owner′s manual - SSR Motorsports

owner′s manual - SSR Motorsports
READ THIS MANUAL CAREFULLY
BEFORE YOU USE THIS VEHICLE!
It contains important safety information.
OWNER′S MANUAL
PLEASE CHECK YOUR LOCAL RIDING LAWS AND
REGULATIONS BEFORE OPERATING THIS VEHICLE.
This UTV should not be ridden by anyone under 10 years of age.
215mm*140mm
WARNING
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Operation of this UTV by children under the age of 10 increase if the risk of severe injury or death.
An adult supervision required always.
Never permit children under age 10 to operate this UTV.
Overloading can adversely affect vehicle handling.
Operator use only, passengers prohibited.
This vehicle is designed and manufactured for OFF-ROAD use only.
Driving on public streets roads or highways is illegal.
Always wear helmet and other protective equipment.
Do not operate this vehicle after consuming Alcohol Drugs.
Gasoline flammable, when refueling. Please shut off engine to avoid sparks and open flame.
Read owner’s manual carefully before riding. Keep owner’s manual with vehicle.
WARNING
Read, understand, and follow 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.
WARNING
The engine exhaust from this product contains chemicals known to the State of California to cause
cancer, birth defects or other reproductive harm.
1
PAY ATTENTION TO YOUR SAFETY
This section presents some of the most important information and recommendations to help you ride your
UTV safely. Please take moments to read these pages. This section also includes information about
the location of safety labels on your UTV.
Important safety information
Your UTV can provide many years of service and pleasure-if you take responsibility for your own safety and
understand the challenges you can meet while riding.
There is much that you can do to protect yourself when you ride. You’ll find many helpful recommendations
throughout this manual. The following are a few that we consider most important.
Follow the age recommendation
The minimum recommended age of this UTV model is 10.Children under age 10 should never operate this
vehicle.
Always wear a helmet
It’s a proven fact: helmets significantly reduce the number and severity of head injuries. So always wear an
approved motorcycle helmet. We also recommend that you wear eye protection, sturdy boots, gloves, and
other protective gear.
Ride off-road only
Your UTV is designed and manufactured for off-road use only. The tires are not made for pavement, and the
UTV does not have turn signals and other features required for use on public roads. If you need to cross a
paves or public road, get off and walk your UTV across.
Take time to learn & practice
Even if you have ridden other UTV, take time to become familiar with your skills and get accustomed to the
UTV’s size and weight.
Because many accidents involve inexperienced or untrained riders, we urge all riders to take a training
course approved by the UTV safety institute.
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Contact an authorized UTV dealer to find out about the training courses nearest you.
Be alert for off-road hazards
The terrain can present a variety of challenges when you ride off-road.
Continually “read” the terrain for unexpected turns, drop-offs, rocks ruts, and other hazards. Always keep
your speed low enough to allow time to see and react to hazards.
Ride within your limits
Pushing limits is another major cause of UTV accidents. Never ride beyond your personal abilities or faster
than conditions warrant.
Remember that alcohol, drugs, fatigue, and inattention can significantly reduce your ability to make good
judgments and ride safely.
Don’t drink and ride
Alcohol and riding don’t mix. Even one drink can reduce your ability to respond to changing conditions, and
your reaction time gets worse with every additional drink. So don’t drink and ride, and don’t let your friends
drink and ride either.
Keep your UTV in safe condition
It’s important to keep your UTV properly maintained and in safe riding condition. Having a breakdown can be
difficult, especially if you are stranded off-road far from your base. To help avoid problems, inspect your UTV
before every ride and perform all recommended maintenance.
Your UTV comes with a hangtag and several labels containing important safety information. Anyone who
rides the vehicle should read and understand this information before riding.
The labels should be considered permanent parts of the vehicle. If a label comes off or becomes hard to read,
contact your dealer for replacement.
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GUIDELINES ON SAFE DRIVING
1.
2.
3.
When approaching corners or bends to reduce speed. Upon the completion of turn, may gradually
increase the speed.
When crossing of turn, may gradually increase the speed.
Brake hose may be wet and useless so before walking away you should check all the brake system
and clean the ends.
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INSTRUMENTS & CONTROLS
This section shows the location of all indicators and controls you would normally use before or while riding
your UTV.
These items listed on this page are described in this section. Instructions for other components are
presented in other sections of this manual where they will be most useful.
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WELCOME
Dear parents:
We believe your children should have the opportunity to enjoy The Way Out, experience along with you. We
encourage you to teach your children to ride safely, and to help ensure the future of recreational sports,
please teach them to show respect for our environment and for the rights of others while operating the
vehicle.
This vehicle is not a toy and can be hazardous to operate. We’ve provided this owner’s manual to help you
and your children learn about the safe operation and care of your new vehicle. Before your children drive or
ride in the vehicle, please read and make sure they read the owner’s manual. Make sure they understand
that the vehicle must be used under adult supervision at all times.
After reading the owner’s manual, help your child practice the New Operator Driving Procedures on pages
47-48.
Never allow a child age 10 and under to operate or ride as a passenger In this vehicle. Children differ in shills,
physical abilities and Judgment.
Please supervise the use of the vehicle at all times. Permit continued use only if you determine that your
child has the ability and maturity to operate safely.
Make sure your child is not too tall to ride safely in this vehicle. See page 17.The vehicle’s speed control
system allows limiting vehicle speed for new and inexperienced operators. Please see page 40 for more
information. The preventive maintenance program outlined in this manual is designed to ensure that all
critical components on your child’s vehicle are thoroughly inspected at specific intervals. Always all of the
instructions and recommendations in this manual to ensure the vehicle remains in safe operating condition at
all times.
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Your vehicle is not designed for adult use. Serious damage may occur if the maximum weight capacity is
exceeded. Refer to vehicle labels and to the specifications section beginning on page 97 for the maximum
weight capacity.
Dear Young Operators:
Before you ride your new vehicle, there are some important things that you need to know. You must learn
how to keep yourself and those around you safe while you’re riding.
You parents want you to be safe while you enjoy riding your new vehicle, and that’s why it’s very important
that you read this owner’s manual. Make sure you understand and follow all of the instructions and warning
in the owner’s manual. Ask your parents to explain anything you don’t understand.
Your safety and the safety of others is the most important thing to think about at all times. Pay attention you
see this symbol:
This is the safety alert symbol. When you see this symbol on your vehicle or in this manual it means
PAY ATTENTION because you could die or be seriously injured if you don’t follow the instructions.
After reading the owner’s manual, complete the New Operator Driving Procedures on pages 47-48. Show
your parent that you understand how to drive safely.
Enjoy riding your new vehicle!
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TABLE OF CONTENTS
Introduction.............................................................................11
Safety................................................................................... 14
Features and Controls............................................................29
Operation.............................................................................. 41
Emission Control Systems.....................................................57
Maintenance........................................................................... 58
Specifications.........................................................................97
Troubleshooting......................................................................99
Maintenance Log....................................................................103
YOUR WARRANTY RIGHTS AND OBLIGATIONS…………………………..104
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INTRODUCTION
The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is
involved when these words and symbols are used. Become familiar with their meanings before reading the
manual.
The safety alert symbol indicates a potential personal injury hazard.
WARNING
A WARNING indicates hazardous situation which, if not avoided, may result death or serious injury.
CAUTION
A CAUTION indicates a hazardous situation which, if not avoided, may result death or serious injury.
CAUTION
A CAUTION indicates a hazardous situation which, if not avoided, may result in minor or moderate injury.
NOTICE
A NOTICE indicates a situation that may result in property damage.
The Prohibition Sign indicates an action NOT to take in order to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard.
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INTRODUCTION
! WARNING
Failure to follow the warnings and safety precautions contained in this manual can result in severe injury or
death. Your vehicle is not a toy and can be hazardous to operate. This vehicle handles differently than cars,
trucks or other off road vehicles. A collision or rollover can occur quickly, even during routine maneuvers like
turning, or driving on hills or over obstacles, if you fail to take proper precautions.
 Read this owner’s manual. Understand all safety warnings, precautions and operating procedures
before driving the vehicle. Keep this manual with the vehicle.
 Never operate this vehicle without proper instruction. All operators and supervising adults must watch
the instructional video that was provided with the vehicle.
 Complete the New Operator Driving Procedures outlined on pages 47-48.
 Always follow the age guidelines for your vehicle. Operation is prohibited for anyone age 10 and under.
Never operate with a passenger age 10 and under.
 Never allow a guest to operate this vehicle until the guest has watched the instructional video and has
completed the New Operator Driving Procedures on pages 47-48.
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INTRODUCTION
Vehicle identification Numbers
Record your vehicle’s identification numbers and key number in the spaces provided. Remove the spare key
and store it in a safe place. An ignition key can be duplicated only by ordering a key blank and mating it with
one of your existing keys.
The ignition switch must be replaced if all keys are lost.
Engine Serial Number
(Under the back cover)
Vehicle identification Number
Vehicle Model Number:
Vehicle identification Number:
Engine Serial Number:
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SAFETY
Equipment Modifications
Your vehicle is designed to provide safe operation when used as directed. Modifications to your vehicle may
negatively impact vehicle stability. Failure of critical machine components may result from operation with any
modifications, especially those that increase speed or power. This vehicle may become less stable at speeds
higher than those for which it is designed. Loss of control may occur at higher speeds.
Do not install on any equipment that may increase the speed or power of the vehicle, or make any other
modifications to the vehicle for these purposes. Any modifications to the original equipment of the vehicle
create a substantial hazard and increase the risk of bodily injury.
The warranty on your vehicle is terminated if any equipment has been added to the vehicle, or if any
modifications have been made to the vehicle, that increases its speed or power.
The addition of certain accessories may change the handling characteristics of the vehicle. Use only
approved accessories, and familiarizes you with their function and effect on the vehicle.
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Safe Riding Gear
Always wear appropriate clothing when riding your vehicle. Wear protective clothing for comfort and to
reduce chance of injury.
Helmet
Wearing a helmet can prevent a severe head injury. Whenever riding this yours vehicle, always wear a
helmet that meets or exceeds established safety standards.
Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. The ECE mark consists of a circle
surrounding the letter E, followed by the distinguishing number of the country which has granted approval.
The approval number and serial number will also be displayed on the label.
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Safe Riding Gear
Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a vehicle, always wear
shatterproof goggles or use a shatterproof helmet face shield. Your recommends wearing approved
Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure
protective eye wear is kept clean.
Gloves
Wear gloves for comfort and for protection from sun, cold weather and other elements.
Boots
Wear sturdy footwear. Do not ride a vehicle with bare feet.
Clothing
Wear long sleeves and long pants to protect arms and legs.
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Safety Warnings
! WARNIG
Failure to operate this vehicle properly can result in a collision, loss of control, accident or overturn, which
may result in serious injury or death.
Be sure to read all of the following warnings about driving hazards and how to avoid them. These warnings
are provided for your child’s safety. Be sure to explain to your young driver that the hazards outlined in this
section of the owner’s manual MUST be avoided at all times. See the OPERATION section the owner’s
manual for proper operating procedures.
Operating Without Instruction
Operating this vehicle without proper instruction increases the risk of an accident.
The operator and the supervising adult must understand how to operate the vehicle
properly in different situations and on different types of terrain. Complete the New
Operator Driving Procedures outlined on pages 47-48.
All operators must read and understand the owner’s manual and all warning and
Instruction labels before operating the vehicle. Never allow a guest to operate this
vehicle until the guest has read this manual and all product labels and has completed
the New Operator Driving Procedures outlined on pages 47-48.
Age Restrictions
This vehicle is for recreational use by young operators under adult supervision ONLY.
