Stampede XTR.book - Textron Off Road

Stampede XTR.book - Textron Off Road
2017
Owner’s Manual
Read and comply with all of the instructions and safety precautions in this manual and on all product
labels.
Failure to follow the safety precautions could result in serious injury or death.
CALIFORNIA Proposition 65
Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals
known to the State of California to cause cancer and birth defects or other reproductive harm. In addition,
certain fluids contained in vehicles and certain products of component wear contain or emit chemicals
known to the State of California to cause cancer and birth defects or other reproductive harm.
NOTICE: Your BAD BOY OFF ROAD STAMPEDE XTR is equipped with sophisticated exhaust and evaporative
emission control systems. BAD BOY OFF ROAD has engineered the entire vehicle for optimum performance and minimal impact on the environment. As the owner, you may choose a qualified repair
shop or person to maintain, replace, or repair emission control devices and systems with original or
equivalent replacement parts. However, warranty, recall and all other services paid for by BAD BOY
OFF ROAD must be performed at an authorized BAD BOY OFF ROAD service center.
Installing non-equivalent or non-original components, neglecting maintenance, removing after
treatment components, adjusting calibrations or otherwise disabling your emission control systems may void your warranty, cause injury or be a violation of Federal Law.
WELCOME
Thank you for purchasing a BAD BOY OFF ROAD vehicle. Before driving your new vehicle, read this owner’s manual
to familiarize yourself with safe driving practices, operation, features and controls.
Visit us online at www.badboyoffroad.com for the latest news, new product information, career opportunities and
more.
This manual contains instructions for minor maintenance only. Information about major repairs can be found in the
BAD BOY OFF ROAD repair manual. Your BAD BOY OFF ROAD dealer has thorough knowledge of your vehicle and
wants your total satisfaction with your purchase. We recommend you return to your dealership for all of your service
needs during, and after the warranty period.
Repair or replacement parts can be purchased at your BAD BOY OFF ROAD dealer or through the manufacturer’s
parts and accessories department.
To locate your nearest dealer,
call 1-888-438-3946 or
visit www.badboyoffroad.com
TEXTRON SPECIALIZED VEHICLES
1451 Marvin Griffin Rd.
Augusta, GA 30906 USA
1
All information in this owner’s manual is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some discrepancies may be found between
your vehicle and the information presented in this publication. The content in this publication is intended for reference
use only. The manufacturer is not liable for omissions or inaccuracies. Any reprinting or reuse of the content in this
publication, whether whole or in part, is expressly prohibited.
Printed in USA
2017 STAMPEDE XTR Owner’s Manual
P/N 657202-A
2
TABLE OF CONTENTS
INTRODUCTION
MANUFACTURER’S INTENDED USE ..................................................................................................................... 8
NOISE CONTROL SYSTEM ..................................................................................................................................... 8
SPARK ARRESTOR AND USE ON PUBLIC LANDS ............................................................................................... 8
WARRANTY AND REGISTRATION ......................................................................................................................... 8
VEHICLE IDENTIFICATION NUMBERS ................................................................................................................. 9
REPAIR AND PARTS MANUALS ........................................................................................................................... 10
SAFETY
REQUIRED RIDING APPAREL .............................................................................................................................. 11
Helmet ............................................................................................................................................................. 11
Eye Protection ................................................................................................................................................. 11
Gloves ............................................................................................................................................................. 11
Boots ............................................................................................................................................................... 11
Clothing ........................................................................................................................................................... 11
SAFETY LABELS .................................................................................................................................................... 12
Operator Warning (P/N 642599) ..................................................................................................................... 12
Safety Warning (P/N 642600) ......................................................................................................................... 12
Front Passenger Safety Warning (P/N 645330) .............................................................................................. 12
Rear Passenger Safety Warning (P/N 657309) .............................................................................................. 13
Overload Warning and Tire Pressure Warning (P/N 657272) ......................................................................... 13
Storage Compartment Warning (P/N 643606) ................................................................................................ 13
Underseat Storage Compartment Warning (P/N 657555) .............................................................................. 13
Shifting Transmission Warning (P/N 643602) ................................................................................................. 13
ROPS Warning (P/N 657270) ......................................................................................................................... 14
Clutch Cover Warning (P/N 643600) ............................................................................................................... 14
Hitch Warning (P/N 645329) ........................................................................................................................... 14
Service Label (P/N 643605) ............................................................................................................................ 14
Hot Warning (P/N 608823) .............................................................................................................................. 14
SEAT BELTS ........................................................................................................................................................... 15
MAXIMUM CARGO LOAD / MAXIMUM WEIGHT CAPACITY ............................................................................... 15
TIRE PRESSURE ................................................................................................................................................... 15
OPERATOR SAFETY ............................................................................................................................................. 15
Unauthorized Use ........................................................................................................................................... 16
Operating without Instruction .......................................................................................................................... 16
Alcohol or Drugs .............................................................................................................................................. 16
Seat Belts ........................................................................................................................................................ 16
Passenger ....................................................................................................................................................... 16
Protective Riding Apparel ................................................................................................................................ 16
Cab Doors ....................................................................................................................................................... 16
Before Operating ............................................................................................................................................. 16
Load Operation ............................................................................................................................................... 17
Fuel Handling Guidelines ................................................................................................................................ 17
Carbon Monoxide Exposure ............................................................................................................................ 17
Driving in Reverse ........................................................................................................................................... 17
Driving a Damaged Vehicle ............................................................................................................................. 17
Driving at High Speeds ................................................................................................................................... 17
Driving on Pavement ....................................................................................................................................... 18
3
TABLE OF CONTENTS
Driving on Public Roads ..................................................................................................................................18
Turning ............................................................................................................................................................18
Jumps and Stunts ............................................................................................................................................18
Unfamiliar Terrain ............................................................................................................................................18
Obstacles ........................................................................................................................................................18
Climbing Hills ...................................................................................................................................................18
Driving Downhill ...............................................................................................................................................18
Stalling on a Hill ...............................................................................................................................................18
Tires ................................................................................................................................................................18
Slippery Terrain ...............................................................................................................................................18
Driving Through Water ....................................................................................................................................18
Driving on Ice ..................................................................................................................................................19
HOT EXHAUST SYSTEMS .....................................................................................................................................19
VEHICLE LIFTING ..................................................................................................................................................19
VEHICLE MODIFICATION ......................................................................................................................................19
EMISSIONS RELATED CONTROL SYSTEMS AND COMPONENTS ...................................................................19
FEATURES AND CONTROLS
CONSOLE ...............................................................................................................................................................21
KEY SWITCH ..........................................................................................................................................................21
HEADLIGHT SWITCH ............................................................................................................................................21
REAR DIFFERENTIAL LOCK SWITCH ..................................................................................................................22
ALL-WHEEL DRIVE (AWD) SWITCH .....................................................................................................................22
DRIVER INFORMATION CENTER .........................................................................................................................22
Display Control Pad ........................................................................................................................................22
Adjust Backlight ...............................................................................................................................................22
Indicator Lights ................................................................................................................................................23
SELECTABLE DISPLAYS .......................................................................................................................................24
Display 3 - MAINT ...........................................................................................................................................24
Display 4 - SETUP ..........................................................................................................................................25
Display 5 - CLOCK ..........................................................................................................................................26
Display 6 - INFO ..............................................................................................................................................26
GEAR SHIFTER ......................................................................................................................................................27
Using Low Range ............................................................................................................................................27
SEAT BELTS ...........................................................................................................................................................27
Seat Belt Inspection ........................................................................................................................................27
ADJUSTABLE STEERING WHEEL ........................................................................................................................28
BRAKE PEDAL .......................................................................................................................................................28
ACCELERATOR PEDAL .........................................................................................................................................28
CUP HOLDER .........................................................................................................................................................28
PASSENGER HAND HOLD ....................................................................................................................................28
EPAS - ELECTRONIC POWER ASSISTED STEERING ........................................................................................28
SEAT BOTTOM REMOVAL ....................................................................................................................................28
AUXILIARY OUTLET .............................................................................................................................................29
USB PORT (IF EQUIPPED) ....................................................................................................................................29
STORAGE COMPARTMENTS ...............................................................................................................................29
HITCH RECEIVER ..................................................................................................................................................29
FUEL TANK CAP ....................................................................................................................................................30
4
TABLE OF CONTENTS
OPERATION
SAFETY .................................................................................................................................................................. 31
PRE-RIDE INSPECTION ........................................................................................................................................ 31
ENGINE BREAK-IN ................................................................................................................................................. 31
CVT BELT BREAK-IN ............................................................................................................................................. 32
FUEL ....................................................................................................................................................................... 32
STARTING THE ENGINE ....................................................................................................................................... 32
STOPPING THE ENGINE ....................................................................................................................................... 32
ACCELERATING .................................................................................................................................................... 33
BRAKING ................................................................................................................................................................ 33
DRIVING PROCEDURE ........................................................................................................................................ 33
DRIVING WITH PASSENGERS ............................................................................................................................. 33
SLIPPERY SURFACES .......................................................................................................................................... 34
OBSTACLES IN DRIVE PATH ............................................................................................................................... 34
DRIVING UPHILL ................................................................................................................................................... 34
TRAVERSING HILLSIDES ...................................................................................................................................... 35
DRIVING DOWNHILL ............................................................................................................................................. 35
STALLING ON A HILL ............................................................................................................................................. 35
DRIVING THROUGH WATER ................................................................................................................................ 35
DRIVING IN REVERSE .......................................................................................................................................... 36
PARKING THE VEHICLE ........................................................................................................................................ 36
HAULING CARGO .................................................................................................................................................. 37
Maximum Cargo Load / Maximum Weight Capacity ....................................................................................... 37
TOWING LOADS .................................................................................................................................................... 38
DUMPING THE TRUCK BED ................................................................................................................................. 38
DIFFERENTIAL OPERATION MODES .................................................................................................................. 39
Rear Differential Locking Switch ..................................................................................................................... 39
All-Wheel Drive (AWD) ................................................................................................................................... 39
Two-Wheel Drive (2WD) ................................................................................................................................. 39
WINCH
WINCH SAFETY ..................................................................................................................................................... 41
WINCH OPERATION .............................................................................................................................................. 42
WINCH CABLE CARE ............................................................................................................................................ 43
SHOCK LOADING .................................................................................................................................................. 44
WINCH MAINTENANCE SAFETY .......................................................................................................................... 44
EMISSION CONTROL SYSTEM
CRANKCASE EMISSION CONTROL SYSTEM ..................................................................................................... 45
EXHAUST EMISSION CONTROL SYSTEM .......................................................................................................... 45
EMISSION CONTROL INFORMATION LABEL ...................................................................................................... 46
EMISSIONS HANG TAG ......................................................................................................................................... 46
MAINTENANCE
TOOL KIT ................................................................................................................................................................ 47
SCHEDULED MAINTENANCE ............................................................................................................................... 47
Initial Service Requirements ........................................................................................................................... 47
Severe Use Conditions ................................................................................................................................... 47
SCHEDULED MAINTENANCE CHART .................................................................................................................. 48
5
TABLE OF CONTENTS
RECOMMENDED LUBRICANTS AND FLUIDS .....................................................................................................50
REPLACEMENT OF MAINTENANCE ITEMS ........................................................................................................50
LIFTING THE VEHICLE ..........................................................................................................................................50
Lifting Front ....................................................................................................................................................51
Lifting Rear ......................................................................................................................................................51
Lowering Vehicle .............................................................................................................................................51
TRUCK BED REMOVAL .........................................................................................................................................52
Truck Bed Installation ......................................................................................................................................52
ENGINE OIL ............................................................................................................................................................53
CHECK OIL .............................................................................................................................................................53
Add Oil .............................................................................................................................................................53
CHANGE OIL ..........................................................................................................................................................54
Remove Engine Oil .........................................................................................................................................54
Replace the Oil Filter ......................................................................................................................................54
Refill Engine Oil ..............................................................................................................................................55
FRONT DIFFERENTIAL ........................................................................................................................................55
Front Differential Oil Check .............................................................................................................................55
Front Differential Oil Replacement ..................................................................................................................55
REAR DIFFERENTIAL ............................................................................................................................................56
Rear Differential Oil Check ..............................................................................................................................56
Rear Differential Oil Replacement (Upper Chamber) ......................................................................................56
Rear Differential Oil Replacement (Lower Chamber) ......................................................................................56
SPARK PLUGS ......................................................................................................................................................57
Spark Plug Inspection and Replacement ........................................................................................................57
COOLING SYSTEM ................................................................................................................................................58
Coolant ............................................................................................................................................................58
Reservoir Coolant Level ..................................................................................................................................58
Radiator and Cooling Fan ...............................................................................................................................59
Radiator Coolant Level ...................................................................................................................................59
CONTINUOUSLY VARIABLE TRANSMISSION (CVT) ..........................................................................................60
CVT Belt Inspection .........................................................................................................................................60
Draining the CVT .............................................................................................................................................60
PROP SHAFT .........................................................................................................................................................60
VEHICLE IMMERSION ...........................................................................................................................................60
AIR FILTER .............................................................................................................................................................61
SPARK ARRESTER ................................................................................................................................................61
BRAKES ..................................................................................................................................................................62
Brake Fluid ......................................................................................................................................................62
Brake Inspection ..............................................................................................................................................62
STEERING WHEEL ...............................................................................................................................................63
SPRING ADJUSTMENT ........................................................................................................................................63
TIRES ......................................................................................................................................................................63
Tire Tread Depth .............................................................................................................................................63
Tire Repair .......................................................................................................................................................64
Tire Replacement ............................................................................................................................................64
WHEELS .................................................................................................................................................................64
Wheel Removal ...............................................................................................................................................64
Wheel Installation ............................................................................................................................................64
6
TABLE OF CONTENTS
ELECTRONIC POWER ASSISTED STEERING (EPAS) ....................................................................................... 65
FUSES .................................................................................................................................................................... 65
LIGHTS ................................................................................................................................................................... 65
Headlight Bulb Replacement ........................................................................................................................... 65
Headlight Beam Adjustment ............................................................................................................................ 66
Brake Light ...................................................................................................................................................... 66
Brake Light Bulb Replacement ........................................................................................................................ 66
BATTERY ................................................................................................................................................................ 67
Battery Cleaning .............................................................................................................................................. 67
Battery Charging ............................................................................................................................................. 67
Battery Storage ............................................................................................................................................... 67
CLEANING .............................................................................................................................................................. 68
Washing the Vehicle ....................................................................................................................................... 68
Polishing the Vehicle ....................................................................................................................................... 68
STORAGE ............................................................................................................................................................... 68
Clean the Exterior ........................................................................................................................................... 68
Stabilize the Fuel ............................................................................................................................................. 68
Oil and Filter .................................................................................................................................................... 68
Air Filter ........................................................................................................................................................... 68
Inspect and Lubricate ...................................................................................................................................... 69
Battery ............................................................................................................................................................. 69
Fluid Levels ..................................................................................................................................................... 69
Fog the Engine ................................................................................................................................................ 69
Storage Area ................................................................................................................................................... 69
REMOVE FROM STORAGE ................................................................................................................................... 69
TRANSPORTING THE STAMPEDE XTR ............................................................................................................... 70
SPECIFICATIONS
SPECIFICATIONS CHART ..................................................................................................................................... 71
FAULT TESTING
DIAGNOSTICS ........................................................................................................................................................ 73
Display 1 - FAULTS - Engine .......................................................................................................................... 74
Display 2 - FAULTS - EPAS ............................................................................................................................ 75
CVT BELT WEAR ................................................................................................................................................... 76
ENGINE DOES NOT CRANK ................................................................................................................................. 76
ENGINE CRANKS, BUT DOES NOT START ......................................................................................................... 77
ENGINE STALLS AND CAN BE RESTARTED ...................................................................................................... 77
ENGINE STALLS AND CANNOT BE RESTARTED ............................................................................................... 77
ENGINE OUTPUT IS INTERRUPTED .................................................................................................................... 77
ENGINE BACKFIRES ............................................................................................................................................. 77
ENGINE PINGS OR KNOCKS ................................................................................................................................ 78
ENGINE RUNS IRREGULARLY, STALLS OR MISFIRES .................................................................................... 78
ENGINE STOPS OR LOSES POWER ................................................................................................................... 79
ENGINE DOES NOT REACH FULL ENGINE SPEED ........................................................................................... 79
7
INTRODUCTION
INTRODUCTION
The STAMPEDE XTR is an off road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area.
The following symbols appear throughout this manual and on your vehicle. Your safety is involved when these symbols are used. Become familiar with their meanings before reading the manual.
DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.
WARNING indicates a hazardous situation, if not avoided, could result in death or serious injury.
CAUTION indicates a hazardous situation that, if not avoided, could result in minor or
moderate injury.
The PROHIBITION SAFETY SIGN indicates an action NOT to take in order to avoid hazard.
The MANDATORY ACTION SIGN indicates an action that NEEDS to be taken to avoid a hazard.
Failure to comply with the warnings in this manual can result in severe injury or death.
Read this entire manual carefully before operating this vehicle. Do not attempt to operate
this vehicle until you have thorough knowledge of the controls and features.
Regular inspections and maintenance, along with good operating techniques, will help
ensure your safe enjoyment of the capabilities and reliability of this vehicle.
MANUFACTURER’S INTENDED USE
• The BAD BOY OFF ROAD STAMPEDE XTR is designed and manufactured for off road use only. Use on public
streets, roads or highways is illegal in most areas and increases the risk of an accident involving other vehicles and
people. This vehicle does not meet FMVSS (Federal Motor Vehicle Safety Standards) for public street, road or highway use.
• Check all laws and regulations before choosing an area to operate the STAMPEDE XTR.
NOISE CONTROL SYSTEM
Do not modify the engine, intake or exhaust components. Modifications to these components can affect compliance
with ROHVA 1 - 2016 and local noise level requirements. Modifications to these components can also affect the emissions control system. See Vehicle Modification on page 19 and Emissions Related Control Systems and Components
on page 19 for more information.
SPARK ARRESTOR AND USE ON PUBLIC LANDS
The BAD BOY OFF ROAD vehicle has a spark arrester that was tested and qualified to be in compliance with the
USFS standard 5100-1. Federal law requires that this spark arrester be installed and functional when the vehicle is
operated on public lands.
Off road vehicle operation on public lands in the USA is regulated by 43 CFR 420. Violations are subject to monetary
penalties. Go to www.www.gpo.gov/fdsys to see federal regulations.
WARRANTY AND REGISTRATION
The STAMPEDE XTR includes product and emission warranties. All information, including coverage, limitations,
exclusions and how to obtain warranty service is included in the literature package with the purchase of the vehicle. It
can also be found at badboyoffroad.com.
Registration of the vehicle will be done by the dealer at the time of purchase.
8
INTRODUCTION
VEHICLE IDENTIFICATION NUMBERS
Serial Number Label on Steering Column
Frame PIN
(vehicle frame
under seat)
Front
Serial Number Labels
under Front Cowl
Access Panel
Certification Label
Record the vehicle identification numbers and key number (on the key) in the spaces provided below.
Remove the spare key and store it in a safe place. An ignition key can be duplicated only if the key number is provided. If all keys are lost and the key number is unknown, the ignition switch must be replaced.
The information below is required when ordering parts from BAD BOY OFF ROAD.
