This vehicle can be hazardous to operate.€¦ · If you must cross the side of a hill, drive...

This vehicle can be hazardous to operate.A collision or rollover can occur quickly, even during what you think are routinemaneuvers such as driving or turning on flat terrain, driving on hills, or crossingobstacles, if you fail to take proper precautions. For your safety, understand and fol-low all the warnings contained in this Operator’s Manual and on the labels on thisvehicle.Keep this Operator’s Manual with this vehicle at all times. If you lose your manual,contact the manufacturer for a free replacement. The labels should be considered per-manent parts of the vehicle. If a label comes off or becomes hard to read, contact yourauthorized dealer for a replacement.FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUALCAN RESULT IN SERIOUS INJURY OR DEATH.Particularly important information is distinguished in this manual by the followingnotations:

FREE ROV TRAINING

Free training is available for Recreation Off-Highway Vehicles (ROV) operators and pas-sengers from Recreational Off-Highway Vehicle Association (ROHVA). The manufac-turer recommends that you complete this course before you first use your new ROV.This online course takes approximately two hours to complete and presents you witha certificate of accomplishment as soon as you complete the course. The course doesnot have to be completed all at one time. It will remember where you left off andbring you back to that point when you return.ALWAYS USE COMMON SENSE WHEN OPERATING THIS VEHICLE.Visit www.ROHVA.org to start your training.

California Proposition 65

!The Safety Alert Symbol means ATTENTION!BE ALERT! YOUR SAFETY IS INVOLVED.

! WARNING WARNING indicates a hazardous situationwhich, if not avoided, could result in death orserious injury.

CAUTION CAUTION, without the safety alert symbol, isused to address practices not related to per-sonal injury.

NOTE: A NOTE provides key information to make pro-cedures easier or more clear.

! WARNINGThe Engine Exhaust from this product contains chemicalsknown to the State of California to cause cancer, birthdefects or other reproductive harm.

www.ROHVA.org

ForewordCongratulations and thank you for pur-chasing a Tracker Off RoadTM vehicle.Built with American engineering andmanufacturing know-how, it is designedto provide superior ride, comfort, utility,and dependable service.This Operator’s Manual is furnished toensure that the operator is aware of safeoperating procedures. It also includesinformation about the general care andmaintenance of this vehicle.Carefully read the following pages. Ifyou have any questions regarding thisvehicle, contact an authorized dealer forassistance. Remember, only authorizeddealers have the knowledge and facilitiesto provide you with the best service pos-sible.

• Become familiar with all local andstate/provincial laws governing ROVoperation,

• Respect your vehicle,• Respect the environment, and• Respect private property and do not

trespass.The manufacturer advises you to strictlyfollow the recommended maintenanceprogram as outlined. This preventivemaintenance program is designed toensure that all critical components on thisvehicle are thoroughly inspected at vari-ous intervals.All information in this manual is basedon the latest product data and specifica-tions available at the time of printing.The manufacturer reserves the right tomake product changes and improvementswhich may affect illustrations or explana-tions without notice.You have chosen a quality vehicledesigned and manufactured to givedependable service. Be sure, as theowner/operator of this vehicle, to becomethoroughly familiar with its basic opera-tion, maintenance, and storage proce-dures.

Read and understand the entire Opera-tor’s Manual before operating this vehi-cle to ensure safe and proper use. Alwaysoperate the vehicle within your level ofskill and current terrain conditions.Division II of this manual covers opera-tor-related maintenance, operatinginstructions, and storage instructions. Ifmajor repair or service is ever required,contact an authorized dealer for profes-sional service.At the time of publication, all informa-tion and illustrations in this manual weretechnically correct. Some illustrationsused in this manual are used for claritypurposes only and are not designed todepict actual conditions. Because themanufacturer constantly refines andimproves its products, no retroactiveobligation is incurred.

Operation of this vehicle is restricted topeople 16 years of age and older whopossess a valid driver’s license. Passen-gers must be able to place both feet flaton the floor while keeping their backagainst the seat and holding onto anavailable handhold.

Protect Your Sport

Parts and Accessories

When in need of replacement parts, oil,or accessories for this vehicle, be sure touse only GENUINE PARTS, OIL, ANDACCESSORIES. Only genuine parts,oil, and accessories are engineered tomeet the standards and requirementsof this vehicle. For a complete list ofaccessories, refer to the current ROVAccessory Catalog.To aid in service and maintenance pro-cedures on this vehicle, a Service Man-ual is available through your localauthorized dealer.

