited Emission Control System Warranty issued by Massimo. IV. LEGAL RIGHTS. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. V. This warranty is in addition to the limited vehicle warranty. VI. ADDITIONAL INFORMATION. Any replacement part that is equivalent in performance and durability may be used in the performance of any maintenance or repairs by the owner. However, Massimo is not liable for these parts. The owner is responsible for the performance of all required maintenance. Such maintenance may be performed at a service establishment or by any individual. The warranty period begins when the vehicle is placed into service. If you have any questions regarding your warranty rights and responsibilities, you should contact Massimo Motor Sports LLC, or the U.S. Environmental Protection Agency at 2000 Traverwood Drive, Ann Arbor, MI 48105. Massimo Motor Sports LLC 3101 W Miller RD Garland, TX 75041 Phone: 972-243-4555 Fax: 214-540-1163 Toll-Free: 877-881-6376