Vehicle Model Number: _________________________________________________________________
Frame PIN: __________________________________________________________________________
Key Number: _________________________________________________________________________
9
INTRODUCTION
REPAIR AND PARTS MANUALS
The following manuals can be purchased through a BAD BOY OFF ROAD dealer:
• repair manual
• parts manual
• engine manual
10
SAFETY
SAFETY
REQUIRED RIDING APPAREL
The driver and all passengers must wear the following protective riding
gear to decrease the risk of injury:
• helmet
• eye protection
• gloves
• boots
• long sleeve shirt or jacket
• long pants
Long Sleeve
Shirt or Jacket
Gloves
Helmet
Wear a helmet designed for off road use to decrease the risk of head
injury. A full face helmet is recommended. A properly fitting helmet is
snug and will not wiggle excessively when shaking the head from side to
side. Always wear a helmet that meets or exceeds established safety
standards when riding the STAMPEDE XTR.
Approved helmets in the USA and Canada have a U.S. Department of
Transportation (DOT) label attached.
E4
Helmet
Eye Protection
Long Pants
Boots
Approved helmets in Europe, Asia and Oceania have the
ECE 22.05 label attached. The ECE mark consists of a circle around the letter E, followed by the distinguishing number of the country that has permitted approval. The approval number and serial number is
also shown on the label.
051039
0006.31
Eye Protection
Always wear shatterproof goggles or a shatterproof helmet face shield. Personal eye glasses or sun glasses are not
adequate eye protection. BAD BOY OFF ROAD recommends wearing approved Personal Protective Equipment
(PPE) with markings such as VESC8, V-8, Z87.1, or CE. Keep protective eye wear clean and free of scratches.
Gloves
Wear gloves to protect hands.
Boots
Wear sturdy, over the ankle boots with low heels for support and protection. Never ride with bare feet or sandals.
Clothing
Wear long sleeve shirt or jacket to protect arms, and long pants to protect legs.
11
SAFETY
SAFETY LABELS
Safety and warning labels are on the vehicle for your protection. Read and comply with the instructions on the labels.
If any label shown in this manual is different from the label on your vehicle, always follow the instructions on the vehicle label.
If a label comes off or becomes illegible, contact your BAD BOY OFF ROAD dealer to get a replacement. Replacement safety labels are available at no charge to you. The part number is provided in this manual, printed on the label,
or can be provided by your dealer.
Operator Warning (P/N 642599)
Located on the dash.
Safety Warning (P/N 642600)
Located on the dash to the left of the steering column.
DRIVER
UNDER
16
Require Proper Use of Your Vehicle
Do not allow careless or reckless driving.
Make sure operators are 16 years or older with a valid drivers license.
Do not let people ride or drive after using drugs or alcohol.
Do not allow operation on public roads (unless roads are designated
for off-highway vehicles access) - collisions with cars and trucks can
occur.
Maximum front seat capacity: 2 persons.
Be Sure Riders Pay Attention and Plan Ahead
If you think or feel the vehicle may tip or roll, reduce your risk of injury:
Keep a firm grip on the steering wheel or handhold and brace yourself.
Do not put any part of your body outside of the vehicle for any reason.
Locate and Read the Owner’s Manual
Follow ALL Instructions and Warnings
642600
Front Passenger Safety Warning (P/N 645330)
Located on the dash in front of the front passenger seat.
Be Prepared
Fasten seat belt.
Wear an approved helmet and protective gear.
Make sure the door is latched securely.
Passengers must be able to sit with their back
against the seat, feet flat on the floor and hands on handhold.
12
Do not ride or drive after using drugs or alcohol.
Maximum front seat capacity: 2 persons.
Stay completely inside the vehicle when vehicle is moving.
Use handhold and brace yourself on slopes and in turns.
645330
SAFETY
Rear Passenger Safety Warning (P/N 657309)
Rear passenger safety label located on the back of the front seat.
Maximum rear seating capacity: 2 passengers
Make sure the doors are latched securely.
Fasten seat belt.
If you think or feel the vehicle may tip or roll, reduce risk of injury:
- Brace yourself with a firm grip on the handhold.
- Keep all parts of your body inside the vehicle at all times.
Wear an approved helmet and protective gear.
Passengers must be able to sit with their back against
seat, feet flat on floor and hands on handhold.
Improper use of off-highway vehicles can cause severe
injury or death.
Stay completely inside vehicle when vehicle is moving.
Read and comply with all instructions and warnings in the
vehicle owner’s manual.
Do not ride in vehicle after using drugs or alcohol.
657309
Overload Warning and Tire Pressure Warning (P/N 657272)
Located in the truck bed.
Never carry passengers in cargo bed.
Always secure cargo.
Always make sure cargo bed is latched before operating vehicle.
DO NOT fill fuel containers in cargo bed.
DO NOT overload cargo bed. The weight of operator, passengers, accessories
and carry rack items must be deducted from overall vehicle weight capacity.
Reduce cargo and speed for stability on hilly or rough terrain.
* California: Total Rear
Payload of cargo areas
is 600 lbs. Max.
MAX WEIGHT CAPACITY
STAMPEDE 900
STAMPEDE 900 XTR
Cargo Bed *
600 lbs (272 kg)
600 lbs (272 kg)
Total Weight
1200 lbs (544 kg)
Improper tire pressure or overloading can cause loss
of control that can result in serious injury or death.
Tire pressure must be adjusted to accommodate load
being carried.
Tire pressure must be adjusted when operating on
hilly or rough terrain to maintain vehicle stability.
TIRE PRESSURE (COLD)
1500 lbs (680 kg)
See owner’s manual for more detailed loading information.
PAYLOAD UNDER
800 lbs (362 kg)
PAYLOAD OVER
800 lbs (362 kg)
FRONT
12 psi (83 kPa)
15 psi (103 kPa)
REAR
12 psi (83 kPa)
15 psi (103 kPa)
657272
Storage Compartment Warning (P/N 643606)
Located on the inside of both hinged storage box doors.
No passengers allowed in this area.
DO NOT fill fuel containers in this area.
Always make sure the extended cab doors are latched securely.
Always secure the cargo.
Maximum load in this area is 170 lbs (77 kg).*
*California: See Rear Bed Load Label or Owner’s Guide for capacity limits.
643606
Underseat Storage Compartment Warning (P/N 657555)
Maximum storage capacity under front seat is 100 lbs (45 kg).
Do not allow passengers in storage area under front seat.
Do not fill fuel containers in storage area under front seat.
657555
Located in the storage area under the front seat.
Shifting Transmission Warning (P/N 643602)
Located on the dash above the gear shifter.
13
SAFETY
ROPS Warning (P/N 657270)
Located on the ROPS.
The protection offered by this ROPS will be
impaired if it has been subjected to any
modification or structural damage. This
ROPS must be replaced after a rollover.
This ROPS was tested in accordance
with the requirements of
ISO 3471 per ANSI/ROHVA 1.
Test GVW: 1633 kg (3600 lbs)
Vehicle Model: Stampede 900 XTR
Type: ROV
This vehicle is in compliance with all
functional, operational, and performance
requirements of ANSI/ROHVA 1-2016.
Textron Specialized Vehicles
1451 Marvin Griffin Rd.
Augusta, GA 30906
USA
657270
Clutch Cover Warning (P/N 643600)
Located on the clutch cover.
Hitch Warning (P/N 645329)
Located on the rear hitch.
Service Label (P/N 643605)
Located under the front cowl access panel.
Hot Warning (P/N 608823)
Two located on the frame under the truck bed; one located under the front body access panel.
608823
14
SAFETY
SEAT BELTS
Operating the vehicle while not wearing the seat belt increases the risk of serious injury
or death in the event of rollover, loss of control, or sudden stopping.
All riders must wear seat belts at all times.
MAXIMUM CARGO LOAD / MAXIMUM WEIGHT CAPACITY
Exceeding the weight capacities can cause loss of vehicle control and possible injury or
death.
•
•
•
•
Maximum Cargo Load (bed)
600 lbs. (272 kg)
Maximum Cargo Load (underseat)
100 lbs. (45 kg)
Maximum Cargo Load (extended cab storage compartment)
170 lbs. (77 kg)
Maximum Vehicle Weight Capacity
1500 lbs. (680 kg)
Do not exceed the maximum cargo load for any area of the vehicle.
Do not exceed the maximum vehicle weight capacity (includes weight of operator, passengers, cargo and accessories).
Do not exceed 35 mph (56 kph) if the maximum vehicle weight capacity is greater than 600 lbs. (272 kg).
Do not exceed 25 mph (40 kph) if the maximum vehicle weight capacity is greater than 900 lbs. (408 kg).
TIRE PRESSURE
Improper tire pressure or uneven tire pressure can cause loss of vehicle control and
possible injury or death.
Maintaining correct tire inflation pressure is essential for safe vehicle operation.
Tire Pressure (Front and Rear)
Payload
12 psi (83 kPa)
under 800 lbs. (362 kg)
15 psi (103 kPa)
over 800 lbs. (362 kg)
OPERATOR SAFETY
Safe and responsible use of this vehicle is necessary to prevent dangerous conditions for the operator, passengers
and other people in the area of operation. This section of the manual provides information on the safe operation of the
vehicle. Make sure you read, understand and comply with all of this information to decrease the risk of personal injury
or death.
Serious injury or death can occur if you do not follow the instructions and procedures
shown in this owner’s manual.
• Read this entire manual and all product labels carefully. Follow the safety information and operating procedures
described.
• Do not carry a passenger until you have a minimum of two hours driving experience on this vehicle.
• Keep feet, legs, hands and arms inside the vehicle at all times.
• The driver must keep both hands on the steering wheel and both feet on the floor or pedals.
• Inspect the vehicle before each use to make sure it is in safe operating condition. Perform the pre-ride inspection
described in this manual. See page 31.
• Always have the vehicle checked by an authorized dealer after an accident.
• Always put the transmission in P (park) before you leave the vehicle.
• Remove the ignition key when the vehicle is not in use to prevent accidental starting, unauthorized use by someone
below the age of 16, or someone without a driver’s license and proper training.
15
SAFETY
Additional information about safety is included throughout this manual or can be obtained from your local BAD BOY
OFF ROAD dealer.
Failure to operate the STAMPEDE XTR as instructed can cause collision, loss of control
or rollover resulting in severe injury or death. Follow all safety warnings in this section
of the owner’s manual. See the OPERATION section of the owner’s manual for operating
procedures and additional safety information.
Unauthorized Use
This vehicle is for adult use only. Any person below the age of 16 is not permitted to operate the vehicle. Any person who does not have a valid driver’s license is not permitted to operate the vehicle.
Do not allow any person below the age of 12 to ride as a passenger. Any passenger must be able to sit
with their back against the seat, both feet on the floor and both hands on a passenger hand hold.
Leaving the keys in the ignition allows unauthorized use of the vehicle by someone under 16 years of
age or an unlicensed driver. Always remove the ignition key when the vehicle is not in operation.
Operating without Instruction
Operation of this vehicle without proper instruction increases the risk of an accident. The operator
must understand how to operate the vehicle correctly in different situations and on different types of
terrain.
All operators must read, understand and comply with the owner’s manual and all warning and instruction labels before operating the vehicle.
All operators should take a ROHVA training course (www.rohva.org).
Alcohol or Drugs
Operation of the vehicle during or after consuming alcohol or drugs can adversely affect operator judgment, reaction time, balance and perception.
Never drink alcohol or use drugs or medications before or during operation of the vehicle.
Seat Belts
Riding in this vehicle without wearing the seat belt increases the risk of serious injury in the event of
rollover, loss of vehicle control, accident or sudden stop. Seat belts can decrease the severity of injury
in these circumstances.
The operator and passengers must wear seat belts at all times.
The speed of the vehicle is limited to 15 mph (24 kph) or less when the driver’s seat belt is not fastened.
Passenger
Do not carry any passenger below the age of 12 years. All passengers must be able to sit with their backs against the
seat, both feet on the floor and both hands on a passenger hand hold. For additional safety and operational information, see Driving with Passengers on page 33.
Protective Riding Apparel
A complete list of protective apparel is shown on page 11. Riding in this vehicle without wearing protective gear
increases the risk of serious injury if an accident occurs.
Cab Doors
Riding in this vehicle with doors removed or with doors not securely latched increases the risk of serious injury or
death if a rollover or accident occurs.
Keep the cab doors closed and latched securely during operation of this vehicle.
Keep arms, hands, legs and feet inside the vehicle at all times.
Before Operating
Perform the PRE-RIDE INSPECTION on page 31 before each use to make sure the vehicle is in safe operating condition. Failure to inspect and confirm that the vehicle is safe to operate increases the risk of an accident.
Follow all inspection and maintenance procedures and schedules described in this owner’s manual. See SCHEDULED MAINTENANCE on page 47.
16
SAFETY
Load Operation
The weight of cargo and occupants affects vehicle operation. Carefully calculate how the vehicle is loaded and how to
safely operate it. Follow the instructions in this manual for loading, tire pressure, gear selection and speed.
Do not exceed weight capacities specified for your vehicle. Capacities are listed in Maximum Cargo Load / Maximum
Weight Capacity on page 15 of this manual, and also on the label affixed to the truck bed. As passenger weight
increases, cargo weight needs to be adjusted to ensure the maximum vehicle weight capacity is not exceeded.
Tire pressure must be adjusted to accommodate the load being carried. See Tire Pressure on page 15 for pressure
specifications. Tire pressure specifications can also be found on the label affixed to the truck bed.
Verify tire pressure, and drive slowly and carefully to maintain control of the vehicle if driving under any of the following
conditions:
• passengers and/or cargo exceeds half the maximum weight capacity
• driving in rough terrain
• driving over obstacles
• towing
• climbing a hill
Fuel Handling Guidelines
Gasoline is flammable and can be explosive in some conditions. Use the following guidelines when handling fuel:
• Always use caution when handling gasoline.
• Refuel in a well-ventilated area.
• Turn off the engine before refueling.
• Use an approved gasoline container to store fuel.
• Remove portable gasoline containers from the vehicle and place on the ground before filling to prevent ignition
caused by electrical static discharge.
• Do not smoke or allow open flames or sparks in or near the area where refueling is done or where gasoline is
stored.
• Do not overfill the tank. Do not fill the tank neck.
• If gasoline contacts skin, immediately wash with soap and water. If gasoline gets on clothing, change immediately.
For refueling procedure, refer to Fuel on page 32.
Carbon Monoxide Exposure
Carbon monoxide is an odorless gas that is formed as a natural part of the combustion of hydrocarbon fuels.
Carbon monoxide is poisonous, and can cause loss of consciousness or death in a short period of time. Never start
the engine or allow it to run in an enclosed area.
If you experience any of the following symptoms, stop the engine and get fresh air immediately:
• dizziness
• intense headache
• weakness and sleepiness
• vomiting
• muscular twitching
• throbbing in temples
Operate this vehicle outdoors or in well-ventilated areas only.
Driving in Reverse
Make sure the area behind the vehicle is clear before operating in reverse. After making sure it is clear and safe to
operate in reverse, accelerate slowly. Avoid making sharp turns in reverse. Refer to Driving in Reverse on page 36 for
operational information.
Driving a Damaged Vehicle
Driving a damaged vehicle is not safe.
If your vehicle has been involved in any type of accident, have it inspected by a qualified service dealer to verify that it
is safe for operation.
Driving at High Speeds
High speed operation increases risk of loss of control. Always drive at a speed that is appropriate for the terrain, visibility, operating conditions and your skill and experience level. Use the brake to control speed and maintain control of
the vehicle.
17
SAFETY
Driving on Pavement
The tires on your STAMPEDE XTR are designed only for off road use; not for use on pavement. Driving the vehicle on
paved surfaces can affect handling characteristics and increase tire wear.
If possible, avoid driving on paved surfaces. If unavoidable, drive slowly, travel short distances and avoid sudden turns
or stops.
Driving on Public Roads
Driving your STAMPEDE XTR on public streets, roads or highways could result in a collision with another vehicle.
Never drive this vehicle on any public street, road or highway, including dirt and gravel roads, unless they are designated for off road use. Most areas prohibit the operation of this vehicle on public streets, roads or highways, and can
result in traffic violations and fines.
Turning
Improper or careless turning can cause loss of traction, loss of control, accident or rollover. Do not turn quickly or at
sharp angles. Do not turn at high speeds. Practice turning at slow speeds before attempting to turn at faster speeds.
Jumps and Stunts
Attempting wheelies, jumps or other stunts increases the risk of an accident or rollover. Never attempt wheelies,
jumps or other stunts. Avoid exhibition driving.
Unfamiliar Terrain
Drive slowly and cautiously on unfamiliar terrain to prevent an accident or rollover. Unfamiliar terrain can contain hidden rocks, bumps or holes that can cause loss of control or rollover. Constantly monitor for changing terrain conditions.
Obstacles
Check for obstacles before operating in an unfamiliar area. Do not drive over obstacles that are too large for the vehicle or your driving abilities. Refer to Obstacles in Drive Path on page 34 for operational information.
Climbing Hills
Do not climb hills that are too steep for the vehicle or your driving abilities. Practice driving on small hills before
attempting to drive on larger hills. Loss of vehicle control or rollover can result from climbing hills incorrectly. Refer to
Driving Uphill on page 34 for operational information.
Driving Downhill
Inspect the terrain before descending a hill. Avoid driving across hills. Use the brake to limit speed and maintain control. Loss of vehicle control or rollover can result from driving downhill incorrectly. Refer to Driving Downhill on page 35
for operational information.
Stalling on a Hill
A rollover can result from stalling or rolling backward while climbing a hill. Drive uphill at a constant speed. See procedure on page 35 for maintaining control of your vehicle if it stalls on a hill.
Tires
Operating the vehicle with incorrect tires or with incorrect or uneven tire pressure can cause loss of control or an accident. Always use the size and type tires specified for the vehicle. See SPECIFICATIONS CHART on page 71. Always
maintain correct tire pressures as specified in Tire Pressure on page 15.
Slippery Terrain
Driving on rough, wet or loose terrain increases the risk of loss of traction or control, accident or rollover. Drive slowly
and use correct turning procedures when operating on slippery surfaces.
Tires that have lost traction, and then regain traction suddenly, can cause loss of vehicle control or rollover.
Refer to Slippery Surfaces on page 34 for operational information.
Driving Through Water
Do not drive the vehicle through fast flowing water or in water deeper than that specified in the operation section of
this manual. Refer to Driving Through Water on page 35 for operational information.
Test the brakes after you drive through water. Wet brakes can reduce stopping ability. If necessary, apply pressure to
the pedal lightly several times to allow friction to dry the brake pads.
18
SAFETY
Driving on Ice
Severe injury or death can result if the vehicle and operator fall through ice. Never operate the vehicle on a frozen
body of water unless the ice is determined to be thick enough to support the weight and moving force of the vehicle,
occupants, cargo and other vehicles operating in the same area.
Check with local authorities and residents to confirm ice conditions and thickness over your entire route. Operators
assume all risk associated with frozen bodies of water.
HOT EXHAUST SYSTEMS
Exhaust system components are very hot during and after use. To avoid burn injuries, do not touch hot exhaust system components. Hot components can also cause fire. Keep combustible materials away from the exhaust system.
Check for buildup around the exhaust system after driving through high and dry grass.
VEHICLE LIFTING
The vehicle must be on a firm and level surface for lifting. Remain constantly aware that the vehicle is not stable
during the lifting process. Do not get under a vehicle until you verify that it is stable on the jack stands. Never get
under a vehicle while it is on a jack only. Put wheel chocks in front and behind the wheels that are not being lifted. Do
not allow anyone to remain or get on the vehicle at any time during the lifting process.
Read and comply with all warnings and follow the lifting procedures described on page 50.
VEHICLE MODIFICATION
Do not install any accessory not approved by BAD BOY OFF ROAD. Do not modify the vehicle to increase speed or
power. Any modifications or installation of accessories not approved by BAD BOY OFF ROAD can create a safety
hazard and increase the risk of injury.
