Cub Cadet 37DZ7CKK010 Challenger MX 550 Yellow User Manual

Safe Operation Practices • Introduction • Set-Up • Controls & Operation • Product Care • Specications

WARNING

READ AND FOLLOW ALL SAFETY RULES AND INSTRUCTIONS IN THIS MANUAL

BEFORE ATTEMPTING TO OPERATE THIS VEHICLE.

FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.

OperatOr’s Manual

Form No. 769-26020

(January 29, 2021)

NOTE: This Operator’s Manual covers several models. Features may vary by model. Not all features in this manual are applicable to all

models and the model depicted may differ from yours.

Utility Vehicle

MX 550/750

Safe Operation Practices ........................................ 2

Introduction ............................................................. 5

Set-Up ....................................................................... 6

Controls & Operation .............................................. 7

Product Care ...........................................................12

Specications .......................................................... 21

Warranty ................................................................ 23

Table of Contents

Safe Operation Practices 1

Operation

General Operation

1. Read, understand, and follow all

instructions on the vehicle and in

the manual before attempting to

operate or service vehicle. Keep this

manual in a safe place for future and

regular reference and for ordering

replacement parts.

2. This is an off-highway utility vehicle

and it should not be operated on public

highways. Know and comply with all

laws and regulations governing the use

of off-highway vehicles in your area.

3. This vehicle handles and maneuvers

differently than a normal passenger

car. Sharp high speed turns and abrupt

maneuvers can cause vehicle to roll over

or go out of control. Slow down when

turning and avoid abrupt maneuvers.

4. Handling and maneuvering

characteristics of vehicle change

depending upon cargo load. Heavy

loads affect steering, braking, stability,

and overall handling of vehicle.

5. Be familiar with all instructions and

controls and their proper operation

before starting vehicle.

6. Never allow adults to operate this

vehicle without proper instruction.

7. Never allow children under 16 years

old to operate this vehicle. Children

16 years old and over should read

and understand the operation

instructions and safety rules in this

manual and should be trained and

supervised by a parent unless driver has

obtained a state-issued motor vehicle

driver’s licence.

8. Watch for traffic when operating near

or crossing roadways. This vehicle is not

intended for use on any public roadway.

9. Do not operate this vehicle while under

the influence of alcohol or drugs.

10. Never carry more than one passenger.

This vehicle is designed to carry the

driver and one passenger only. No riders

are allowed in cargo box or anywhere

else on vehicle, except in the driver and

passenger seats.

11. Keep all body parts (i.e. head, arms,

hands, legs, feet) inside vehicle when

vehicle is in motion.

12. Always remain seated and keep both

hands on the steering wheel when

driving the vehicle.

13. Sit on the center of the seat and keep

both feet within the foot platform

perimeter. Clean foot platform if dirty

and remove any debris from around foot

controls, e.g. brake pedal.

14. Do not misuse the vehicle. Reckless

operation can lead to accidents, severe

bodily injury or death.

15. Inspect area around vehicle before

moving, especially in reverse. Back up

slowly. Always look down and behind

before and while backing to avoid a

back-over accident. Keep bystanders out

of area.

16. Avoid driving through water, since loss

of control may occur. Drive belt may

slip if exposed to water thus reducing

vehicle pulling power and stopping

vehicle entirely. Water depth should not

exceed 15” (38 cm).

17. Always use vehicle lights while

operating in low light situations.

18. Do not mount or leave vehicle while it is

in motion or in actual operation.

19. Avoid sudden starts, stops, or turns and

always use a level turn-around area.

20. Never leave vehicle unattended with the

engine running. Move the shift lever to

“PARK” position, turn ignition key to the

“OFF” position and remove the key.

21. Check overhead clearances carefully

before driving under low hanging tree

branches, wires, power lines, bridges,

before entering or leaving buildings,

or in any other situation where the

operator and/or occupant protection

structure (OPS) may be struck, which

could result in serious injury.

22. Always use the occupant protection

structure (OPS) and seat belt for safe

operation. Overturning the utility

vehicle without an OPS, or with an OPS

and the seat belt unfastened, can result

in death or injury.

23. Always use the seat belt and never

remove the occupant protection

structure (OPS) or operate the vehicle

without the OPS.

24. The doors are designed to assist in

keeping the operator and passenger

inside the vehicle during operation.

Do NOT operate vehicle without doors

in place.

25. Improper use of the vehicle or failure

to properly maintain it could result

in decreased vehicle performance or

personal injury.

26. Engine must be stopped when cleaning,

servicing, adjusting, repairing, or

installing attachments on utility vehicle.

27. After striking foreign objects, stop the

vehicle and shut off the engine. Inspect

for damage and repair the damage

before restarting and operating.

28. Do not start or operate vehicle in an

inside area, unless it is adequately

ventilated. Engine exhaust contains

carbon monoxide fumes, which are very

poisonous and can be deadly.

29. Assure safety interlock switch is adjusted

correctly so engine cannot be started

unless gearshift is in the “PARK” position

with the brake pedal depressed.

30. Do not touch engine or exhaust

components while engine is running or

soon after it is stopped. They will be hot

and can cause a burn.

31. Always inspect your vehicle each time

you use it to make sure it is in safe

operating condition. Always follow the

inspection and maintenance procedures

and schedules described in this manual.

32. Do not use the differential lock when

driving down hill. Do not use the

differential lock at speeds over 25

mph. Allow for greater turning radius

and more difficult steering when the

differential lock is engaged.

33. If situations occur which are not covered

in this manual, use care and good

judgement. Contact your local service

center or call toll free 1-877-282-8684 for

the name of your nearest service center.

Occupant Size and Capacity

1. Make sure operators are at least 16 years

old and have a valid driver’s license.

2. Each occupant should be able to sit with

their back against the seat, feet flat on

the floor, and hands on the steering

wheel or handholds.

FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.

Particularly important information is distinguished in this manual by the following notations:

This symbol points out important safety instructions which, if not followed, could endanger the personal safety and/or property of yourself and others.

Read and follow all instructions in this manual before attempting to operate this vehicle. Failure to comply with these instructions may result in personal

injury. When you see this symbol. HEED ITS WARNING!

DANGER: Indicates death or serious injury will result if proper precautions are not taken.

WARNING: Indicates death, serious injury, or property damage can result if proper precautions are not taken.

CAUTION: Indicates some injury or property damage may result if proper precautions are not taken.

Note: Provides key information to make procedures easier or clearer.

WARNING

California Proposition 65

Engine Exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

DANGER

This vehicle was built to be operated according to the safe operation practices in this manual. As with any type of off-highway utility vehicle, carelessness or error on the part of the operator

can result in serious injury. Failure to observe the following safety instructions could result in serious injury or death.

3Section 1 — Safe operation practiceS

3. The operator should be tall enough to

wear the seat belt properly and reach

all controls.

4. Passengers should also be tall enough

for the seat belt to fit properly and be

able to brace themselves, as necessary,

by placing both feet firmly on the

floor while gripping the handholds.

Keep all body parts completely inside

the vehicle.

Dress Properly

1. Proper clothing can reduce the severity

of injury in the event of an accident.

2. Always wear appropriate eye protection

and protective clothing. It is also

recommended that you wear a properly

fitting D.O.T. approved helmet.

Slope Operation

Slopes are a major factor related to loss of

control and rollover accidents, which can result

in severe injury or death. If a slope is steeper

than a 15° incline, do not operate this vehicle

on that area. Exercise extreme caution while

operating on slopes.

Do:

1. Travel straight up and down slopes, not

across. Exercise extreme caution when

changing direction on slopes.

2. Travel slowly while on a slope. Always

keep the forward speed limited when

going down slopes to take advantage of

the engine braking action.

3. Keep all movement on the slopes slow

and gradual. Avoid starting or stopping

on a slope.

4. Avoid slopes with slippery, loose, or bumpy

surfaces as they are especially hazardous.

5. Use extra care while carrying cargo. It

may affect the stability of the vehicle.

Spread the load evenly and tie down.

Do Not:

1. Do not travel near drop-offs, ditches,

or embankments. The vehicle could

suddenly turn over if a wheel is over

the edge of a cliff, ditch, or if an edge

caves in.

2. Do not stop or start suddenly when

going uphill or downhill. Be especially

cautious when changing direction on

slopes.

3. Do not turn sideways to the hill. The

vehicle may roll over. If you must turn, go

slow and do so carefully and gradually.

4. Do not carry cargo or tow loads on

steep slopes.

Towing

1. Always use an approved hitch and hitch

point provided on the utility vehicle.

2. Do not tow more than 1200 lbs (544 kg)

rolling weight (i.e. trailer plus cargo).

3. Never load more than 110 lbs (50 kg)

tongue weight on tow bracket provided.

4. Go slow and use extra care when towing

a trailer. Allow for increased braking

distance. Load trailer properly.

5. Do not tow heavy loads on slopes

greater than 5° incline. When going

downhill or turning, the extra weight

tends to push the tow vehicle and may

cause you to lose control (i.e. braking

and steering ability are reduced, towed

equipment may jack-knife and cause

utility vehicle to overturn).

Cargo Box Loading/Operation

1. Do not exceed vehicle’s Total Load

Capacity rating of 1000 lbs (453.5 kg)

This includes operator, passenger,

accessories, and cargo.

2. Do not exceed 500 lbs. (226.7 kg) load in

cargo box.

3. Spread load evenly and secure to

prevent movement.

4. Do not load above height of cargo box

front panel. Load could shift forward and

injure driver or passenger.

5. Avoid loads which exceed the physical

dimensions of cargo box.

6. Go slow. Heavy loads will affect steering,

braking, stability, and overall handling of

the vehicle. Limit loads to those that can

be safely controlled.

7. Avoid sudden starts, stops, and turns

which could cause load to shift.

Cargo Box Lift

1. Stop vehicle on level ground, move

the shift lever into the “PARK” position

before raising cargo box.

2. On manual lift units, unload cargo box

before raising cargo box.

3. Do not operate vehicle with cargo box in

raised position.

4. Do not operate vehicle with cargo box

latch unlatched. Always re-latch upon

manually lowering cargo box.

When using optional electric lift:

a. Stay in driver’s seat.

b. Keep body parts away from

cargo box and keep all

bystanders away.

c. Do not allow rear wheels to hang

over the edge of a drop-off when

raising cargo box. The load in the

cargo box may shift causing the

vehicle to tip over backwards.

Safety Frame (OPS)

1. Your vehicle is equipped with an

occupant protection structure (OPS)

which must be maintained in a fully

functional condition. Use care when

driving through doorways or spaces

with a low overhead.

a. Never modify the OPS in any way.

b. Never attempt to straighten

or reweld any part of the main

frame or retaining brackets that

have been damaged. Doing so

may weaken the structure and

endanger your safety.

c. Never secure any parts other

than manufacturer approved

accessories on the main frame

or attach the safety frame with

anything other than the special

fasteners specified.

d. Never attach ropes, chains,

or cables to the OPS for

pulling purposes.

e. Although the OPS, when used

with a properly secured seat

belt, provides a crush-protective

environment in the event of a

tip-over or rollover, never take

unnecessary risks.

Children

1. Tragic accidents can occur if the

operator is not alert to the presence of

children. Children are often attracted to

the vehicle. They do not understand the

dangers. Never assume that children will

remain where you last saw them. Avoid

run over accidents.

a. Keep children out of the

immediate area of the vehicle

and in watchful care of a

responsible adult other than

the operator.

b. Be alert and turn the vehicle off if

a child enters the area.

c. Before and while backing,

look behind and down for

small children.

d. Never carry small children, they

may fall off and be seriously

injured or interfere with safe

vehicle operation.

e. Use extreme care while

approaching blind corners,

doorways, shrubs, trees, or other

objects that may block your

vision of a child who may run into

the path of the vehicle.

f. Remove key when vehicle

is unattended to prevent

unauthorized operation.