Operation is prohibited for anyone age 10 and under. Never operate with a passenger
age 10 and under. Make sure any passenger is tall enough to comfortably and safely
reach the hand holds and place both feet on the floor.
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Safety Warnings
Rider Height
Some riders may be too tall to ride safely in this vehicle. Do not operate or ride in this vehicle if the
clearance between the top of your helmet and the overhead cab frame is less than 2 inches (5 cm).
Failure to Inspect Before Operating
Failure to inspect and verify that the vehicle is in safe operating condition before
operating increases the risk of an accident. Always inspect the vehicle before
each use to make sure it’s in safe operating condition. Always follow the inspection
and maintenance procedures and Schedules described in the owner’s manual.
Accessories
Installing non-approved accessories may seriously affect vehicle handing and stability,
which could result in loss of control or an accident? Never install accessories not
approved by for use on this vehicle.
Protective Apparel
Riding in this vehicle without wearing an approved helmet and protective
Eyewear increases the risk of serious injury in the even of an accident.
Operator and passenger must always wear an approved helmet that fits
properly and eye protection (goggles or face shield).
Seat Belts
Riding in this vehicle without wearing the seat belt increases the risk of serious
injury in the event of an accident or sudden stop. Riders must wear seat belts at
all times. Seat belts reduce the severity of injury in
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Safety Warnings
In the event of a sudden stop or accident. Always make sure the seat belts are secured for both the operator
and passenger before riding.
Cab Nets/Side Guards
Riding in this vehicle without using the cab nets and side guards increases the risk of serious injury or death
in the event of an accident or overturn. Always use the cab nets and side guards while riding in this vehicle.
Always keep hands and feet inside the vehicle at all times.
Using Alcohol or Drugs
Riding in this vehicle after consuming alcohol or drugs could adversely affect operator
judgment, reaction time, balance and perception. Never consume alcohol or drugs
before or while operating or riding in this vehicle.
Carrying a Passenger
Never carry a passenger until you have operated this vehicle for at least four hours and
Have completed the New Operator Driving Procedures outlined on pages 47-48.
Carrying Multiple Passengers
Carrying more than one passenger in this vehicle can affect the operator’s ability to steer
and operate the controls, which increases the risk of loss of control and accident or overturn.
Never carry more than one passenger in this vehicle.
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Safety Warnings
Operating on Pavement
Operating this vehicle on paved surfaces (including sidewalks, paths, parking lots, and driveways)may
seriously affect handling and control of the vehicle, and may cause the vehicle to go out of control. This
vehicle’s tires are designed for off-road only, not for use on pavement.
Avoid operating the vehicle on pavement. If you must operate on a paved surface, travel slowly and do not
make sudden turns or stops.
Operating on Public Roads
Operating this vehicle on public streets, roads or highways could result in a
collision with another vehicle. Never operate this vehicle on any public street,
road or highway, including dirt and gravel roads. In many areas it’s unlawful to
operate vehicles of this type on public streets, roads and highways.
Operating at Excessive Speeds
Operating this vehicle at excessive speeds increases the operator’s risk of
losing control. Always operate at a speed that’s appropriate for the terrain,
the visibility and operating conditions, your skills and your passenger’s skills.
Turning Improperly
Turning improperly could cause loss of traction, loss of control, accident or
overturn. Always follow proper procedures for turning as described in the
owner’s manual. Never turn abruptly or at sharp angles. Never turn at high
speeds. Practice turning at slow speeds before attempting to turn at faster speeds.
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Physical Control of the Vehicle
Removing hands from steering wheel or hand holds or removing feet from the floor while riding increases the
risk of loss of control and accident or overturn.
The operator should always keep both hands on the steering wheel during operation. A passenger should
always be seated in the passenger seat with both feet on the floor and with both hands securely grasping the
hand holds. Always keep hands and feet inside the vehicle at all times.
Jumps and Stunts
Exhibition driving increases the risk of an accident or overturns. DO NOT do
power sides,”donuts”, jumps or other driving stunts. Avoid exhibition driving.
Driving Downhill Improperly
Driving down a hill improperly could cause loss of control or overturn. Always follow
proper procedures for driving down a hill as described in the owner’s manual.
 Always drive down a hill with the transmission in forward gear .Never drive
down a hill with the transmission in neutral.
 Never operate the vehicle on hills steeper than 15 degrees.
 Always check the terrain carefully before driving down a hill.
 Never travel down a hill at high speed.
 Avoid traveling down a hill at an angle ,which would cause the vehicle to lean
sharply to one side. Travel straight downhill.
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Improper Hill Climbing
Improper hill climbing could cause loss of control or overturn. Use extreme caution
when operating on hills. Always follow proper procedures for hiss climbing as
described in the owner’s manual. See page 51.Never operate the vehicle on hill
steeper than 15 degrees.
Stalling While Climbing a Hill
Stalling or rolling backwards while climbing a hill Could cause an overturn. Maintain
a steady Speed when climbing a hill.
If you lose all fort/yard speed:
Apply the brakes gradually until the vehicle is fully stopped. Place the transmission
in reverse and slowly allow the vehicle to roll straight downhill while applying light
brake pressure to Control speed.
Crossing Hillsides
Driving on a side hill is not recommended. Improper procedure could cause loss of
control Or overturn. Avoid crossing the side of any hill Unless absolutely necessary.
If crossing a hillside is unavoidable, always follow procedures as Described in the
owner’s manual. See page 52.
Operating in Unfamiliar Terrain
Failure to use extra caution when operating on unfamiliar terrain could result in an
accident or overturn.
Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss
of control or overturn.
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Travel slowly and use extra caution when operating on unfamiliar terrain. Always be alert to changing terrain
conditions.
Operating on Sand or Slippery Terrain
Operating on sand or on excessively, rough, slippery or loose terrain could cause
loss of traction, loss of control, accident or overturn. Always use extra caution
when operating on sand or on rough, slippery or loose terrain.
Do not operate on excessively rough, slippery or loose terrain.
Operating Improperly in Reverse
Improperly operating in reverse could result in a collision with an obstacle or person.
Always follow proper operating procedures as outlined in this manual. See page 55.
Before shifting into reverse gear, always check for obstacles or people behind the
vehicle. When it’s safe to proceed, back slowly.
Improper Tires and Maintenance
Installing non-approved tires may seriously affect vehicle handling and stability, which
could result in loss of control or an accident. Never install tires not approved for use on this vehicle.
Operating this vehicle with improper or uneven tire pressure could cause loss of control,
accident or overturn. Always maintain proper tire pressure as described in the owner’s
manual and on safety labels.
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Safety Warning
Operating Over Obstacles
Improperly operating over obstacles could cause loss of control or overturn.
Before operating in a new area, check for obstacles. Never attempt to
operate over large obstacles such as rocks or fallen trees. Always follow
the proper procedures outlined in this manual when operating over obstacles.
Skidding or Sliding
Skidding or sliding can cause loss of control or overturn(if tires regain unexpectedly).Always follow proper
procedures for operating on slippery surfaces as described in the owner’s manual.
When operating on slippery surfaces such as ice or loose gravel, reduce speed and use extra caution to
reduce the chance of skidding or sliding.
Do not operate on excessively slippery surfaces.
Operating Through Water
Operating through deep or fast-flowing water can cause loss of traction, loss
of control, overturn or accident. Never operate in fast-flowing water or in
water that exceeds the floor level. Always follow proper procedures for
operating in water as described in the owner’s manual. Wet brakes may have
reduced stopping Ability. After leaving water, test the brakes, Apply them lightly
several times while driving slowly. The friction will help dry out the pads.
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Safety Warnings
Overloading the Vehicle
Overloading the vehicle or carrying/towing loads may cause changes in stability and handling, which could
cause loss of control or an accident.
 Never tow objects or carry loads with this vehicle.
 Never exceed the maximum weight capacity for this vehicle.
Operating a Damaged Vehicle
Operating a damaged vehicle can result in an accident with serious injury or death. After any overturn or
accident, have a qualified service dealer inspect the entire vehicle for possible damage, including (but not
limited to) brakes, throttle and steering systems.
Operating on Frozen Bodies of Water
Operating on frozen bodies of water can result in the vehicle and/or riders falling
through the ice. Never operate this vehicle on a frozen body of water.
Handing Gasoline
Gasoline is highly flammable and is explosive under certain conditions. Always
extreme caution whenever handling gasoline.
 Never allow a child to refuel or handle gasoline.
 Always stop the engine when refueling.
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Always refuel outdoors or in a well ventilated area.
Do not smoke or allow open flames or sparks in or near the refueling area or where gasoline is stored.
Never refuel while a person is in the vehicle.
Do not over fill the tank. Do not fill the tank neck.
If gasoline spills on your skin or clothing, immediately wash it off with soap and water and change
clothing.
Turn the fuel valve off whenever the vehicle is stored or parked.
Exposure to Exhaust
Engine exhaust fumes are poisonous and can cause loss of consciousness or death in short time. Never
start the engine or let it run in an enclosed area. Operate this vehicle only outdoors or in well-ventilated
areas.
Hot Exhaust Systems
Exhaust system components are very hot during and after use of the vehicle. Hot components can cause
burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from
the exhaust system.
Use caution when traveling through tall grass, especially dry grass. Always inspect the underside of the
vehicle and areas near the exhaust system after driving through tall grass, weeds, brush and other tall
ground cover. Promptly remove any grass or debris clinging to the vehicle.
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Unauthorized Use of the Vehicle
Leaving the keys in the ignition can lead to unauthorized use of the vehicle, which could result in an accident
or overturn. Always remove the ignition key when the vehicle is not in use.
Safety Labels and Locations
Warning labels have been placed on the vehicle for your protection.
Read and follow the instructions on each label carefully. If any of the labels shown in this manual differ from
the labels on your vehicle, always read and follow the instructions of the labels on the vehicle.
If an informational or graphic label becomes illegible or comes off, contact your dealer to purchase a
replacement. Replacement safety labels are provided at no charge. The part number is printed on the label.
Safety Labels and Locations
Rear warning label
WARNING
Improper vehicle use can result in SEVER INJURY or DEATH.
NEVER ALLOW TO BE OPERATED:
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Without all occupants first viewing and understanding safety video, and warning labels.
With more than one passenger.
On hills steeper than 15 degrees ∠ 15º.
On paved surfaces-pavement may seriously affect handling and control.
With non approved accessories – they may seriously affect stability.
At speeds that are too fast for the operator’s skills, the conditions and/or the terrain.
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ALWAYS REQUIRE OPERATOR AND PASSENGER TO:
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Wear seat belts, grab hand holds (passenger) and plant feet firmly on the floor.
Secure cab nets.
Keep hands and feet inside vehicle.
Avoid quick turns of the steering wheel and driving stunts such as jumps, donuts or power slides.
Reduce speed and use extra caution when carrying a passenger.
Watch for branches or other hazards that could enter vehicle.
WARNING
Operation of this vehicle by children age 16 and under increases the risk of severe injury or death.
NEVER PERMIT CHILDREN AGE 16 AND UNDER TO OPERATE OR RIDE IN THIS VEHICLE.
WARNING
VEHICLE OVERTURN COULD CAUSE SEVERE INJURY OR DEATH. THE CAB FRAME IS NOT
DESIGNED OR INTENDED TO PROVIDE RELIEVER PROTECTION.
TIRE PRESSURE IN PSI (KPA):
Front: 24psi (170kpa)
Rear: 24psi (170kpa)
MAXIMUM WEIGHT CAPACITY 330lbs.(150kg)
INCLUDES WEIGHT OF OPERATOR, PASSENGER AND ACCESSORIES.LOCATE AND READ
OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.IF OWNER’S MANUAL IS
MISSING,
CONTACT A DEALER FOR A REPLACEMENT.