The warranty will be terminated if the vehicle is modified to increase vehicle speed or power.
The warranty may be terminated if original (or equivalent) replacement parts are not installed on the vehicle.
The addition of some accessories can change the handling characteristics of the vehicle. Use only BAD BOY OFF
ROAD approved accessories, and familiarize yourself with their function and effect on the vehicle.
EMISSIONS RELATED CONTROL SYSTEMS AND COMPONENTS
Installing non-equivalent or non-original components, neglecting maintenance, removing after treatment components,
adjusting calibrations or otherwise disabling your emission control systems may void your warranty, cause injury or be
a violation of Federal Law.
19
SAFETY
20
FEATURES AND CONTROLS
FEATURES AND CONTROLS
CONSOLE
Some features on the console are optional and may not be on all vehicles.
Rear Differential
Switch
AWD
Switch
Display
Control Pad
Driver Information
Center
Headlight
Switch
AWD
2WD
H
L
N
R
P
Key
Switch
Gear
Shifter
12V
USB Port
Outlet (if equipped)
KEY SWITCH
The key switch is a three-position switch.
• OFF
• First position to the right is ON; activates vehicle electronics and accessory power.
• Second position is momentary; turn the key until the engine starts, then release. Engage the starter for no more
than five seconds.
HEADLIGHT SWITCH
The headlight switch is a two-position or three-position switch.
Two-position:
• upper – on
• lower – off
Three-position switch (if equipped):
• upper – low beam
• middle – high beam
• lower – off
21
FEATURES AND CONTROLS
REAR DIFFERENTIAL LOCK SWITCH
The rear differential lock switch is a two-position switch.
• upper – locked
• lower – unlocked
ALL-WHEEL DRIVE (AWD) SWITCH
The AWD switch is a two-position switch.
• upper – power is transferred to the front wheels and the vehicle is in AWD
• lower – front differential is unlocked and the vehicle is in 2WD (two-wheel drive)
DRIVER INFORMATION CENTER
All segments on the LCD display screen will display for one second at start-up. The brightness of the
display backlight is adjustable and will be the same at start-up as it was at last shutdown.
Display Control Pad
The display control pad beside the display screen allows the user to perform the following functions:
• navigate through the selectable displays in the driver information center
• enter and navigate through the diagnostic mode (see Diagnostics on page 73)
• clear the service reminder light after service is completed (see Diagnostics on page 73)
• adjust the brightness of the LCD display screen
Adjust Backlight
Press the up and down buttons on the control pad to brighten and dim the backlight of the display screen and all of the
lighted switches (if equipped).
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Clock
Gear Indicator
Headlight Beam Indicator
Drivetrain Mode Indicator
Engine Temperature Indicator
Fuel Level Indicator
Tachometer
Low Oil Pressure Indicator
Engine Malfunction Indicator
Engine Maintenance Indicator
Multifunction Display*
EPAS Fault Indicator
Speedometer
Seat Belt Indicator
EPAS Enabled Indicator
Diagnostic Mode Indicator
Low Battery Voltage Indicator
1
2
3
4
5
6
14
17
13
15
12
* Use the left and right buttons on the
11
10 9 16 8
7
display control pad to scroll through the
following options in the multifunction display (11):
• odometer (MI or km)
• trip odometer (MI TRIP or km TRIP) - With this option displayed, the trip odometer can be reset by pressing and
holding OK on the display control pad until the number resets to 0.0 (approximately 3 seconds).
• engine hours (HRS)
22
FEATURES AND CONTROLS
Indicator Lights
Number
8
Indicator
Low Oil Pressure Indicator
Light
Description
Low oil pressure indicator and backlight flashes when low oil pressure
is detected. Automatically shuts the engine down.
AWD; rear differential is locked
2WD; rear differential is locked
4
Drivetrain Mode Indicator
2WD; rear differential is unlocked
AWD; rear differential is unlocked
Low beam
3
Headlight Beam Indicator
High beam
14
Seat Belt Indicator
Flashes on startup; remains illuminated until fastened.
6
Fuel Level Indicator
Bars indicate level of fuel in the tank.
Last bar flashes when fuel is low.
Park
Reverse
2
Gear Indicator
Neutral
Low
High
15
EPAS (Electronic Power
Assisted Steering) Enabled
Indicator
Illuminates when the EPAS is in the enabled mode.
12
EPAS Fault Indicator
Illuminates when a malfunction is detected in the EPAS.
9
Engine Malfunction Indicator
Illuminates when a malfunction is detected in the engine.
10
Engine Maintenance Indicator
Illuminates when scheduled maintenance (engine oil and spark plugs)
is required.
5
Engine Temperature Indicator
Bars indicate the engine temperature.
Bars and backlight flash when high engine temperature is detected.
17
Low Battery Voltage Indicator
Illuminates when the battery voltage is low.
23
FEATURES AND CONTROLS
SELECTABLE DISPLAYS
There are six selectable top level displays in the driver information center:
• DISPLAY 1 - Engine FAULTS - Indicates trouble codes for the engine. For information and use, see Diagnostics on
page 73.
• DISPLAY 2 - EPAS FAULTS - Indicates trouble codes for the EPAS. For information and use, see Diagnostics on
page 73.
• DISPLAY 3 - MAINT - Indicates status of serviceable items and allows user to reset or clear the maintenance
reminder.
• DISPLAY 4 - SETUP - Allows the user to set up vehicle preferences.
• DISPLAY 5 - CLOCK - Allows the user to set up clock and time preferences.
• DISPLAY 6 - INFO - Provides vehicle information.
To enter the selectable displays:
1. Make sure the key is in the OFF position.
2. Press and hold the OK button on the display control pad while turning the ignition key to the
ON position. Turning the key past the ON position and starting the engine will exit the display.
3. Release the OK button.
4. Use UP and DOWN on the control pad to scroll through the top level displays.
Display 3 - MAINT
NOTICE: All options in this menu are editable.
1.
With MAINT displayed, press the RIGHT arrow to enter the maintenance menu.
2.
The first display (A or B) indicates the status of oil maintenance:
• Display A - OIL OK indicates no maintenance required.
A
• Display B - OIL REPL indicates that oil replacement is
required.
B
3.
4.
24
Press DOWN to toggle to the second display (C or D) which
will be either:
• Display C - SPARK OK indicates no maintenance
required.
C
• Display D - SPARK REPL indicates that spark plug
replacement is required.
D
In either of the OK displays (A or C) there are two options:
• Do nothing. No maintenance is required at this time.
• If the service is performed before the scheduled maintenance reminder is indicated, the maintenance reminder
can be reset.
– In OIL OK or SPARK OK, press OK on the display control pad to enter edit mode (wrench displays).
– Use the LEFT and RIGHT arrows to toggle between OK
and COMP (for complete).
– Select the COMP option and press the OK button to
reset the maintenance reminder. If the OK option is
selected when the OK button is pressed, edit mode exits
without resetting the reminder.
FEATURES AND CONTROLS
5.
Either of the REPL displays (B or D) indicates scheduled
maintenance is due. After the maintenance is complete, the
maintenance reminder can be cleared.
• In OIL REPL or SPARK REPL, press OK on the display
control pad to enter edit mode (wrench displays).
– Use the LEFT and RIGHT arrows to toggle between
REPL and COMP (for complete).
– Select the COMP option and press the OK button to
clear the maintenance reminder. If the REPL option is
selected when the OK button is pressed, editing exits
without clearing the reminder.
6.
Press LEFT arrow to return to top level display.
Display 4 - SETUP
NOTICE: All options in this menu are editable.
1.
With SETUP displayed, press the RIGHT arrow to enter the setup
menu.
2.
Press the UP and DOWN arrows to scroll through the
setup menu:
• Display A indicates the unit of measure selected.
– Press OK to enter edit mode.
– Press the LEFT and RIGHT arrows to toggle
between USCS (US Customary System) and METR
(Metric).
– Press OK to select preference.
• Display B is the enable/disable EPAS option.
– Press OK to enter edit mode.
– LEFT and RIGHT arrows toggle YES and NO.
– Press OK to select preference.
• Display C is the leading zero option for the speed display.
– Press OK to enter edit mode.
– LEFT and RIGHT arrows toggle YES and NO.
– Press OK to select preference.
3.
A
A
B
C
Press LEFT arrow to return to top level display.
25
FEATURES AND CONTROLS
Display 5 - CLOCK
NOTICE: All options in this menu are editable.
1.
With CLOCK displayed, press the RIGHT arrow to enter the clock
menu.
2.
Press the UP and DOWN arrows to scroll through the clock preferences menu:
• Display A indicates the 24 hour mode selected.
– Press OK to enter edit mode.
– LEFT and RIGHT arrows toggle YES and NO.
– Press OK to select preference.
A
• Display B allows the hour value to be set.
– Press OK to enter edit mode.
– LEFT and RIGHT arrows for input values 00 - 23.
– Press OK to select preference.
B
• Display C allows the minute value to be set.
– Press OK to enter edit mode.
– LEFT and RIGHT arrows for input values 00 - 59.
– Press OK to select preference.
C
Display 6 - INFO
NOTICE: None of the options in this menu are editable.
1.
With INFO displayed, press the RIGHT arrow to enter the information
menu.
• Display A indicates remaining oil life based on scheduled maintenance.
• Display B indicates remaining spark plug life based on
maintenance schedule.
• Display C indicates the dash calibration number.
• Display D indicates the dash firmware number.
26
A
B
C
D
FEATURES AND CONTROLS
GEAR SHIFTER
The gear shifter has five positions. The positions from top to bottom are:
• H – high
• L – low
• N – neutral
• R – reverse
• P – park
High Gear Position
High range is the primary driving gear. High gear is intended for use on hard-packed surfaces with light loads.
To change gears, stop the vehicle and move the lever to the desired gear. Do not try to
shift gears with engine speed above idle or while the vehicle is moving.
When the vehicle is not in operation or is left unattended, put the transmission in P (park).
NOTICE: Maintaining the shift linkage adjustment is important for proper transmission function. See an authorized BAD BOY OFF ROAD dealer if you experience any shifting problems.
Park Position
Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage. Always shift when the vehicle is stationary and the engine is at idle.
Using Low Range
Use low range gear in the following conditions:
• operating in rough terrain or over obstacles
• loading the STAMPEDE XTR onto a trailer
• towing a trailer or hauling a heavy load
SEAT BELTS
The STAMPEDE XTR has a three-point seat belt on each seat. Make sure the seat belts for all occupants are fastened before operating the vehicle. The speed of the vehicle is limited to 15 mph (24 kph) or less when the driver’s
seat belt is not fastened.
Falling from a moving vehicle could cause serious
injury or death. All occupants must fasten their seat
belts prior to vehicle operation.
Use the following procedure to make sure all seat belts are correctly fastened:
1. Pull the seat belt latch down and across the chest toward the buckle on the
inner edge of the seat.
• Make sure the belt fits snug across the hips and diagonal across the chest.
• Make sure the belt is not twisted.
2. Push the latch into the buckle until it clicks.
3. Release the strap. It will self-tighten.
4. To release the seat belt, press the release button on the buckle.
Seat Belt Inspection
Inspect all seat belts for proper operation before each use.
1. Push the latch plate into the buckle until it clicks. The latch plate must slide
smoothly into the buckle. A click indicates that it is latched.
2. Press the release button in the buckle to make sure it releases freely.
3. Pull each seat belt completely out and inspect the full length for damage. If damage is found, or if the seat belt
does not operate correctly, have the seat belt system inspected by an authorized BAD BOY OFF ROAD dealer.
4. To clean dirt from the seat belts:
• Use a sponge, mild soap and water.
• Do not use bleach or household detergents.
• Rinse the full length of the belt with water.
• Use a garden hose to flush out the retractor and buckles regularly.
• Leave the wet seat belt pulled out of the retractor until it is dry.
27
FEATURES AND CONTROLS
ADJUSTABLE STEERING WHEEL
The steering wheel can be adjusted to suit different drivers.
Press the adjustment lever down. Move the steering wheel to
the most comfortable driving position and pull the lever back up
to lock the steering wheel in place.
Steering Wheel
Adjustment Lever
BRAKE PEDAL
The brake pedal is the left pedal on the floorboard.
Press the brake pedal to slow vehicle speed or bring the vehicle
to a complete stop.
ACCELERATOR PEDAL
Cup Holder
Accelerator Pedal
The accelerator pedal is the right pedal on the floorboard. It controls the acceleration of the vehicle.
Press the pedal to increase engine speed. Spring pressure
returns the pedal to the rest position when it is released. Always
make sure the pedal has returned properly before starting the
engine.
CUP HOLDER
The STAMPEDE XTR has front and rear cup holders that will
accommodate two beverage containers each.
Brake Pedal
PASSENGER HAND HOLD
The passenger hand hold is adjustable. Remove the pins
from the hand hold and slide the hand hold in or out to
achieve the most comfortable position. Secure with pins.
Adjustment Pin
EPAS - ELECTRONIC POWER ASSISTED
STEERING
EPAS engages when the ignition key is turned to the ON position. EPAS remains engaged while the engine is running.
To conserve battery power, the EPAS will shut down five minutes after the engine is stopped and the key remains in
the ON position. The EPAS fault indicator will illuminate to indicate the EPAS has shut down. Turn the key off and back
on to reset the unit.
See page 23 for EPAS indicator information.
SEAT BOTTOM REMOVAL
The seat bottom can be removed to access the storage area underneath. Use the two hand holds in the front of the
seat bottom to lift up and remove it from the vehicle.
28
FEATURES AND CONTROLS
AUXILIARY OUTLET
A 12-volt auxiliary outlet is located on the dash.
With the key switch in the ON position, the auxiliary outlet supplies power
for any lights and accessories that have a 12-volt plug.
USB PORT (IF EQUIPPED)
A USB port (if equipped) is located on the dash.
With the key switch in the ON position, the USB port supplies power to
electronic devices via a USB cable.
Auxiliary
USB
ROLLOVER PROTECTION STRUCTURE (ROPS)
A vehicle rollover can cause
severe injury or death. Never
operate the vehicle in a manner that could cause the vehicle to roll over.
ROPS
ROPS
Warning Label
The Rollover Protection Structure (ROPS) on the
STAMPEDE XTR meets ISO 3471 per ANSI/ROHVA
1 rollover performance requirements.
Always have the ROPS inspected by an authorized
BAD BOY OFF ROAD dealer if it is damaged in any
way.
No device can ensure occupant protection in the
event of a rollover. To avoid vehicle rollover, follow all
safe operating practices described in this manual and
on the warning label on the ROPS (Shifting Transmission Warning (P/N 643602) on page 13).
Storage Access
Panel
STORAGE COMPARTMENTS
The STAMPEDE XTR has several open storage compartments and a lockable glove box in the dash panel. There is a
storage area under the front seat that can be accessed by removing the seat. There is also a storage area behind the
rear seat for larger objects. Both side panels behind the doors are hinged for access to the storage area behind the
rear seat.
HITCH RECEIVER
The STAMPEDE XTR is equipped with a hitch receiver. Trailer towing equipment is not supplied with the vehicle.
To prevent injury and property damage, follow all warnings, procedures, and towing capacities described in TOWING
LOADS on page 38.
TRUCK BED
The tailgate can be opened for loading and unloading cargo.
Open the tailgate latches and lower the tailgate.
Lift the tailgate and secure the latches to close the tailgate.
The truck bed can be tilted by lifting up the release lever on either
side of the vehicle.
To prevent injury and property damage, follow all warnings, procedures, and weight capacities described on the label in the truck bed
as well as the ones in this owner’s manual. See HAULING CARGO
on page 37 and DUMPING THE TRUCK BED on page 38.
Truck Bed
Release Lever
29
FEATURES AND CONTROLS
FUEL TANK CAP
Always make sure the fuel cap is reinstalled after
filling the tank. Do not operate the vehicle without the fuel cap correctly installed and tightened.
The fuel cap is located on the passenger side of the vehicle.
See Fuel on page 32 for fueling information.
Fuel Cap
30
OPERATION
OPERATION
SAFETY
Failure to operate the vehicle correctly can result in a collision, loss of control, accident
or rollover, and cause serious injury or death. Read and comply with all safety warnings
in the safety section of this owner’s manual.
PRE-RIDE INSPECTION
Inspect and verify that the vehicle is in safe operating condition before each use to decrease the risk of an accident.
Check the items in the table to help ensure safe and reliable operation.
Item
Check
Page
Brake system/pedal travel
Check for proper operation.
62
Brake fluid
Check for correct level.
62
Park gear
Ensure vehicle does not roll when in park (P), and P light illuminates in the driver information center.
Front suspension
Inspect. Lubricate if necessary. Check for loose or missing hardware.
Rear suspension
Inspect. Lubricate if necessary. Check for loose or missing hardware.
CV boots
Inspect for damage. Replace if necessary.
Steering
Check for smooth and free operation.
Tires
Check condition and pressure.
Wheel hardware
Check for loose or missing hardware.
Frame hardware
Check for loose or missing hardware.
63
15
Fuel and engine oil
Check for correct levels.
53
Coolant
Check for correct level.
58
Coolant hoses and radiator
Inspect for leaks.
53
Switches and indicator lights
Check operation.
21
Air filter
Inspect; clean or replace if necessary.
61
Headlights
Check operation.
65
Brake light / taillights
Check operation.
65
Seat belts
Check entire length of belt for damage. Check latch operation.
15
27
CVT belt
Check condition.
60
ENGINE BREAK-IN
Correct operation of the engine during the break-in period is essential to the performance, reliability and life of the
engine.
The engine break-in period is:
• the first 5 operating hours of a new engine
• the first 5 operating hours of an engine that has been completely disassembled
• the first few minutes until the engine is warm at each operation
During these break-in periods, operate the vehicle in the following manner:
• Avoid engine speeds over 6000 rpm.
• Avoid long periods of idle time.
• Avoid long operating times at low engine speed.
• Avoid long operating times at the same engine speed.
• Avoid long operating times with a full load.
• Vary the engine speed during operation.
• Apply quick bursts of acceleration after the engine has warmed up.
31
OPERATION
CVT BELT BREAK-IN
During the first 30 minutes of operation on a new CVT belt, operate the vehicle in the following manner:
• Drive conservatively; keep engine at half-throttle or less.
• Avoid constant engine rpm; vary engine speed.
• Avoid abrupt acceleration; accelerate and decelerate smoothly.
FUEL
Refer to Fuel Handling Guidelines on page 17 for more information regarding handling and storage of fuel.
Always turn off the engine before refueling.
Never use cigarettes in or near the area where refueling is done or fuel is stored.
Do not add fuel near open flame or electrical items that can cause a spark.
Refuel only in well-ventilated areas.
Wear eye protection to protect from splashed fuel and fuel vapors.
Inspect the fuel cap, tank and other components for leaks or damage that can cause a
hazardous condition.
Do not overfill the tank. Do not fill the tank neck.
Fill the tank with clean, automotive grade gasoline.
Fuel
NOTES
Recommended grade
91, 92 or 93 octane
Recommended for maximum engine performance and fuel economy.
Minimum grade requirement
87 octane
Permissible, however the use of lower octane fuels can cause loss of engine
power and/or increased fuel consumption.
Ethanol content
10% maximum permissible
Exceeding the maximum permissible ethanol concentration can deteriorate
the engine fuel system and starting performance.
Methanol content
Not permissible
The use of fuels containing methanol is not permissible.
STARTING THE ENGINE
Always start the engine outdoors or in a well-ventilated space.