2. Never allow children under 16 years

old to operate this vehicle. Children

16 years old and over should read and

understand the operation instructions

and safety rules in this manual, should

be trained and supervised by a parent

and have obtained a state-issued motor

vehicle driver’s license.

3. Do not let children ride in the cargo

box, in the driver’s or passenger’s lap

or anywhere other than the passenger

seat. Never give small children a ride; not

even in the passenger seat. They may

fall off.

Service

Safe Handling of Fuel:

1. To avoid personal injury or property

damage use extreme care in handling

fuel. Fuel is extremely flammable

and the vapors are explosive. Serious

personal injury can occur when fuel is

spilled on yourself or your clothes which

can ignite. Wash your skin and change

clothes immediately.

a. Use only an approved

fuel container.

b. Never carry or fill containers

inside the vehicle’s bed or on

a truck or trailer. Always place

containers on the ground away

from your vehicle before filling.

c. When practical, remove gas-

powered vehicle from the truck

or trailer and refuel it on the

ground. If this is not possible,

then refuel on a trailer with a

portable container, rather than

from a fuel dispenser nozzle.

d. Keep the nozzle in contact

with the rim of the fuel tank or

container opening at all times

until fueling is complete. Do not

use a nozzle lock-open device.

e. Extinguish all cigarettes, cigars,

pipes, and other sources

of ignition.

4 Section 1 — Safe operation practiceS

f. Never fuel indoors.

g. Never remove gas cap or

add fuel while the engine is

hot or running. Allow engine

to cool at least five minutes

before refueling.

h. Never over fill fuel tank. Fill

tank to no more than one

inch below bottom of filler

neck to allow space for fuel

expansion. Leave additional

room for fuel expansion if the

utility vehicle will be in a high-

altitude situation.

i. Replace fuel cap and

tighten securely.

j. If fuel is spilled, wipe it off

immediately. Move vehicle to

another area. Wait 5 minutes

before starting the engine.

k. To reduce fire hazards, keep

engine compartment and

exhaust system free of grass,

leaves, or other debris build-up.

Clean up oil or fuel spillage and

remove any fuel soaked debris.

l. Never store the vehicle or fuel

container inside where there

is an open flame, spark or pilot

light as on a water heater, space

heater, furnace, clothes dryer, or

other gas appliances.

General Service

1. Never run an engine indoors or in a

poorly ventilated area. Engine exhaust

contains carbon monoxide, an odorless,

and deadly gas.

2. Before cleaning, repairing, or inspecting,

make certain all moving parts have

stopped. Remove the key to prevent

unintended starting.

3. Check brake operation frequently

as it is subjected to wear during

normal operation. Adjust and service

as required.

4. The cooling system is under pressure,

never remove the radiator cap when

the system is hot. Slowly turn the cap to

the first stop to release pressure before

removing the cap.

5. Keep all nuts, bolts, and screws tight to

be sure the vehicle is in safe working

condition.

6. Never tamper with the safety interlock

system or other safety devices. Check

their proper operation regularly.

7. Never attempt to make adjustments or

repairs to the vehicle while the engine

is running.

8. Wait for vehicle to cool before servicing

exhaust or coolant system.

9. Stop vehicle on level ground. Place shift

lever in park before servicing.

10. Maintain or replace safety and

instruction labels, as necessary.

11. Follow the vehicle maintenance and

service schedules to ensure that

all mechanical and safety systems

are working properly and not worn

excessively. Failure to do so can result in

accidents, injuries, or death.

12. Observe proper disposal laws and

regulations for gas, oil, etc. to protect

the environment.

13. Prior to disposal, determine the proper

method to dispose of waste from your

local Environmental Protection Agency.

Recycling centers are established to

properly dispose of materials in an

environmentally safe fashion.

14. Use proper containers when draining

fluids. Do not use food or beverage

containers that may mislead someone

into drinking from them. Properly

dispose of the containers immediately

following the draining of fluids.

15. Do NOT pour oil or other fluids into the

ground, down a drain or into a stream,

pond, lake, or other body of water.

Observe Environmental Protection

Agency regulations when disposing

of oil, fuel, coolant, brake fluid, filters,

batteries, tires, and other harmful waste.

16. We do not recommend the use of a

pressure washer to clean your vehicle.

They may cause damage to electrical

components; wheel spindles; pulleys;

bearings; or the engine. The use of high-

pressure water will result in shortened

life and reduce serviceability.

Do not modify engine

To avoid serious injury or death, do not modify

engine in any way. Tampering with engine

can lead it to operate at unsafe speeds. Never

tamper with factory setting of the engine and

its components.

Notice Regarding Emissions

Where applicable, this vehicle is certified to

federal EPA and California Air Resources Board

(CARB) emissions standards for Off-Highway

Recreational Vehicles (OHRV). The Engine

Owner’s Manual is supplied by the engine

manufacturer, and provides additional

information relating to the emission system,

warranty, and maintenance of the engine in

accordance with EPA and/or CARB regulations.

Consult your engine manual for the fuel

requirements for your engine.

Gasoline powered products may be equipped

with the following emission control systems:

Engine Modification (EM), Oxidizing Catalyst

(OC), Oxygen Sensor (O2S), Multi-port Fuel

Injection (MFI), Electronic Control Module

(ECM), Secondary Air Injection (SAI) and Three

Way Catalyst (TWC). When required, models

are equipped with low permeation fuel lines

and fuel tanks for evaporative emission

control. Please contact Customer Support

for information regarding the evaporative

emission control configuration for your model.

Spark Arrestor

WARNING

This vehicle is equipped with an internal combustion

engine and should not be used on or near any

unimproved forest-covered, brush-covered, or grass-

covered land unless the engine’s exhaust system is

equipped with a spark arrestor meeting applicable

local or state laws (if any).

The spark arrestor should be maintained in

effective working order by the operator. In the

State of California the above is required by law

(Section 4442 of the California Public Resources

Code). Other states may have similar laws.

Federal laws apply on federal lands.

A replacement spark arrestor for the muffler

is available through your nearest engine

authorized service dealer or contact the service

department, P.O. Box 361131, Cleveland, Ohio

44136-0019.

Safety Labels

Safety labels that may appear on the product

are reproduced on this page. Read, understand,

and follow all instructions on the machine

before attempting to assemble and/or operate.

Battery

Remove rubber cap Connect exhaust tube

Exhaust opening

Instruction:

Preparing the battery for

lling with electrolyte (acid)

Take o the rubber sealing cap

and remove lling plugs.

Replace rubber cap with

exhaust tube provided.

Filling electrolyte (acid):

Fill battery with electrolyte (diluted sulphuric acid) with a specic

Gravity of: cool or temperate climate 1.270-1.280

Tropical climate 1.250-1.260

The electrolyte temperature when lling must not be lower than 15°c or

higher than 30°c.

Fill battery to upper level as indicated on the battery case.

Leave battery to stand for at least 30 minutes after lling.

Electrolyte level may fall during this period, rell to upper level

before charging.

WARNING

The battery contains or emits chemicals known in certain quantities to

cause cancer, birth defects or other reproductive harm.

Introduction

Important Notice

This UTV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this UTV on any public street, road or highway.

This UTV complies with all applicable OFF-ROAD noise level and spark arrestor laws and regulations in effect at the time of manufacture.

Please check your local riding laws and regulations before operating this UTV.

When the temperature is below -4° F (-20° C), park the UTV in a place where the temperature is higher than -4° F (-20° C). Start the UTV after the UTV has warmed up. Please see the manual on the warming up process.

Follow the proper parking procedures when the temperature is higher than 100° F (38° C): turn off the engine; make sure the radiator fan is on for 3 minutes before turning off the power switch.

Starting the UTV for the first time will take longer because the fuel will need to reach the fuel injectors. To start the UTV the first time, hold the ignition key on at 5-second intervals. Allow the starter to rest 15 seconds

between each start attempt.

Universal Symbols

As a guide to the operation of your vehicle, various universal symbols have been utilized on the instruments and controls. The symbols are shown below with an indication of their meaning.

Warning/Danger/Caution Symbol

Diesel Fuel

Engine Coolant -- Temperature

Parking Brake

Battery Charging Condition

Engine Oil -- Pressure

Turn Signal/Hazard

Differential Lock

Position Light Bulb

Lift Cylinder -- Retract

Lift Cylinder -- Extend

Lift Cylinder -- Float

Hazard Warning Lights

Master Lighting Switch

Audible Warning Device

Fault Indicator Light of EPS System

2WD/4WD

Record Product Information

Before setting up and operating your new utility vehicle please locate the model

plate and record the information in the provided area to the right. You can locate the

model plate by looking on the frame above the left rear tire. See the image below.

This information will be necessary, should you seek technical support via our web

site, Customer Support Department, or with a local authorized service dealer.

Model NuMber

Serial NuMber

Set-Up

Note: This Operator’s Manual covers several models. Utility vehicle features may vary by model. Not all features in this manual are applicable to all utility vehicle

models and the utility vehicle depicted may differ from yours.

Note: All references in this manual to the left or right side and front or back of the utility vehicle are from the operating position only. Exceptions, if any, will be specified.

Note: Some components may come already assembled. If they are already assembled, skip ahead to the next step.

Thank you for purchasing this product. It was carefully engineered to provide

excellent performance when properly operated and maintained.

Please read this entire manual prior to operating. It instructs you how to

safely and easily set up, operate and maintain your vehicle. Please be sure

that you, and any other persons who will operate the vehicle, carefully follow

the recommended safety practices at all times. Failure to do so could result in

personal injury or property damage.

All information in this manual is relative to the most recent product information

available at the time. Review this manual frequently to familiarize yourself

with the vehicle, its features and operation. Please be aware that this

Operator’s Manual may cover a range of product specifications for various

models. Characteristics and features discussed and/or illustrated in this

manual may not be applicable to all models. We reserve the right to change

product specifications, designs and vehicle without notice and without

incurring obligation.

If applicable, the power testing information used to establish the power rating of

the engine equipped on this vehicle can be found at www.opei.org or the engine

manufacturer’s web site.

If you have any problems or questions concerning the vehicle, phone your

local authorized service dealer or contact us directly. We want to ensure your

complete satisfaction at all times.

Throughout this manual, all references to right and left side of the vehicle are

observed from the operating position.

Thank You

CAUTION

To avoid personal injury: Be sure to check and service the vehicle on a level surface with the engine shut off, the parking brake “ON” and any attachments lowered to the ground.

Pre-Start Check Items

To better prevent or avoid unnecessary repairs, it is important to know the condition of the vehicle well. Check it before operating.

Contents of Crate

• Utility Vehicle (1) • Operator’s Manual (1) • Tool Kit

• Product Registration Card (1)

P Visually inspect the vehicle

P Check engine oil level

P Check air filter

P Check brake fluid level

P Check coolant level

P Clean radiator screen (when used in dusty or muddy conditions)

P Check brake and pedal

P Check parking brake

P Check indicators, gauges and meters

P Check lights

P Check seat belts and roll-over protective structures

P Check front and rear joint boots

P Check tire inflation pressure

P Check fuel

P Check danger, warning and caution labels

Controls & Operation

(A)

(B)

(E)

(F)

(H, I & D)

(C)

(D)

(G)

(J)

(K)

(L)

(M)

(N)

Figure 4-1

Features

Refer to Figure 4-1 for the location of the features

described below.

Fuel Cap (A)

The fuel cap is located on the right side of the

vehicle to the rear of the passenger door.

Bumper (B)

The bumper is located on the front of the

utility vehicle.

Headlights (C)

The headlights are located on the front of the

utility vehicle and are illuminated when the

headlight switch is in the “ON “ position.

Turn Signals (D)

The turn signals are on the front and rear of the

vehicle and are activated by the turn signal switch.