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FEATURES AND CONTROLS
Component Locations
Your vehicle is equipped with cab nets and side guards in both sides of the vehicle. Cab nets and side
guards must be used by both operator and passenger at all times promptly replace worn or damaged cab
nets with new cab nets available from your authorized dealer. The vehicle illustrated below is shown without
cab nets only to allow component identification. Always use the cab nets and side guards.
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Component Locations
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Seats
Driver’s Seat Adjustment
1. Lift the seat latch lever located under the right front edge of the
driver’s seat.
2. While holding the lever upward, slide the seat forward,
or rearward to the desired position, then release the lever.
3. Slide the seat forward and rearward to ensure the latch is engage.
Before operating the vehicle, always make sure both seats are
securely installed.
Seat Removal
1. To remove the driver’s seat lift the seat latch lever.
2. While holding the lever upward slide the seat completely forward
to remove it from the seat mounting rails.
3. Before operating the vehicle, always make sure the driver’s seat is
installed and securely latched.
4. To remove the passenger seat, remove the two bolts located at the
front of the seat mounting rails. Slide the seat forward to remove it
from the vehicle. Always reinstall the passenger seat before
operating the vehicle. After reinstalling the seat and bolts, the nuts
to 10 ft. lbs.(13.5Nm).
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Steering Wheel
The steering Wheel can be adjusted upward or downward for rider
preference.
1. Loosen the steering wheel adjustment bolt.
2. Mow the steering wheel upward or downward to the desired
position.
3. Tighten the bolt 10 ft. lbs.(13.5Nm)
Passenger Hand Hold
Always adjust the hand hold to a comfortable position for your
passenger before operating. Make sure the adjustment pin and
retainer are securely installed after making adjustments.
1. Remove the retainer from the end of the adjustment pin.
Remove the pin from the post.
2. Slide the post inward or outward to the desired position.
3. Reinstall the pin through the mounting bracket hole, trough
both post adjustment holes, and through the remaining bracket
hole.
4. Reinstall the retainer to the pin.
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Seat Belts
This vehicle is equipped with three-point lap and diagonal
seat belts for the operator and passenger .Always make sure the
seat belts are secured for both the operator and passenger before
riding.
To wear the seat belt properly, follow this procedure:
1. Pull the seat belt latch downward and across your chest
toward the buckle at the inner edge or the seat. The belt
should fit snugly across your hips and diagonally across your
chest. Make sure the belt is not twisted.
Tip: The position of the shoulder strap can be adjusted to the height
of the operator. Have an adult relocate the mounting bolt to a different
position, making sure the nut and bolt are tightened securely.
2. Push the latch plate into the buckle until it clicks.
3. Release the strap, it will self-tighten,
4. Press the red release latch on the buckle to release the seat belt.
Nut and bolt
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Seat Belts
Seat Belt Inspection
Inspect all belts for before each of the vehicle.
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’s securely latched.
2. Push the red release latch in the middle of the buckle to make sure it releases freely.
3. Pull each seat belt completely out and inspect the full length for any damage, including cuts, wear,
fraying or stiffness. If and damage is found, or if the seat belt does not does not operate properly, have
the seat belt system checked and/or replaced by an authorized dealer.
4. To clean dirt or debris from the seat belts, sponge the straps with mild soap and water. Do not use bleach,
dye or household detergents
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Cab Nets/Side Guards
Riding in this vehicle without using the cab nets and side guards
increases the risk or serious injury or death in the event of an
accident or overturn.
Cab nets and side guards must be used by both operator and
passenger at all times. Make sure all latches are secure before
operating the vehicle.
Always inspect cab nets for tightness, wear and damage
before each use of the vehicle. Use the strap adjusters to tighten
any loose straps. Promptly replace worn or damaged cab nets
with new cab nets, available from your authorized Yours dealer.
Storage Box
The storage box is attached to the cab frame behind the
seats. Use the storage box to carry lightweight items such
as water bottles or apparel.
Do not carry heavy items in the storage box.
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Fuel Cap
Never allow a child to refuel or handle gasoline.
The fuel lank filler cap is located on the right-hand side of the
Vehicle near file passenger seat. When refueling always use
either leaded or unleaded gasoline with a minimum pump octane
number of 87 R+M/2 octane. Do not use fuel with ethanol content
greater than 10 percent, such as E-85 fuel.
Fuel Valve
The fuel valve is located on the right side of the vehicle near the fuel cap. It has there settings.
OFF: For vehicle storage and when transporting.
ON: For normal operation.
RES: For reserve supply if main supply is exhausted.
The reserve setting allows operation for approximately 7-10 miles(11-16 km).Always refill the gas tank as
soon as possible after using the Main supply, Always return the valve to the ON position after refueling.
34
Ignition Switch
The ignition switch is a three-operated switch. Use the ignition switch to start the engine. See page 45 for
starting procedures.
The key can be removed from the switch when it is in the OFF position.
OFF
The engine is off. Electrical circuits are off, except accessory 12v.
ON
Electrical circuits are on. Electrical equipment can be used.
START
Turn the key to the START position to engage the electric starter. The key returns to the ON
position when released.
Ignition switch
35
Gear Selector
F: Forward
N: Neutral
R: Reverse
The gear selector is located between the seats. To change gears, stop the
Vehicle, and with the engine idling, move the lever to the desired gear.
Do not attempt to shift gears with engine speed above idle or while the
vehicle is moving.
Tip: Maintaining shift linkage adjustment is important to assure proper
transmission function. See your dealer if you experience any shifting problems.
NOTICE: Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission
could result. Always shift when the vehicle is stationary and the engine is at idle.
Parking Brake
1. Apply tile brakes.
2. When the vehicle is fully stopped, pull the parking brake lever rearward as far as possible to set the
parking brake.
3. Stop the engine.
4. To release the parking brake apply the brakes and push the lever toward the passenger seat and
forward.
Tip: Always set the parking brake whenever the vehicle is left unattended.
Operating the vehicle while the parking brake is engaged could cause an accident resulting in
serious injury or death. It could also result in driveline or engine or engine damage. Always be sure to
disengage the parking brake before operating the vehicle.
36
Brake Pedal
Depress the brake pedal to slow or stop the vehicle. Apply the brakes while starting the engine.
Throttle Pedal
Push the pedal down to increase engine speed. Spring pressure returns the pedal to the rest position
when released. Always check that the throttle pedal returns normally before starting the engine.
Make sure there’s adequate throttle pedal free play. See page 75 for throttle pedal adjustment procedures.
37
Speed Control System
The speed of this vehicle is restricted to less than 25MPH (40km/h) at manufacture; the speed limiting device
may be adjusted by supervising when they determine that their child is capable of handling additional speed.
The unrestricted top speed for this model is approximately 35MPH (56km/h).
The adjustable throttle limiting screw is located behind the throttle pedal.
Use the following procedure to control how far the throttle opens.
1. Loosen the jam nut.
2. Turn the screw outward to reduce speed. Turn the screw inward to increase speed,
3. Tighten the jam nut after adjusting.
38
OPERATION
!WARNING
Failure to operate the vehicle properly can result in a collision, loss of control. Accident or overturn, which
may result in serious injury or death. Read and understand all safety warnings outlined in the safety section
of this owner’s manual.
Vehicle Break-in Period
The break-in period for your new vehicle is defined as the first ten hours of operation, or the time it takes to
use the first two full tanks of gasoline.
No single action on your part is as important as a proper break-in period.
Careful treatment of a new engine and drive components will more efficient performance and longer life for
these components. Perform the following procedures carefully.
NOTICE:
Excessive heat build-up during the first three hours of operation will damage close-fitted engine parts and
drive components. Do not operate at full throttle or high speeds during the first three hours of use.
Mixing brands or using non-recommended oil may cause serious engine damage. Always use the
recommended oil. Never substitute or mix oil brands.
39
Engine and Drive train Break-in
1. Fill the tank with gasoline. Always exercise extreme caution. Whenever handling gasoline. Never allow a
child to handle gasoline.
2. Choke the oil level. See page 63.Add the recommended oil, as needed to maintain the oil level in the
safe operating range.
3. Complete the New Operator Driving Procedures outlined on pages 47-48.
4. Avoid aggressive use of the brakes. See Brake System Break-in below.
5. Vary throttle positions. Do not operate at sustained idle.
6. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride inspection
checklist .See page 43.
7. Change the engine oil at 10 hours or one month.
8. Adjust and lubricate the drive chain at 10 hours or one month.
Brake System Break-in
Apply only moderate braking force for the first 50 stops. Aggressive or overly forceful braking when the brake
system is new could damage brake pads and rotors.
CVT Break-in (Clutches/Belt)
A proper break-in of the clutches and drive belt will ensure a longer life and better performance. Break in the
clutches and belt by operating at slower speeds during the break-in period as recommended. Avoid
aggressive acceleration and high speed operation during the break-in period.
40
Pre-Ride Inspection
Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk
of an accident. Always inspect the vehicle before each use to make sure it’s in safe operating condition.
Item
Brake system/pedal travel
Brake fluid
Front suspension
Rear suspension
Steering
Tires
Wheels/fasteners
Frame nuts, bolts, fasteners
Fuel and oil
Grass and debris
Throttle
Indicator lights/switches
Air filter, pre-filter
Daytime running lights
Brake light
Seat Latches
Seat Belts
Cab Nets
Remarks
Ensure proper operation
Ensure proper level
Inspect, lubricate if necessary
Inspect, lubricate if necessary
Ensure free operation
Inspect condition and pressure
Inspect, ensure fastener tightness
Inspect, ensure tightness
Ensure proper levels
Remove, grass and debris from the vehicle, especially on the underside
and near the exhaust system
Ensure proper operation
Ensure proper operation
Inspect, clean or replace
Ensure proper operation
Ensure proper operation
Move the seats forward and rearward to ensure correct installation
Check length of belt for damage, check latches for proper operation
Check for wear or damage, ensure proper installation
Page
39 /77
78
63
63
79
28/81
82
36/64
74
72
83
31
33
35
41
Safe Operation practices
1. Complete the New Operator Driving Procedures outlined on pages 47-48.
2. Do light ride at night or when visibility is poor (rain, fog, dusk).Your vehicle does not have lights that are
designed for driving in these conditions.
3. Never tow objects or carry loads with this vehicle.
4. Engine exhaust fumes are poisonous. Never start the engine or let it run in an enclosed area. Never
allow a child to handle gasoline.
5. Never install accessories not approved by for use on this vehicle.
6. Ride this vehicle only in areas permitted by a supervising adult. Never operate the vehicle on pavement
or on any public street, road or highway, including dirt and gravel roads.
7. Drive in a manner appropriate for your skills and operating conditions. Never operate at excessive
speeds. DO NOT attempt to do power slides, ”donuts” jumps or other driving stunts. Keep both hands on
the steering wheel at all times.
8. Never consume alcohol or drugs before or while operating this vehicle.
9. Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure.
10. Never operate a damaged vehicle. After any overturn or accident, have a qualified service dealer inspect
the entire machine for possible damage.
11. Never operate the vehicle on a frozen body of water.
12. Do not touch hot exhaust system components. Always keep combustible materials away from the
exhaust system.
13. Always remove the ignition key when the vehicle is not in use to prevent unauthorized use.
42
Starting the Engine
1. Turn the fuel valve on.
2. Sit in the driver’s seat and fasten the seat belt.
3. Secure the cab nets.
4. Place the transmission in neutral. Set the parking brake.
5. Apply the brakes.
6. Do not press the throttle pedal while starting the engine.
7. Turn the ignition key past the ON/RUN position to START. Engage the starter for a maximum of five
seconds. Release the key when the engine starts.
NOTICE:
Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up
for several minutes before operating the vehicle.