1. Sit in the driver’s seat and fasten the seat belt. Close the cab doors.
2. Press the brake pedal.
3. Move the gear shifter to the P (park) position.
4. Do not press the accelerator pedal. The engine will not start with the accelerator pedal pressed.
5. Insert the key and turn it past the ON position to the START position until the engine starts, then release. Engage
the starter for no more than five seconds.
6. If the engine does not start within five seconds, release the ignition switch and wait five seconds.
7. Repeat steps 5 and 6 until the engine starts.
NOTICE: Operating the vehicle immediately after starting the engine can cause engine damage. Allow the
engine to warm up for several minutes before operation begins.
STOPPING THE ENGINE
1.
2.
3.
Release the accelerator and press the brake pedal to stop the vehicle.
Bring the vehicle to a complete stop and move the gear shifter to the P (park) position.
Turn the key to the OFF position to shut down the engine and vehicle electronics.
A rolling vehicle can cause serious injury. Always move the shifter to the P (park) position when stopping the engine.
32
OPERATION
ACCELERATING
1.
2.
Release the brake pedal completely.
Press the accelerator pedal with gradual and steady pressure until the vehicle reaches the desired speed.
BRAKING
When carrying cargo or towing a trailer, the weight of the load will increase the braking
distance required to slow or stop the vehicle. Not allowing for increased braking distance under load can cause an accident or injury.
1.
2.
3.
Release the accelerator pedal completely.
Press the brake pedal firmly.
Practice starting and stopping using the brake until you are familiar with the controls.
DRIVING PROCEDURE
1.
2.
3.
4.
5.
6.
7.
8.
9.
Perform the pre-ride inspection. See
page 31.
Wear protective riding gear:
• helmet
• eye protection
• gloves
• long-sleeve shirt
• long pants
• over-the-ankle boots
Sit in the driver’s seat and fasten the seat
belt. Close the door.
Start the engine and allow it to warm up.
Check surroundings and determine the path
of travel.
Press the brake pedal and shift the transmission into L (low) or H (high) gear.
With both hands on the steering wheel, release the brake pedal and immediately start to apply gradual and
steady pressure to the accelerator pedal.
Practice maneuvering the vehicle using the accelerator and brake pedals. Drive slowly and cautiously until you
are comfortable with the controls.
Do not drive with a passenger until you have at least two hours of experience driving this vehicle.
DRIVING WITH PASSENGERS
• All passengers must be at least 12 years old.
• All passengers must be able to sit with their back against the seat, both feet on the floor and both hands on the passenger hand hold.
• Do not allow more than three passengers in the vehicle; one in the front seat, two in the rear seat.
• Do not allow any passenger to ride anywhere on the vehicle except the passenger’s seats.
• Travel at speeds appropriate for your skills, your passenger’s skills and the operating conditions. Avoid unexpected
or aggressive maneuvers that could cause discomfort or injury to the passengers.
• The handling characteristics can change with the added weight of passengers. Allow more time and distance for
braking.
• Follow all operating guidelines as described on the safety labels on the vehicle and in this manual.
1.
2.
3.
4.
Perform the pre-ride inspection. See page 31.
Make sure you and your passengers are wearing protective riding gear:
• helmet
• long-sleeve shirt
• eye protection
• long pants
• gloves
• over-the-ankle boots
Make sure you and your passengers have seat belts correctly fastened.
Close all cab doors.
33
OPERATION
SLIPPERY SURFACES
Skidding or sliding can cause loss of control. Skidding or sliding can cause rollover if
tires have lost traction, then regain traction suddenly. When operating on slippery surfaces, travel at reduced speed to help maintain control of the vehicle.
When operating in conditions such as ice, water, muddy trails, loose gravel or freezing temperatures, follow these
guidelines:
• Do not operate on excessively rough, slippery or loose terrain.
• Slow down before entering potentially slippery areas.
• Maintain a high level of alertness, carefully evaluate the path of travel and avoid quick, sharp turns.
• Engage AWD before the wheels begin to lose traction.
NOTICE: Severe damage to the drive train can occur if AWD is engaged while the wheels are spinning.
Always allow the wheels to stop spinning before engaging AWD.
• Correct a skid by turning the steering wheel in the direction of the skid. Never apply the brakes during a skid.
OBSTACLES IN DRIVE PATH
When driving in an area with obstacles such as
logs and rocks in the travel path, follow these
guidelines:
• Check for obstacles before driving in an unfamiliar area.
• Stay alert and continuously monitor the path
of travel.
• Drive slowly when on unfamiliar terrain. Some
obstacles are not easily or immediately
detected.
• Avoid driving over very large obstacles such
as large rocks and fallen trees. If unavoidable,
drive cautiously and slowly.
• Do not drive over obstacles that could potentially cause a rollover when a passenger is in
the vehicle. Have all passengers exit the vehicle and move away to a safe distance.
DRIVING UPHILL
When driving up a hill, follow these guidelines:
• Drive straight up the hill.
• Avoid excessively steep hills.
• Keep both feet on the floor or pedals.
• Check the terrain before driving up a hill. Do not try to
climb hills that have excessively slippery or loose surfaces.
• Drive at a steady rate of acceleration and speed.
• Do not drive over the crest of a hill at high speed. An
obstacle, sharp drop, or another person or vehicle could
be on the other side of the hill.
• Do not attempt to drive up a hill that is beyond your skill
level.
34
OPERATION
TRAVERSING HILLSIDES
Traversing a hillside is not recommended. Improper procedure can cause loss of control or a rollover. Avoid crossing
the side of a hill unless absolutely necessary. Check the terrain and determine if traversing the hill can be accomplished safely. Do not proceed if the terrain is beyond the vehicle or driver’s ability.
If traversing a hillside is unavoidable, follow these guidelines:
• Drive slowly.
• Use extreme caution.
• Avoid crossing the side of a hill that has a slippery surface.
• Avoid crossing the side of a steep hill.
• When traversing a hillside that has soft terrain, it may be necessary to steer slightly uphill to keep the vehicle traveling in a straight line.
• If you feel that you are losing control of the vehicle, steer downhill if possible to regain control.
DRIVING DOWNHILL
When carrying cargo or towing a
trailer, the weight of the load will
increase the braking distance
required to slow or stop the vehicle. Not allowing for
increased braking distance under load can cause an
accident or injury.
When driving down a hill, follow these guidelines:
• Avoid excessively steep hills.
• Check the terrain carefully before descending any hill.
• Never drive down hills with excessively slippery or loose
surfaces.
• Drive slowly.
• Drive straight down the hill. Avoid descending the hill at
an angle that could cause the vehicle to lean sharply to
one side.
• Apply light and constant pressure to the brakes to maintain slow speed and control of the vehicle.
STALLING ON A HILL
A rollover can result from stalling or rolling backward while climbing a hill. Drive uphill at a constant speed.
If your vehicle completely stalls while climbing a hill:
1. Apply the brakes.
2. Verify that the area behind you is clear.
3. Put the transmission in R (reverse).
4. Use steady brake pressure to control speed, and allow the vehicle to slowly roll straight downhill.
If your vehicle begins to roll downhill:
1. Do not press the accelerator.
2. Apply the brakes gradually until the vehicle fully stops.
3. Verify that the area behind you is clear.
4. Put the transmission in R (reverse).
5. Use steady brake pressure to control speed, and allow the vehicle to slowly roll straight downhill.
DRIVING THROUGH WATER
The STAMPEDE XTR can be driven through water that is up to the bottom of the floorboard. Do not drive in water
deeper than the bottom of the floorboard.
NOTICE: To decrease risk of major damage, the vehicle must be serviced correctly and promptly after immersion in water deeper than the floorboard. Always take the vehicle to your dealer for service. DO NOT
START THE ENGINE. If it is impossible to take the vehicle to your dealer before starting the engine,
perform the service procedure described under VEHICLE IMMERSION on page 60, and then take the
vehicle to your dealer as soon as possible.
35
OPERATION
When driving through water, follow this procedure:
1. Determine the depth of water and
strength of current before entering the
water.
2. Choose a crossing where both banks
have gradual inclines.
3. Proceed slowly. Avoid rocks and other
obstacles.
4. Avoid driving through water that exceeds
the height of the floorboard.
5. Avoid water with a fast-flowing current.
Floorboard
Deep or fast-flowing water can cause loss of vehicle control and lead to possible injury
or death. Never cross water that is deeper than the bottom of the floorboard.
6.
After leaving the water, dry the brakes by applying light pressure to the pedal repeatedly until braking action is
normal.
NOTICE: After driving your vehicle in water, it is critical that the services listed in the SCHEDULED MAINTENANCE CHART on page 48 be performed. Pay particular attention to engine oil, front and rear differential and all grease fittings.
DRIVING IN REVERSE
When driving in reverse, follow these guidelines:
• Check that the area behind the vehicle is clear of
obstacles and people.
• Check left and right fields of vision before driving in
reverse.
• Do not back down a steep hill.
• Drive in reverse slowly.
• Press the brakes lightly for stopping.
• Accelerate slow and steady.
• Avoid turning at sharp angles.
PARKING THE VEHICLE
NOTICE: When parking the vehicle inside a garage or structure, the space must be well ventilated. Park the
vehicle away from any source of flame or sparks, including any appliance with a pilot light.
Park the vehicle on a flat surface if possible. If parking on an incline is unavoidable, be sure to
chock the wheels as shown in the following illustration to keep the vehicle from rolling.
1.
2.
3.
4.
5.
36
Press the brake to stop the vehicle.
Put the transmission in P (park).
Turn the engine off.
Remove the key from the ignition to prevent unauthorized use.
If parking on an incline, chock the wheels on the downhill end as shown in the following illustration.
OPERATION
HAULING CARGO
Hauling cargo incorrectly can alter vehicle handling characteristics and cause loss of
control, brake instability, and possibly lead to serious injury or death.
Never exceed the maximum weight capacity of the vehicle. The total load (operator, passengers, accessories, cargo and load on hitch) must never exceed the maximum weight
capacity of the vehicle. See the following chart in Maximum Cargo Load / Maximum
Weight Capacity on page 37.
Position the load as far forward, and as low as possible in the truck bed.
Secure all loads before operating. Unsecured loads can shift and create unstable operating conditions.
When operating over rough or hilly terrain, reduce speed and cargo (if possible) to maintain stable driving conditions.
Use low gear and drive slowly.
Operate only with stable and safely arranged loads. When handling loads that are impossible to center in the truck bed, make sure the load is secured as tightly as possible and
operate the vehicle with extra caution.
Always attach a tow load to the rear hitch of the vehicle.
Reduce speed and allow greater distances for braking when hauling cargo.
Heavy loads affect braking and handling characteristics. Use extra caution when applying brakes with a heavily loaded vehicle. Avoid terrain or situations that may require
reverse downhill travel.
Use extra caution when operating with loads that extend over the truck bed sides. Stability and maneuverability can be affected and increase risk of rollover.
The STAMPEDE XTR is designed to carry or tow specific capacities. Read and comply with the load distribution warnings on the warning label affixed to the bed. The total load (operator, passengers, accessories, cargo and load on
hitch) must never exceed the maximum weight capacity of the vehicle.
Maximum Cargo Load / Maximum Weight Capacity
Exceeding the weight capacities can cause loss of vehicle control and possible injury or
death.
Maximum Cargo Load (bed)
600 lbs. (272 kg)
Maximum Cargo Load (underseat)
100 lbs. (45 kg)
Maximum Cargo Load (extended cab storage compartment)
170 lbs. (77 kg)
Maximum Vehicle Weight Capacity
1500 lbs. (680 kg)
• Do not exceed 35 mph (56 kph) if the maximum vehicle weight capacity is greater than 600 lbs. (272 kg).
• Do not exceed 25 mph (40 kph) if the maximum vehicle weight capacity is greater than 900 lbs. (408 kg).
37
OPERATION
Operating the
vehicle with passengers in the
truck bed can result in severe injury
or death. Never allow anyone to ride in
the truck bed. Passengers must
always ride seated in the passenger
seats with the seat belts fastened.
TOWING LOADS
Towing loads incorrectly can alter vehicle handling characteristics and cause loss of
control, brake instability, and possibly lead to serious injury or death.
When towing a load, follow these guidelines:
• Never load more than 150 lbs. (68 kg) tongue weight on the hitch receiver.
• Drive slow and use low gear for towing.
• If towing a disabled vehicle, put the disabled vehicle transmission in neutral.
• Towing a trailer or another vehicle increases braking distances required for slowing or stopping the vehicle.
• Do not tow more than the recommended towing weight for the vehicle. See the following table and the SPECIFICATIONS CHART on page 71.
Maximum Towing Capacity (Level Ground)
2000 lbs. (907 kg)
Hitch Tongue Weight
150 lbs. (68 kg)
• Attach a trailer to the tow hitch only. Attaching the trailer at any other location can cause loss of vehicle control.
• Do not drive faster than the maximum speed.
Maximum Towing Speed
Trailer Load
15 mph (24 kph)
under 500 lbs. (227 kg)
10 mph (16 kph)
over 500 lbs. (227 kg)
• Do not tow a trailer on an incline greater than 15°.
To extend the CVT belt life, use the L (low) gear to haul or tow heavy cargo.
DUMPING THE TRUCK BED
If the bulk of the cargo weight is at the rear of the bed, the bed may unexpectedly dump
when the release lever is pulled, causing serious injury to anyone close. Never pull the
release lever unless the load is positioned evenly, or located at the front of the truck bed.
Never leave the truck bed in the upright position after emptying the cargo. The bed can
unexpectedly close and cause serious injury. Never drive the vehicle with the truck bed
in the raised position.
1.
Select a level location to dump the truck bed load. Do not attempt to dump or
unload the vehicle if it is on an incline.
2. Apply the brakes.
3. Put the transmission in P (park).
4. Exit the vehicle.
5. Make sure the cargo is positioned evenly or located at the front of the truck bed.
6. Release the tailgate latches.
7. Stand clear and pull the release handle. Lift up on the truck bed to dump the
cargo.
8. When the truck bed is empty, lower the bed back into place.
9. Push down to latch the bed.
10. Close and latch the tailgate.
38
Truck Bed
Release Lever
OPERATION
DIFFERENTIAL OPERATION MODES
Rear Differential Locking Switch
The differential on the rear axle has two options:
• Press the top of the rocker switch to lock the differential. The rear wheels are locked and rotate at
the same rate. This option provides optimum traction on slippery or low traction conditions.
• Press the bottom of the rocker switch to unlock the differential. The rear wheels operate independently. This option should be used for basic use on normal terrain. An unlocked differential
makes maneuvering easier and reduces the potential to damage the terrain.
NOTICE: Do not switch rear differential modes while the vehicle is traveling at high speeds or
while the rear wheels are spinning. Slow the vehicle to nearly or completely stopped
before engaging the differential to prevent damage.
Allow for a larger turning radius when the differential is locked.
All-Wheel Drive (AWD)
Press the top of the rocker switch to engage All-Wheel Drive (AWD). When in AWD, power is transferred to both the front and rear wheels.
AWD OPERATION:
The AWD icon on the driver information center illuminates when the vehicle is in AWD
mode.
In AWD mode, the front differential automatically engages any time the rear wheels lose traction. When the
rear wheels regain traction, the front differential automatically disengages. There is no limit to the length of
time the vehicle may remain in AWD.
Once enabled, the AWD remains enabled until the AWD switch is moved to the 2WD position. If the switch is moved
from AWD to 2WD while the front differential is moving, it will not disengage until the rear wheels regain traction.
Engage AWD before getting into conditions where front wheel drive may be needed. If the rear wheels are spinning,
release the accelerator pedal before switching to AWD mode.
NOTICE: Switching to AWD while the rear wheels are spinning can cause severe drive shaft and clutch damage. Slow the vehicle to nearly or completely stopped before engaging the differential to prevent
damage.
DISENGAGING AWD:
Some conditions make it possible for the front differential to remain locked unnecessarily. This condition causes
increased steering effort and speed restriction. To disengage AWD, follow these steps:
1. Stop the vehicle completely.
2. Operate in reverse for a minimum of 10 feet.
3. Stop completely again.
4. Shift into low gear and drive forward.
If the front differential still remains locked, take the vehicle to your dealer for service.
Two-Wheel Drive (2WD)
Press the bottom of the rocker switch to change operation mode from AWD to 2WD. The front differential is unlocked
in this position.
39
OPERATION
40
WINCH OPERATION
WINCH
The safety warnings and information in this section apply if your vehicle has a winch.
Improper or irresponsible use of the winch can result in severe injury or death. Always
follow all winch instructions and warnings in this manual.
WINCH SAFETY
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Read and understand this entire section before operating your winch.
Inspect your winch and winch cable for damage before each use.
Never use alcohol or drugs before or during operation of the winch.
Do not allow any person below the age of 16 to operate the winch.
Always wear eye protection and heavy gloves while operating the winch.
Always keep body, hair, clothing and jewelry clear of the winch cable and hook while operating the winch.
Never attempt to jerk a load attached to the winch with a moving vehicle. See Shock Loading on page 44.
Always keep the area around the vehicle, winch, winch cable and load clear of people and distractions while operating the winch.
Always turn the vehicle ignition switch OFF when the vehicle and winch are not being used.
Maintain at least five full turns of winch cable wrapped around the winch
drum at all times. The friction provided by the wrapped cable allows the drum
to pull on the winch cable and move the load.
Minimum five (5)
full turns of cable
on drum at all times.
If pulling yourself, put your vehicle in N (neutral). If pulling something else,
put your vehicle in P (park) to prevent it from moving while winching. Use
wheel chocks if needed.
Always align the vehicle and winch with the
Do not pull at an angle.
load directly in front of the vehicle as much
as possible. Avoid winching with the winch
cable at an angle to the vehicle’s centerline
whenever possible.
If winching at an angle is unavoidable, follow
these precautions:
• Be observant of the winch drum. Do not
allow the winch cable to stack or accumulate at one end of the winch drum. If
the winch cable stacks, damage to the
Incorrect
Correct
winch and winch cable can occur.
• If stacking occurs, stop winching. Follow step 13 on page 43 to feed and rewind the cable evenly before continuing the winch operation.
Never winch up or down at sharp angles. It can destabilize the winching vehicle and possibly cause unexpected
movement.
Never winch loads that exceed the rated capacity of the winch.
The winch motor can become hot during use. After winching for more than 45 seconds, or if the winch stalls during
operation, stop winching and allow the winch motor to cool down before using it again.
Never touch, push, pull or straddle the winch cable while winching a load.
Even if wearing heavy gloves, never let the winch cable run through your hands.
Never release the clutch on the winch when the winch cable is under load.
Never use the winch for lifting or transporting people.
Never use the winch to hoist or suspend a vertical load.
Never immerse the winch in water. Take your winch to your dealer for service if immersion occurs.
Never winch the hook fully into the winch. It can damage winch components.
Disconnect the remote control from the vehicle when the winch is not in use to prevent
accidental activation and use by unauthorized persons.
Never apply grease or oil to the winch cable. Grease and oil will cause the winch cable to
collect debris and shorten the life of the cable.
41
WINCH
WINCH OPERATION
Read all of the Winch Safety beginning page 41 before operating your winch.
NOTICE: Practicing operation and use of the winch before it is needed to perform a job is recommended.
Improper or irresponsible winch use can result in severe injury or death. Comply with all
winch instructions and warnings in this manual.
Since all winching situations are different, follow these important guidelines:
• Evaluate the winching operation you are about to perform.
• Proceed slowly and deliberately.
• Maintain constant awareness of your surroundings.
• Maintain constant awareness that your winch is very powerful.