Door Handles (E)

The door handles are used to open the doors and

are located on the doors.

Cargo Bed (F)

The cargo bed is used to haul materials and is

located on the back of the utility vehicle. See the

Specifications chart for information on cargo bed

capacity and dimensions.

Cargo Bed Release Levers (G)

The cargo bed release levers are located on both

the RH and LH side of the cargo bed and are used

to dump/tilt the cargo bed.

Brake Lights (H)

The brake lights are located on the rear of the

cargo bed and are illuminated by depressing the

brake pedal or when the hazard button is in the

“ON” position.

Tail Lights (I)

The tail lights are illuminated when the headlight

switch is turned to the “ON” position.

Tailgate (J)

The tailgate is located on the rear of the cargo bed

and can be opened by using the tailgate lever.

Tailgate Lever (K)

The tailgate lever is located on the tailgate and is

used to open the tailgate.

Hand Grip (L)

The hand grip is located on the passenger side of

the utility vehicle on the OPS.

Mirrors (M) (Optional, If equipped)

The mirrors are located on the passenger and

driver’s side of the vehicle and are used to see

behind the utility vehicle.

Winch (N)

The winch is located on the front of the utility

vehicle inside the bumper. The winch is controlled

by the winch control.

Occupant Protection Structure (OPS) & Seat Belts

(Not shown)

This utility vehicle is equipped with an Occupant

Protection Structure (OPS) and seat belts. When

used together they are effective in reducing

crushing injuries to the operator and passenger

in the event of an accidental rollover or tip-over.

The safety provided by the OPS is minimized if the

seat belt is not properly adjusted AND buckled.

Adjust the seat belts for proper fit and connect

the buckle. This seat belt is an auto-locking,

retractable type.

To wear the 3-point seat belt properly:

1. Pull the seat belt latch down and across your

chest toward the buckle. The belt should fit

snugly across your hips and diagonally across

your chest. Make sure the belt is not twisted.

2. Push the latch plate into the buckle until it

clicks. Pull up on the strap to tighten.

3. Press the red release latch on the buckle to

release the seat belt.

WARNING

Always wear the seat belt when operating the utility vehicle.

Use the following guidelines when using a utility

vehicle equipped with OPS:

1. Be aware of overhead clearances in the area

of operation. Check for clearance of door (or

gate) openings and other overhead objects

such as utility lines and tree branches.

Overhead objects could catch the OPS and

upset the utility vehicle.

2. Do not modify the OPS by drilling holes for,

or welding accessories to, the structure.

3. Do not use the OPS to pull objects with the

utility vehicle. Use ONLY the utility vehicle

hitch for pulling.

4. Do not operate the utility vehicle without

the OPS and do not remove the OPS.

5. In the event of an accident, have the OPS

carefully inspected and, if necessary,

replaced by your authorized dealer. Do not

attempt to repair the OPS.

8 Section 4 — controlS & operation

(A)

(B)

(E)

(F)

(H)

(C)

(D)

(Q)

(I)

(J)

(K)

(N)

(L)

(M)

(O)

(P)

(G)

Figure 4-2

Controls

Refer to Figure 4-2 for location and information of

the controls described below.

Steering Wheel (A)

The steering wheel is used to control the direction

of the utility vehicle.

Ignition (Not shown)

The Ignition is located on the right side of the

steering column.

High Beam Switch (B)

The high beam switch is used to turn

the high beams on the headlights “ON”

and “OFF.”

Headlight/Tail Light Switch (C)

The headlight/tail light switch turns the

headlights, instrument cluster lights and

tail lights “ON” and “OFF.”

Horn (D)

The horn activates the horn under the hood

when depressed.

Hazard Switch (E)

The hazard switch turns the hazards “ON”

and “OFF.”

Turn Signal Switch (F)

The turn signal switch controls the

turn signals and activates the LH or RH

turn signals.

Shift Lever (N)

The shift lever changes the gears of the utility

vehicle between PARK (“P”), REVERSE (“R”),

NEUTRAL (“N”), HIGH (“H”) and LOW (“L” ).

Parking Brake Lever (O)

The parking brake lever activates the utility

vehicle’s parking brake.

Glove Box (P)

The glove box is a small storage area in the dash on

the passenger side of the utility vehicle.

Instrument Cluster (Q)

The instrument cluster contains:

1 - Tachometer 11 - Differential Lock Indicator

2 - Parking Brake Indicator 12 - 2WD/4WD Indicator

3 - Battery Indicator 13 - Gear Indicator

4 - Oil Pressure Indicator 14 - Seat Belt Indicator

5 - Engine Indicator 15 - Hazards

6 - EPS System Fault * 16 - High Beam Indicator

7 - Left Turn Signal 17 - Fuel Gauge

8 - Right Turn Signal 18 - Coolant Temperature

9 - Hour Meter 19 - Low Beam Indicator

10 - Speedometer 20 - Coolant Over-

temp Indicator

* -- If equipped

12V Power Outlet (G)

The 12V power outlet is used for the convenience

of plugging in accessories that require a power

source with a maximum load of 5A at 12V.

Brake Pedal (H)

The brake pedal is used to slow down/stop the

utility vehicle.

Gas Pedal (I)

The gas pedal is used to control the speed of the

utility vehicle.

2WD/4WD Switch (J)

The 2WD/4WD switch is used to switch

between 2WD and 4WD.

Front Axle Differential Switch (K)

The front axle differential switch can

“LOCK” or “UNLOCK” the front

axle differential.

Rear Axle Differential Switch (L)

The rear axle differential switch

can “LOCK” or “UNLOCK” the rear

axle differential.

Winch Control (M)

The winch control releases cable on the

winch (“OUT”) or pulls the cable in (“IN”).

9Section 4 — controlS & operation

Operation

First 50 Hours

How a new vehicle is handled and maintained

determines the life of the vehicle.

A new vehicle just off the factory production line

has been, of course, tested, but various parts are

not fully aligned, so the operator should pay more

attention to operating the vehicle for the first

50 hours at a slower speed and avoid excessive

work or operation until the various parts become

“broken-in.” The manner to which you handle the

vehicle during the “breaking-in” period greatly

affects the life of your vehicle. Therefore, to obtain

the maximum performance and the longest life of

the vehicle, it is very important to properly break-

in your vehicle. For better handling a new vehicle,

the following precautions should be observed.

• Do not operate the vehicle at full speed for

the first 50 hours.

• Do not start quickly nor apply the

brakes suddenly.

• In winter, operate the vehicle after fully

warming up the engine.

• Do not run the engine at speeds faster

than prescribed.

• On rough roads, slow down to

suitable speeds.

• Do not operate the vehicle at fast speed.

The above precautions are not limited to new

vehicles. However, they should be especially

observed for new vehicles.

Note: The lubricating oil is especially important

for a new vehicle. Various parts need time to wear

and polish themselves to the correct operating

clearances. Small pieces of metal grit may develop

during the operation of the vehicle; and this

may wear out or damage the parts. Therefore,

change the lubricating oil a little earlier than

would ordinarily be required. For further details

of change interval hours, see the Product Care

section of this manual.

Starting the Utility Vehicle

WARNING

Seat belts reduce injury. Always wear your seat belts. The

lap-style seat belts may not provide adequate protection

for small children. Pay special attention when carrying a

child passenger. Always use the seat belts when operating

and riding in the vehicle.

General Safety

• RECEIVE INSTRUCTION — Entirely read

this operator’s manual. Learn to operate

this vehicle SAFELY. Do not risk INJURY or

DEATH. Allow only those who have become

competent in its usage to operate this

utility vehicle.

• Before starting the engine or beginning

operation, be familiar with the controls.

• Read the danger, warning and caution labels

located on the vehicle.

• To avoid the danger of exhaust fumes, do

not operate the utility vehicle in closed

buildings without proper ventilation.

• Start engine only from operator’s seat.

Never start the engine while standing

outside the utility vehicle.

• Make sure the shift lever is in the NEUTRAL

(N) or PARK (P) position before starting

the engine.

Starting the Engine

Note: Do not use starting fluid or ether.

Note: To protect the battery and the starter, make

sure that the starter is not continuously turned for

more than 5 seconds.

1. Engage the parking brake.

Note: The parking brake indicator is

illuminated when the parking brake is

applied and turns off when it is released.

See Figure 4-2.

2. Place the shift lever in the NEUTRAL (N) or

PARK (P) position.

Note: The engine will not start without the

gear shift in the NEUTRAL (N) or PARK (P)

position and the brake depressed.

3. Insert the key into the ignition and turn it to

the START position. Release the key when

the engine starts. See Figure 4-3.

(D)

(C)

(B)

(A)

Figure 4-3

Note: The ignition is a 4-position switch,

the positions and brief descriptions of each

are below:

a. OFF — Engine is off and the key can

be removed.

b. ACC — Accessories such as radio are

on, but engine is off.

c. ON — Engine and all accessories

are on.

d. START — Starter motor on, the

key will return to the ON position

when released.

Note: When the ambient temperature is

below -15° C (5° F), the engine is very cold. If

the engine fails to start after 5 seconds, turn

off the key for 30 seconds and start again.

Stopping the Engine

1. After slowing the engine to idle, turn the key

to the OFF position.

2. Remove the key.

Warming Up

CAUTION

Be sure to set the parking brake during warm-up. Be sure to

set the shift lever to the PARK position during warm-up.

For 5 minutes after engine start-up, allow the

engine and transmission to warm up without

applying any load. This is to allow oil to reach

every engine part. If load applied to the engine

or transmission without warming up, damage

may occur.

Driving the Utility Vehicle

1. Adjust the seat belt to fit comfortably

around your lap, then buckle the seat belt.

WARNING

Do not operate the vehicle without the OPS in place and the

seat belt fastened securely around your waist and chest.

2. Start the engine as instructed in the Starting

the Engine section and make sure the front

wheels are turned to the desired direction

of travel.

CAUTION

Immediately stop the engine if the engine suddenly slows

down or accelerates, unusual noises are suddenly heard, or

exhaust fumes suddenly become very strong.

3. Push down on brake pedal, pull slightly back

on the parking brake lever while depressing

the lock button and then slowly push

forward to release the parking brake.

4. Push down on brake pedal and move the

shift lever into the desired setting. To avoid

damaging the transmission, depress the

brake pedal fully and make sure the vehicle

is completely stopped before shifting into

HIGH (H), LOW (L) or REVERSE (R).

WARNING

Do not stop or start suddenly when going uphill or downhill.

Be cautious when changing direction on slopes. Apply brakes

when going down slopes to maintain control of vehicle.

5. Release brake pedal and slowly apply

pressure to the gas pedal.

6. Release gas and apply brake pedal evenly

and firmly to slow down or stop.

2WD/4WD

CAUTION

When traveling at road speed, use only 2WD. When driving on

icy, wet, or loose surfaces, make sure the vehicle is correctly

loaded to avoid skidding and loss of steering control. Reduce

the speed and engage front wheel drive. Accident may

occur if the vehicle is suddenly braked, such as heavy towed

loads shifting forward causing loss of control. The braking

characteristics are different between two and four wheel

drive. Be aware of the differences and operate carefully.

To activate the 4WD stop the utility vehicle and

press down on the upper half of the 2WD/4WD

switch. To return to 2WD, stop the utility vehicle

and press down on the lower half of the 2WD/4WD

switch. When in 2WD just the two rear tires will be

filled on the instrument cluster indicator, when in

4WD all four tires will be filled. See Figure 4-4.

2WD 4WD

Figure 4-4

10 Section 4 — controlS & operation

Differential Lock

WARNING

To avoid transmission damage, injury, or turf damage, drive

slow when operating utility vehicle with differential lock

engaged as steering response is noticeably reduced. Also,

do not drive the utility vehicle with the differential lock

engaged on concrete, asphalt, or any high traction surfaces.