8. If the engine does not start within five seconds, return the ignition switch to the OFF position and wait
five seconds. Repeat steps 7 and 8 until the engine starts. If your vehicle has Hand-choke:
Tip: If warm engine has cooled to a point where it does not readily start, intermittent use of the choke (pulled
half way out)may be necessary. If the engine is over-choked when warm, depress the throttle lever fully while
cranking to aid in starting. Release the throttle lever immediately after the engine starts. If the engine does
not start and all conditions are favorable, change the spark plug and try again.
9. Vary the engine RPM slightly with the throttle to aid in warm-up until the engine idles smoothly.
10. Release the parking brake before driving.
43
Stopping the Engine
1.
2.
3.
4.
5.
Release the throttle pedal completely and brake to a complete stop.
Place the transmission in neutral.
Set the parking brake.
Stop the engine.
Turn the fuel valve off.
Braking
1. Release the throttle pedal completely. (When the throttle pedal is released completely and engine speed
slows to near idle, the vehicle has engine braking.)
2. Press on the brake pedal evenly and firmly. Practice starting and stopping (using the brakes) until you’re
familiar with the controls.
Parking the Vehicle
1. Stop the vehicle on a level surface. When parking inside a garage or other structure, be sure that the
structure is well ventilated and that the vehicle is not close to any source of flame or sparks, including any
appliance with pilot lights.
2. Place the transmission in neutral.
3. Set the parking brake.
4. Stop the engine.
5. Turn the fuel valve off.
6. Remove the ignition key to prevent unauthorized use.
44
New Operator Driving Procedures
1. Read and understand the owner’s manual and all warning
and instruction labels before operating this vehicle.
2. Watch the instructional video with the supervising adult.
3. Review the section of this owner’s manual about starting the
engine stopping the engine, braking and parking(pages 45-46).
4. Perform the Pre-ride inspection(page 43)
5. Wear appropriate riding gear, including an approved helmet
and protection (goggles or face shield).
6. Select a level open area to practice driving. Make sure you
have adult supervision and permission to drive in this area.
7. Sit in the driver’s seat and fasten the seat belt.
8. Do not operate or ride in this vehicle if the clearance between
the top of your helmet and the overhead cab frame is less than
2 inches(5 cm).
(continued on next page)
45
New Operator Driving Procedures
9. Do not carry a passenger until you have at least four hours of driving experience with this vehicle. See
page 49.
10. Make sure all cab nets and side guards are properly secured.
11. Set the transmission in neutral.
12. Place the transmission in neutral.
13. Start the engine.
14. Apply the brakes and shift into gear.
15. Release the parking brake.
16. Check your surroundings. Make sure the area is clear of people and obstacles.
17. Keeping both hands on the steering wheel, slowly release the brakes and press the throttle with your
right foot to begin driving.
18. Drive slowly at first. Practice starting, stopping, turning, using the throttle and brakes and driving in
reverse. Learn how the vehicle handles when making both left and right turns at a slow speed.
19. In case speed only after mastering all maneuvers at slow speed.
20. After you become skilled at making turns and begin to operate at faster speeds, follow these precautions:
 Avoid sharp turns. Make turns gradually.
 Never turn while applying heavy throttle.
 Never turn the steering heavy throttle.
 Operate at speeds appropriate for your skills, the conditions and the terrain.
 DO NOT attempt to do power slides, ”donuts”, jumps or other driving stunts.
45
Driving with a passenger
1.
2.
3.
4.
Complete the New operator driving procedures outlined on pages 47-48.
Perform the pre-ride inspection. See page 43.
Do not carry a passenger until hours or driving experience with this vehicle.
Never operate with a passenger age 16 and under. Make sure the
passenger is tall enough to comfortably and safely sit in the passenger
seat with the seat belt secured, put both feet on the floor and grasp the
hand holds.
5. Make sure the passenger has at least 2 inches (5cm)of clearance between
his helmet and the top of the cab frame.
6. Never carry more than one passenger in this vehicle.
7. Never allow a passenger to ride on the back of the vehicle. Allow a passenger to ride only in the
passenger seat.
8. Make sure the passenger is wearing appropriate riding gear, including an approved helmet and eye
protection. See page 15.
9. Make sure the passenger secures the seat belt.
10. Tell your passenger to always keep hands and feet inside the vehicle at all times.
11. Make sure all cab nets and side guards are properly secured.
12. Drive slowly. Vehicle handling may change with a passenger on board. always travel at a speed
appropriate for your skills, your passenger’s skills, and operating conditions. Avoid unexpected or
aggressive maneuvers that could cause discomfort or injury to a passenger.
13. Always follow all operating guidelines as outlined on safety label and in this manual.
47
Driving on Slippery Surfaces
When driving on slippery surfaces such as wet trails, loose
gravel, sand or ice, be alert for the possibility of skidding
and sliding,
Skidding or sliding can cause loss of control or
overturn, especially if tires regain traction
unexpectedly. When operating on slippery
surfaces such as ice or loose gravel, slow sown
down and use extra caution to help prevent
skidding or sliding. Always use extra caution
when operating on sand or on rough, slippery or
loose terrain. Do not operate on excessively
rough, slippery or loose terrain.
Follow these precautions when driving in slippery conditions:
1. Slow down before entering slippery areas.
2. Be alert, watch the path ahead and avoid quick turns, which can
cause skids.
3. Correct a skid by turning the steering wheel in the direction of the
Skid. Never apply the brakes during skid.
48
Driving Uphill
Whenever traveling uphill, follow these precautions:
1. Always check the terrain carefully before ascending a hill
2. Avoid steep hills (15ºmaximum).
3. Drive straight uphill.
4. Never climb hills with excessively slippery or loose
surfaces.
5. Drive at a steady rate of speed. Never press the throttle
suddenly
6. Avoid unnecessary changes in speed or direction.
7. Never go over the crest of a hill at a high speed. An obstacle,
a sharp drop, or another vehicle or person could be on the other
side of hill.
8. If the vehicle stalls while climbing a hill, apply the brakes.
Place transmission in reverse and slowly allow the vehicle to roll
straight downhill while applying the brakes lightly to control speed.
49
Driving on a Side hill (Side hilling)
Driving on a side hill is not recommended. Driving on a side hill improperly cause loss of control or overturn.
If crossing a hill is unavoidable, follow these precautions:
1. Drive slowly and use extreme caution.
2. If the vehicle begins to overturn, or if it feels as if it may overturn, immediately turn downhill.
3. Avoid obstacles and changes in terrain that may lower or raise one side the vehicle or cause the vehicle
to slide.
4. If the vehicle begins to slide downhill, immediately turn downhill to stop the slide.
Driving Downhill
Whenever driving down a hill, follow these precautions:
1. Avoid steep hills (15º maximum).
2. Slow down. Never travel down a hill at high speed.
3. Always check the terrain carefully before driving down a hill.
4. Always drive down a hill with the transmission in forward gear. Never ”coast” or drive down a hill with the
transmission in neutral.
5. Avoid driving down a hill at an angle, which would cause the vehicle lean sharply to one side. Always
drive straight downhill.
6. Apply the brakes lightly to keep speed slow.
50
Driving Through Water
Your vehicle can drive through shallow water. Make sure the
water is no deeper than the floor of the vehicle. Follow these
precautions when driving through water:
1. Check water depth. Never drive through water that is
deeper than the floor level.
2. After driving through water, test the brakes. Apply them
lightly several times while driving slowly. The friction
will help dry out the pads.
NOTICE:
Major engine damage can result if the vehicle is not thoroughly
inspected after operation in water. Perform the services outlined
in maintenance chart. See page 58.Give special attention to
engine transmission oil and all grease fittings.
If your vehicle is operated in water deeper than the floor level, take it
to your dealer for service before starting the engine. If it’s
impossible to bring the vehicle to your dealer starting the engine,
perform the service outlined on page 84,and take the vehicle to
your dealer as soon as possible.
51
Driving Over Obstacles
Follow these precautions when driving over obstacles
1. Always check for obstacles before driving in a new area.
2. Look ahead and watch the terrain. Always be alert for hazards such as logs, rocks and low hanging
branches.
3. Drive slowly and use extra caution when driving on unfamiliar terrain. Obstacles are not always clearly
visible.
4. Do not drive over large obstacles such as rocks and fallen trees. If it’s unavoidable, use extreme caution
and drive slowly.
5. Always have a passenger dismount and move away from the vehicle before driving over an obstacle that
could cause an overturn.
52
Driving Reverse
Follow these precautions when driving in reverse:
1. Always check for obstacles or people behind the vehicle.
2. Apply the throttle lightly. Never apply the throttle suddenly.
3. Back slowly.
4. Apply the brakes lightly for stopping.
5. Avoid making sharp turns.
53
Parking on an Incline
A rolling vehicle can result serious injury. Avoid parking on an Incline. If parking on an incline is unavoidable,
follow these precautions:
1. Place the transmission in neutral.
2. Set the parking brake.
3. Stop the engine.
4. Turn the fuel valve off.
5. Always block the rear wheels on the downhill side.
54
EMISSION CONTROL SYSTEMS
Noise Emission Control System
Do not modify the engine, intake or exhaust components, doing may affect compliance with U.S.A. EPA
noise control requirement, CFR 205 and local noise level requirements.
Operation on Public Lands in the U.S.A.
Your vehicle has a spark arrestor that was tested and qualified to be in accordance with the USFS standard
5100-1c.Federal law requires that this spark arrestor be installed and functional when the vehicle is operated
on public lands.
Operation of off-road vehicles on public lands in the U. S. A. is regulated by 43 CFR 420.Violations is subject
to monetary penalties.
Crankcase Emission Control System
This engine is equipped with 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
The emissions from the exhaust of this vehicle are controlled by engine design, including factory-set fuel
delivery and ignition. The engine and related components must be maintained at specifications to achieve
optimal performance.
Engine idle speed is the only adjustment recommends that you perform. Any other adjustments should be
performed by an authorized dealer.
The emissions label is located on the frame behind the right front wheel.
Electromagnetic Interference
This spark ignition system complies with Canadian ICES-002.
This vehicle complies with the EMC requirements of European directives 97/24/EC and 2004/108/EC.
55
MAINTENACE
Periodic Maintenance Chart
Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition .Inspection;
adjustment and lubrication of important components are explained in the periodic maintenance chart.
Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for
replacement parts, use genuine parts available from your dealer.
Record maintenance and service in the Maintenance Log beginning on page 111.
Service and adjustments are important for proper vehicle operation. If you’re not familiar with safe service
and adjustment procedures, have a qualified dealer perform these operations.
Maintenance intervals in the following chart are based upon average riding conditions and an average
vehicle speed approximately ten (10) miles per hour. Vehicles subjected to severe use must be inspected
and serviced more frequently.
Severe Use Definition
 Frequent immersion in mud, water or sand
 Racing or race-style high RPM use
 Prolonged low speed operation
 Extended idle
 Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants
collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil
level, and if it continues to rise, discontinue use and determine the cause see your dealer.
56
! WARNING
Improperly performing the procedures marked with a ■ could result in component failure and lead to serious
injury or death. Have an authorized your dealer perform these services.
Maintenance Chart Key
▲
E
Perform these operations more often for vehicles subjected to severe use.
Emission-related service (Failure to conduct this maintenance will not void the emissions warranty
but may affect emissions.)
■ Have an authorized sealer perform these services.
57
Periodic Maintenance Chart
Perform all services at whichever maintenance interval is reached first.