1

Table of ContentsForeword.................................................. 1Parts and Accessories............................ 1

Division I — SafetySafety Alert .............................................. 4Hangtags ............................................... 5-6Important Safety Information ................. 7Warning Labels..................................... 8-9Location of Parts and Controls............ 10Warnings ........................................... 11-19

Division II — Operation/MaintenanceSpecifications ........................................ 20Vehicle Operation............................. 21-25General Information ......................... 26-35

Control Locations and Functions.......... 26Occupant Side Restraints .................... 28Digital Gauge ....................................... 28Diagnostic Trouble Codes.................... 31Oil Level Stick ...................................... 32Load Capacity Ratings Chart ............... 32Trailering and Towing........................... 33Transporting ......................................... 33Gasoline—Oil—Lubricant..................... 34Engine Break-In ................................... 35Burnishing Brake Pads......................... 35

General Maintenance ....................... 36-50Maintenance Schedule......................... 36Liquid Cooling System ......................... 37Shock Absorbers.................................. 37

General Lubrication.............................. 38Hydraulic Brake.................................... 39Gas Hoses ........................................... 40Protective Rubber Boots ...................... 40Battery.................................................. 41Spark Plug............................................ 44Air Filter/Housing Drain ........................ 44Draining V-Belt Cover .......................... 45Tires ..................................................... 46Wheels ................................................. 46Muffler/Spark Arrester .......................... 46Light Bulb Replacement ....................... 47Checking/Adjusting Headlight Aim ....... 48Fuses ................................................... 48Electrical Output Terminals .................. 49Storage Compartments/Tools .............. 49Seat Belts............................................. 50Occupant Side Restraints .................... 50ROPS ................................................... 50

Preparation for Storage ........................ 51Preparation after Storage ..................... 52Maintenance Record ............................. 53Limited Warranty ................................... 54Warranty Procedure/Owner

Responsibility.................................... 55U.S. EPA Emission Control Statement/

Warranty Coverage — ROV (U.S. Only)56Change of Address, Ownership, or

Warranty Transfer ............................. 57Identification Numbers Record ......Inside

Back Cover

2

Division I — SafetyThis vehicle is not a toy and can be hazardous to operate.

• Always go slowly and be extra care-ful when operating on unfamiliar ter-rain. Always be alert to changingterrain conditions when operatingthis vehicle.

• Never operate on excessively rough,slippery, or loose terrain.

• Always follow proper procedures forturning as described in this manual.Practice turning at slow speedsbefore attempting to turn at fasterspeeds. Do not turn at excessivespeed.

• Always have the vehicle checked byan authorized dealer if it has beeninvolved in an accident.

• Never operate on hills too steep foryour abilities. Practice on smallerhills before attempting larger hills.

• Always follow proper procedures forclimbing hills as described in thismanual. Check the terrain carefullybefore you start up any hill. Neverclimb hills with slippery or loose sur-faces. Never depress the acceleratorsuddenly or make gear changeswhile moving. Never go over the topof any hill at high speed.

• Always follow proper procedures forgoing down hills and for braking onhills as described in this manual.Check the terrain carefully beforeyou start down any hill. Never godown a hill at high speed. Avoidgoing down a hill at an angle whichwould cause the vehicle to leansharply to one side. Go straightdown the hill where possible.

• Always be careful when you decideto climb or descend a hill and neverturn on a hill. Drive straight up ordown inclines and not across them.If you must cross the side of a hill,drive slowly and stop or turn downhillif you feel the vehicle may tip over.

• Always use proper procedures if youstall or roll backward when climbinga hill. To avoid stalling, maintain asteady speed when climbing a hill. Ifyou stall or roll backwards, follow thespecial procedure for brakingdescribed in this manual.

• Always check for obstacles beforeoperating in a new area. Neverattempt to operate over large obsta-cles, such as large rocks or fallentrees. Always follow proper proce-dures when operating over obstaclesas described in this manual.

• Always be careful of skidding or slid-ing. On slippery surfaces, such asice, go slowly and be very cautiousin order to reduce the chance ofskidding or sliding out of control.

• Never operate this vehicle in fastflowing water or in water deeper thanthe floorboard. Remember that wetbrakes may have reduced stoppingcapability. Test your brakes afterleaving water. If necessary, applythem lightly several times to let fric-tion dry out the pads.

• Always be sure there are no obsta-cles or people behind you when youoperate in reverse. When it is safe toproceed in reverse, go slowly. Avoidturning at sharp angles in reverse.

• Always use the size and type tiresspecified in this manual. Alwaysmaintain proper tire pressure asdescribed in this manual.

• Never improperly install or improp-erly use accessories on this vehicle.

• Never exceed the stated load capac-ity for this vehicle. Cargo should beproperly distributed and securelyattached. Reduce speed and followinstructions in this manual for carry-ing cargo or pulling a trailer andallow greater distance for braking.

• Operation of this vehicle is restrictedto people 16 years of age and olderwho possess a valid driver’s license.Passengers must be able to placeboth feet flat on the floor while keep-ing their back against the back of theseat and holding on to an availablehandhold.

! WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. 3

Safety AlertYou should be aware that THIS VEHI-CLE IS NOT A TOY AND CAN BEHAZARDOUS TO OPERATE. Thisvehicle handles differently from othervehicles, including motorcycles and cars.A collision or rollover can occur quickly,even during what you think are routinemaneuvers such as turning, driving onhills, and going over obstacles, if you failto take proper precautions.TO AVOID SERIOUS INJURY OR DEATH:

* Always read the Operator’s Manualcarefully and follow the operatingprocedures described. Pay specialattention to the warnings contained inthe manual and on all labels.

* Always wear the seat belt when oper-ating or riding in this vehicle.