The front and rear axle differentials can be

activated when the utility vehicle is stopped

and the shift lever is in the NEUTRAL position. To

activate either axle differential press the upper

portion of the front/rear axle differential switch.

To deactivate the axle differential press the lower

portion of the front/rear axle differential switch.

Both, one or neither of the differentials can

be active. When activated the differential lock

indicator display will show an “X” on the indicator

as shown in Figure 4-5.

OFF OFF

OFF

Figure 4-5

Important! Engage the differential as the last

option when stuck in mud or similar situation or

when the left and right side wheels are turning at

slightly different speeds.

Loading the Cargo Bed

WARNING

The utility vehicle may become unstable if the cargo bed

is loaded incorrectly. Avoid loose and unsecured loads or

uneven loading of material.

1. Verify cargo bed is securely latched

before loading.

2. Securely anchor all loads in cargo bed and

do not load beyond maximum capacity.

Note: The maximum box capacity is 500 lb

(227 kg).

3. When loading objects into cargo bed,

be sure load is securely anchored and

evenly distributed.

4. Do not load above height of cargo bed.

Load could shift forward striking driver or

passenger or cause driver to lose control

of vehicle.

5. Avoid loads which exceed physical

dimensions of cargo bed.

6. Avoid concentrated loads at rear or sides of

cargo bed. Be sure load is distributed evenly.

7. Reduce load and ground speed when

operating over rough or hilly terrain. Do

NOT overload vehicle. Limit loads to those

that can be safely controlled.

Raising & Lowering the Tailgate

To open up the tailgate (a), pull up on the tailgate

lever (b) and slowly lower the tailgate (a). To close

the tailgate (a) lift the tailgate (a) and push it

forward until it locks into place. See Figure 4-6.

(a)

(b)

Figure 4-6

Raising & Lowering the Cargo Bed (Dumping Load)

WARNING

To prevent the possibility of bodily injury from unintentional

lowering of the cargo bed, be sure vehicle is on a level and

stable surface and parking brake is set before raising cargo bed.

WARNING

A loaded cargo bed can be very heavy. Do not attempt to

dump a heavily loaded cargo bed.

1. Park the vehicle safely on level ground and

set parking brake.

2. Empty heavy loads by hand.

3. For light loads, unlatch cargo bed by pulling

up on one of the cargo bed release levers.

While holding the cargo bed release lever

lift the cargo bed. See Figure 4-7.

Figure 4-7

4. Once unloaded, lower the cargo bed and

securely latch it before operating the utility

vehicle. Do not drive the utility vehicle with

cargo bed in the raised position.

Towing Loads

WARNING

To help prevent personal injury due to loss of control or

tipping, always tow a load slow enough to maintain control.

1. Do not tow a load that exceeds 1200 lb (544

kg) rolling weight (i.e. trailer plus cargo) and

never exceed 110 lb (50 kg) tongue weight.

2. Go slow when towing a heavy load. Allow

for increased braking distance. Tow load at a

speed slow enough to maintain control.

3. Do not tow on slopes greater than 5°.

4. Be cautious when towing downhill, even

on a gradual slope or when turning. The

extra weight tends to push the tow vehicle

and may cause you to lose control (braking

and steering ability are reduced; towed

equipment may jack-knife).

Important! Extreme angles such as high

railroad crossings can place high bending

loads on hitch connection.

5. Do not modify the hitch in any way.

Loading a Utility Vehicle into a Truck or onto a Trailer

WARNING

Always park the truck or trailer in a flat area, set the parking

brake, turn the ignition off, and chock the wheels to prevent

any unexpected movement while loading the utility vehicle.

WARNING

Fully secure the loading ramps to the truck or trailer with

tie-down straps or cables to prevent the ramps from sliding

off while loading. Keep bystanders and/or helpers away

from ramps while loading.

Due to the overall size and dimensions, loading a

utility vehicle into a truck or onto a trailer is a task

that requires precision and the proper equipment

to be achieved safely. By following the steps

outlined below you’ll be able to select the proper

equipment to do the job and safely load and

unload your utility vehicle.

Determine if your truck or trailer is sufficient

for the task

Loading a utility vehicle into a truck or trailer that

can’t support its weight is extremely dangerous. It

is important that before any actual loading is done,

make sure your truck or trailer and loading ramps

are sufficient for loading and hauling the utility

vehicle. Here are some of the variables you need to

take into account:

• Length and Width: Measure the size of

your truck or trailer by taking width and

length measurements at the floor level.

Compare these measurements to the width

and length of your utility vehicle to make

sure it will fit comfortably.

• Weight Capacity: Making sure your truck or

trailer can handle the payload of your utility

vehicle is another critical task before any

loading is done. If using a truck, the payload

capacity must be a minimum of 3/4 ton. If

hauling on a trailer, remember that the towing

capacity of the vehicle will be reduced by the

added weight of the utility vehicle.

• Tailgate Considerations: If the payload

capacity is sufficient for hauling in a truck,

the last thing left to consider is your truck’s

bed length. Make certain that your truck

bed is long enough to allow the truck’s

tailgate to close completely when the utility

vehicle is loaded into the truck bed.

11Section 4 — controlS & operation

Choosing the proper loading ramp(s)

Choosing a reliable ramp and understanding how

to properly use it is far and above the best option

for safely loading a utility vehicle into your truck or

onto your trailer. Take a look at the considerations

you should have in mind when choosing the

proper ramp(s):

• Capacity: Utility vehicles are not evenly

balanced, meaning it’s necessary to check

the axle weights before you make any

choices regarding ramps. A typical ramp’s

capacity is based upon two axles with

equally distributed loads. We recommend

3000-lb minimum capacity ramp(s) as the

appropriate option for your two-person

utility vehicle.

• Offset Track Widths: Your utility vehicle

has an offset track width front and rear, it’s

important to factor this in to your ramp

placement and ramp width needs. Ramps

need to be wide enough to accommodate

the difference in the distances between the

front two wheels and the rear two wheels.

• Ground Clearance and Wheelbase:

Utility vehicles which have low ground

clearance (under 4”) and a relatively long

wheelbase (98” or more), make them prone

to bottoming out at the crest when using

straight ramps. As a solution to this issue we

suggest using arched ramps.

• Load Height: As with any ramp application,

the distance from the ground to the truck

bed or trailer impacts the overall length

of the ramp you will need, the greater the

load height, the longer the ramp should

be. Some ramp manufacturers and retailers

provide load height calculators to help you

determine the correct ramp length you will

need to safely load your vehicle.

Note: If you are still unsure of what types

of ramps you will need to get the job done

and are having trouble understanding these

instructions, check with your local ramp or

utility vehicle retailer for assistance.

Loading the Utility Vehicle

If your truck or trailer’s load capacity is sufficient

to transport the utility vehicle and you obtain the

proper loading ramps and equipment to safely

secure the utility vehicle to the truck or trailer, the

only thing left to do is load it. Here’s how to best

accomplish this task:

1. Proceed with extreme caution. It is very

difficult to overcome a mistake while in the

loading process.

2. Park the truck or trailer in a flat area, set

the parking brake, turn the ignition off and

chock the wheels.

3. Face the truck bed or trailer towards a slight

incline, which will reduce the steepness of

the loading angle by bringing the bottom

of the ramps up on the slight incline. See

Figure 4-8.

Figure 4-8

4. Place the ramp fingers or plate edges on the

edge of the trailer or truck bed. See Figure 4-9.

Figure 4-9

5. Use tie-down straps or cables to secure the

ramps to the trailer or truck, via the bumper

(steel bumpers only) or trailer hitch safety

chain loops. Refer to instructions provided

with the ramp.

6. If your utility vehicle is supplied with a

roof and/or windshield, remove or fully

secure them prior to loading. Roofs and

windshields are not designed to withstand

the wind speeds that the open road can

generate, so it’s best to remove them

entirely to prevent any damage or accidents.

7. Follow all safety rules provided in this

manual along with the manuals supplied by

the trailer and ramp manufacturer. Carefully

load the utility vehicle onto the truck

or trailer.

8. Once the utility vehicle is on the truck or

trailer, set the utility vehicle’s parking brake

and secure the utility vehicle to the truck

or trailer. Tie-down strap placement will

depend on your truck or trailer. Be sure

to use only tie-down straps sufficient for

the load capacity. If loaded onto a truck,

close the tailgate once the utility vehicle is

secured to the truck bed.

9. Stop periodically to ensure that your tie-

down straps have not loosened and that the

utility vehicle remains securely in place.

Important! Know the total height of your

vehicle with the utility vehicle loaded

before transporting. Be sure to check

for low clearance bridges, doorways, etc.

prior to traveling under them. The added

height above the height of your truck could

cause clearance issues and damage to

both vehicles.

Product Care

Maintenance Chart

Intervals

Items

First 20

hours

First 50

hours

Every 50

hours

Every 100

hours

Every 150

hours

Every 200

hours

Every 300

hours

Every 500

hours

Every 3900

hours

Every year

Every

2 years

Every

4 years

Grease utility vehicle

Clean muffler/spark arrestor

PP PP

Clean spark arrestor

Check lug nuts

PP PP

Check battery condition

Adjust front wheel toe-in

Change oil

PP PP

Check fuel line

PP PP

Replace fuel line

Clean air filter element *

PP PP PP

Check brake pedal

PP PP

Adjust parking brake

PP PP PP

Check brake light switch

PP PP

Check radiator hose & clamp

Replace radiator hose & clamp

Check PCV Accumulator

PP PP

Check intake air line

Replace intake air line

Check brake hose & pipe

PP PP

Replace brake hose & pipe

Check tires

PP PP

Change axle case oil

Adjust engine valve clearance

Check fuel injection

Check injection

Check CV shaft boots

Check exhaust system

Check wheel bearings

PP PP

Check engine timing

Change brake fluid

Replace remote hydraulic hose

Replace rear brake cylinder seal

Replace front brake cylinder seal

Flush cooling system

Change engine coolant

* — Perform more often in dusty conditions.

13Section 5 — Product care

Troubleshooting

1. Engine will not start:

• Battery has low voltage

• Loose or corroded battery connections

• Fuse is blown

• Spark plug wire is loose

or disconnected

• Faulty spark plug or coil

• No fuel or improper fuel

• Plugged fuel filter

• Defective starter solenoid

• Open-circuit in wiring

2. Engine is difficult to start:

• Engine is cold

• Plugged fuel filter

• Engine oil viscosity too heavy

• Spark plug is fouled

• Faulty spark plug or wire

• Loose or corroded

electrical connections

• Stale or improper fuel

3. Engine misfires under load:

• Faulty spark plug

• Stale or dirty fuel

• Plugged fuel filter

• Faulty coil or wire

4. Engine does not restart when warm:

• Poor quality fuel

• Very hot weather conditions

• Fuel tank vent plugged

• Dirt in fuel filter

5. Entire electrical system does not work:

• Blown fuse

• Loose or corroded connections

• Dead or faulty battery

6. Dead battery:

• Shorted starter solenoid

• Key switch not turned to

STOP position

• Faulty battery

7. Battery will not take a charge:

• Dead battery

• Loose or corroded connections

8. Difficult to shift:

• Idle speed too fast

• Gears not lined up. Tap throttle

and let it return to idle. If still hard

to shift, contact your nearest

authorized service dealer

9. Indicator lights do not come on when key

switch is in START position:

• Faulty bulb

• Faulty wiring

• Faulty sensor

10. Engine runs unevenly:

• Loose electrical connections

• Choke (if equipped) or throttle

cable sticking

• Fuel line or fuel filter plugged

• Stale or dirty fuel

• Check the joint boots on the drive shaft for

damage. If the joint boots are damaged, see

an authorized service dealer.

• Check tire pressure. See Tire Pressure in

this section.