Maintenance Interval
(whichever comes first)
Item
Hours
■
▲
▲
▲
▲
▲
▲
E
▲
E
▲
■
Calendar
Remarks
Miles(Km)
Steering
-
Daily
-
Front suspension
-
Daily
-
Rear suspension
-
Daily
-
Tires
-
Daily
-
Brake pedal level
-
Daily
-
Brake pedal travel
-
Daily
-
Brake system
-
Daily
-
Wheels/fasteners
-
Daily
-
Frame fasteners
-
Daily
-
Engine oil level
-
Daily
-
Air filter, pre-filter
-
Daily
-
Inspect; clean often ;replace as needed
Daytime running
lights/taillight
Drive chain
CVT housing (if equipped )
-
Daily
-
Check operation
-
Daily
Weekly
-
Inspect daily; adjust and lubricate if needed
Drain water as needed, check often if driving wet conditions
Air filter, main element
-
Weekly
-
Inspect; replace as needed
Brake pad wear
10
Monthly
100(160)
Inspect periodically
Idle speed
10
Monthly
100(160)
Check; adjust as needed
Check each day before driving the vehicle. Make adjustments
as needed. See the Pre-Ride Checklist on page 43.
58
Periodic Maintenance Chart
Item
▲
E
▲
▲
▲
E
▲
▲
■
E
■
E
E
■
Maintenance Interval
(whichever comes first)
Hours
Calendar
Miles(Km)
Remarks
Choke
10
Monthly
100(160)
Check for proper operation; see dealer for
adjustments
Engine oil change (break-in)
10
1M
-
Perform a break-in oil change at one month
Drive chain(break-in)
10
1M
-
Adjust and lubricate
Battery
25
Monthly
250(400)
Check terminals; clean; test
Main gear case oil
25
Monthly
25(400)
Inspect level; change yearly
Engine breather
25
Monthly
150(250)
Inspect; replace if necessary
Engine oil change
General lubrication
Throttle cable/
ETC switch
Carburetor float
30
50
50
6M
3M
6M
300(480)
500(800)
300(480)
Perform a break-in oil change at one month
Lubricate all fittings. pivots. cables, etc.
Inspect; adjust; lubricate; replace if necessary
50
6M
500(800)
Drain bowl periodically and prior to storage
Choke cable
50
6M
500(800)
Inspect; adjust; lubricate; replace if necessary
50
6M
500(800)
Inspect duct for proper sealing/air leaks
50
50
6M
6M
500(800)
500(800)
Inspect, lubricate. adjust
Lubricate
Carburetor air
intake ducts/flange
Shift Linkage
Steering
▲
▲
Front Suspension
Rear Suspension
50
50
6M
6M
500(800)
500(800)
Lubricate
Lubricate
59
Periodic Maintenance Chart
Maintenance Interval
(whichever comes first)
Item
Hours
Calendar
Remarks
Miles(Km)
■
E
Fuel system/filter
100
12M
600(1000)
Check for leaks at tank cap, lines, fuel valve,
filter, pump carburetor; replace lines every two
years
▲
E
▲
Spark plug
100
12M
1000(1600)
Inspect
Engine mounts
Exhaust muffler/pipe
100
12M
1000(1600)
Inspect
■
Ignition timing
100
100
12M
12M
1000(1600)
1000(1600)
Inspect
Inspect
Wiring
100
12M
1000(1600)
Inspect for wear, routing, security; apply dielectric
grease to connectors subjected to water, mud. etc.
100
12M
1000(1600)
Inspect; clean; replace worn parts
100
100
200
300
12M
12M
24M
36M
1000(1600)
1000(1600)
2000(3200)
3000(4800)
Inspect; replace as needed
Inspect; replace as needed
Change every two years
Clean out
Adjust as needed
Inspect periodically; adjust when parts are replaced
▲
■
■
■
■
Clutches (drive and
driven)
Drive belt
Front wheel bearings
Brake fluid
Spark arrestor
ldle speed
Toe adjustment
-
▲ Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service
■ Have an authorized Yours dealer perform these services.
60
Lubrication Recommendations
Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on
page 58, or more often under severe use, such as wet or dusty conditions. Items not listed in the chart
should be lubricated at the general lubrication interval.
Item
Engine Oil
Brake Fluid
Transmission Oil(Main Gear case)
Drive Chain
A-Arm Pivots
▲ Steering Arm Pivots
Lube
Method
Yours Synthetic Youth Oil or Synthetic SAE40
DOT 4
Premium AGL Synthetic Gear case Lube
Yours Chain Lube or SAE 80/90
Yours All Season Premium Grease or grease
conforming to NLGL No.2
See page 64
See page 78
See page 66
See page 67
Grease at general Lubrication interval, also
after washing vehicle or driving in water.
▲ Perform these procedures more often for vehicles subjected to severe use
61
Engine Oil
Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart
beginning on page 58.Oil may need to be changed more frequently if Yours oil is not used. Do not use
automotive oil. see page 99 for the part numbers of Yours products.
Oil Recommendations
These Operating Conditions
Use This Recommended Oil
Outside air temperature is above 32°F/0°
Yours Synthetic Youth Oil(or Synthetic SAE40)
Outside air temperature is below 32°F/0°
Semi-Synthetic 20W-40
NOTICE:
Mixing brands or using a non-recommended oil may cause serious
engine damage. Always use the recommended oil. Never substitute
or mix oil brands.
Oil Check
Maintain the oil level within the safe range on the dipstick.
Do not overfill.
1. Position the vehicle on a level surface.
2. Remove the dipstick. Wipe it dry with a clean cloth.
3. Reinstall the dipstick completely.
4. Remove the dipstick and check the oil level.
Tip: A rising oil level between checks in cool weather driving can indicate
contaminants such as gas or moisture collecting in the crankcase. If the
oil level is over the full/safe mark, change the oil immediately.
5. Add the recommended oil as needed.
6. Reinstall the dipstick.
62
Engine Oil
1.
2.
3.
4.
Position the vehicle on a level surface. Set the parking brake.
Clean the area around the pre-filter plug.
Start the engine. Allow it to idle for two to three minutes.
Stop the engine.
Hot oil can cause burns to skin. Do not allow hot oil
to contact skin.
5. Place a drain pan under the engine crankcase.
6. Remove the pre-filter plug. Allow the oil to drain completely.
7. Wash the oil pre-filter screen with solvent to remove debris. Allow the screen to air dry.
8. Clean the pre-filter plug. Install a new sealing washer on the plug. The sealing surfaces on the pug and
crankcase should be clean and free of burrs, nicks or scratches.
9. Reassemble the pre-filter screen and spring to the pre-filter plug
10. Reinstall the pre-filter drain plug. Torque to 11.lbs.(15Nm).
11. Remove the dipstick. Add 30 oz.(0.9 liters)of the recommended oil. Do not overfill. See the specifications
section beginning on page 97 for capacities.
12. Reinstall the dipstick.
13. Start the engine. Allow it to idle for one to two minutes.
14. Stop the engine and inspect for leaks.
15. Check the oil level. Add oil as needed to bring the level to the upper mark on the dipstick.
16. Dispose of used oil properly.
63
Transmission (Main Gear case)
Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart beginning on
page 58.Yours recommends the use of Premium AGL Synthetic Gear case Fluid for this vehicle.
Fluid Check
The fill plug is located on the rear of the gear case. Access the fill plug through the left rear wheel well.
Maintain the fluid level at the bottom of the fill plug hole.
1. Position the vehicle on a level surface.
2. Remove the fill plug.
3. Check the fluid level.
4. Add the recommended fluid as needed.
5. Reinstall the fill plug.
Fluid Change
The drain plug is located on the bottom of the gear case.
1. Remove the fill plug.
2. Place a drain pan under the drain plug.
3. Remove the drain plug. Allow the fluid to drain completely.
4. Clean the drain plug.
5. Reinstall the drain plug with a new o-ring. Torque to 11ft.lbs.(15Nm).
6. Add 3.3 oz.(110ml)of the recommended fluid to the fill hole. Maintain the fluid level at the bottom of the fill
plug hole. Do not overfill.
7. Reinstall the fill plug.
8. Check for leaks.
9. Discard used fluid properly.
64
Drive Chain Lubrication
Lubricate the drive chain with Yours chain spray lube or an approved chain lube at the general lubrication
interval specified in the Periodic Maintenance Chart beginning on page 58.Lubricate more often under
severe use. Such as in dirty or wet conditions. See page 99 for the part numbers of yours products.
NOTICE:
Washing the drive chain with a high pressure washer or gasoline
can cause premature wear and drive chain failure. Don’t use a
high pressure washer or gasoline to clean the drive chain.
Adjusting or operating the vehicle with improper rear drive chain
slack can result in severe damage to the transmission and drive
components. Always make sure the slack is within the stated
specifications.
Drive Chain Slack
1. Check the amount of chain slack by moving the vehicle slightly
forward to gain slack at the top side of the chain.
2. Raise the rear of the vehicle and support securely under
the mainframe .Allow the swing arm to hang at full shock
extension without touching the ground. This establishes the
tightest chain position.
3. Pull down on the chain tensioned to move it out of the way,
Then measure chain slack. It should have 1/4”-1/2”
(6-12mm) deflection.
4. If the chain needs adjustment, use the procedure on page 68.
65
Drive Chain Slack Adjustment
1. Loosen the one rear housing mount bolts .
2. Loosen the chain adjuster lock nuts.
3. Turn the chain adjusters clockwise to 1/4”-1/2”(6-12mm) deflection.
4. Tighten the chain adjuster lock nuts to 43 ft. lbs.(60Nm).Hold the adjuster stud securely while tightening
the nut to avoid breaking tile stud.
5. Tighten the four rear housing mount bolts to 18 ft. lbs.(25Nm).
66
Spark Plugs
Spark Plugs Gap/Torque
Electrode Gap
0.6-0.7mm
New Plug Torque
9-11 ft. lbs.(12-15Nm)
Used Plug Torque
17-20 ft. lbs.(23-27Nm)
NOTICE:
Using non-recommended spark plugs can result in serious engine damage. Always use
Yours-recommended spark plugs. Refer to the specifications section beginning on page 97.Spark plug
condition is indicative of engine operation. The spark plug firing end condition should be read after the
engine is warmed up and the vehicle is driven at higher speeds. Immediately check the spark plug for
correct color.
A hot exhaust system and engine can engine can cause burns. Wear protective gloves when
removing a spark plug for inspection.
67
Spark Plug Gap/Torque
Normal Plug
The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are
not burned or eroded. This indicates the proper type and heat range for the engine and the service.
lip: The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper
spark plug or incorrect throttle body adjustments.
Wet Fouled Plug
The wet fouled insulator tip is black. A damp oil film covers the firing end.
There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. General causes of
fouling are excessive oil, use of non-recommended oil, improper use of the choke, or incorrect throttle
Body / carburetor adjustments.
Spark Plug Removal and Replacement
1. Remove the spark plug cap.
2. Using the spark plug wrench provided in the tool kit, remove the plug by rotating it counter-clockwise.
3. Reverse the procedure for spark plug installation.
4. Torque to specification.
68
Constant Variable Transmission (CVT) System
! WARNING
Failure to comply with the instructions in this warning can result in severe injury or death.
Do not modify any component of the CVT system. Doing so may reduce its strength so that a failure may occur at
a high speed. The CVT system has been precision balanced. Any modification will cause the system to be out of
balance, creating vibration and additional loads on components.
The CVT system rotates at high speeds, creating large amounts of force on clutch components. Extensive
engineering and testing has been conducted to ensure the safety of this product. However, as the owner, you
have the following responsibilities to make sure this system remains safe:
 Always follow all recommended maintenance procedures. See your dealer as outlined is the owner’s manual.
 This CVT system is intended for use on yours products only. Do not install in any other product.
 Always make sure the CVT housing is securely in place during operation.
CVT Drying
There may be some instances when water is accidently ingested into the CVT system. Use the following
instructions to dry it out before operating. The drain plug is located on the bottom of the CVT cove.