• Change your winching strategy if what you are doing is not working.
• Seek assistance if needed.
1.
2.
3.
Inspect the vehicle, winch, winch cable and winch controls for any signs of damage or parts in need of repair or
replacement before each use. Replace the cable if signs of wear or damage is visible. Never operate a winch in
need or repair or service.
If pulling yourself, put your vehicle in N (neutral). If pulling something else, put your vehicle in P (park) to prevent
it from moving while winching. Use wheel chocks if needed.
Use a hook strap when handling the hook.
Never put your fingers into the hook. Doing so
could lead to severe injury.
a.
Attach the hook onto the load or use a tow strap or chain to
secure the load to the winch cable.
Hook Strap
Do not use a recovery strap as a tow strap.
Recovery straps are designed to stretch so they store energy. The stored energy in the
recovery strap will release if the winch cable breaks. The use of recovery straps can
cause severe injury or death.
Do not hook the winch cable back onto itself. Doing so will damage
the winch cable and can result in winch cable failure.
Replace the winch cable at the first sign of damage to prevent severe
injury or death in the event of failure. Replace winch parts with genuine BAD BOY OFF ROAD or equivalent replacement parts.
b.
c.
d.
e.
4.
5.
42
If possible, keep the winch cable aligned with the centerline of the winching vehicle to
help maintain even spooling of the winch cable.
If freeing a stuck vehicle by attaching to a tree, use an item such as a tow strap to avoid damaging the tree
during winch operation. Sharp cables and chains can damage or kill trees.
The safety latch on the winch cable hook must be fully seated when the
Correct
Incorrect
load is attached.
Never operate the winch with a damaged hook or latch. Damaged parts
must be replaced before winch operation.
Never remove the hook strap from the hook until the operation is complete.
Release the winch clutch and pull out the winch cable.
WINCH
6.
7.
8.
9.
10.
11.
12.
13.
Pull out as much cable as possible to maximize the winch’s pulling capacity. Maintain at least five full turns of winch cable wrapped around the
winch drum at all times. The friction provided by the wrapped cable allows
the drum to pull on the winch cable and move the load.
Minimum five (5)
full turns of cable
on drum at all times.
Read and follow the information below for winch damping to ensure safe
winch use.
a. To absorb energy that could be released by a winch cable failure,
always put a damper on the winch cable. A damper can be a heavy
Damper
jacket, tarp or other soft, dense object. A damper can absorb much
Hook
of the energy released if the winch cable breaks when winching. Use Strap
of a tree limb can help as a damper if no other items are available.
b. Lay the damper on top of the mid-point of the winch cable length that
is spooled out.
c. On a long pull, it may be necessary to stop winching and reposition the damper so that it is always near the
mid-point of the cable. Always release the tension on the winch cable before repositioning the damper.
d. Never stand in direct line with the winch cable. Never allow others to stand near or in line with the winch
cable during winch operation.
Never use damaged or worn straps, chains or other rigging items.
The only time a winch-equipped vehicle should be moving when the winch is in use is when the winching vehicle
itself is stuck. Follow these guidelines when winching a stuck vehicle.
a. Release the winch clutch and spool out the necessary length of winch cable.
b. Align the cable as close as possible to the winching vehicle centerline.
c. Attach the cable hook to the anchor point or the stuck vehicle frame.
d. Re-engage the clutch on the winch.
e. Slowly winch in cable slack.
f.
Shift the stuck vehicle to the lowest gear available.
g. Slowly and carefully press the accelerator pedal and winch together to free the vehicle.
h. Stop winching as soon as the stuck vehicle is able to propel itself without the help of the winch.
i.
Remove the cable hook.
j.
Rewind the cable evenly back onto the drum.
To prevent damage to the vehicle, do not attempt to winch another stuck vehicle by attaching the cable to a suspension component, brush guard, bumper or cargo rack. Always attach the cable to the vehicle frame or hitch.
Extensive winching will drain the battery on the winching vehicle. If winching for long periods of time, allow the
engine to run while operating the winch to prevent battery drainage.
The winch motor can become hot during use. After winching for more than 45 seconds, or if the winch stalls
during operation, stop winching and allow the winch to cool down for 10 minutes before using it again.
If it is necessary to redistribute the winch cable on the drum after winching in complete, use the following procedure:
a. Find an assistant to help.
b. Release the clutch on the winch.
c. Pull the cable out.
d. Re-engage the clutch.
e. Have the assistant pull the winch cable tightly with about 100 lbs. (45 kg) of tension using the hook strap.
f.
Slowly retract the cable while the assistant moves the end of the cable back and forth horizontally to evenly
distribute the cable on the drum. This process reduces the chance of the cable wedging itself between lower
layers of the cable.
WINCH CABLE CARE
For your safety, use original BAD BOY OFF ROAD or equivalent winch replacement parts.
Replace the winch cable at the first sign of damage to prevent severe injury or death in
the event of failure.
43
WINCH
• Always inspect the winch cable before each use. Inspect for wear or kinks in the cable.
– A kinked winch cable made of wire rope is shown at right. Even after
being straightened out, this cable has been permanently and severely
damaged. Discontinue use of a cable in this condition.
– A winch cable made of synthetic rope should be inspected for signs of
fraying. Replace the cable if fraying is visible.
– Inspect the winch cable for fused or melted fibers, indicated by stiffness
and a smooth or glazed appearance. Discontinue use of a winch cable
Kinked
in this condition.
Bent
Stressed or Frayed
SHOCK LOADING
The winch cable is designed and tested to withstand the loads produced by the winch motor when operated from a
stationary vehicle. The winch and winch cable are not designed for shock loading.
Practices that produce shock loading on a winch cable include:
• Abrupt acceleration of the vehicle against the pull of the winch cable, which causes immediate force on the winch
cable that exceeds the force the cable is designed to withstand.
• Jogging the winch by quickly turning the winch ON and OFF repeatedly, which puts extra load on the winch, winch
cable and generates excessive heat from the motor.
• Using the winch to tow vehicles or other objects.
A winch cable is not designed for shock loading. Shock loading can tension a cable
beyond its strength and cause it to break. A broken winch cable under high loading conditions can cause severe injury or death to anyone in the area.
When using the winch, use the following guidelines:
• To avoid generating high winch cable loads that may exceed the strength of the cable:
– Never use the winching vehicle to take up slack in the winch cable by moving the vehicle.
– Never use the winching vehicle to move the object being winched; use the winch only.
• Never jog the winch (quickly turn the winch ON and OFF repeatedly).
• Never tow a vehicle or other objects with a winch. Towing an object with a winch produces shock loading of the
cable even when towing at low speeds.Towing from a winch also positions the towing force high on the vehicle and
cause instability of the vehicle.
• Never use recovery straps with your winch. Recovery straps are designed to stretch, so they store energy. The
stored energy in the recovery strap will release if the winch cable breaks. The use of recovery straps can cause
severe injury or death.
• Never use the winch as a tie down to secure a vehicle to a trailer or other transportation vehicle. Using a winch as a
tie down can also cause shock loading that can damage the winch, winch cable or vehicles.
WINCH MAINTENANCE SAFETY
Improper or lack of maintenance and service could lead to severe injury or death. Always
follow all winch instructions and warnings in this manual.
• Always inspect the winch before each use. Inspect for worn or loose parts including mounting hardware. Never use
the winch if any part needs repair or replacement.
• Make sure the winch motor is cool before servicing the winch.
• Always disconnect the battery connections before working on your winch to prevent accidental activation of the
winch.
• For your safety, always replace winch parts, including the cable, with genuine BAD BOY OFF ROAD replacement
or equivalent parts.
• Replace the winch cable with one of the exact type.
44
EMISSION CONTROL SYSTEMS
EMISSION CONTROL SYSTEM
NOTICE: A qualified repair shop or person of the owner’s choosing may maintain, replace, or repair emission
control devices and systems with original or equivalent replacement parts. However, warranty,
recall and all other services paid for by BAD BOY OFF ROAD must be performed at an authorized
BAD BOY OFF ROAD service center.
CRANKCASE EMISSION CONTROL SYSTEM
The BAD BOY OFF ROAD engine has a closed crankcase system. Blow-by gases are forced back to the combustion
chamber by the intake system. All exhaust gases exit through the exhaust system.
EXHAUST EMISSION CONTROL SYSTEM
Exhaust emissions are controlled by the engine and catalyst. The catalyst is part of the exhaust system. This system
should not be altered in any way.
An electronic fuel injection (EFI) system controls fuel delivery. The engine and EFI components are set at the factory
for optimal performance and are not adjustable.
Separate inserts supplied in packaging with the vehicle provide information on Product Warranty and on Emissions
Warranty. Failure to follow instructions for emission parts replacement may violate Federal Law (40 CFR part
1068.105 (b)) and be subject to fines and other penalties as described in the Clean Air Act.
NOTICE: Emission-related components also include any other part whose only purpose is to reduce emissions or whose failure will increase emissions without significantly degrading engine/equipment
performance.
Installing non-equivalent or non-original components, neglecting maintenance, removing after
treatment components, adjusting calibrations or otherwise disabling your emission control systems may void your warranty, cause injury or be a violation of Federal Law.
45
EMISSION CONTROL SYSTEMS
EMISSION CONTROL INFORMATION LABEL
The Emission Control Information label is located on the left rear frame, under the truck bed. It is visible and accessible without the removal of any parts. The Date of Manufacture will be identified on the label (MM/YYYY).
VEHICLE EMISSION CONTROL INFORMATION
ENGINE FAMILY:
643601
EXHAUST EMISSION CONTROL SYSTEM (ECS): TWC, SFI, ECM, O2S
EVAP FAMILY:
DOM (MM/YYYY)
TUNE-UP SPECIFICATIONS
VALVE CLEARANCE (ENGINE COLD) INTAKE: 0.1 - 0.2 mm EXHAUST: 0.2 - 0.3 mm
SPARK PLUG: CHAMPION RC7PYCBX ELECTRODE GAP (COLD): 0.69 - 0.84 mm
THIS VEHICLE IS CERTIFIED TO OPERATE ON UNLEADED GASOLINE
ENGINE OIL: SAE 0W-40 FULL SYNTHETIC (see owner’s manual)
THIS VEHICLE MEETS U.S. EPA AND CALIFORNIA REGULATIONS FOR
MY ATVbs. IT
IS CERTIFIED TO EPA 1.5 g/km HC+NOx AND 35.0 g/km CO PER §1051.107 AND TO CALIFORNIA
1.2 g/km HC AND 15.0 g/km CO PER 13CCR § 2412 EXHAUST EMISSIONS STANDARDS AND
MEETS U.S. EPA AND CALIFORNIA EVAP STANDARDS USING CERTIFIED COMPONENTS.
EMISSIONS HANG TAG
The Emissions Hang Tag is attached to the steering wheel/column with a zip tie.
TEXTRON SPECIALIZED VEHICLES
ATVb MODEL: STAMPEDE 900 XTR
MODEL YEAR: 2017
ENGINE: 846cc, 4 CYCLE
THE NORMALIZED EMISSION RATE (NER) AS
DEVINED BY U.S. ENVIRONMENTAL PROTECTION
AGENCY IN 40 CFR §1051.137.
THE NER FOR THIS VEHICLE IS 2.2
CLEANEST
LEAST CLEAN
657303
46
MAINTENANCE
MAINTENANCE
NOTICE: A qualified repair shop or person of the owner’s choosing may maintain, replace, or repair emission
control devices and systems with original or equivalent replacement parts. However, warranty,
recall and all other services paid for by BAD BOY OFF ROAD must be performed at an authorized
BAD BOY OFF ROAD service center.
TOOL KIT
A tool kit is provided that contains tools required to perform some of the scheduled maintenance procedures. The
tools included in the kit are:
• spark plug wrench
• shock adjustment tool
• tire pressure gauge
• bit driver
• T-30 Torx bit
• flat head bit
• 5 mm Allen wrench
SCHEDULED MAINTENANCE
Consistent inspection, adjustment and lubrication of some components are necessary to maintain your STAMPEDE
XTR so that it remains in safe and reliable condition. Refer to the SCHEDULED MAINTENANCE CHART on page 48
for detailed requirements.
Inspect, clean, lubricate, adjust and replace parts as necessary. Use original BAD BOY OFF ROAD or equivalent
replacement parts.
Record the maintenance items performed along with details in the MAINTENANCE LOG beginning on page 81.
NOTICE: Service and adjustments are important for safe and reliable vehicle operation. If not familiar with
safe service and adjustment procedures, have your dealer perform the operations.
Initial Service Requirements
Perform the additional inspection or maintenance at the initial service interval indicated, in addition to regular intervals.
See SCHEDULED MAINTENANCE CHART on page 48. The initial service is required for optimum performance and
reliability.
• engine oil and filter
• valve lash
• front differential oil
• rear differential oil
Severe Use Conditions
Vehicles subjected to heavy or severe use must be inspected and serviced more frequently than those of normal use
patterns.
The following conditions are considered severe use:
• frequent or prolonged use in a dusty environment
• prolonged low speed operation
• prolonged heavy load operation
• frequent use or immersion in mud, water or sand
• short trips in cold weather
• extended idle
• racing or high RPM use
47
MAINTENANCE
SCHEDULED MAINTENANCE CHART
Perform all services at the maintenance interval reached first.
S – Indicates operations that need to be performed on vehicles subjected to severe use.
E – Indicates emission-related services. Failure to do this maintenance will not void the emissions warranty but may affect emissions.
D – Indicates services that must be performed by an authorized BAD BOY OFF ROAD dealer.
Interval
Item
(perform at interval that comes first)
Hours
Steering
D
E
Calendar
Remarks
Page
Miles (km)
Daily
Check for smooth and free operation.
Front suspension
Daily
Inspect. Check for leaks and loose or missing
hardware.
63
Rear suspension
Daily
Inspect. Check for leaks and loose or missing
hardware.
CV boots
Daily
Inspect. Replace as needed.
Tires
Daily
Check condition and pressure.
15
Brake fluid level
Daily
Check for correct level.
62
Wheel lug nuts
Daily
Check for loose or missing.
64
62
Brake system function
Daily
Check for proper operation.
Frame hardware
Daily
Check for loose or missing.
Engine oil level
Daily
Check for correct level.
53
Air filter
Daily
Inspect. Clean or replace as needed.
61
Coolant
Daily
Check level.
58
Headlights and taillights
Daily
Check operation. Replace bulbs as needed.
65
54
Engine oil and filter
Initial Service
Replace oil and filter between first 12 and 25
hours or 250 miles (402 km).
Valve Lash
Initial Service
Check and adjust between first 12 and 25
hours or 250 miles (402 km).
See engine manual or take to dealer.
Front differential oil
Initial Service
Check oil between first 12 and 25 hours.
55
Rear differential oil
Initial Service
Check oil between first 12 and 25 hours.
56
S
E
Air filter
Weekly
Inspect. Replace as needed.
61
S
D
Brake pads
10
Monthly
Inspect. Replace as needed.
62
Battery
20
Monthly
Inspect terminals. Clean as needed.
67
Prop shaft
50
3 Months
Inspect and lubricate.
60
Lubricate all fittings, pivots, cables, etc. where
required.
50
Inspect, lubricate and adjust.
50
S
General lubrication
50
3 Months
Shift linkage
50
6 Months
D
Steering
50
6 Months
500 (800)
Inspect. Replace if excessive play is found.
63
S
Front suspension
50
6 Months
500 (800)
Inspect. Replace if wear or leaks are detected.
50
S
Rear suspension
50
6 Months
500 (800)
Inspect. Replace if wear or leaks are detected.
50
E
Throttle body, air intake
ducts and flange
50
6 Months
500 (800)
Inspect for proper sealing. Clean as required.
500 (800)
S
48
500 (800)
CVT belt
50
6 Months
Inspect. Replace as needed.
60
Cooling system
50
6 Months
Inspect coolant strength seasonally.
58
Oil lines, fasteners
50
6 Months
Inspect for leaks and loose fittings.
MAINTENANCE
Interval
Item
(perform at interval that comes first)
Hours
Calendar
Miles (km)
Remarks
Page
S
Front differential oil
(Inspection)
100
6 Months
1000 (1600)
Inspect for leaks and contamination; change if
required. Also change yearly.
55
S
Rear differential oil
(Inspection)
100
6 Months
1000 (1600)
Inspect for leaks and contamination; change if
required. Also change yearly.
55
S
Engine oil and filter
100
Yearly
1500 (2400)
Change when preparing for storage (no operation for 90 days).
53
D
Valve lash
100
Yearly
2800 (4500)
See engine manual or take to dealer.
1000 (1600)
Check for leaks at tank cap, lines, throttle body.
Replace with OEM parts if needed.
D
E
Fuel system
100
S
Radiator and cooling fan
100
Cooling system
Yearly
Yearly
Inspect; clean exterior surfaces.
59
Yearly
Pressure test system.
58
58
S
Cooling system
100
Yearly
Inspect for leaks.
S
Engine mounts
100
Yearly
Inspect. See repair manual for replacement.
Exhaust muffler
100
Yearly
Inspect. See repair manual for replacement.
S
Front differential oil
(Replacement)
Yearly
Replace at interval and also after immersion.
55
S
Rear differential oil
(Replacement)
Yearly
Replace at interval and also after immersion.
56
S
Wiring
100
Yearly
Inspect for wear, routing, security. Apply dielectric grease to connectors subjected to water,
mud, etc.
D
S
Clutches
100
Yearly
D
Wheel bearings
100
Yearly
Coolant
1000 (1600)
Clean and inspect. Replace worn parts.
Inspect. Replace as needed.
Completely drain and replace with new mixture.
58
5600 (9000)
Replace.
57
5600 (9000)
Inspect. Adjust as needed.
24 Months
S
E
Spark plug
200
D
E
Valve lash
200
S
Fuel lines
D
Brake fluid
200
24 Months
Change.
62
Spark arrester
300
36 Months
Clean.
61
D
Toe adjustment
24 Months
24 Months
Replace. See repair manual.
Inspect periodically. Adjust when parts are
replaced.
49
MAINTENANCE
RECOMMENDED LUBRICANTS AND FLUIDS
Check and lubricate all components at the intervals shown in the SCHEDULED MAINTENANCE CHART beginning
on page 48.
Item
Capacity
Engine oil
~3 qt. (2.8 L)
Lubricants/Fluids
Mobil 1 0W40 Full Synthetic meeting at least API SJ or ACEA
A3/B3
Notes
See page 53.
Ethylene Glycol, silicate- and nitrate-free coolant suitable for
aluminum engines
Engine Coolant
~8 qt. (7.6 L)
Mixing ratio 50% water/50% coolant
Approved
coolants
See page 58.
Chevron Havoline Coolant
Valvoline Zerex
~9 gal. (34 L)
Unleaded; 87 octane min; 91, 92 or 93 octane recommended
10% ethanol content max.
See page 32.
DOT 4 brake fluid
See page 62.
Front differential oil
6 oz. (180 ml)
Mobil 424 recommended; Mobil Fluid LT or equivalent suitable
See page 55.
Rear differential oil
(upper chamber)
13.5 oz.
(400 ml)
Mobil 80W90 recommended or equivalent
See page 56.
Rear differential oil
(lower chamber)
94.7 oz.
(2.8 L)
Mobil 80W90 recommended or equivalent
See page 56.
Universal joint grease or equivalent
Locate fittings on two
u-joints and apply grease
Fuel
Brake fluid
Prop shaft
REPLACEMENT OF MAINTENANCE ITEMS
These items or their equivalents can be purchased through your dealer, directly from BAD BOY OFF ROAD or any
other qualified source.