Maintenance

WARNING

To avoid personal injury, be sure to check and service the

vehicle on a flat surface with the engine off and the parking

brake ON. If servicing under the cargo bed, be sure that the

cargo bed is supported so that it can not inadvertently close.

Do not touch muffler or exhaust pipes while they are hot;

Otherwise, severe burns could result.

WARNING

If vehicle diagnosis requires the vehicle to be run with the

wheels off the ground, the free wheeling state will cause

the engine management system to create a lean condition.

This lean condition will cause the exhaust system to become

hotter than normal operating conditions. Exercise extreme

caution when working around the exhaust components and

allow extra time for the exhaust components to cool.

Tire Pressure

The recommended operating tire pressure is

14 psi (70 kPa) for all tires. Over-inflating above

recommended tire pressure can reduce the life of

the tire. Check tire pressures before each use.

Note: If the cargo bed is at maximum capacity

(1000 lbs), the rear tire pressure can be increased

to 18 psi (124 kPa).

Lug Nuts

Check torque of lug nuts after first 50 hours of use

and every 100 hours thereafter. Tighten lug nuts in

a diagonal pattern. Torque lug nuts to 65-75 lb-ft

using a torque wrench.

Removing the Hood & Interior Hood Panel

CAUTION

To avoid personal injury from contact with moving parts never

open operator’s seat or hood cover while the engine is running.

To open the hood, pull up on the center of the

upper edge of the cover (a) and lift the hood off.

To close, insert the front bottom hooks into the

hood. Push down on the perimeter of the cover.

See Figure 5-1.

(a)

Figure 5-1

• Improper fuel

• Air cleaner element plugged

• Spark plug is fouled

11. Engine overheats:

• Air cleaner element missing

or plugged

• Air intake plugged

• Engine oil low

• Engine operated too long at slow

engine speed

• Cooling fan not turning

12. Engine loses power:

• Engine overheating

• Too much oil in engine

• Faulty spark plug

• Fuel supply being restricted

• Fuel filter plugged

• Fuel line pinched or kinked

• Fuel pump output not adjusted

to specification

• Improper fuel

• Air cleaner element plugged

13. Starter does not work:

• Loose or corroded connections

• Low battery output

• Dead or faulty battery

• Faulty starter

14. Starter cranks slowly:

• Low battery output

• Dead or faulty battery

• Engine oil too heavy

• Loose or corroded connections

15. Battery light comes on when engine

is running:

• Low engine speed

• Faulty voltage regulator

• Faulty battery

• Faulty rotor or stator

• Damaged wiring harness

16. Vehicle will not move:

• Shift Lever still in NEUTRAL

• Parking Brake still set

• Broken or cut drive belt

• Safely check to see if the vehicle

will go in reverse and then try to

go forward. If vehicle still will not

move forward, contact your nearest

authorized dealer

Pre-Start Checklist

• Check parking brake. Make sure the parking

brake indicator light comes on when the

parking brake is ON.

• Inspect the instrument panel for broken

gauges and warning lamps.

• Check the headlights and turn signals.

Replace if broken.

• Check seat belt and OPS. Do not operate

utility vehicle until repaired if either

is broken.

14 Section 5 — Product care

To remove the interior hood panel (a), grasp

the upper left corner of the panel and pull. See

Figure 5-2.

(a)

Figure 5-2

Removing the Seat

To remove the seat, lift up on the front edge of the

seat and after the two pins (a) clear the bushings

pull towards the front of the vehicle. See Figure

5-3. When re-installing the seat, make sure the

pins (a) in the seat are inserted into the holes (b) in

the frame.

(a)

(b)

Figure 5-3

Removing the Battery Access Panel

Unlock the battery access panel under the seat

by rotating the lock knob, then lifting the battery

access panel. See Figure 5-4.

(a)

Figure 5-4

Removing the Engine Access Panel

Lift up on the handle (a) near the front of the

engine access panel under the seat, then remove

the engine access panel. See Figure 5-5.

(a)

Figure 5-5

Removing the Air Filter Access Panel

Remove the two screws (a) securing the air filter

access panel (b) to the front of the seat box. See

Figure 5-6.

(a)

(b)

(a)

Figure 5-6

Jacking Up the Utility Vehicle

WARNING

To avoid personal injury, death, or vehicle damage do not

work under the vehicle unless it is secured by safe stands or

suitable blocking.

1. Jack up the front end of the utility vehicle on

the front frame tube (a) only. See Figure 5-7.

(a)

Figure 5-7

2. Jack the rear of the utility vehicle only after

placing a wooden block under the right

(a) and left frame tube (b) for securing the

engine and then supporting it. Do not apply

jack pressure on the steel plate directly

under the engine. See Figure 5-8.

(a)

(b)

Figure 5-8

Adjusting the Doors

If the gaps around the doors are uneven, the

door can be adjusted. To adjust the doors, loosen

the two bolts (a) on each hinge, adjust the door

until an equal gap is achieved all the way around.

Retighten all four bolts (a). See Figure 5-9.

(a)

Figure 5-9

If the door is not latching properly, the latches (a)

can be adjusted. Loosen the two bolts (b) securing

the latch (a), position the latch (a) so that the door

closes and latches properly, then re-tighten the

two bolts (b). See Figure 5-10.

(a)

(b)

Figure 5-10

15Section 5 — Product care

Checking & Refilling Fuel

CAUTION

Do not smoke while refueling. Be sure to stop the engine

before refueling.

1. Turn the key switch to ON, check the

amount of fuel by the fuel gauge.

2. Fill fuel tank when fuel gauge shows 1/4 or

less fuel in the tank.

3. The fuel tank holds approximately 7.4

gallons (28 L) of fuel.

Checking & Adding Oil

Important! If oil level is low, do not run the engine.

1. Park the vehicle on a flat surface with

engine off, remove the seat and engine

access panel to access the engine.

2. To check the oil level, remove the dipstick (a),

wipe it clean, replace it without re-threading

the dipstick, and pull it out again, check to

see if the level is too low and add new oil to

the full level on the dipstick (a). See Figure

5-11 for the location of dipstick.

(a)

Figure 5-11

3. After the new filter has been replaced,

the engine oil normally decreases a little.

Make sure that the engine oil does not leak

through the seal and check the oil level on

the dipstick. Add oil if necessary.

4. See Figure 5-12 for oil recommendations.

SAE 0W-30

SAE 10W-30

SAE 10W-40

SAE 20W-50

SAE 15W-40

SAE 20W-40

Figure 5-12

CAUTION

Only use engine oil with API Service Classification of SJ or

Higher and JASO-MA Grade.

5. The engine oil capacity is 2.22 quarts (2.1 L).

Checking & Adding Engine Coolant

CAUTION

Do not remove radiator cap while coolant is hot. When

cool, slowly rotate to the first stop and allow sufficient

time for excess pressure to escape before removing the

cap completely.

1. Park the vehicle on a flat surface, remove

the hood panel, set the parking brake and

shut off the engine.

2. Check to see that the coolant level is

between the FULL (a) and LOW (b) marks of

recovery tank (c). See Figure 5-13.

(a)

(b)

(c)

Figure 5-13

3. When the coolant level drops due to

evaporation, add water only up to the FULL

(a) level. In case of leakage add anti-freeze

and water in the specified mixing ratio up to

the FULL (a) level. (See Flushing the Coolant

System and Changing Coolant section).

• Use clean fresh water and anti-freeze

to fill the recovery tank.

• If water should leak, consult your

local authorized service dealer.

Note: If the radiator cap has to be removed,

follow the cautions above and securely

retighten the cap.

Cleaning the Radiator Screen

CAUTION

Be sure to stop the engine before removing the screen.

Note: Radiator screen must be cleaned of debris to

prevent engine from overheating.

1. Park the utility vehicle on a flat surface.

2. Remove the radiator cover.

3. Detach the screen and clean the radiator and

radiator screen and radiator fins of all debris.

See Figure 5-14.

Figure 5-14

Checking & Adding Brake Fluid

CAUTION

Never operate the vehicle if the brake fluid is below the

minimum mark. Use only DOT3 from a sealed container.

Other types of brake fluid may ruin synthetic resin or rubber

installed in brake system components and may cause brake

failure. Avoid contamination of the brake fluid, thoroughly

clean around the filler cap before removing. Do not open

the brake fluid reservoir cap unless absolutely necessary.

Use extreme care when filling the reservoir. If brake fluid

spills on coolant hose, wash off with water immediately, as

brake fluid quickly ruins synthetic resin or rubber hoses.

1. Check to see that the brake fluid level of the

brake fluid reservoir (a) is up to the MIN (b)

level. See Figure 5-15.

(a)

(c)

(b)

Figure 5-15

2. If it is below the MIN (b) level add brake

fluid, but do not exceed the MAX (c) level.

Checking the Brake Pedal

WARNING

Stop the engine and chock the wheels before checking

brake pedal.

Inspect the brake pedals for free play (a), pedal

stroke (b) and smooth operation. Refer to

Figure 5-16.

(a)

(b)

Figure 5-16

1. Release the parking brake.

2. Step on the pedal and measure the free

play (a). There should be between .3” and

.5” (7-14 mm) of free play (a). If the free

play (a) measurement is outside of these

specifications, see an authorized service

dealer to have the brake adjusted.

16 Section 5 — Product care

3. Step on the pedal and measure the stroke

(b). There should be less than 4.7” (120 mm)

of stroke (b). If the measurement is outside

of these specifications, see an authorized

service dealer to have the brake adjusted.

Checking & Adjusting the Parking Brake

Pull the parking brake to apply the brakes with

the key switch in the ON position and the parking

brake indicator should come on. To release the

parking brake, depress the parking pedal. Make

sure the parking brake warning lamp on the

display goes off when parking brake is OFF.

If the parking brake is in need of adjustment,

proceed as follows:

1. Locate the parking brake adjustment nut

near the engine. See Figure 5-17.

(a)

(b)

Figure 5-17

2. Loosen the lock nut (a) and then tighten the

bolt (b) to adjust the parking brake. Turn

the bolt until it touches, then back it off a

1/4-turn. See Figure 5-17.

If there is play in the parking brake handle there is

a secondary adjustment that can be performed.

1. Look inside the driver’s side wheel well and

locate the adjustment point. Slide back the

rubber cover (a) on the adjustment nuts (b).

See Figure 5-18.

(a)

(b)

Figure 5-18

2. Adjust the parking brake handle nuts (b)

until the free play in the handle is gone. See

Figure 5-18.

Checking & Adjusting the Shift Lever

If the shifter and the display image on the

instrument cluster do not match or the utility

vehicle is not shifting, a shift cable adjustment can

be performed.

1. Remove the hood and the interior hood panel.

2. Locate the shift lever adjustment nuts (a).

See Figure 5-19.

(a)

Figure 5-19

3. Adjust the nuts (a) up or down until the shift

lever is working properly. See Figure 5-19.

Checking the Engine Start System

WARNING

Do not allow anyone near the vehicle while testing. If the

vehicle does not pass the test, do not operate the vehicle.

1. Sit on the operator’s seat.

2. Place the shift lever in the NEUTRAL position.

3. Set the parking brake and stop the engine.

4. Move the shift lever to: LOW, HIGH, PARK

or REVERSE position. Do not step on the

brake pedal.

5. Turn the key to START position.

6. The engine should not crank.

7. If it cranks see an authorized service dealer.

8. Repeat Steps 4 and 5 but when turning the

key to start position step on the brake pedal.

The engine should crank.

9. If it does not crank see an authorized

service dealer.

Adjusting the Shocks

There are three adjustment points on the shocks.

The rebound (a), pre-load spring (b) and damping

rate (c) can be adjusted. Refer to Figure 5-20 for the

following instructions.