1. Remove the drain plug. Allow the water to drain. Reinstall the drain plug.
2. Shift the transmission to neutral, set the parking brake.
3. Start the engine. Apply varying throttle for 10-15 seconds to expel the moisture and air-dry the belt and
clutches. Do not hold the throttle wide open for more than 10 seconds.
4. Allow the engine RPM to settle to idle speed.
5. Test for belt slippage. It the belt slips, repeat the process.
6. Take the vehicle to your dealer for service as soon as possible.
NOTICE: Exposure to salt water will cause corrosion to metal components. If your vehicle is operated in salt water
areas, rinse it off frequently with fresh water.
69
Filter Systems
Air Filter
Always change the air filter at the intervals outlined in the Periodic
Maintenance Chart beginning on page 58.Access cover on the
forward surface of the rear body panel.
1. Move or remove the storage bag.
2. Remove the four (4) access cover fasteners to remove the
access cover.
3. Release the air box cover spring clips and remove the cover.
4. Remove the foam air filter. Wash the foam filter is warm
soapy water, then rinse and let dry. If the filter is damaged,
install a new foam filter.
5. Apply a commercially available foam filter lubricant to the foam
filter.
6. Clean away any oil or sediments in the air box.
7. Reinstall the filter and air box cover. Secure the clips.
NOTICE:
Never operate the vehicle with the filter element removed, Dirt will
enter the engine, causing rapid wear and severe damage to the
engine.
8. Reinstall the access cover, and storage bag.
70
Spark Arrestor (If there is in design)
! WARNING
Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or
death.
 Do not perform service on the spark arrestor while the system is hot. Allow components to cool
sufficiently before proceeding.
 Wear eye protection and gloves.
 Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas.
To remove accumulated carbon, clean the spark arrestor at the intervals recommended in the Periodic
Maintenance Chart beginning on page 58.
1. Remove the six bolts and remove the arrestor from the end of the muffler.
2. Use a non-synthetic brush to clean the arrestor screen. A synthetic brush may melt if components are
warm. If necessary, blow debris from the screen with compressed air.
3. Inspect the screen for wear and damage. Replace the arrestor damage is found.
4. Reinstall the arrestor.
5. Torque the bolts to 7 ft. lbs.(9.5 Nm).
71
Throttle System
! WARNING
Failure to check or maintain proper operation of the throttle system can result in an accident and lead to
serious injury or death if the throttle pedal sticks during operation.
Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal.
Immediately contact your dealer for service if throttle problems arise.
Always check the pedal for free movement and return before starting the engine and occasionally during
operation.
Throttle Free play
If the throttle pedal has excessive play due to cable stretch or
maladjustment, it will cause a delay in throttle response, especially
at low engine speed. The throttle may also not open fully. If the throttle
pedal has no free play, the throttle may be hard to control, and the
idle speed may be erratic.
Check the throttle pedal free play at the intervals outlined in the
Periodic Maintenance Chart beginning on page 58.Adjust the free play
if necessary.
Throttle Free play Inspection
1. Place the transmission in neutral. Set the parking brake.
2. Start the engine. Allow it to warm up thoroughly.
3. Measure the distance the throttle pedal moves before the engine
begins to pick up speed. Free play should be 1/16 to 1/8 inches (1.5-3mm).
72
Throttle System
Throttle Free play Adjustment
Access the throttle cable adjuster through the right front
wheel well.
1. Slide the cable adjuster boot off the cable adjuster.
2. Squeeze the end of the rubber boot and slide it far enough
to expose the end of the inline cable adjuster.
3. Loosen the adjuster lock nut.
4. Move the cable adjuster until 1/16”to1/8”(1.5-3mm)of free
Play is achieved at the throttle pedal. See page 74.While
adjusting, lightly flip the throttle pedal up and down.
5. Tighten the lock nut.
6. Apply a small amount of grease to the inside of the boot
and slide it over the cable adjuster to its original position.
73
Carburetor
Your yours vehicle is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000
feet(1800m)and temperatures of +40 degrees F.(4 degrees C.) or higher. Above 6000 feet (1800m) the
engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for each
1000-foot (304.8 in) increase in elevation. Although this power cannot be regained, adjustments to the
carburetor and drive system can be made to allow more efficient operation. Optional jets, available from your
yours dealer, are required for operation above 6,000 feet and temperatures below +40 degrees F.(4 degrees
C.)
Tip: Continuous operation of the engine without proper jetting when required can cause poor performance,
overheating, or engine damage. See your yours dealer for more information about jetting the vehicle for
conditions in your area.
Carburetor/Engine Idle RPM Adjustment
If the engines idle speed is not satisfactory and all other
conditions
are favorable, the carburetor can be adjusted.
1. Place the transmission in neutral.
2. Set the parking brake.
3. Start the engine and allow it to warm up for approximately
five minutes.
4. Turn the carburetor idle screw in(clockwise)to raise RPM.
Turn the screw out (counterclockwise) to lower RPM.
74
Brakes
The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See page 39.
Always check brake pedal travel and the brake fluid reservoir level before each use of the vehicle. When
applied, the brake pedal should feel firm, Any sponginess would indicate a possible fluid leak or low brake
fluid level, which must be corrected before riding. See page 78 for brake fluid information.
If you discover any irregularities in brake system operation, including excessive pedal travel, contact your
dealer for proper diagnosis and repairs.
Operating the vehicle with a spongy brake pedal can result in loss of braking, which could cause an
accident resulting in severe injury or death. Never operate the vehicle with a spongy-feeling brake
pedal.
Brake Inspection
1. Check the brake system for fluid leaks.
2. Check the brake pedal for excessive travel or a spongy feel.
3. Check the friction pads for wear, damage and looseness.
4. Inspect the rake pad wear surface for excessive wear.
5. Change pads when worn to 3/64” (1mm).
75
Brakes
Brake Fluid
Inspect the level of the brake fluid before each operation. If the fluid level is low add DOT 4 brake fluid only.
See page 99 for the part numbers of yours products.
After opening a bottle of brake fluid, always discard any unused portion, Never store or us a partial
bottle. Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air. The moisture
causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the
possibility of accident or severe injury.
Change tile brake fluid every two year any time the fluid becomes
contaminated, the fluid level is below the minimum, or if the type
and brand of the fluid in the, reservoir are unknown.
Access the brake fluid reservoir through the left front wheel well.
1. Position the vehicle on a level surface.
2. Place the transmission in neutral. Set the parking brake.
3. View the brake fluid level in the reservoir. The level should be
between the maximum and minimum level lines. Add brake fluid
as needed.
4. Apply the brake forcefully for a few seconds and check for fluid
leakage around the fittings.
76
Steering Wheel Inspection
Check the steering wheel for specified and smooth operation at the intervals outlined in the Periodic
Maintenance Chart beginning on page 58.
1. Position the vehicle on level ground.
2. Lightly turn the steering wheel left and right.
3. There should be 0.8”-1.0” (20-25mm) of free play.
4. If there is excessive free play or strange noises, or the steering feels rough or “catchy,” have the steering
system inspected by an authorized yours dealer.
Shock Spring Adjustment
The front and rear shock absorber springs are
adjustable to increase or decrease spring tension.
Rotate the adjuster either clockwise or counterclockwise to make adjustments. Always apply
the same adjustment setting to all four wheels.
WARNING! Uneven adjustment may cause poor
handling of the vehicle, which could result in an
accident. Always adjust both the left and right
spring preloads equally or have your yours dealer
perform the adjustments.
77
MAINTENANCE
Toe Alignment
Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is
1/8” to 1/4” (3-6mm) toe out.
WARNING!
Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie
rod alignment. All tie rod adjustments should be performed by an authorized yours dealer.
1. Position the vehicle on a level surface.
2. Set the handlebars in a straight-ahead position and
secure them is this position.
3. Place a chalk mark on the center line of the front tires
approximately 10”(25.4 cm) from the floor, or as close to
the hub / axle center line as possible. Make sure both
marks are the same distance from the floor.
4. Measure the distance between the marks and record the
measurement(1).
5. Move the vehicle to rotate the tires 180~.Position
the wheels with the chalk marks at the rear of the tires,
even with the hub/axle center line.
6. Measure the distance between the marks and record the
measurement (2).
7. Subtract measurement 2 from measurement 1.The difference is the vehicle toe-out alignment.
8. If you discover improper alignment, see your dealer for service.
78
Tires
!WARNING
Operating your vehicle with worn tires will increase the possibility of skidding, loss of control and an accident,
which could result in serious injury or death,
Always replace tires when the tread depth measures 1/8”(3mm) or less.
Improper tire inflation or the use of non-standard size or type of tires may adversely affect vehicle handling,
which could result in vehicle damage or personal injury. Always maintain proper tire pressure. When
replacing tires, always use original equipment size and type.
Tire tread Depth
Always replace tires when tread depth is worn to 1/8”(3 mm)
or less.
Front Wheel Hub Tightening
Front wheel bearing tightness and spindle nut retention are
Critical component operations. All service must be performed
by your authorized dealer.
Wheel Removal
1. Position the vehicle on a level surface.
2. Place the transmission in neutral. Set the parking brake. Stop the engine.
3. Loosen the wheel nuts slightly.
4. Elevate the side of the vehicle by placing a suitable stand under the frame.
5. Remove the wheel nuts. Remove the wheel.
79
Tires
Wheel Installation
1. Place the transmission in neutral.
2. Set the parking brake.
3. Place the wheel on the wheel hub with
the valve stem toward the outside
and the rotation arrows on the tire
pointing toward forward rotation.
4. Attach the wheel nuts and finger tighten.
5. Carefully lower the vehicle to the ground.
6. Torque the wheel nuts to specification.
Improperly installed wheels can adversely affect tire wear and vehicle
handling, which can result in serious injury or death. Always ensure
that all nuts are torqued to specification. Do not service axle nuts that
have a cotter pin installed. See your dealer.
Wheel Nut Torque Specifications
Check the wheel nut torques occasionally and when they’ve been loosened for service.
Location
Front Wheel
Rear wheel
Nut Torque
27 ft. lbs.(37 Nm)
27 ft. lbs.(37 Nm)
80
Lights
Daytime Running Lights Lamp Replacement
If the daytime running lights do not operate, replace the lamps. Yours recommends that you install
replacement lamps obtained from your authorized Yours dealer.
1. Disconnect the lights from the harness.
2. Remove the rubber cover from the back of the light assembly.
3. Press the lamp retainer inward and turn it counter-clockwise to remove it. Note the position of the lamp
positioning tab, then carefully pull the lamp out.
4. Install the new lamp. Make sure the filament is horizontal.
5. Reinstall the lamp retainer. Press the retainer inward and turn it clockwise about 1/4 turn.
6. Start the engine to make sure the lights come on. If the lights do not operate, see your Yours dealer for
service.
7. Reinstall the rubber cover, and reconnect the lights to the harness.
Tail Light Lamp Replacement
If the brake light doesn’t work, the lamp may need to be replaced.
1. Remove the two screws securing the lens cover. Remove the lens cover.
2. Remove the lamp and replace it with a new recommended lamp.
3. Test the light for proper operation.
4. Reinstall the lens cover.
81
Vehicle immersion
NOTICE:
If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly
inspected. Take the vehicle to your dealer before starting the engine. If it’s impossible to take your vehicle to
a dealer before starting it, follow the steps outlined below.
1. Move the vehicle to dry land.
2. Turn the fuel valve off.
3. Check the air box. If water is present, dry the air box
and replace the filter with a new filter. Thoroughly dry the
air pre-filter. See page 72.
4. Remove the spark plugs.
5. Loosen the carburetor drain screw.
6. Turn the engine over several times.
7. Dry the spark plugs and reinstall them, or install new
plugs.