Item
Part Number
Air filter
652091
Engine oil filter
105041
LIFTING THE VEHICLE
Read and comply with all of the following warnings and lifting procedures to prevent the
possibility of the vehicle falling and causing severe injury or death.
The vehicle must be on a firm and level surface for lifting.
Remain constantly aware that the vehicle is not stable during the lifting process.
Place the jack and jack stands only in the areas indicated in the following illustration.
Do not get under a vehicle until it’s stability on the jack stands is verified; never get
under a vehicle while it is on a jack only.
Put wheel chocks in front and behind all wheels that are not being lifted.
Do not allow anyone to remain or get on the vehicle at any time during the lifting process
or when the vehicle is lifted.
When performing any service to the drivetrain, lift all four wheels off the ground.
NOTICE: If the skid plates need to be removed from the underside of the vehicle to perform maintenance,
remove before lifting the vehicle.
50
MAINTENANCE
Tools
• jack
• jack stands (4)
• wheel chocks
Lifting Front
1.
2.
3.
4.
5.
6.
7.
Chock the rear wheels to keep the vehicle from rolling backward.
Put a jack under the center of the vehicle frame at
the differential mounting plate.
Raise the vehicle with the jack.
Install a jack stand under each side of the vehicle
frame just behind the front wheels.
Lower the vehicle until it rests on the jack stands.
Remove the jack.
Confirm that the vehicle is stable on the jack stands
before proceeding with any service.
FRONT
Lifting Rear
1.
2.
3.
4.
5.
6.
7.
Chock the front wheels to keep the vehicle from rolling forward.
Put a jack under the center of the vehicle frame at
the hitch mounting plate.
Raise the vehicle with the jack.
Install a jack stand under each side of the vehicle
frame just in front of the rear wheels.
Lower the vehicle until it rests on the jack stands.
Remove the jack.
Confirm that the vehicle is stable on the jack stands
before proceeding with any service.
Lowering Vehicle
1.
2.
3.
4.
REAR
Make sure chocks are still in place on any wheels
that remain on the ground.
Put the jack in the same location that was used to
raise the vehicle.
Raise the vehicle enough to remove the jack stands.
Remove the jack stands from underneath the vehicle.
Slowly lower the vehicle to the ground and remove the jack.
51
MAINTENANCE
TRUCK BED REMOVAL
NOTICE: You may choose to remove the truck bed for full access to the engine compartment when performing some maintenance items.
Tools
• ratchet
• socket, 10 mm
• needle nose pliers
The truck bed is heavy and difficult to handle. To prevent possible injury, it is necessary
to have an assistant or a lifting device to remove the truck bed from the vehicle.
1.
2.
With the truck bed in the down position, remove the
two bolts that secure the truck bed bracket to the
bed frame. Remove the bracket.
Raise the truck bed until the gas spring is fully
extended.
Bolt
Bolt
Truck Bed Bracket
NOTICE: Before you can remove the truck bed from the vehicle, the pressure from the gas spring has to be
relieved. Failure to do this as the first step can damage the spring pivot components.
Disconnecting the gas spring
from the underside of the truck
bed requires two people. One
person needs to hold the bed to keep it from falling
while the second person removes the cotter and
clevis pins. The truck bed unexpectedly falling can
cause serious injury.
3.
4.
5.
6.
With a person on the opposite side of vehicle to hold
the bed, remove the cotter and clevis pins that connect the gas spring to the truck bed. Swing the gas
spring down to rest on the frame.
Lower the truck bed.
Remove the cotter pins and clevis pins at the pivot
points of the truck bed.
Lift the bed from the vehicle.
Gas Spring Connection
to Underside of
Truck Bed
Truck Bed Installation
1.
2.
3.
4.
5.
52
Position the truck bed onto the truck bed frame.
Install a clevis and cotter pin at each bed pivot.
Raise the truck bed and connect the gas spring to the underside of the truck bed.
Lower the truck bed.
Install the truck bed bracket.
MAINTENANCE
ENGINE OIL
See RECOMMENDED LUBRICANTS AND FLUIDS on page 50 for oil capacity and grade. The use of an incorrect
grade of engine oil can damage the engine. Always use the recommended grade. Do not mix engine oils of different
grades or viscosity.
NOTICE: Your engine features a dry sump lubrication system. Engine oil is pumped from the oil tank into the
engine while the engine is operating. When the engine is turned off, some oil flows slowly from the
engine back into the oil tank. Check the oil level immediately after turning off the engine.
Monitor the oil level in cold conditions. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change the oil immediately if the level begins to rise.
Monitor the oil level closely. If it continues to rise, discontinue operation and determine the cause of
the oil level increase or take the vehicle to your dealer.
CHECK OIL
Check the engine oil level when the engine is warm.
1. Start the engine and let it to run until it is warm.
2. Turn off the engine.
Wear protective gloves to prevent scalding from hot engine oil.
3.
4.
Remove the dipstick from the oil tank.
To get an accurate level reading, wipe the oil from the dipstick and
insert back into the oil tank. Do not tighten the dipstick.
5.
Remove the dipstick from the tank again and check the level. The oil
level must be in the area between MIN and MAX on the dipstick.
Dipstick
NOTICE: The lack of oil or low oil level can damage the engine.
6.
If the oil level is below the MIN line, refer to the following section, Add Oil.
NOTICE: Excessive oil can damage the engine.
7.
8.
If the oil level is above the MAX line, pump out the excessive oil with a
siphon pump.
Replace the dipstick and tighten to secure.
Add Oil
NOTICE: Do not overfill the oil tank. Excessive oil can damage the engine.
Add oil in small quantities with repeated level checks. The area
between MIN and MAX is approximately 0.5 qt. (0.5 L) engine oil.
1.
2.
Add engine oil into the dipstick hole until the level is between MIN and MAX.
When the level is correct, replace and tighten the dipstick.
53
MAINTENANCE
CHANGE OIL
Tools
• ratchet
• socket, 13 mm
• universal strap wrench
• funnel
• drain pan
• torque wrench, ft.lbs.
Remove Engine Oil
1.
2.
Start the engine and let it to run until it is warm.
Turn off the engine.
Wear protective gloves to prevent scalding from hot engine oil.
3.
Remove the engine oil.
a. Put a drain pan under the oil tank.
b. Remove the drain plug and seal.
c. Allow the oil to completely drain from the tank into
the pan.
Seal
Drain Plug
Make sure you remove the correct
(15A service) relay to prevent the engine
from starting. Removing the wrong relay
or fuse may allow the engine to start when the key is turned.
Starting the engine after the oil is drained can cause serious
engine damage.
d. Remove the 15A service relay in the main fuse box
under the rear passenger seat. Removing this fuse will
interrupt the power supply circuit to the ignition coil,
injectors and O2 sensor so that the engine will turn over
without starting.
e. Turn the key to activate the starter and let it crank for
five seconds. As the engine turns over, the oil is
pumped out of the engine.
f.
Let the oil drain until it stops and then repeat two more
times to remove the remaining oil from the tank.
g. When all of the oil is pumped out of the tank, replace the
seal and reinstall the drain plug. Tighten the plug to 13.3
- 14.8 ft.lb (18 - 20 Nm).
5A (SPARE)
15A (SPARE) 15A (SERV RLY) 15A (FUEL)
5A (KEY SW)
25A (FAN)
MAIN RLY
15A (DIR
BAT)
FAN RLY
BRAKE
EN Rly
15A (BAT
RLY
ACC BLCK RLY
FUEL
Rly
Replace the Oil Filter
1.
54
Remove the oil filter with a universal strap wrench.
Oil Filter
MAINTENANCE
2.
3.
4.
Clean the sealing surface with a lint free cloth.
Lightly coat the new oil filter seal with clean engine oil.
Install the oil filter by hand and then tighten to 7.4 ft.lbs.
(10 Nm).
Sealing Surface
Oil Filter Seal
Refill Engine Oil
NOTICE: Do not overfill or under fill the engine. Low or excessive
oil can damage the engine.
Dipstick
The use of an incorrect grade of engine oil can damage
the engine. Always use the recommended grade. Do not
mix engine oils of different grades or viscosity.
1.
2.
3.
4.
5.
6.
7.
8.
Remove the dipstick from the oil tank.
Add new engine oil into the dipstick hole. See RECOMMENDED
LUBRICANTS AND FLUIDS on page 50 for grade and capacity.
Install the dipstick.
Reinstall the 15A service relay in the fuse box.
Verify that the oil level is correct. See CHECK OIL on page 53.
Clear the service counter for the service light.See Diagnostics on
page 73.
Clear the trouble codes. See Diagnostics on page 73.
Test drive the vehicle and check for oil leaks.
FRONT DIFFERENTIAL
Tools
•
•
•
•
ratchet
socket, 8 mm Allen bit
ratchet extension
drain pan
Check and replace the front differential oil at the intervals indicated in the SCHEDULED MAINTENANCE CHART on
page 48.
Fill Plug
Front Differential Oil Check
NOTICE: Check the front differential oil at the Initial Service and then at regular intervals indicated.
Remove the fill plug and inspect the oil for water or any other
contamination. If the oil is contaminated, it must be replaced.
Front Differential Oil Replacement
1.
2.
3.
4.
5.
6.
Put a drain pan under the front differential.
Remove the drain plug from the bottom of the front differential and allow the oil to drain completely.
Install the plug.
Remove the fill plug.
Add oil to full capacity. See RECOMMENDED LUBRICANTS AND FLUIDS on page 50 for type and capacity.
Install the fill plug.
Drain Plug
(view of underside of
front differential)
55
MAINTENANCE
REAR DIFFERENTIAL
The rear differential has two chambers; top and bottom.
Tools
• ratchet, 3/8”
• socket, 1/2”
• Torx bit, T30
• drain pan
• Allen wrench, 5 mm
NOTICE: You may choose to remove the truck bed, side panel and/or skid plate for full access to the rear differential fill and drain plugs.
Rear Differential Oil Check
NOTICE: Check the rear differential oil in the upper and lower chambers at the Initial Service and then at regular intervals indicated.
Remove the fill plug and inspect the oil in each chamber for water or any other contamination. If the oil is contaminated, it must be replaced.
Rear Differential Oil Replacement (Upper Chamber)
1.
2.
3.
4.
5.
Fill Plug
Remove the drain plug from the upper chamber of the
differential and allow the oil to drain completely.
Install the plug.
Remove the fill plug.
Add oil to full capacity or until the oil level is 3/8 - 1/2 in.
(10 to 13 mm) below the bottom of the fill hole. See
RECOMMENDED LUBRICANTS AND FLUIDS on
page 50 for type and capacity.
Install the fill plug.
Drain Plug
Rear Differential Oil Replacement (Lower Chamber)
Drain Plug
NOTICE: The rear differential is shown at right with axle
removed and axle hole plugged.
1.
2.
Remove the drain plug from the lower chamber of the
differential and allow the oil to drain completely.
Replace the drain plug.
NOTICE: The lower chamber will be filled by adding oil
through the PTO fill plug, and then adding more
oil through the vehicle speed sensor to bring
the level to full capacity.
See RECOMMENDED LUBRICANTS AND FLUIDS on page 50 for type and capacity.
3.
4.
5.
56
Remove the fill plug from the PTO (driver side of vehicle).
Add oil until it is level with the bottom of the fill plug.
Install the fill plug.
Fill Plug in PTO
MAINTENANCE
6.
7.
8.
Remove the vehicle speed sensor.
To fill the lower chamber to capacity, add 22 oz. (650 ml)
through the speed sensor hole.
Replace the speed sensor.
Fill Plug - Speed Sensor
SPARK PLUGS
Tools
•
•
•
•
spark plug socket, 5/8”
hex head screwdriver, 5 mm
anti-seize compound
extension
• torque wrench
• feeler gauge
• ratchet
Recommended spark plug: Champion RC7PYCBX
Spark Plug Inspection and Replacement
Remove the spark plugs when the engine is cold.
1. Disconnect the engine from the power supply.
2. Disconnect the wire harness connectors from the ignition
coils.
Wire Harness to
Ignition Coil
Connector
3.
4.
Remove the bolts.
Pull straight up on the ignition coils to remove from the
engine.
Bolt
Ignition Coil
57
MAINTENANCE
5.
Remove the spark plugs.
NOTICE: A piece of rubber fuel line works well to remove the
plug from the cylinder head after it is loosened.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Spark Plug
If the electrodes are extremely sooty, clean carefully with a
wire brush.
Inspect for cracks in the porcelain insulator. If cracks are visible, spark plugs must be replaced.
Determine the condition of the spark plugs by checking the
Gap
gap with a feeler gauge. The gap must be within the range
0.028 - 0.032 in. (0.69 - 0.84 mm)
indicated in the illustration.
• If both spark plugs are within the range, reinstall them.
• If the gap on either spark plug is not within the correct
range, replace both spark plugs with new ones. Always
replace spark plugs in pairs.
Apply a light coat of anti-seize compound to the spark plug
threads.
To avoid altering the gap or damaging the threads, carefully insert the spark plugs in the engine and tighten to
16.2 - 23.6 ft.lb (22 - 32 Nm).
Insert the ignition coils. Replace the serrated lock nuts with new ones. Install the bolts, washers and serrated lock
washers and tighten to 5.9 - 7.4 ft.lb (8 - 10 Nm).
Reconnect the wire harness to the ignition coils.
Reconnect the power supply to the engine.
Clear the service counter for the service light. See Diagnostics on page 73.
Test drive the vehicle.
COOLING SYSTEM
The vehicle’s cooling system components that require periodic maintenance consists of:
• radiator
• coolant reservoir
• coolant
• cooling fan
• hoses and clamps
See SCHEDULED MAINTENANCE CHART on page 48 for maintenance requirements and intervals.
Coolant
See RECOMMENDED LUBRICANTS AND FLUIDS on page 50 for recommended coolants and mixing ratio.
The use of incompatible coolant will cause insufficient cooling of the engine. Combining different coolants can trigger
a chemical reaction and cause loss of effectiveness. The recommended coolants listed have been tested for compatibility by the engine manufacturer. Verify compatibility of any coolant not recommended in the list before use.
An incorrect mixing ratio reduces the cooling capacity. When topping off coolant, do not change the mixing ratio. Use
the same coolant through the year in the mixing ratio specified on page 50.
Reservoir Coolant Level
Tools
• funnel
• drain pan
58
MAINTENANCE
Check the coolant level when the engine is cold.
1. Verify that the coolant level in the reservoir is
between the MIN and MAX lines.
2. If the level is below the MIN line, add coolant.
Correct
Level
MAX
MIN
Scalding can result from steam
if the cap is removed while the coolant reservoir is hot. Open the tank only when the
engine is cold.
a.
b.
c.
d.
e.
Remove the cap from the coolant reservoir.
Add coolant until the level is between the MIN and MAX lines.
Replace the cap.
Start the engine and allow it to idle for 10 seconds.
Recheck the level to make sure it is correct.
NOTICE: If coolant runs low often, or if the coolant reservoir runs completely dry, check for leaks within the
cooling system.
Radiator and Cooling Fan
Do not install unauthorized accessories in front of the radiator or behind the cooling fan that could obstruct or deflect
air flow. Interference with air flow can lead to overheating and cause engine damage.
Proper radiator maintenance is important to help prevent engine damage or failure. Check and clean the radiator
screen and fins at the intervals indicated in the SCHEDULED MAINTENANCE CHART on page 48.
NOTICE: Do not use a high pressure hose to wash the vehicle. Water from a high pressure hose could damage the radiator fins and impair radiator function.
Radiator Coolant Level
NOTICE: This procedure is required only if the cooling system has
been drained for scheduled maintenance or repair.
If the coolant reservoir has run dry, the coolant level in the
radiator must be checked.
Radiator Cap
Steam from the radiator can cause burns if the
pressure cap is removed when the engine is warm or hot. Do not remove the radiator
pressure cap while the engine is warm of hot. Always allow the engine to cool before
removing the pressure cap.
Check the coolant level when the engine is cold.
1. Slowly remove the radiator pressure cap.
2. Observe the coolant level through the opening. The level should be level with the filler neck.
3. Use a funnel and slowly add coolant if it is low.
Make sure the engine speed is held at 1900 - 2200 rpm for 15 - 20 seconds so the water
pump has enough force to push all the air out of the system. If the engine is allowed to
idle, the water pump seal and valve shaft seals can be damaged.
4.
5.
Run the engine at 1900 - 2200 rpm for 15 - 20 seconds to push the air out of the system.
Reinstall the pressure cap.
59
MAINTENANCE
CONTINUOUSLY VARIABLE TRANSMISSION (CVT)
Check and replace the CVT belt at the intervals indicated in the SCHEDULED MAINTENANCE CHART on page 48.
The CVT cover is located under the driver side truck bed. Lift the bed and/or remove the rear fender liner and side
panel to access the cover.
CVT Belt Inspection
1.
2.
3.
4.
Remove the air outlet and inlet hoses from the
CVT cover.
Remove the CVT cover screws and CVT cover to
access the belt.
Inspect the belt. If the belt needs to be replaced,
refer to the repair manual for procedure and
safety information.
Reinstall the cover and hoses.
CVT Belt
Draining the CVT
If water gets into the CVT, use the following procedure to dry it out before operating:
1. Park the vehicle on a level surface.
2. Remove the drain plug from the bottom of the CVT cover.
3. Allow the water to drain completely.
4. After all of the water has drained out, replace the drain plug.
5. Move the gear shifter to the P (park) position.
6. Start the engine.
7. Alternately press and release the accelerator pedal for 10-15 seconds to
remove moisture and air-dry the belt and clutches. Do not hold the throttle wide
open for more than five seconds at a time.
8. Allow the engine to settle to idle speed.
9. Apply the brakes.
10. Move the gear shifter to L (low) range.
11. Test for belt slippage. If the belt slips, repeat the process.
12. Take the vehicle to your dealer for service as soon as possible.
CVT Drain Plug
PROP SHAFT
There are two universal joints on the prop shaft that require lubrication; one
in the center of the vehicle and one at the rear. Inspect and apply lubricant
to the universal joints at the intervals indicated in the SCHEDULED MAINTENANCE CHART on page 48.
1. Inspect the prop shaft. A visible coat of grease must always be present at both universal joints.
2. If lubricant cannot be seen, or if the lubricant appears contaminated,
apply universal joints grease or equivalent to the grease fittings.
Prop Shaft
VEHICLE IMMERSION
NOTICE: Vehicle immersion can cause major engine and drivetrain damage. Take a vehicle that has been
immersed to the dealer for thorough inspection to verify that it is safe for operation BEFORE starting the engine.
If taking the vehicle to the dealer before starting it is impossible, perform the following procedure:
1. Remove the vehicle from the water completely. If it is impossible to remove the vehicle completely from the
water, at least move it to an area where the water is below the floorboard.
60
MAINTENANCE
NOTICE: Never try to start the engine if the water level is higher than the floorboard.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Inspect the air box.
a. Dry out any water inside the air box.
b. Dry or replace the filter if it is wet.
Thoroughly dry the engine intake.
Disconnect the wire harness from the ignition coils and remove the ignition coils from the engine.
Remove the spark plugs.
Check the engine oil for signs of water contamination. Change and flush if needed.
Using the electric starter, turn the engine over several times.
Dry the spark plugs and reinstall, or install new plugs.
Install the ignition coils and reconnect the wire harness.
Try to start the engine. It may be necessary to repeat the drying steps.
Even if you successfully start the engine, take the vehicle to your dealer for service as soon as possible.
If water has been ingested into the CVT, see Draining the CVT on page 60.