(a)

(b)

(c)

Figure 5-20

Rebound Adjuster (a)

The rebound adjuster is located near the bottom

of the shock and controls the “bounce back” speed

of the utility vehicle. To adjust the rebound or

“bounce-back” speed, follow the steps below:

Note: Each position has a stop or “click” to indicate

the setting.

1. Insert a standard screw driver into the

adjustment.

2. Rotate the screw into one of the 18 positions

between “S” (position 0) and “F” (18). Rotate

the screw clockwise (towards the “S” or “0”

position) to slow the rebound and counter-

clockwise (towards the “F” or “18” position)

to speed up the rebound.

Pre-Load Spring Adjuster (b)

The pre-load adjuster is located in the body of

the shock and controls the height of the vehicle.

It can be adjusted to accommodate for different

load situations.

Note: This adjustment requires a spanner wrench

to complete. A spanner wrench is included in the

tool kit shipped with this utility vehicle.

1. Using a spanner wrench, loosen the upper

lock nut.

2. Adjust the pre-load adjuster nut to the

desired setting. Turn the pre-load adjuster

clockwise to increase the compression

force (raise the utility vehicle) and turn the

pre-load adjuster nut counter-clockwise to

decrease the compression force (lower the

utility vehicle).

Damping Rate Adjuster (c)

The compression adjuster is located on the upper

part of the shock and controls the ride of the utility

vehicle and the impact resistance of the shocks.

Note: Each position has a stop or “click” to indicate

which of the 18 positions it is in.

1. To increase the stiffness of the suspension

and increase the absorption of impacts,

rotate the compression adjuster screw

clockwise towards the “SLOW” (or

“0”) position.

2. To decrease the stiffness (soften the ride)

rotate the compression adjuster screw

counter-clockwise towards the “FAST” (or

“18”) position.

To return the utility vehicle to its stock setting, use

the chart below:

Rebound

Adjuster

Pre-Load

Adjuster

Compression

Adjuster

Front Position 7 295 mm Position 5

Rear Position 4 300 mm Position 3

* -- These settings are based on a “full load”

condition. 250 lb (113 kg) driver, 250 lb (113 kg)

passenger and 500 lb (227 kg) cargo load.

Service

WARNING

To avoid personal injury, be sure to check and service the

vehicle on a flat surface with the engine off and the parking

brake ON. If servicing under the cargo bed, be sure that the

cargo bed is supported so that it can not inadvertently close.

Do not touch muffler or exhaust pipes while they are hot;

Otherwise, severe burns could result.

Changing the Oil

WARNING

Be sure to stop the engine before replacing oil. Allow engine

to cool down sufficiently, oil can be hot and can burn.

1. Park the vehicle on a flat surface and raise

the cargo bed.

2. To drain the used oil, remove the drain plug

at the bottom of the engine and completely

drain the oil into an oil pan.

3. After draining, reinstall the drain plug.

17Section 5 — Product care

4. Fill with the new oil up to the upper notch

on the dipstick.

5. See Figure 5-21 for oil recommendations.

SAE 0W-30

SAE 10W-30

SAE 10W-40

SAE 20W-50

SAE 15W-40

SAE 20W-40

Figure 5-21

CAUTION

Only use engine oil with API Service Classification of SJ or

Higher and JASO-MA Grade

6. The engine oil capacity is 2.22 quarts (2.1 L).

Replacing Oil Filter

WARNING

Be sure to stop the engine before replacing oil filter. Allow

engine to cool down sufficiently, oil can be hot and can burn.

1. Park the vehicle on a flat surface, remove

the seat and open the engine access cover.

2. Make sure the engine is warm.

3. Remove the oil filter (a). See Figure 5-22.

(a)

Figure 5-22

4. Put a film of clean engine oil on the rubber

seal of the new filter.

5. Tighten the filter until it contacts the

mounting surface.

6. Tighten filter by hand an additional 1/2-

turn only.

Draining the PCV Accumulator

The PCV accumulator should be drained at each

oil change to remove oil condensation. There are

two PCV accumulators, one near the front of the air

intake box and one near the rear. To drain the PCV

accumulator, pinch the valve at the bottom of the

tube and allow the condensation to run out. See

Figure 5-23.

Figure 5-23

Replacing Mini Fuses

The mini fuses are intended to protect the

electrical system. If any of them have blown out,

be sure to pinpoint the cause. (See Specifications

section, Figure 6-1 for fuse box layout.)

1. Disconnect the negative battery cable.

2. Open the mini fuse box cover. See Figure 5-24.

++ ++ ++ ++ ++ ++

++ ++

303025

10 51 5

10 15 10

Figure 5-24

3. Pull out the mini fuse.

4. Insert a new mini fuse into the box.

5. Close the mini fuse box cover.

6. Re-connect the negative battery cable.

Changing the Front & Rear Axle Case Oil

See your authorized service dealer to have the axle

case oil changed.

Changing the Brake Fluid

See your authorized service dealer to have the

brake fluid changed.

Replacing Radiator Hose

See your authorized service dealer to have the

radiator hose changed.

Replacing Fuel Hose

See your authorized service dealer to have the fuel

hose changed.

Replacing Brake Master Cylinder

See your authorized service dealer to have the

brake master cylinder changed.

Replacing Front Brake Seal

See your authorized service dealer to have the

front brake seal changed.

Replacing Rear Brake Cylinder Seal

See your authorized service dealer to have the rear

brake seal changed.

Replacing Intake Air Line

See your authorized service dealer to have the air

intake line changed.

Replacing Brake Hose

See your authorized service dealer to have the

brake hoses changed.

Flushing the Coolant System & Changing Coolant

CAUTION

Do not remove radiator cap while coolant is hot. When

cool slowly rotate to the first stop and allow sufficient

time for excess pressure to escape before removing the

cap completely.

1. Stop the engine and let it cool down.

2. To drain the coolant, open the radiator drain

plug and remove radiator cap. The radiator

cap must be removed to completely drain

the coolant.

3. After all coolant is drained, close the drain plug.

Note: Do not start engine without coolant.

4. Fill with clean water and cooling

system cleaner.

5. Follow directions of the cleaner container.

6. After flushing, fill with clean water and anti-

freeze until the coolant level is just below

the radiator cap.

Note: When the antifreeze is mixed with

water, the antifreeze mixing ratio must be

50-50. See the Antifreeze section.

7. Install the radiator cap securely. If the cap is

loose or improperly fitted, water may leak

out and the engine could overheat.

8. Fill with fresh water/antifreeze up to the

“FULL” mark on the recovery tank. See

Figure 5-13.

9. Start and operate the engine for a

few minutes.

10. Stop the engine and let cool.

11. Check coolant level of recovery tank and

coolant if necessary.

12. Burp (remove air from) the coolant system

as instructed in the Burping (Removing Air

From) the Coolant System section.

Anti-Freeze

WARNING

When using antifreeze, put on some protection such as

rubber gloves. (Antifreeze contains poison.) If you should

drink antifreeze, throw up at once and seek medical

attention. If antifreeze comes in contact with the skin or

clothing, wash it off immediately. Do not mix different

types of antifreeze. The mixture can produce a chemical

reaction between substances. Antifreeze is extremely

flammable and explosive under certain conditions. Keep

fire away from antifreeze. Keep children away from

antifreeze. When draining fluids from the engine, place

some container underneath the engine body. Do not

pour waste onto the grounds, down a drain or into any

water source. Also, observe the relevant environmental

protection regulations when disposing of antifreeze.

If it freezes, coolant can damage the cylinders and

radiator. If the ambient temperature falls below

0° C (32° F) or before a long-term storage, let out

coolant completely, or mix fresh water with long-

life coolant and fill the radiator and recovery tank

with the mixture.

1. Long-life coolant comes in several types.

Use an ethylene glycol (EG) type for

this engine.

18 Section 5 — Product care

2. Before employing long-life coolant-mixed

cooling water, fill the radiator with fresh

water and empty it again.

3. Repeat this procedure two or three times to

clean up the inside.

4. Mix the long-life coolant.

5. The procedure for the mixing of water

and antifreeze differs according to the

make of the antifreeze and the ambient

temperature. Refer to SEA J1034 standard,

more specifically also to SAE J814c.

6. Add the long-life coolant.

7. If there is a mixture leak, add long-life

coolant from the same manufacturer and

type in the same mixture percentage.

Note: Never mix long-life coolant from

different manufacturers. (Different brands

may have different additive components,

and the engine may fail to perform

as specified.)

8. When the long-life coolant is mixed, do not

employ any radiator cleaning agent. The

long-life coolant contains anticorrosive

agent. If mixed with the cleaning agent,

sludge may build up, adversely affecting the

engine parts.

9. The utility vehicle’s genuine long-life

coolant has a service life of 2 years. Be sure

to change the coolant every 2 years.

10. Burp (remove air from) the coolant system

as instructed in the Burping (Removing Air

From) the Coolant System section.

Burping (Removing Air From) the Coolant System

To “burp” the coolant system, proceed as follows:

Note: When re-filling the coolant system, this

procedure should be performed every time to

avoid an overheating risk.

1. Chock the rear wheel, engage the parking

brake place the shift lever in NEUTRAL or

PARK and jack up the front of the utility

vehicle approximately 6”.

2. Remove the bleeder screw (a) on the

radiator, fill the radiator and when fluid

begins to come out of the bleeder screw

hole, replace the bleeder screw (a). The

bleeder screw (a) can be accessed via the

front right wheel well. See Figure 5-25.

(a)

Figure 5-25

3. Start the utility vehicle and let it idle.

4. Remove the second bleeder screw (a) where

the radiator hose (b) connects to the engine

and let the engine run until a steady stream

of fluid comes out of the bleeder screw

(a) hole indicating there are no more air

pockets in the coolant system. Replace the

bleeder screw (a). See Figure 5-26.

(a)

(b)

Figure 5-26

5. Top off the radiator and replace the radiator

cap. Then lower the front of the utility

vehicle off the jack.

Cleaning Primary Air Filter Element

Open the air cleaner cover once a week under

ordinary conditions — or daily when used in a dusty

place — to get rid of large particles of dust and dirt.

Note: Do not run the engine with filter element

removed.

1. Remove the air filter access panel.

2. Remove the air filter cover (a) from the three

air filter cover holders (b). See Figure 5-27.

(a)

(b)

Figure 5-27

3. Remove the air filter element. See Figure 5-28.

Figure 5-28

4. Remove the inner filter (a) from the paper

element (b). See Figure 5-29.

(a)

(b)

Figure 5-29

5. Clean the paper element with a soft brush

or low pressure air. Be careful not to damage

the paper pleats during cleaning.

6. Inspect the inner filter for deposits or damage.

7. If either filter are excessively dirty or

damaged, replace filters as a set.

8. Re-install the primary air filter element.

9. Install the air filter case cover and be sure

the crankcase breather hose is connected.

Note: Be sure to refit the air filter cover with

the arrow (on the rear of air filter cover)

upright. If the air filter cover is improperly

fitted the evacuator valve will not function

and dust will adhere to the air filter element.

Cleaning the Air Intake

Air Intake Screen

1. Remove the hood and locate the air intake.

2. Remove the rubber seal (b) around the front

of the air intake (a) and remove the air intake

screen (c). See Figure 5-30.

(a)

(b)

(c)

Figure 5-30

3. Rinse the air intake screen (c) with water and

replace the air intake screen (c) and rubber

seal (b). See Figure 5-30.

19Section 5 — Product care

Drain the Air Intake

1. Remove the nine Allen-head bolts (a) and

washers (a) securing the middle skid plate

to the bottom of the utility vehicle. See

Figure 5-31.

(a)

(a)(a)

(a)

Figure 5-31

2. Remove the drain and allow the water to

run out (a). Then replace the drain and the

middle skid plate. See Figure 5-32.

(a)

Figure 5-32

Check Fuel Line & Fuel Filter

WARNING

Be sure to stop the engine and remove the key. Check the

fuel lines periodically. The fuel lines are subject to wear

and old fuel may leak onto a running engine which may

cause a fire.