8. Tighten the carburetor drain screw.
9. Turn the fuel valve on.
10. Attempt to start the engine. If necessary, repeat the drying
procedure.
11. Take the vehicle to your dealer for service as soon as possible,
whether you succeed in starting it or not.
12. If water has been ingested into the transmission follow the
procedure on page 71 for drying.
82
Battery
!WARNING
Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or
death. When reinstalling the battery, always disconnect the negative(black) cable first. When reinstalling the
battery, always connect the negative (black)cable last.
!WARNING
Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin,
eyes or clothing.
External: Flush with water.
Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg ,or vegetable oil.
Call physician immediately.
Eyes: Flush with water for 15 minutes and get prompt medical attention.
Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away. Ventilate when charging or
using in an enclosed space. Always shield eyes when working near batteries. KEEP OUT OF REACH OF
CHILDREN.
Your vehicle may have either a sealed battery, which requires little maintenance, or a conventional battery. A
sealed battery can be identified by its flat covers on the top of the battery. A conventional battery has six filler
caps on the top of the battery.
Always keep battery terminals and connections free of corrosion. If cleaning is necessary, remove the
corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water.
Rinse well with tap water and dry off with clean shop towels. coat the terminals with dielectric grease or
petroleum jelly. Be careful not to allow cleaning solution or tap water into a conventional battery.
83
Battery
Battery Removal
1. Remove the driver’s seat. See page 31.
2. On conventional batteries, remove the battery vent tube (sealed batteries do not have a vent tube).
3. Disconnect the black (negative) battery cable first.
4. Disconnect the black (positive) battery cable last.
5. Lift the battery out of the vehicle. Be careful not to tip a
conventional battery sideways, which could spill electrolyte.
NOTICE:
If electrolyte spills, immediately wash it off with a solution
of one tablespoon baking soda and one cup water to
prevent damage to the vehicle.
84
Battery
Battery Installation
Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can
also hinder vehicle performance. Follow the battery charging instructions on page 89 before installing the
battery.
1. Ensure that the battery is fully charged.
2. Place the battery in the battery holder.
3. On conventional batteries, install the battery vent tube. The vent tube must be free of obstructions and
securely installed. Route the tube away from the from the frame and vehicle body to prevent contact with
electrolyte.
Battery gases could accumulate in an improperly installed vent tube and cause an explosion, resulting
in serious injury or death. Always ensure that the vent tube is free of obstructions and is securely
installed as recommended.
4. Coat the terminals with dielectric grease or petroleum jelly.
5. Connect and tighten the red (positive) cable first.
6. Connect and tighten the black (negative) cable last.
7. Verify that cables are properly routed.
8. Reinstall the driver’s seat.
85
Battery
Battery Storage
Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle,
ensure that it’s fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each
month during storage and recharge as needed to maintain a full charge. See page 89.
Tip: Battery charge can be maintained by using a Yours Battery Tender charger or by charging about once a
month to make up for normal self-discharge. Battery Tender can be left connected during the storage period,
and will automatically charge the battery if the voltage drops below a pre-determined point .See page 99 for
the part numbers of Yours products.
Battery Fluid (Conventional Battery)
A poorly maintained battery will deteriorate rapidly.
Check the battery fluid level often. Maintain the
fluid level between the upper and lower level marks.
Add only distilled water. Tap water contains minerals
that are harmful to a battery.
86
Battery
Battery Charging (Conventional Battery)
1. Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during charging.
2. Charge the battery with a charging output no larger that 1/10 of the battery’s amp / hr rating. Charge as
needed to raise the specific gravity to 1.270 or greater.
3. Reinstall the battery. See page 87. Make sure the positive terminal is toward the front of the vehicle.
Battery Charging (Sealed Battery)
The following battery charging instructions apply only to the installation of a sealed battery. Read all
instructions before proceeding with the installation of this battery.
The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory.
Never pry the sealing strip off or add any other fluid to this battery.
The single most important thing about maintaining a sealed battery is to keep it fully charged. Since the
battery is sealed and the sealing strip cannot be removed, you must use a voltmeter or multimeter to
measure DC voltage.
An overheated battery may explode, causing severe injury or death. Always watch charging times
carefully. Stop charging if the battery becomes very warm to the touch. Allow it to cool before
resuming charging.
For a refresh charge, follow all instructions carefully.
1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or
higher.
2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less until battery voltage is 12.8 or
greater.
Tip: When using an automatic charger, refer to the charger manufacturer’s instructions for recharging. When
using a constant current charger, use the guidelines on the next page for recharging.
87
Battery
Battery Charging (Sealed Battery)
Always verify battery condition before and 1-2 hours after the end of barging.
State of charge
Voltage
Action
100%
12.8-13.0 volts
5%-100%
12.5-12.8 volts
50%-75%
12.0-12.5 volts
None, check at 3 mos. from
date of manufacture
May need slight charge, if no
charge, given check in 3
months
Needs charge
25%-50%
11.5-12.0 volts
Needs charge
0%-25%
11.5 volts or less
Needs charge with Desolating
charger
Charge Time
(Using constant current
charger @ standard amps
specified on top battery)
None required
3-6 hours
5-11 hours
At least 13 hours, verify state
of charge
At least 20 hours
88
Cleaning and Storage
Washing the Vehicle
Keeping your vehicle clean will not only improve its appearance
but it can also extend the life of various components.
Before washing the vehicle, locate the CVT inlet and outlet ducts. The
ducts are located under the rear wheel wells. Avoid spraying water
directly toward the ducts when washing the vehicle from the rear.
NOTICE:
Water in the CVT system could cause the drive belt to become wet and
slip in the clutches. Always avoid spraying water directly toward the CVT
inlet and outlet ducts when washing the vehicle from the rear.
High water pressure may damage components. Yours recommends
washing the vehicle by hand or with a garden hose, using mild soap.
Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these
types of products to contact the vehicle.
The best and safest way to clean your vehicle is with a garden hose and a pail of mild soap and water.
1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts last.
2. Rinse with clean water frequently.
3. Dry surfaces with a chamois to prevent water spots.
Washing Tips
 Avoid the use of harsh cleaners, which can scratch the finish.
 Do not use a power washer to clean the vehicle.
 Do not use medium to heavy duty compounds on the finish.
 Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and pads may contain
dirt particles that will scratch the finish.
89
Cleaning and Storage
Washing the Vehicle
If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The
water may damage components and could remove paint and labels. Avoid directing the water stream at the
following items:
 Wheel bearings
 Radiator
 Transmission seals
 CVT inlet and outlet ducts
 Brakes
 Cab and body panels
 Labels and decals
 Electrical components and wiring
If an informational or graphic label becomes illegible or come s off, contact your dealer to purchase a
replacement. Replacement safety labels are provided by you dealer at no charge.
Grease all zerk fittings immediately after washing. Allow the engine to run for a while to evaporate any water
that may have entered the engine or exhaust system.
Polishing the Vehicle
Yours recommends the use of common household aerosol furniture polish for polishing the finish on your
vehicle. Follow the instructions on the container.
Polishing Tips
 Avoid the use of automotive products, some of which can scratch the finish of your vehicle.
 Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and pads may contain
dirt particles that will a scratch the finish.
90
Cleaning and Storage
Chrome Wheel Care (if equipped)
Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a “like new”
appearance for many years.
Tip: Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to
corrosion if not properly cleaned. Clean chrome wheels more often if they’re exposed to salt or other
corrosive elements.
1. Wash chrome wheels frequently. Use a mild detergent. Never use abrasive cleaners on plated or painted
surfaces.
2. Rinse well clear water. Soap, detergents, salt, dirt, mud and other elements can cause corrosion.
3. Polish the clean chrome wheels periodically. Use an automotive grade chrome polish.
4. Routinely and liberally apply a weather resistant wax to each polished chrome wheel. Choose a product
suitable for chrome finishes. Read and follow the product labels and instructions.
Removing Corrosion
If light rust is found on the chrome finish, use steel wool (#0000-OTT grade) to remove it. Gently rub the
affected areas with the steel wool until the corrosion has been removed. Clean and polish the wheel as
outlined above.
91
Cleaning and storage
Storage Tips
NOTICE:
Starting the engine during the storage period will disturb the protective film created by fogging and damage
could occur. Never start the engine during the storage period.
Clean the Exterior
Make any necessary repairs and clean the vehicle as recommended. See page 91.
Stabilize the Fuel
1. Fill the fuel tank.
2. Add Your Carbon Clean Fuel Treatment or Your Fuel Stabilizer. Follow the instructions on the container for
the recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes
carbon deposits from pistons, rings, valves and exhaust systems.
3. Allow the engine to run for 15-20 minutes to allow the stabilizer to disperse through the fuel in the tank and
carburetor.
4. Turn the fuel valve off.
5. Drain the carburetor bowl.
Air Filter/Air Box
Inspect and clean or replace the pre-filter and air filter. See page 72. Clean the air box. Drain the sediment
tube.
Fluid Levels
Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Chart beginning
on page 58.
 Transmission fluid
 Brake fluid (change every two years and any time the fluid looks dark or contaminated)
Engine oil
Change the oil. See page 65.
92
Cleaning and Storage
Storage Tips
Inspect and Lubricate
Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart
beginning on page 58.
Fog the Engine
Use Your Engine Fogging Oil. Follow label directions carefully.
Battery Maintenance
See pages 88-90 for storage and charging procedures.
Storage Area/Covers
Be sure the storage area is well ventilated. Cover the vehicle with a genuine cover. Do not use plastic or
coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion
and oxidation.
Removal from Storage
1. Check the battery electrolyte level and charge the battery if necessary. Install it in the vehicle. Make sure
the battery vent hose is routed properly and that it’s not pinched or restricted in any way.
2. Make sure the spark plug is tight.
3. Fill the fuel tank with fuel.
4. Check all the points listed in the Daily Pre-Ride Inspection section on page 43. Tightness of the bolts, nuts
and other fasteners should be checked by an authorized dealer.
5. Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page 58.
93
Transporting the Vehicle
Follow these procedures when transporting the vehicle.
1. Place the transmission in neutral. Set the parking brake.
2. Stop the engine.
3. Turn the fuel valve off.
4. Remove the key to prevent loss during transporting.
5. Secure the fuel cap and seats.
NOTICE:
Always tie the frame of the vehicle to the transporting unit securely with suitable straps or rope. Do not
attach tie straps to the front control arm bolt pockets.
6. Wrap the front tie strap through the frame tubes, or attach a tie-down hook around each of the tubes.
7. Wrap the rear tie strap around the swing arm.
Maximum Rider Weight
Maximum Weight Capacity
Gross Vehicle Weight
Dry weight
Fuel Capacity
Engine Oil Capacity
Transmission Oil Capacity
Overall Length x Width x Height
Wheelbase
Ground Clearance
Engine Type
Displacement
Cooling
Bore x stroke
Alternator Output
Compression Ratio
Starting System
Ignition System
Spark Plug/Gap
94
SPECIFICATIONS
GKV200
75 kg(each rider)
150Kg
402kg
252 kg
11.0 Itr
0.9 Itr
0.11 ltr
2440x1220x1470mm
1860mm
130mm
4-Stroke
168.9 cc
air-cooled
61mm x 57.8mm
110 watts
9.2:1
Electric
CDI
A7TC/0.6-0.7mm
95
SPECIFICATIONS
GKV200
Lubrication System
Driving System Type
Final Drive
Shift Type
Tire Size-Front
Tire Size-Rear
Tire Pressure-Front
Tire Pressure-Rear
Brakes, Front/Rear
Parking Brake
Daytime Running Lights
Brake Light
Wet Sump
Automatic Constant Variable Transmission
Chain
F/N/R
21x7-10
22x10-10
24 psi (170kPa)
24 psi (170kPa)
Foot Activated,4-wheel hydraulic disc
Mechanical, Rear(Lever)
Dual, Standard
Standard
96
TROUBLESHOOTING
Drive Belt Wear/Burn
Part cause
Driving at low RPM or ground speed
Insufficient warm-up at low ambient
temperatures
Slow/easy clutch engagement
Belt slippage from water or snow
ingestion into the CVT system
Clutch malfunction
Poor engine performance
Wrong or missing belt
Improper break-in
Engine Doesn’t Turn Over
Possible Cause
Low battery voltage
Loose battery connections
Loose solenoid connections
Solution
Drive at a higher speed.