See the SCHEDULED MAINTENANCE CHART on page 48 for additional components to check after immersion.
AIR FILTER
Inspect and replace the air filter cartridge at the intervals indicated in the SCHEDULED MAINTENANCE CHART on
page 48.
Air Filter Cartridge
NOTICE: The filter is a dry filter. Do not apply oil.
1.
2.
3.
4.
Remove the seat bottom to access the air filter housing
that is located below the rear passenger seat.
Unlatch the cover to access the air filter cartridge.
Remove the filter from the housing.
Inspect and replace if needed.
NOTICE: A lightly soiled filter can be cleaned by tapping out dust. Do not use compressed air on the filter. If
the filter is heavily soiled, it must be replaced.
5.
6.
7.
Reinstall or replace the filter, making sure it is fully seated in the housing.
Replace the housing and secure with latches.
Replace the seat bottom.
SPARK ARRESTER
The spark arrestor on your vehicle requires periodic cleaning to remove trapped particles of carbon that accumulate
from the exhaust. Clean the spark arrestor at the intervals indicated in the SCHEDULED MAINTENANCE CHART on
page 48.
The spark arrester must be functioning properly
to provide adequate fire protection.
Wear eye protection and gloves.
Do not service the spark arrester while the system is hot. The exhaust system can reach very
high temperatures. Allow the components to cool
completely.
Do not operate the vehicle with the spark arrestor
removed.
Clean the spark arrestor when the exhaust system is cool.
1. Remove the screw from the bottom of the muffler tailpipe and remove
the screen from inside the tailpipe.
2. Clean the accumulated carbon from the screen with a brush.
3. Reinstall the screen into the tailpipe and secure with the screw.
Screen Retaining
Screw
61
MAINTENANCE
BRAKES
The STAMPEDE XTR has front and rear hydraulic disc brakes. Perform scheduled maintenance on the brake system
at the intervals indicated in the SCHEDULED MAINTENANCE CHART on page 48.
Check the brake fluid level before each operation. Test the brakes for function before each use.
Brake Fluid
When adding or changing brake fluid, always use brake fluid from an unopened bottle.
After opening a bottle of brake fluid, always discard the unused portion. Do not store, or
use from an opened bottle. Brake fluid rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop. This can lead to premature brake fade and the
possibility of an accident that can result in severe injury or death.
The brake fluid reservoir is under the cowl at the
driver’s side front wheel. Remove the panel from the
cowl to access the reservoir.
In addition to the scheduled maintenance interval for
changing the brake fluid (page 48), the brake fluid
must also be changed in the following conditions:
• the fluid becomes contaminated
• the fluid level falls BELOW the MIN mark
• the type and brand of the fluid in the reservoir are
unknown (see page 50 for recommended fluid)
Return the vehicle to the dealer for brake fluid replacement or refer to the STAMPEDE XTR repair manual.
1. Park the vehicle on a level surface.
2. Check the brake fluid level at the reservoir. The
fluid level should be between the upper MAX and
lower MIN lines.
3. If the level is below the upper MAX line, add brake fluid:
a. Clean any dirt and debris from around the reservoir cap.
b. Remove the cap.
c. Add fluid until it reaches the upper MAX line.
d. Reinstall the cap.
e. Clean any spilled brake fluid from the area.
f.
Dispose of the unused portion of the brake fluid.
4. Press and hold the brake pedal fully down for a few seconds.
5. Check for fluid leakage around the fittings.
Brake Inspection
1.
2.
Check the brake system for fluid leaks.
Check the brake pedal for excessive travel or a spongy feel.
NOTICE: Return the vehicle to the dealer for the replacement of
any brake system components or refer to the vehicle
repair manual.
3.
4.
5.
6.
7.
Check the brake calipers for looseness.
Check the brake pads for wear or damage.
Replace the brake pads if worn to 3/64 inch (1 mm).
Check the brake rotors for cracks, corrosion, warping or other
damage.
Clean any grease found on the brake discs with an approved brake
cleaner or alcohol.
3/64 inch
(1 mm)
Never apply WD-40 or any petroleum product
to the brake discs. These products are flammable and can also reduce the friction
between the brake pad and caliper and increase the possibility of an accident that can
result in severe injury or death.
62
MAINTENANCE
STEERING WHEEL
Perform scheduled maintenance on the steering system at the intervals
indicated in the SCHEDULED MAINTENANCE CHART on page 48.
Inspect the steering operation before each use using the following procedure:
1. Park the vehicle on a level surface.
2. Lightly turn the steering wheel to the left and then to the right.
3. There should be ~1 inch (25 mm) of free play.
4. If there is excessive play, unusual noises, or the steering feels
rough or catchy, have the steering system inspected by your BAD
BOY OFF ROAD dealer.
~1 inch
(25 mm)
SPRING ADJUSTMENT
Tools
• shock adjustment tool
The spring pre-load adjuster can be adjusted in the front and rear shock absorber
springs to suit your needs and preference.
To adjust, rotate the adjustment cam:
• to the right to increase spring pre-load
• to the left to decrease spring pre-load
TIRES
Follow the tire maintenance procedures as instructed in this manual and on the labels on the vehicle.
Always use approved size and type of replacement tires. See SPECIFICATIONS CHART on page 71.
Worn, improperly inflated, improper sized, or incorrectly installed tires will affect vehicle
handling and could cause an accident resulting in severe injury or death.
To decrease the risk of tire explosion, do not exceed the tire inflation rating on the tire
sidewall. Make sure the tires are properly inflated at all times of operation. See Tire Pressure on page 15.
Inflate all tires to the same pressure. Operating with unequal or incorrect pressure can
adversely affect steering and handling and could cause an accident resulting in severe
injury or death.
Tire Tread Depth
Replace the tires when the tread depth is worn to 3.5 mm or less.
Not less than 3.5 mm
63
MAINTENANCE
Tire Repair
Use a tire plug to repair small holes in the tread part of the tire. For large holes or holes/cuts in the tire sidewall, the tire
must be replaced.
1. Remove the wheel from the vehicle. See Wheel Removal on page 64.
2. Locate the leak in the tire.
a. If the tire is very low or flat, fully inflate the tire.
b. Brush soapy water over the surface of the tire. Air bubbles will be visible where the air is leaking from the
tire.
c. Mark the hole with chalk.
3. Install the plug according to the manufacturer’s instructions.
4. Install the wheel on the vehicle. See Wheel Installation on page 64.
5. Fully inflate the tire. See Tire Pressure on page 15.
NOTICE: Tire plug tools and plugs are available at automotive outlets. The tire does not have to be removed
from the wheel to install the tire plug.
Tire Replacement
Tire replacement requires a tire mounting machine and must be done by a qualified tire center or BAD BOY OFF
ROAD dealer.
WHEELS
Worn, improperly inflated, improper sized, or incorrectly installed tires will affect vehicle
handling and could cause an accident resulting in severe injury or death.
Check lug nuts for tightness at the intervals indicated in the SCHEDULED MAINTENANCE CHART on page 48.
Lug Nut Torque
85 - 100 ft.lbs. (115 - 135 Nm)
Wheel Removal
Tools
•
•
•
•
1.
2.
3.
lug wrench, 19 mm
impact wrench
impact socket, 19 mm
torque wrench, ft.lbs.
Lift the vehicle. See LIFTING THE VEHICLE on page 50.
Remove the lug nuts.
Remove the tire.
Wheel Installation
NOTICE: The STAMPEDE XTR rear tires are wider than the front tires. Make sure you reinstall the wheels in
their correct position.
To decrease the risk of component damage, do not tighten the lug nuts
to more than the specified torque.
Always install lug nuts using a cross sequence pattern to ensure even
seating of the wheel against the hub.
1.
2.
3.
64
Install the wheel on the hub with lug nuts. Make sure the valve stem is to the outside.
Finger tighten the lug nuts.
Using the tightening pattern shown at right, tighten the lug nuts to 85 - 100 ft.lbs.
(115 - 135 Nm). Tighten in increments of 20 ft. lbs. (27 Nm).
Lug Nut Tightening Pattern
MAINTENANCE
ELECTRONIC POWER ASSISTED STEERING (EPAS)
The EPAS (if equipped) is not a serviceable system and requires no maintenance. If it is not working properly, refer to
the repair manual for replacement procedures or contact the dealer.
FUSES
NOTICE: Have the vehicle inspected by your dealer if fuses and relays continue to blow after they have been
replaced.
Do not use fuses with a higher amp rating than indicated.
A single fuse box is located under the front cowl and two fuse boxes are located under the seat.
1. Remove the access panel in the cowl or the seat.
2. Press the tabs on the sides of the fuse box covers to remove.
3. Refer to the chart on the inside of the fuse block cover or the following illustrations for identification of fuses and
relays.
4. Inspect the fuses and replace if blown.
5. Replace the relays as necessary.
ACC 12V
(30A)
2A (SPARE) 15A (DIFF LCK) 2A (LCD)
15A (SPARE)
15A (ACC)
KEY RLY
2A (SPD SNSR)
5A (TAIL LTS) DIODE 2
2A (LCD EN) 15A (HD/TL) DIODE 1
ACC
RLY
FR DIFF RLY
TAIL LT
RLY
CHMSL
RLY
DIR BAT
(30A)
MAIN
(50A)
5A (SPARE)
15A (SPARE) 15A (SERV RLY) 15A (FUEL)
5A (KEY SW)
25A (FAN)
MAIN RLY
15A (DIR
BAT)
FAN RLY
15A (BAT
RLY
ACC BLCK RLY
BRAKE
EN Rly
FUEL
Rly
LIGHTS
• Clean the lights frequently to maximize visibility.
• Replace burned out bulbs promptly.
• Always make sure the headlights are adjusted properly.
Do not operate this vehicle at night or in low light if any bulbs are burned out. Poor lighting reduces visibility that could cause an accident resulting in severe injury or death.
Headlight Bulb Replacement
to the skin.
Light components can get hot if they
have been in operation. Allow the lights
to cool before servicing to prevent burns
Adjustment Screws
Headlight Bulb
NOTICE: Do not touch a halogen bulb with bare fingers. Oil
from skin leaves a reside that causes a hot spot and
will diminish the life of the bulb.
1.
2.
3.
4.
Rotate the headlight bulb to the left and pull it from the light
housing.
Disconnect the bulb from the wire harness.
Connect the new bulb to the wire harness.
Insert the bulb back into the headlight and turn to the right to
secure in place.
65
MAINTENANCE
Headlight Beam Adjustment
1.
2.
3.
4.
5.
6.
Park the vehicle on a flat surface adjacent to a vertical wall. The front of the vehicle should be approximately 25
ft. (7.6 m) from the wall.
Measure the distance from the ground to the center of the headlight.
Mark the wall at the measured height.
Turn the key to the ON position.
Press the headlight switch to activate the headlights.
With a rider in the vehicle, the brightest part of the headlight beam should be 8 in. (20 cm) below the mark on the
wall.
Headlight center line
Top of beam
4 in. (10 cm)
below
center line
~25 ft. (7.6 m)
7.
8.
9.
10.
Check both headlights in low and high (if equipped) beam settings.
If a headlight needs to be adjusted, locate the three adjustment screws in the back of the headlight.
Turn the screws to adjust vertically and horizontally.
Repeat steps until the headlight is properly adjusted.
Brake Light
Pressing the brake pedal activates the brake light. Check the function of brake light before each operation.
1. Turn the key to the ON position.
2. Press the brake pedal to activate the brake light.
3. If the light does not activate when the pedal is pressed, check the bulb.
Brake Light Bulb Replacement
Light components can get hot if they have been in operation. Allow the lights to cool
before servicing to prevent burns to the skin.
NOTICE: Do not touch a halogen bulb with bare fingers. Oil
from skin leaves a reside that causes a hot spot and
will diminish the life of the bulb.
1.
2.
3.
4.
5.
6.
66
Use a screwdriver to remove four rivets from the back of the
light and remove the back cover.
Rotate the bulb and pull it from the light housing.
Disconnect the bulb from the wire harness.
Connect the new bulb to the wire harness.
Insert the bulb and turn to secure in place.
Install the cover.
MAINTENANCE
BATTERY
The STAMPEDE XTR has a sealed battery, which requires no maintenance except to keep it corrosion-free, and to
test for functionality.
The sealed battery is filled with electrolyte and sealed at the factory. Never pry the seal strip off, or add fluid to the battery.
Inspect the battery terminals at the intervals indicated in the SCHEDULED MAINTENANCE CHART on page 48.
Clean and tighten as needed.
Battery Cleaning
Use insulated wrenches to prevent direct contact of a wrench with the battery terminals.
Direct contact of a bare wrench with battery terminals can cause an explosion resulting
in severe injury or death
Always wear eye protection when charging the battery.
NOTICE: To decrease the risk of damage to electrical components surrounding the battery while cleaning, do
not use a pressure washer.
1.
2.
3.
4.
Remove corrosion with a wire brush.
Wash with a solution of:
• 1 tsp. (5 ml) baking soda
• 1 cup (236 ml) water
Rinse with tap water and dry with shop towels.
After the battery is clean and dry, coat with a commercially available battery terminal spray.
Battery Charging
Do not overcharge the battery. Overcharging the battery can cause overheating and possible explosion, resulting in severe injury or death.
NOTICE: Use a battery charger that is designed for charging sealed batteries.
Keep battery fully charged.
Heavy use of accessories can drain the battery and leave insufficient charge to start the vehicle.
The sealed battery is a 12 V starter battery that supplies power to the starter and accessories. A starter starts the
engine and an internal generator charges the battery while the engine is running. Due to heavy use of accessories,
the battery can become discharged even if the engine is running and the generator is operating.
It is important to keep the battery fully charged. Since the battery is sealed, a voltmeter or multimeter is required to
check voltage.
1. Check the battery voltage with a voltmeter or multimeter.
• If the voltage measured is 12.8 V or higher, the battery is fully charged and requires no further action.
• If the voltage measured is less than 12.8 V, recharge the battery.
2. Charge the battery with a charger designed for sealed batteries. Follow the instructions supplied with the manufacturer of the charger.
Battery Storage
NOTICE: A battery will self-discharge over time. The rate of discharge varies depending on ambient temperature, age and condition of the battery. Check the battery each month during storage and charge as
needed to maintain full charge.
A full charge will prevent the battery from freezing in winter conditions.
If the vehicle is going to be out of operation for three (3) months or longer, do the following:
1. Remove the battery from the vehicle.
2. Make sure the battery is fully charged.
3. Store it out of the sun, in a cool, dry place.
4. Check battery voltage each month during storage and recharge as needed to maintain a full charge.
67
MAINTENANCE
CLEANING
Keeping your STAMPEDE XTR clean is not only beneficial to its appearance, but can also help extend the life of various components.
Washing the Vehicle
• Use an automotive type cleaner or mild soap to wash the vehicle. Harsh cleaners can scratch the finish.
• Do not use a pressure washer to clean the vehicle.
• Use clean or new cloths and pads for washing. Reused cloths and pads can contain dirt particles that will scratch
the finish.
• Inspect all grease fittings for dirt intrusion or lack of grease after washing. Apply grease as required to maintain
proper function.
• Start engine and let it run for a few minutes to dry any water that may have entered the engine or exhaust system.
NOTICE: Do not use a pressure washer to wash your vehicle. High water pressure can damage components.
Some products, including insect repellents and chemicals, will damage plastic surfaces. Do not
allow these types of products to contact the vehicle.
1.
2.
3.
With an automotive type wash cloth, wash from the top to the bottom.
To prevent the soap from drying on the vehicle, rinse with clean water frequently.
To prevent water spots, dry with a chamois before the water dries.
BAD BOY OFF ROAD does not recommend the use of a pressure washer. High pressure water can damage components, chip paint and remove labels. If the use of a pressure washer cannot be avoided, avoid directing the water
stream at the following items:
• wheel bearings
• body panels
• radiator
• labels and decals
• transmission seals
• switches and controls
• brakes
• electrical components and wiring
Polishing the Vehicle
• Do not use medium to heavy duty compounds on the finish.
• Use clean or new cloths and pads for polishing. Old or reused cloths and pads can contain dirt particles that will
scratch the finish.
STORAGE
NOTICE: Do not start the engine during the storage period. Starting the engine during a storage period will
disturb the protective film created by fogging and damage could occur.
Clean the Exterior
Clean the vehicle. See CLEANING on page 68.
Stabilize the Fuel
1.
2.
Fill the fuel tank.
Add approved fuel treatment or fuel stabilizer. Follow the instructions on the container for the recommended
amount. Fuel treatment removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust system. Start the engine and let it run for 15-20 minutes to allow the stabilizer to
disperse through the entire fuel system.
Oil and Filter
Change the oil and filter. See ENGINE OIL on page 53.
Air Filter
1.
2.
68
Inspect and clean or replace the air filter. See AIR FILTER on page 61.
Clean the air box.
MAINTENANCE
Inspect and Lubricate
1.
2.
Inspect the shifter cable.
Lubricate all areas of the vehicle as recommended in the SCHEDULED MAINTENANCE CHART on page 48.
Battery
Remove the battery. Fully charge the battery. See BATTERY on page 67.
Fluid Levels
Inspect all fluid levels. Add or change fluids as recommended in the SCHEDULED MAINTENANCE CHART on
page 48.
• front and rear differential fluids
• brake fluid
– Change if the fluid is dark or contaminated.
• coolant
– Test coolant level. Add coolant if necessary.
Fog the Engine
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Treat the fuel system with an approved fuel treatment. Follow the instructions on the container.
Start the engine.
Let the engine idle for several minutes for the treatment to reach the injectors. Stop the engine.
Disconnect the wire harness from the ignition coils and remove ignition coils from the engine.
Remove the spark plugs.
Add 1 oz. (25 ml) of engine oil to each cylinder through the spark plug hole.
Reinstall the spark plugs. Recommended spark plug: Champion RC7PYCBX
Leave the ignition coils disconnected and disconnect the fuel injectors. Turn over the engine for 2-3 seconds.
Reconnect the ignition coils and fuel injectors and clear the engine codes (see Diagnostics on page 73).
Put the vehicle in storage.
NOTICE: If fuel additive is not used, the fuel tank, lines and injectors must be completely drained of fuel.
Storage Area
Store your STAMPEDE XTR in an area that is well ventilated. Cover the vehicle. Covers designed specifically for vehicles are recommended because they allow enough ventilation to prevent condensation and corrosion.
REMOVE FROM STORAGE
1.
2.
3.
4.
5.
6.
Charge the battery to full charge.
Install battery in the vehicle.
Check the spark plug for tightness. Tighten if necessary.
Fill the fuel tank with fuel.
Check all items in the daily pre-ride inspection. See PRE-RIDE INSPECTION on page 31.
Lubricate according to the SCHEDULED MAINTENANCE CHART on page 48.
69
MAINTENANCE
TRANSPORTING THE STAMPEDE XTR
Loose cargo or vehicle components can fly off when the vehicle is being transported.
Secure or remove all cargo. Inspect the vehicle for loose components prior to transport.
1.
2.
3.
4.
5.
6.
7.
8.
70
Drive the vehicle onto the trailer or truck.
Press the brake pedal.
Move the gear shifter to P (park).
Turn the engine off.
Make sure the fuel cap is tight and the cowl access panel and cargo box are secured.
Make sure the seats are secured and the doors are latched correctly.
Secure the frame of the STAMPEDE XTR with tie downs, straps or ropes.
To prevent loss of the key, remove it from the ignition switch.