The fuel line connections should be checked

annually or every 100 service hours whichever

comes first. The fuel line is made of rubber and

wears regardless of service period.

Important! When the fuel line is disconnected

for maintenance or repair, close both ends of the

fuel line with a piece of clean cloth or paper to

prevent dust and dirt from entering. Particular

care must be taken not to allow dust and dirt into

the fuel pump entrance. Even a small amount

of dust or dirt can cause premature wear and

the malfunction of the fuel pump and injector

components.

1. Park the vehicle on a flat surface and

remove the engine access panel. There is

a primary fuel filter on the gas tank and an

in-line fuel filter between the gas tank and

the engine.

2. If the fuel line and clamps are damaged or

deteriorated, replace them.

3. There are two main lines (a) coming into

the primary fuel filter (b) and one main line

Figure 5-33.

(a)

(b)

(a)(c)

Figure 5-33

4. Check the fuel filter, if it is clogged by debris

or contaminated with water, replace it.

5. To remove the in-line fuel filter clamps (b),

slide the clamps (b) away from the in-line

fuel filter (a). Twist and pull the fuel lines off

of the in-line fuel filter (a). See Figure 5-34.

(a)

(b)

Figure 5-34

6. Check the in-line filter (a) for debris and/or

water contamination. Replace as necessary.

Battery

Note: If you store a battery that is not completely

charged, the battery may need to be replaced.

WARNING

Never remove the battery while the engine is running.

Keep electrolyte away from eyes, hands, and clothes. If you

are spattered with it, wash it away completely with water

immediately and get medical attention. Wear eye protection

and rubber gloves when working around the battery.

Note: The factory installed battery is the non-

refillable type. If the battery is weak, charge or

replace it.

Charging the Battery

WARNING

When the battery is being active, hydrogen and oxygen gases

in the battery are extremely explosive. Keep open sparks and

flames away from the battery at all times, especially when

charging the battery. When disconnecting the cable from the

battery start with the negative terminal; when connecting the

cable to the battery start with the positive terminal. Always

check battery charge by using a voltmeter.

1. To slow charge the battery connect the

battery positive terminal to the charger

positive terminal and the negative

to the negative. Then recharge the

battery normally.

2. A boost charge is only for emergencies, it

will partially charge the battery as quickly

as possible.

3. When exchanging an old battery for a new

one, use a battery of equal specification.

The battery type is a 12 volt battery with a

minimum of 300 CCA.

Storing the Battery

When storing the vehicle for a long period, remove

the battery and store in a dry place out of direct

sunlight. The battery will self-discharge while it

is stored. Recharge it once every three months

in hot seasons and once every six months in

cold seasons.

Adjusting Toe-In

1. Park utility vehicle on a flat surface.

2. Turn the steering wheel so that the front

wheels are in the straight position.

3. Lock the parking brake and stop the engine.

4. Measure the distance between the center of

the front tires at hub height on the front (a)

and rear (b) of the tires. See Figure 5-35.

(a)

(c)

(b)

Figure 5-35

5. The front distance should be shorter than

rear distance by 0-.47” (0-12 mm) (c). If not,

adjust tie rod length.

6. Loosen the lock nut and turn the inner tie

rod to adjust the rod length until the proper

toe-in measurement is obtained. Retighten

the lock nut.

Note: Keep the length of the left and right

tie-rods equal.

Cleaning the Spark Arrestor & Muffler

WARNING

Before touching any part of the exhaust system, be sure that

it has had sufficient time to cool. Always wear safety goggles

and face mask. The particulate matter contained in the muffler

contains chemicals that are harmful to people, animals, and

marine life. If you are unable to do this work, have it done by

your dealer.

20 Section 5 — Product care

Spark Arrestor

The spark arrestor (a) should be removed, inspected

and cleaned every 100 hours of use. The spark

arrestor (a) is located inside of muffler (b) body and

fastened with bolts. See Figure 5-36.

(a)

(b)

Figure 5-36

1. Remove the back cover, loosen the bolts

and remove the spark arrestor (a).

2. Shake loosened particles out of the screen

assembly and lightly clean the screen with

wire brush. Soak in solvent and clean with

wire brush, if necessary.

3. If there is any damage, the assembly must

be replaced.

4. Return the spark arrestor (a) to the muffler (b)

and reinstall the bolts.

Muffler

1. Visually check the muffler for cracks or

holes in the body, weldment or pipes at

regular intervals.

2. USDA Forestry Division approval requires

clearance between spark arrestor sleeve and

muffler body to be no larger than 0.023”

(0.584 mm).

3. Replace the entire muffler if it is damaged.

4. Do not operate the vehicle with a

damaged muffler.

Storage

WARNING

Do NOT clean the vehicle when the engine is running. To

avoid the danger of exhaust fume poisoning, do not operate

the engine in a closed building without proper ventilation.

When storing, remove the key from the key switch to avoid

unauthorized persons from operating the vehicle and

getting injured.

If you intend to store your vehicle for an extended

period of time, follow the procedures outlined below.

These procedures will ensure that the vehicle is

ready to operate with minimum preparation when

it is removed from storage.

1. Check the bolts and nuts for looseness and

tighten if necessary.

2. Apply grease to vehicle areas where bare

metal will rust and also to pivot areas.

3. Unload from the cargo bed.

4. Inflate tires to 20 psi each.

5. Change the engine oil and run the engine

to circulate oil throughout the engine

block and internal moving parts for about

5 minutes.

6. With all implements lowered to the

ground, coat any exposed rods with grease

(if equipped).

7. Remove the battery from the vehicle.

Store the battery following the battery

storage procedures.

8. Keep the vehicle in a dry place where the

vehicle is sheltered from the elements.

Cover the vehicle.

9. Keep the vehicle indoors in a dry area that

is protected from sunlight and excessive

heat. If the vehicle must be stored outdoors.

Cover it with a waterproof tarpaulin.

10. Put boards under the tires to keep

dampness away from tires.

11. Keep the tires out of direct sunlight and

extreme heat.

Important! When washing the vehicle, be

sure to stop the engine. Allow sufficient

time for the engine to cool before washing.

Do not wash with a high-pressure pressure

washer. Cover the vehicle after the muffler

and the engine have cooled down.

Removing the Vehicle from Storage

1. Check the tire air pressure and adjust

to recommended pressures indicated

on vehicle.

2. Install battery. Before installing the battery,

make sure it is fully charged.

3. Check all fluid levels (engine oil, axle

case oil, engine coolant and any

attached implements).

4. Start the engine. Check to see if the engine

cooling fan works. Observe all gauges.

5. If all gauges are functioning properly and

reading normal and the cooling fan is

working, move the vehicle outside.

6. Once outside, park the vehicle and let the

engine idle for at least 5 minutes. Shut the

engine off. Work around vehicle and make a

visual inspection looking for evidence of oil

or water leaks.

7. With the engine fully warmed up, release

the parking brake and test the brakes for

proper adjustment as you move forward.

Adjust the parking brake as necessary.

Notes

Specifications 6

MAKE SPECIFICATIONS

Engine

Type 1 cylinder, 4-cycle, gasoline, SOHC, liquid cooled

Displacement cc

546CC for 550UTV

735CC for 750UTV

Horsepower Kw (HP)

20.2 (27.1) for 550UTV

28.8 (38.6) for 750UTV

Rated Revolution rpm

5500 rpm for 550UTV

6000 for 750UTV

Low Idling Revolution rpm 1500 ±150

Fuel Capacity L (U.S. gal.) 28 (7.4)

Oil Capacity L (U.S. quart) 2.1 (2.22)

Transmission CVT

Wheels, Drive System 4, Rear 2WD or 4WD

Differential Lock Electronic Control, Switch

Gear Selection H-L range FORWARD, NEUTRAL, REVERSE, PARK

Brakes

Front/Rear Wet disc brake

Parking Brake Axis brake, hand braking

Steering Manual (Electronic Power Steering Optional)

Dimensions

Length mm (in.) 2960 (116.5)

Width mm (in.) 1540 (60.63)

Height mm (in.) 1950 (76.77)

Front Tread Centers mm (in.) 1310 (51.57)

Rear Tread Centers mm (in.) 1290 (50.79)

Wheel Base mm (in.) 1950 (76.77)

Ground Clearance

Front axle

mm (in.)

295 (11.6)

Rear Axle 330 (13.0)

Turning Diameter m (ft.) 8.6 (28.22)

Suspension

Front Independent, Dual A-arm type

Rear Independent, Dual A-arm type

Max rolling weight (Towing capacity) kg (lbs.) 544 (1200)

Payload capacity (Cargo Bed) kg (lbs.) 227 (500)

Vehicle Curb Weight kg (lbs.) 748 (1646)

Cargo Bed

Width mm (in.) 1170 (4 6.0 6)

Length mm (in.) 900 (35.43)

Depth mm (in.) 280 (11)

Volume m3 (cu. ft.) 0.29 (10.24)

Bed height (Unloaded) mm (in.) 810 (31.89)

Cargo bed capacity (1 row/2 row) kg (lbs.) 227 (500)

Sound level, operator ear db (A) 86.5

Tire

Front 26 x 9.00-14NHS

Rear 26 X 11.00-14NHS

Body Color Black, yellow, camo

NOTE:

• The company reserves the right to change the specifications without notice.

22 Section 6 — SpecificationS

Traveling Speeds

550UTV

Range gear shift lever km/h (mph)

Low 54.9 (34.1)

High 64.9 (40.3)

Reverse 20.9 (13.0)

750UTV

Range gear shift lever km/h (mph)

Low 57 (35.4)

High 80 (49.7)

Reverse 40 (24.8)

Vehicle Limitations

The Vehicle has been thoroughly tested for proper performance with implements sold or approved by manufacturer. Use with implements which are not sold or

approved and which exceed the maximum specifications listed below, or which are otherwise unfit for use on this vehicle, may result in vehicle malfunction or

failures with a possibility of vehicle damage, property damage and injury to the operator or others. Any malfunctions or failures of the vehicle resulting from use with

improper implements are not covered by the warranty.

Max cargo loading weight

Cargo Bed Capacity = 227 kg (500 lb)

Vehicle Total Load Capacity = 453.5 kg

(1000 lb)

* (Operator + one passenger + opt +

acc) weight + trailer weight

Max. rolling weight trailer

544 kg (1200 lbs)

Max. tongue weight

50 kg (110 lbs)

1. Above mentioned specifications are based on level ground condition.

Fuse Box

Spare fuse

F1 20A Fan motor fuse

F2 5A Fan control system/Pump

relay fuse

F1 20A Fan motor fuse

F2 5A Fan control system/Pump

relay fuse

F3 5A Winch controller fuse

F5 10A DC fuse

F10 10A Rear axle differential fuse

F11 10A Headlight fuse

F12 5A Meter, ECU energize fuse

F14 30A Eps motor fuse

F4 5A The four-wheel drive

differential control relay fuse

F6 10A Pump/Meter, ECU

switch fuse

F7 10A Horn/Neutral start relay

fuse

F9 5A Speed limiter/EPS controller

fuse

F13 30A Standby connection post

fuse

K1:MODEL: HFV11 12-H-R ( DG )

Fuel pump relay

K3:MODEL: HFV11 12-H-R ( DG )

Ignition switch relay

K2:MODEL: HFV11 12-H-R ( DG )

Neutral start relay

K4:MODEL: HFV9 012-1ZR

All-wheel-drive relay

K5:MODEL: HFV9 012-1ZR

Differential relay

F8 5A Signal light system/Neutral

start relay fuse

K4K3K2K1

Spare fuse

20A

30A

10A

F1 F2 F3 F4 F5 F6

F7 F8 F9 F10 F11 F12

F13 F14

OUT

Flasher

Figure 6-1

CUB CADET LLC -- LIMITED WARRANTY

100016 Rev I (January 8, 2021)

The limited warranty set forth herein is given by Cub Cadet LLC with respect to a new Cub Cadet® product (hereinafter “Product”) purchased and used in the

United States and/or Canada to the Initial Purchaser (as defined herein). This limited warranty does not cover Emission Control Systems and is not a Federal

Emission Control Warranty Statement, as defined by U.S. federal law. Please refer to the Federal Emission Control Warranty Statement in the operator’s manual

for warranties covering Emission Control Systems.