Warm the engine at least 5 minutes. With the transmission in
neutral, apply small amount of throttle in short bursts, 5 to 7 times.
The belt will become more flexible and pre vent belt burning.
Use the throttle quickly and effectively.
Dry out the CVT (see page 71).Prevent water from entering the
CVT inlet and outlet ducts (see page 91).Inspect clutch seals for
damage if repeated leaking occurs.
See your dealer
Check for fouled plugs or foreign material in gas tank or fuel lines.
See your dealer.
Install the recommended belt.
Always break in a new belt and/or clutch. See page 41.
Solution
Recharge the battery to 12.8 VDC
Check all connections and tighten
Check all connections and tighten
97
Engine Turns Over, Fails to Start
Possible Cause
Out of fuel
Clogged fuel valve or filter
Water is present in fuel
Ole or non-recommended fuel
Fuel valve is turned off
Fouled or defective spark plugs
No spark to spark plug
Water or fuel in crankcase
Overuse of choke
Clogged fuel filter
Low battery voltage
Mechanical failure
Solution
Turn the fuel valve to reserve, refuel
Inspect and clean or replace
Drain the fuel system and refuel
Replace with fresh recommended fuel
Turn the fuel valve on
Inspect plugs and replace if necessary
Inspect plugs and replace if necessary
Immediately see your Yours dealer
Inspect, clean and/or replace spark Plugs
Replace the filter
Recharge the battery to 12.8 VDC
See your dealer
Engine Backfires
Possible Cause
Weak spark from spark plug
Incorrect spark plug gap or heat range
Old or non-recommended fuel
Incorrectly installed spark plug wires
Incorrect ignition timing
Mechanical failure
Loose ignition connections
Water present in fuel
Exhaust system leak
Solution
Inspect, clean and/or replace spark plugs
Set gap to specs or replace plugs
Replace with fresh recommended fuel
See your dealer
See your dealer
See your dealer
Check all connections and tighten
Replace with fresh recommended fuel
See your dealer
98
Engine Pings or Knocks
Possible Cause
Poor quality or low octane fuel
Incorrect ignition timing
Incorrect spark plug gap or heat range
Solution
Replace with recommended fuel
See your dealer
Set gap to specs or replace plugs
Engine Runs Irregularly, Stalls or Misfires
Possible Cause
Solution
Fouled or defective spark plugs
Worn or defective spark plug wires
Incorrect spark plug gap or heat range
Loose ignition connections
Water present in fuel
Low battery voltage
Kinked or plugged fuel tank vent line
Incorrect fuel
Clogged air filter
Electronic throttle control malfunction
Other mechanical failure
Inspect, clean and/or replace sparkplugs
See your dealer
Set gap to specs or replace plugs
Check all connections and tighten
Replace with new fuel
Recharge battery to 12.8 VDC
Inspect and replace
Replace with recommended fuel
Inspect and clean or replace
See your dealer
See your dealer
Possible Lean Fuel Cause
Solution
Low or contaminated fuel
Low octane fuel
Clogged fuel filter
Incorrect fuel
Incorrect jetting
Add or change fuel, clean the fuel system
Replace with recommended fuel
See your dealer
Replace with recommended fuel
See your dealer
99
Possible Rich Fuel Cause
Fuel is very high octane
Overuse of choke
Stopping/starting without adequate Warm-up
Incorrect fuel
Clogged air filter
Incorrect jetting
Engine Stops or Loses Power
Possible Cause
Out of fuel
Kinked or plugged fuel vent line
Overuse of choke
Water is present in fuel
Fouled or defective spark plugs
Worn or defective spark plug wires
Incorrect spark plug gap or heat range
Loose ignition connections
Low battery Voltage
Incorrect fuel
Clogged air filter
Electronic throttle control malfunction
Other mechanical failure
Solution
Replace with lower octane fuel
Inspect, clean and/or replace spark plugs
Allow engine to warm up before operating and/or replace
Replace with recommended fuel
Inspect and clean or replace
See your dealer
Solution
Refuel
Inspect and replace
Inspect, clean and/or replace spark plugs
Replace with new fuel
Inspect, clean and/or replace spark plug
See your dealer
Set gap to specs or replace plug
Check all connections and tighten
Recharge the battery to 12.8 VDC
Replace with fresh recommended fuel
Inspect and clean or replace
See your dealer
See your dealer
100
Use the following chart to record periodic maintenance.
DATE MILES(KM) OR HOURS TECHNICIAN
SERVICE PERFORMED/COMMENTS
DATE MILES(KM) OR HOURS TECHNICIAN
SERVICE PERFORMED/COMMENTS
102
! WARNING
Improper vehicle use can result in SEVERE INJURY or DEATH NEVER allow vehicle to be operated:
 Without all occupants first viewing and understanding safety video and warning labels.
 With more than one passenger.
 On hills steeper than 15 degrees ∠15º.
 On paved surfaces-pavement may seriously affect handling and control.
 With non-Yours approved accessories-they may seriously affect stability.
 At speeds that are too fast for the operator’s skills, the conditions and /or the terrain.
ALWAYS require operator and passenger to:
 Wear seat belts; grab hand holds (passenger) and plant feet firmly on the floor.
 Secure cab nets.
 Keep hands and feet inside vehicle.
 Reduce speed and use extra caution when carrying a passenger.
 Watch for branches or other hazards that could enter vehicle.
Operation of this vehicle by children age 10 and under increases the risk of severe injury or death. Adult
supervision required for children under age 10.
NEVER permit children age 10 and under to operate or ride in this vehicle.
LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. IF OWNER’S
MANUAL IS MISS ING, CONTACT A YOURS DEALER FOR A REPLACEMENT.
103
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The U.S. Environmental Protection Agency and SSR Motorsports Inc. are pleased to explain the emission control
system warranty on your Off-Road Vehicle. SSR Motorsports Inc. must warrant the emission control system on your
vehicle for 5,000 km, or at least 30 months, whichever comes first, provided that there has been no abuse, neglect or
improper maintenance of your vehicle. This off-road vehicle was designed to meet the emission standards for 10,000
km, or five years, whichever comes first.
Your emission control system may include parts such as the carburetor or fuel injection system, the ignition system,
catalytic converter and engine computer, if it is equipped. Also included may be hoses, belts, connectors and other
emission-related assemblies.
Where a warrantable condition exists, SSR Motorsports Inc. will repair your vehicle at no cost to you, including
diagnosis, parts and labor.
If an emission-related part on your vehicle is defective, the part will be repaired or replaced by SSR Motorsports Inc.
This is your emission control system DEFECTS WARRANTY.
NOTICE!
Use of any SSR brand vehicle in any type of competitive event completely and absolutely voids this and all
other warranties offered by SSR Motorsports Inc.
OWNER'S WARRANTY RESPONSIBILITIES
As the vehicle owner, you are responsible for the performance of the required maintenance listed in your owner's
manual. SSR Motorsports Inc. recommends that you retain all receipts covering maintenance on your vehicle, but SSR
Motorsports can deny warranty solely for the lack of receipts or for your failure to ensure the performance of all
scheduled maintenance.
You are responsible for presenting your vehicle to the SSR Motorsports Inc. dealer as soon as a problem exists. The
warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.
As the vehicle owner, you should be aware that SSR Motorsports Inc. may deny your warranty coverage if your vehicle
or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.
If you use your vehicle in any type of competitive event, this warranty is immediately and completely void.
If you have any questions regarding your warranty rights and responsibilities, you should contact your nearest SSR
Motorsports authorized dealership using our dealer locator found here:
http://www.ssrmotorsports.com/store/dealer_locator.php, or the U.S. Environmental Protection Agency at 2000
Traverwood Drive, Ann Arbor, MI 48105.
YOUR WARRANTY RIGHTS AND OBLIGATIONS
SSR Motorsports Inc. warrant that each new SSR branded off-road vehicle:
A. Is designed, built and equipped so as to conform at the time of initial retail purchase with all applicable regulations
of the United States Environmental Protection Agency; and
B. Is free from defects in material and workmanship which cause such vehicle to fail to conform to applicable
regulations of the United States Environmental Protection Agency for the periods specified above.
I.
Coverage. Warranty defects shall be remedied during customary business hours at any authorized SSR
Motorsports Inc. dealer located within the United States of America in compliance with the Clean Air Act and applicable
regulations of the United States Environmental Protection Agency. Any part or parts replaced under this warranty shall
become the property of SSR Motorsports Inc.
II.
Limitations
This Emission Control System Warranty shall not cover any of the following:
A. Repair or replacement as a result of
(1) accident,
(2) misuse,
(3) repairs improperly performed or replacements improperly installed,
(4) use of replacement parts or accessories not conforming to specifications set forth by SSR Motorsports Inc.,
which adversely affect performance and/or
(5) use in competitive racing or related events.
B. Inspections, replacement of parts and other services and adjustments required for required maintenance.
C. Any vehicle equipped with an odometer or hour meter on which the odometer mileage or hour meter reading has
been changed so that actual mileage cannot be readily determined.
III.
Limited Liability
A. The liability of SSR Motorsports Inc. under this Emission Control System Warranty is limited solely to the
remedying of defects in material or workmanship by an authorized SSR Motorsports Inc. dealer at its place of business
during customary business hours. This warranty does not cover inconvenience or loss of use of the vehicle or
transportation of the vehicle to or from the SSR Motorsports Inc. dealer. SSR Motorsports Inc. shall not be liable for any
other expenses, loss or damage, whether direct, incidental, consequential or exemplary arising in connection with the
sale or use of or inability to use the SSR branded vehicle for any purpose. Some states do not allow the exclusion or
limitation of any incidental or consequential damages, so the above limitations may not apply to you.
B. No express emission control system warranty is given by SSR Motorsports Inc., except as specifically set forth
herein. Any emission control system warranty implied by law, including any warranty of merchantability or fitness for a
particular purpose, is limited to the express emission control system warranty terms stated in this warranty. The
foregoing statements of warranty are exclusive and in lieu of all other remedies. Some states do not allow limitations on
how long an implied warranty lasts, so the above limitations may not apply to you.
C. No dealer is authorized to modify this Limited Emission Control System Warranty issued by SSR Motorsports Inc.
IV. LEGAL RIGHTS.
This warranty gives you specific legal rights, and you may also have other rights
which vary from state to state.
V.
This warranty is in addition to the SSR Motorsports Inc. limited vehicle warranty.
VI.
ADDITIONAL INFORMATION. Any replacement part that is equivalent in performance and durability may be
used in the performance of any maintenance or repairs. However, SSR Motorsports Inc. is not liable for these parts. The
owner is responsible for the performance of all required maintenance. Such maintenance may be performed at a service
establishment or by any qualified individual. The warranty period begins on the date the OFF-ROAD VEHICLE is
delivered to an ultimate purchaser.
If you have any questions regarding your warranty rights and responsibilities, you should contact your selling dealer or
any authorized SSR Motorsports dealer using our dealer locator:
http://www.ssrmotorsports.com/store/dealer_locator.php or the U.S. Environmental Protection Agency at
2000 Traverwood Drive, Ann Arbor, MI 48105.
SSR Motorsports Inc.
12825 Alondra Blvd. Norwalk, CA 90650
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