SPECIFICATIONS
SPECIFICATIONS
SPECIFICATIONS CHART
Item
Maximum Weight Capacity (includes weight of
operator, passengers, cargo, accessories)
Specification
1500 lbs. (680 kg)
Seating Capacity
4 person
Dry Weight
1860 lbs. (844 kg)
Curb Weight
1900 lbs. (862 kg)
Rollover Protection System (ROPS)
Certified ISO 3471 per ANSI/ROHVA 1
Fuel Capacity
~9 gal. (34 L)
Engine Oil Capacity
~3 qt. (2.8 L)
Coolant Capacity
~8 qt. (7.6 L)
Overall Length
158 in. (401 cm)
Overall Width
58 in. (147 cm)
Overall Height (no canopy)
75 in. (190 cm)
Overall Height (with canopy)
76.5 in. (194 cm)
Wheelbase
117.2 in. (297 cm)
Track Width (front)
49 in. (124 cm)
Track Width (rear)
48 in. (122 cm)
Cargo Box (L x W x H)
32 in. x 49 in. x 12 in. (81 cm x 124 cm x 30 cm)
Ground Clearance (no load)
11.25 in. (28.6 cm)
Cargo Box Load Capacity
600 lbs. (272 kg)
Extended Cab (L x W)
17 in. x 49.5 in. (43 cm x 126 cm)
Extended Cab Load Capacity
170 lbs. (77 kg)
Underseat Storage Volume
6.0 cu.ft.
Underseat Storage Capacity
100 lbs. (45 kg)
Towing Capacity (rear, if equipped)
2000 lbs. (907 kg)
Hitch Tongue Capacity (rear, if equipped)
150 lbs. (68 kg)
Towing Capacity (front)
1000 lbs. (453 kg)
Hitch Tongue Capacity (front)
100 lbs. (45 kg)
Engine Type
Naturally aspirated 4-stroke gasoline, parallel twin with balance shaft
and single overhead camshaft (SOHC)
Engine Weight (without oil and coolant)
130 lbs. (59 kg)
Displacement
846 cc
Number of Cylinders
2
Bore x Stroke
89 mm x 68 mm
Compression Ratio
11.5:1
Starter System
Electric
Fuel System
Sequential multi-point manifold injection
Ignition System
3-position key; electrical starter
Throttle Body
Electronically controlled
Spark Plug
Champion RC7PYCBX (2)
71
SPECIFICATIONS
Item
Specification
Electrical System
12 V
Battery
Single, 12 V starter
Lubrication System
Dry sump
Cooling
Liquid
Shift Type
Single lever on console
Gear Reduction (L)
28.03:1
Gear Reduction (R)
25.49:1
Gear Reduction (H)
12.54:1
Drive Ratio (front)
3.81:1
Transmission
Continuous Variable Transmission (CVT)
Steering
Self-compensating rack and pinion (optional EPAS)
Tire Size, standard (front)
26 x 9-14 Off-road performance
Tire Size, standard (rear)
26 x 11-14 Off-road performance
Tire Size, optional (front)
27 x 9-14 Off-road performance
Tire Size, optional (rear)
27 x 11-14 Off-road performance
Tire Pressure (front)
12 psi (83 kPa)
Tire Pressure (rear)
12 psi (83 kPa)
Wheels, standard
Stamped steel with 4 x 137 mm bolt pattern
Wheels, optional
Aluminum alloy with 4 x 137 mm bolt pattern
Brakes
Foot activated, 4-wheel hydraulic disc
Headlights
65W Halogen
Taillight
7W Halogen
Brake Light
27W Halogen
72
FAULT TESTING
FAULT TESTING
DIAGNOSTICS
The STAMPEDE XTR is equipped with an on-board computer diagnostic system that stores diagnostic trouble codes
(or fault codes). Trouble codes are stored when a sensor in the vehicle reports a reading that is outside the normal/
accepted range.
Trouble codes identify a particular problem area and provides a guide as to where a fault might be occurring within the
vehicle. These codes should be used in conjunction with the STAMPEDE XTR repair manual to identify which systems, circuits or components should be tested to fully diagnose the fault.
NOTICE: A complete list of codes can be found in the STAMPEDE XTR repair manual.
To enter the selectable displays:
1. Make sure the key is in the OFF position.
2. Press and hold the OK button on the display control pad while turning the ignition key to the
ON position. Turning the key past the ON position and starting the engine will exit the display.
3. Release the OK button.
4. Use UP and DOWN on the control pad to scroll through the top level displays.
73
FAULT TESTING
Display 1 - FAULTS - Engine
NOTICE: Only the CLEAR option in this menu is editable.
1.
With FAULTS (with engine symbol) displayed, press the RIGHT arrow
to enter the fault codes display.
2.
Press UP or DOWN to scroll through three fault code
displays:
• Display A indicates no trouble code. No further action
required.
A
• Display B indicates a historical (HIST on right) trouble
code.
B
(example code)
• Display C indicates an active (ACTI on right) trouble
code.
C
(example code)
3.
Press DOWN to scroll through additional trouble codes if there
are any. CLEAR will be the last display.
4.
Press the OK button to enter the edit mode (wrench displays).
LEFT and RIGHT arrows toggle YES and NO.
• Select NO and press OK to exit edit mode without clearing
codes.
• Select YES and press OK to clear codes.
5.
Press LEFT arrow to return to top level display.
74
FAULT TESTING
Display 2 - FAULTS - EPAS
NOTICE: Only the CLEAR option in this menu is editable.
1.
With FAULTS (with EPAS symbol) displayed, press the RIGHT arrow to
enter the fault codes menu.
2.
Press UP or DOWN to scroll through fault code
displays:
• Display A indicates no trouble code. No further action
required.
A
• Display B indicates a historical (HIST on right) trouble
code.
B
(example code)
• Display C indicates an active (ACTI on right) trouble
code.
C
(example code)
• Display D indicates vehicle not EPAS equipped or the
EPAS is disabled.
D
3.
Press DOWN to scroll through additional trouble codes if there
are any. CLEAR will be the last display.
4.
Press the OK button to enter the edit mode (wrench displays).
LEFT and RIGHT arrows toggle YES and NO.
• Select NO and press OK to exit edit mode without clearing
codes.
• Select YES and press OK to clear codes.
5.
Press LEFT arrow to return to top level display.
75
FAULT TESTING
CVT BELT WEAR
Possible Cause
Solution
Driving onto a pickup or trailer in high range
Use low range when loading.
Starting out on a steep hill in high range
Use low range.
Driving at low RPM or low ground speed
Drive at higher speeds or use low range more frequently.
Insufficient warm-up at low ambient temperatures
Warm the engine a minimum of five (5) minutes. Put the transmission in N,
press the throttle five to seven times in short bursts to make the CVT belt
more flexible and prevent belt burning.
Slow clutch engagement
Press the accelerator quickly and effectively.
Towing and pushing at low RPM or low ground speed
Use low range only.
Utility use
Use low range only.
Put the transmission in low range and use fast, aggressive acceleration to
engage the clutch.
Stuck in mud or snow
Excessive acceleration can cause loss of
control and vehicle rollover.
Put the transmission in low range and use fast, brief, aggressive acceleration to engage the clutch.
Climbing over large objects from a stopped position
Excessive acceleration can cause loss of
control and vehicle rollover.
Belt slippage from water or snow ingestion into the
CVT system.
Dry out the CVT. See Draining the CVT on page 60. Inspect the clutch seals
for damage if repeated leaking occurs.
Clutch malfunction
See your BAD BOY OFF ROAD dealer.
Poor engine performance
Check for fouled plugs or foreign material in the fuel tank or lines.
See your BAD BOY OFF ROAD dealer.
Slippage from failure to warm up CVT belt
Always warm up the belt by operating below 30 MP for one mile (5 miles or
more when temperature is below freezing).
Wrong or missing CVT belt
Install the recommended belt.
Improper break-in
Always break in a new belt and/or clutch. See CVT BELT BREAK-IN on
page 32.
ENGINE DOES NOT CRANK
Possible Cause
Ignition is off
Solution
Turn on the ignition.
Accelerator is pressed
Remove foot from accelerator pedal.
Brake pedal is not pressed
Press the brake pedal.
Defective fuse
Check fuses.
Low battery voltage or defective battery
Recharge or replace the battery.
Loose battery connections
Check all connections and tighten.
Corroded battery terminals
Remove corrosion from terminals.
Loose solenoid connections
Check all connections and tighten.
Loose electronic control box connections
Inspect, clean, reinstall connectors.
76
FAULT TESTING
ENGINE CRANKS, BUT DOES NOT START
Possible Cause
Solution
Out of fuel
Refuel.
Clogged fuel filter
See your BAD BOY OFF ROAD dealer.
Water is present in fuel
Drain the fuel system and refuel.
Old or non-recommended fuel
Replace with fresh recommended fuel.
Fouled or defective spark plug
Inspect plug and replace if necessary.
No spark to spark plug
Inspect plug and replace if necessary.
Water or fuel in crank case
See your BAD BOY OFF ROAD dealer immediately.
Low battery voltage or defective battery
Recharge or replace the battery.
Mechanical failure
See your BAD BOY OFF ROAD dealer.
Defective fuse
Check fuses.
ENGINE STALLS AND CAN BE RESTARTED
Possible Cause
Solution
Out of fuel
Refuel.
Low oil pressure
Check and add oil.
ENGINE STALLS AND CANNOT BE RESTARTED
Possible Cause
Out of fuel
Solution
Refuel.
ENGINE OUTPUT IS INTERRUPTED
Possible Cause
Accelerator and brake pedals are pressed at the
same time
Solution
Release the brake pedal.
ENGINE BACKFIRES
Possible Cause
Solution
Weak spark from spark plug
Inspect, clean or replace plug.
Incorrect spark plug gap or heat range
Set gap to specs or replace plug.
Old or non-recommended fuel
Replace with fresh recommended fuel.
Incorrectly installed spark plug wires
See your BAD BOY OFF ROAD dealer.
Incorrect ignition timing
See your BAD BOY OFF ROAD dealer.
Mechanical failure
See your BAD BOY OFF ROAD dealer.
Loose ignition connections
Check all connections and tighten.
Water in fuel
Replace with fresh recommended fuel.
77
FAULT TESTING
ENGINE PINGS OR KNOCKS
Possible Cause
Solution
Poor quality or low octane fuel
Replace with recommended fuel.
Incorrect ignition timing
See your BAD BOY OFF ROAD dealer.
Incorrect spark plug gap or heat range
Set gap to specs or replace plug.
ENGINE RUNS IRREGULARLY, STALLS OR MISFIRES
Possible Cause
Solution
Fouled or defective spark plug
Inspect, clean or replace spark plug.
Worn or defective spark plug wires
Replace.
Incorrect spark plug gap or heat range
Set gap to specs or replace plug.
Loose ignition connections
Check all connections and tighten.
Water in fuel
Replace with fresh recommended fuel.
Low battery voltage or defective battery
Recharge or replace the battery.
Kinked or plugged fuel tank vent line
Inspect and replace.
Incorrect fuel
Replace with fresh recommended fuel.
Clogged air filter
Inspect and clean or replace.
Low fuel pressure
See your BAD BOY OFF ROAD dealer.
Other mechanical failure
See your BAD BOY OFF ROAD dealer.
Possible Lean Fuel Cause
Solution
Low or contaminated fuel
Add or change fuel, clean the fuel system.
Low octane fuel
Replace with recommended fuel.
Clogged fuel filter
See your BAD BOY OFF ROAD dealer.
Possible Rich Fuel Cause
Very high octane fuel
78
Solution
Replace with lower octane fuel.
FAULT TESTING
ENGINE STOPS OR LOSES POWER
Possible Cause
Solution
Out of fuel
Refuel.
Kinked or plugged fuel tank vent line
Inspect and replace.
Water in fuel
Replace with fresh recommended fuel.
Fouled or defective spark plug
Inspect, clean or replace spark plug.
Worn or defective spark plug wires
Replace.
Incorrect spark plug gap or heat range
Set gap to specs or replace plug.
Loose ignition connections
Check all connections and tighten.
Low battery voltage or defective battery
Recharge the battery.
Incorrect fuel
Replace with fresh recommended fuel.
Clogged air filter
Inspect and clean or replace.
Other mechanical failure
See your BAD BOY OFF ROAD dealer.
Overheated engine
Allow engine to cool.Check coolant level and clean radiator. If it still doesn’t
start, see your BAD BOY OFF ROAD dealer.
ENGINE DOES NOT REACH FULL ENGINE SPEED
Possible Cause
Solution
Driver’s seat belt is not fastened
Fasten seat belt.
Poor fuel quality
Refuel.
High coolant temperature
Allow engine to cool.
High intake air temperature
Allow engine to cool.
Accelerator and brake pedals are pressed at the
same time
Release the brake pedal.
Gear shifter is in neutral (N)
Move shifter to high (H), low (L).
Gear shifter is in neutral (R)
Move shifter to high (H), low (L).
Engine malfunction
See your BAD BOY OFF ROAD dealer.
79
FAULT TESTING
80
MAINTENANCE LOG
MAINTENANCE LOG
Record periodic maintenance in the following maintenance log.
DATE
MILES (KM)
AND HOURS
TECHNICIAN
SERVICE PERFORMED
COMMENTS
81
MAINTENANCE LOG
DATE
82
MILES (KM)
AND HOURS
TECHNICIAN
SERVICE PERFORMED
COMMENTS
MAINTENANCE LOG
DATE
MILES (KM)
AND HOURS
TECHNICIAN
SERVICE PERFORMED
COMMENTS
83
MAINTENANCE LOG
DATE
84
MILES (KM)
AND HOURS
TECHNICIAN
SERVICE PERFORMED
COMMENTS
MAINTENANCE LOG
DATE
MILES (KM)
AND HOURS
TECHNICIAN
SERVICE PERFORMED
COMMENTS
85
MAINTENANCE LOG
DATE
86
MILES (KM)
AND HOURS
TECHNICIAN
SERVICE PERFORMED
COMMENTS
MAINTENANCE LOG
DATE
MILES (KM)
AND HOURS
TECHNICIAN
SERVICE PERFORMED
COMMENTS
87
MAINTENANCE LOG
DATE
88
MILES (KM)
AND HOURS
TECHNICIAN
SERVICE PERFORMED
COMMENTS
MAINTENANCE LOG
DATE
MILES (KM)
AND HOURS
TECHNICIAN
SERVICE PERFORMED
COMMENTS
89
MAINTENANCE LOG
DATE
90
MILES (KM)
AND HOURS
TECHNICIAN
SERVICE PERFORMED
COMMENTS
MAINTENANCE LOG
DATE
MILES (KM)
AND HOURS
TECHNICIAN
SERVICE PERFORMED
COMMENTS
91
MAINTENANCE LOG
DATE
92
MILES (KM)
AND HOURS
TECHNICIAN
SERVICE PERFORMED
COMMENTS
INDEX
INDEX
A
accelerator pedal 28
adjustment
backlight 22
hand hold, passenger 28
headlight 66
shock absorber spring 63
steering wheel 28
air filter 61
air filter, replacement part number 50
auxiliary outlet, 12V 29
AWD switch 22
B
backlight, LCD 22
battery maintenance 67
brakes 62
fluid 62
inspection 62
light 66
pedal 28
break-in
CVT belt 32
engine 31
C
cable, winch 43
capacity
cargo load 15, 37
fluids 50, 71
hitch 38, 71
load 71
towing 38, 71
trailer loads 38
carbon monoxide 17
cargo
dumping 38
hauling 37
maximum load 15, 37
cleaning the vehicle 68
clock 26
console, driver controls and information 21
coolant
capacity 50
check level 58
recommended 50
cup holder 28
CVT belt break-in 32
D
dash, see console
diagnostics
engine 74
EPAS 75
differential
AWD 39
front 55
operation modes 39
rear 56
two-wheel drive 39
display control pad 22
driver information center 22
display control pad 22
selectable displays 24
driver information center selectable display
clock 26
fault, engine 74
fault, EPAS 75
information, vehicle 26
maintenance 24
setup 25
driving procedures
accelerating 33
braking 33
downhill 35
obstacles 34
parking 36
passenger 33
reverse 36
slippery surfaces 34
stalling on hill 35
traversing hillsides 35
uphill 34
water 35
E
emissions
crankcase 45
ECI label 46
exhaust 45
hang tag 46
engine
break-in 31
starting 32
stopping 32
engine diagnostics 74
engine maintenance reminder
clear 25
reset 24
engine oil
add 53
capacity 50
93
INDEX
change 54
check 53
recommended 50
engine oil filter 54
replacement part number 50
EPAS 28, 65
EPAS diagnostics 75
F
fault testing 73
fluids
brake 62
capacities 50
recommended 50
fuel
add 32
handling guidelines 17
specifications 32
stabilize 68
tank cap 30
fuses 65
G
gasoline, see fuel
gear shifter 27
H
hand hold, passenger 28
headlights 65
adjustment 65, 66
switch 21
hitch weight capacity 38
I
immersion, vehicle 60
information center, driver 22
initial service items 48
K
key switch 21
L
labels, safety 12
lifting, vehicle 19, 50
lubricants, recommended 50
M
maintenance
chart 48
fluid capacities 50
recommended fluids and lubricants 50
scheduled 47
winch 44
maintenance reminder
94
clear 25
reset 24
N
noise control 8
O
obstacles, driving over 34
oil filter 54
oil filter, replacement part number 50
oil, engine
add 53
capacity 50
change 54
check 53
recommended 50
operator safety 15
P
PIN plate 9
power steering, electronic 28
pre-ride inspection 31
R
rear differential lock switch 22
riding apparel 11
ROPS 29
S
safety
carbon monoxide 17
cargo 15, 37
driving downhill 18
driving in reverse 17
driving uphill 18
driving with passenger 16
emissions control 19
engine exhaust 17
fuel 17
hot exhaust 19
ice 19
labels 12
lifting, vehicle 19, 50
obstacles 18
operation 31
operator 15
pre-ride inspection 31
riding apparel 11
ROPS 29
seat belts 15, 16
slippery surfaces 18
stalling 18
tire pressure 15
tires 18
INDEX
towing 38
unauthorized use 16
vehicle modification 19
water 18
weight capacity 15, 37
winch 41
safety labels 12
safety symbols 8
scheduled maintenance chart 48
seat belts 15, 16, 27
seat bottom 28
serial number labels 9
setup, vehicle 25
shifter 27
shock absorber spring 63
shock loading, winch 44
slippery surfaces 34
spark arrestor 8, 61
spark plug maintenance reminder
clear 25
reset 24
spark plugs 57
specifications, vehicle 71
steering wheel 28
steering wheel inspection 63
storage compartments 29
switches
AWD 22, 39
headlight 21
key 21
rear differential lock 22, 39
identification numbers 9
immersion 60
registration information 8
removing from extended storage 69
specifications 71
transporting 70
warranty information 8
W
washing the vehicle 68
weight capacity, maximum 15, 37
wheels 64
axle and wheel nut torques 64
wheel installation 64
wheel removal 64
winch
cable care 43
maintenance 44
operation 42
safety 41
shock loading 44
T
tires 63
pressure 15
repair 64
replacement 64
tread depth limit 63
towing
capacity 38
speeds 38
trailer load capacity 38
transmission shifter 27
transporting the vehicle 70
troubleshooting, see fault testing
truck bed 29
dumping 38
installation 52
removal 52
V
vehicle
extended storage 68
95
INDEX
96
To locate your nearest dealer,
call 1-888-438-3946 or
visit www.badboyoffroad.com
Textron Specialized Vehicles, Inc.
1451 Marvin Griffin Rd.
Augusta, GA 30906 USA
657202 - A
Printed in USA
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