Scope of the Limited Warranty

Cub Cadet LLC warrants that the Product (except with regard to the components and circumstances defined below as “Exclusions”) will be free from defects in

materials and workmanship during the Warranty Period, as defined below. For purposes of this limited warranty, the “Initial Purchaser” is the first person/company

to purchase this new Product from an authorized Cub Cadet dealer, distributor, and/or retailer of such products, including a party for whom said Product was

purchased as a gift. This limited warranty is non-transferrable. During the Warranty Period, Cub Cadet LLC will, at its option, either repair or replace any original

part that is covered by this limited warranty and is determined to be defective in workmanship or material. “Commercial Use” shall be defined as any commercial,

professional, agricultural, institutional, or income-producing use of the Product. See notes below as to Commercial Use Warranty.

Cub Cadet® Warranty Information

Handheld Product* Warranty Period

Chainsaws, Cultivators, Blowers, Brushcutters, Trimmers 3 Year

Wheeled Chore and Snow Product*

Chipper-Shredders, Chipper-Shredder Vacuums, Blowers, Log Splitters, Snow Blowers 3 Year

Tillers, String Trimmers, Lawn Edgers, Pressure Washers CC3224, CC3425 & CC4033 3 Year†

Pressure Washers 2 Year†

Battery Powered Product

60 Volt Max Product Series, CC30E, XT1 LT42E, ZT1 42E 3 Year†

60 Volt Max Product Series, CC30E, XT1 LT42E, ZT1 42E Batteries 4 Year†

Gas Powered Product

Ultima ZTX Series 4 Year/500 hour (whichever comes first)

Z-Force SX 4 Year/500 hour (whichever comes first)

Walk-Behinds, Wide-Area Walk-Behinds, CC30 Riders, XT1 & XT2 Enduro Series, RZT S/SX, Ultima ZT Series,

Z-Force S

3 Year†

23” Walk-Behinds, XT3 Enduro Series 4 Year†

Rotary Spreader 1 Year

Gas Blowers, PRO HW, PRO X-636 2 Year

PRO Z 500/700/900, PRO X-648/654/660, TANK LZ/SZ 3 Year

PRO Z 100 S 2 Year/NHL (No Hour Limit) or 4 Year/500 hour

(whichever comes first)

Utility Vehicle*

Challenger Series, Volunteer Series 1 Year

Additional Warranty Notes

Lead-Acid Batteries: Are covered by a one (1) year prorated limited warranty against defects in material and workmanship, with 100% replacement during

the first three (3) months, from the date of original purchase by the Initial Purchaser. After three (3) months, the battery replacement credit is based on the

months remaining in the twelve (12) month period, dating back to the date of original purchase by the Initial Purchaser. Any replacement battery will be

warranted only for the remainder of the original warranty period.

Frames: The frame, chassis, and front axle on all XT1, XT2 and XT3 products are covered for “Residential Use” by a five (5) year limited warranty. The frame on

all Ultima ZT and ZTX series products are covered for “Residential Use” by a seven year Limited Lifetime Warranty.

Mowing Decks: 1) Cub Cadet LLC warrants the mowing decks under the warranty of the product it came with unless otherwise stated. 2) When so equipped,

the optional fabricated cutting deck shell (excluding wear parts, etc. thereon) shall be warranted against defects in material and workmanship for the lifetime

of the product, namely for as long as it is owned by its Initial Purchaser or the party for whom it was originally purchased as a gift, or seven (7) years from the

date of its initial sale to an Initial Purchaser, whichever comes first. 3) The deck shell, deck spindles, and deck steel pulleys (collectively the “Deck Assembly”)

on PRO Z 500 / 700 / 900 and PRO X-600 product only, shall also be warranted to be free from defects in material and workmanship for up to an additional

two (2) years (a total of five (5) years from date of purchase) or 1,750 cumulative hours of operation, whichever comes first. For purposes of clarity, no hour

limitation applies during the initial three (3) year period described above.

Snow Blowers: Three-Stage and Two-Stage (excluding 2X 24 models) - Auger gear boxes have a five (5) year limited warranty.

L and S Series: RZT L/LX, Z-Force L/LX/SZ, PRO Z 100 L, Z-Force Commercial (LZ/SZ), and Tank (L/S): Please refer to warranty included with Operator’s

Manual.

Attachments/Accessories: Please refer to warranty with Operator’s Manual.

*Limited Commercial Use Warranty: Handheld products – 90 days; Chipper-Shredder Vacuums, Blowers, Log Splitters, Snow Blowers – 1 year;

Utility Vehicle – 6 month.

† No Commercial Use Warranty: Tillers, String Trimmers, Lawn Edgers, Pressure Washers, Battery Powered Product, Walk Behind Mowers, 60 Volt Max

Product Series, CC30 Riders, Enduro Series, RZT S/SX, Ultima ZT Series, and Z-Force.

The limited warranty is non-transferrable

How to Get Service Under This Limited Warranty

In order to qualify for the limited warranty, as set forth herein, the repairs

made under this warranty must be performed by an authorized Cub Cadet

service provider. To locate a Cub Cadet service provider, contact your

authorized Cub Cadet dealer, distributor, or retailer, or contact Cub Cadet

LLC at P.O. Box 368023, Cleveland, Ohio 44136-0019, or call 1-877-282-8684,

or log on to our Website at www.cubcadet.com. For Canada, contact MTD

Products Limited, 97 Kent Ave, Kitchener, ON N2G 3R2, or call 1-800-668-1238,

or log on to our Website at www.cubcadet.ca. This limited product warranty is

provided by Cub Cadet LLC and is the only product warranty provided by Cub

Cadet LLC for the Product. A COPY OF YOUR SALES RECEIPT IS REQUIRED FOR

WARRANTY SERVICE.

What This Limited Warranty Does Not Cover

This limited warranty does not cover the following (the “Exclusions”):

1. Product purchased outside of the United States or Canada.

2. Emission Control Systems. These items are subject to a separate warranty

under the applicable Federal Emission Control Warranty Statement.

Please refer to the applicable Federal Emission Control Warranty

Statement for terms and conditions relating to Emission Control Systems.

3. Damage due to lack of maintenance and/or improper maintenance, as

described in the operator’s manual.

4. Normal wear and tear resulting from use of the Product.

5. Normal Wear Parts (as defined herein) are warranted to be free from

defects in material and workmanship for a period of thirty (30) days from

the date of original purchase by the Initial Purchaser for residential use,

and for 30 days or 100 hours (whichever occurs first) for Product used

commercially. Depending on Product, Normal Wear Parts include, but

are not limited to items such as: belts, blades, blade adapters, grass bags,

rider deck wheels, seats, shave plates, skid shoes, tines, filters, nozzles,

hoses, O-rings, spray guns, wands, tires, spark plugs, fuses, bump knobs,

outer spools, cutting line, inner belts, starter pulley, starter rope, drive

belts, saw chains, guide bars, and other consumable items.

6. Log splitter pumps, valves, and cylinders are covered for a period of one

(1) year.

7. Use of the product that is not consistent with the intended use thereof,

as described in the operating instructions, including, but not limited

to, abuse, misuse and/or neglect of the Product, or any use inconsistent

with and/or non-compliant with instructions contained in the Operator’s

Manual. This includes operation in sandy and/or corrosive environments.

8. Any Product that has been altered or modified in a manner not

consistent with the original design of the Product or in a manner not

approved by Cub Cadet LLC.

9. Paint repairs or replacements for defective paint (including materials and

application) are covered for a period of three (3) months.

10. Wheel rims (when so equipped) are covered for a period of three (3)

months for manufacturing defects.

This warranty does not cover, and Cub Cadet LLC disclaims any

responsibility for, matters including, but not limited to, the following:

1. Loss of time or loss of use of the Product.

2. Transportation costs and other expenses incurred in connection with the

transport of the Product to and from the authorized Cub Cadet service

provider.

3. Any loss or damage to other equipment or personal items.

4. Damages caused by improper maintenance or the use of other than the

specified fuel, oil, or lubricants, as approved in the operator’s manual.

5. Damage resulting from the installation or use of any accessory or part

not approved by Cub Cadet LLC for use with the Product.

Limitations

1. THERE ARE NO IMPLIED WARRANTIES, INCLUDING, BUT NOT LIMITED

TO, ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR

A PARTICULAR PURPOSE. NO WARRANTY SHALL APPLY AFTER THE

APPLICABLE WARRANTY PERIOD, AS SET FORTH ABOVE, AS TO THE

PARTS AS IDENTIFIED. NO OTHER EXPRESS WARRANTY OR GUARANTY,

WHETHER WRITTEN OR ORAL, EXCEPT AS MENTIONED ABOVE, GIVEN

BY ANY PERSON OR ENTITY, INCLUDING A DEALER OR RETAILER, WITH

RESPECT TO ANY, PRODUCT SHALL BIND CUB CADET LLC. DURING

THE WARRANTY PERIOD, THE EXCLUSIVE REMEDY IS REPAIR OR

REPLACEMENT OF THE DEFECTIVE PART, AS SET FORTH ABOVE. (SOME

STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED

WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU.)

2. THE PROVISIONS, AS SET FORTH HEREIN, PROVIDE THE SOLE AND

EXCLUSIVE REMEDY ARISING FROM THE SALE. CUB CADET LLC SHALL

NOT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL LOSS OR DAMAGES

INCLUDING, WITHOUT LIMITATION, FOR TRANSPORTATION OR FOR

RELATED EXPENSES, OR FOR RENTAL EXPENSES TO TEMPORARILY

REPLACE A WARRANTED PRODUCT. (SOME STATES DO NOT ALLOW

THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL

DAMAGES, SO THE ABOVE EXCLUSION OR LIMITATION MAY NOT APPLY

TO YOU.)

3. IN NO EVENT SHALL RECOVERY OF ANY KIND BE GREATER THAN THE

AMOUNT OF THE PURCHASE PRICE OF THE PRODUCT SOLD. ALTERATION

OF THE SAFETY FEATURES OF THE PRODUCT SHALL VOID THIS LIMITED

WARRANTY. YOU ASSUME THE RISK AND LIABILITY FOR LOSS, DAMAGE,

OR INJURY TO YOU AND YOUR PROPERTY, AND/OR TO OTHERS AND

THEIR PROPERTY, ARISING OUT OF THE USE OR MISUSE OR INABILITY TO

USE THE PRODUCT.

4. This limited warranty extends to the Initial Purchaser only and, except

as otherwise stated herein, the applicable Warranty Period will begin

on the original date of purchase of the Product. In the event that the

original date of purchase of the Product is indeterminable, then the

Warranty Period shall be established as beginning on the Product’s date

of manufacture, as determined by Cub Cadet LLC, and ending six (6)

months after the applicable Product Warranty Period, as defined above.

In no event shall a Product’s warranty extend beyond the applicable

Warranty Period.

How State Law Relates to This Warranty

This limited warranty gives you specific legal rights, and you may also have

other rights, which vary from state to state.

100016 Rev I (January 8, 2021)

Cub Cadet 37DZ7CKK010 Challenger MX 550 Yellow

Product's Documents

User Manual: Operator: ENGL:MX 550 750

Specifications

Cub Cadet 37DZ7CKK010 Questions and Answers