* Always follow these age recommen-dations:

• Operation of this vehicle isrestricted to people 16 years ofage and older who possess avalid driver’s license. Passen-gers must be able to place bothfeet flat on the floor while keep-ing their back against the seatand holding on to the handhold.

* Never carry a passenger in the cargobox of this vehicle.

* Never operate this vehicle on a publicroad, even a dirt or gravel one,because you may not be able to avoidcolliding with other vehicles.

* Never operate this vehicle without anapproved motorcycle helmet, eyeprotection, boots, gloves, long pantsand a long-sleeved shirt or jacket.

* Never consume alcohol or drugsbefore or while operating this vehi-cle.

* Never operate this vehicle at exces-sive speeds. Go at a speed which isproper for the terrain, visibility con-ditions, and your experience.

* Never attempt to do wheelies, jumps,or other stunts.

* Always be careful when operatingthis vehicle, especially whenapproaching hills, turns, and obsta-cles and when operating on unfamil-iar or rough terrain.

* Never operate this vehicle with thecargo box lifted or removed.

* Never operate this vehicle in fastflowing water or in water deeper thanthe floorboard.

* Never operate this vehicle with theROPS (Roll Over Protective Struc-ture) removed. The ROPS provides astructure helping to limit intrusionsby branches or other objects and mayreduce your risk of injury in acci-dents.

* Never put your hands or feet outsidethe vehicle for any reason while thevehicle is in motion. Do not hold ontothe ROPS or hip restraint bar. If youthink or feel the vehicle may tip, donot put your hands or feet outside thevehicle as they will not be able to pre-vent the vehicle from tipping. Anypart of your body (arms, legs, orhead) outside the vehicle can becrushed by passing objects, the vehi-cle, or ROPS.

* Always fasten occupant siderestraints prior to moving the vehicle.


HangtagsThis vehicle comes with hangtags containing important safety information. Anyone who operates the vehicle should read and understand this information before riding.


Hangtags


Important Safety InformationAnyone who operates the vehicle should read and understand this information beforeoperating this vehicle.


Warning Labels

PK015C

4411-964

A

4411-883

B

4411-965

E 3411-970

C

0411-426

D


Warning Labels

TXR083A

4411-961

A

4411-960B

7411-077

C

4411-962

D


Location of Parts and Controls

TXR084A

PK016A

PK015A

TXR085A

1. Accelerator Pedal 2. Brake Pedal 3. In-Dash Storage Compartment4. Digital Gauge

5. Reverse Override Switch6. Drive Select Switch7. Ignition/Start Switch8. Headlight Switch9. Shift Lever

10. Headlights11. Passenger Side Restraint Latch12. Operator’s Manual Location13. Passenger Seat Belt14. Passenger Side Restraints15. Gas Tank Cap16. Outboard Passenger Handhold17. Battery 18. Under-Hood Storage Compartment19. Fuses20. Cargo Box Latch Handle21. Driver Seat Belt22. Tilt Steering Lever 23. Tool Kit24. Driver-Side Restraint25. Driver-Side Restraint Latch26. Hitch Receiver 27. Tailgate Latch28. Tailgate Storage Latch29. Taillight/Brake Light


Warnings! WARNING

POTENTIAL HAZARD Operating this vehicle without proper instruction.

WHAT CAN HAPPENThe risk of an accident is greatly increased if the operator does not know how tooperate this vehicle properly in different situations and on different types of terrain.

HOW TO AVOID THE HAZARDAll operators of this vehicle must read and understand this Operator’s Manual andall warning and instruction labels prior to operating this vehicle.

! WARNINGPOTENTIAL HAZARDAllowing anyone under age 16 to operate this vehicle.

WHAT CAN HAPPENUse of this vehicle by children can lead to serious injury or death of the child.Children under the age of 16 may not have the skills, abilities, or judgment neededto operate this vehicle safely and may be involved in a serious accident.

HOW TO AVOID THE HAZARDOnly people 16 years of age or older with a valid driver’s license should operatethis vehicle.

! WARNINGPOTENTIAL HAZARDOperating or riding in the vehicle without wearing a properly secured seat belt.

WHAT CAN HAPPENSerious injury or death. Occupants can strike objects in the passenger compart-ment, fall out of the vehicle during maneuvers, or be crushed or otherwise injuredin the event of an accident.

HOW TO AVOID THE HAZARDALWAYS WEAR YOUR SEAT BELT and require others to wear their seat belts.See the Operation/Maintenance section of this manual for more information onusing your seat belt and both operator and passenger wearing an approved hel-met.

! WARNINGPOTENTIAL HAZARDOperating this vehicle on public streets, roads, or highways.

WHAT CAN HAPPENYou can collide with another vehicle.

HOW TO AVOID THE HAZARDNever operate this vehicle on any public street, road, or highway.In many states it is illegal to operate a vehicle of this type on public streets, roads,or highways. Always check state and local laws and regulations.


! WARNINGPOTENTIAL HAZARDOperating or riding in this vehicle without wearing anapproved helmet, eye protection, and protective cloth-ing.

WHAT CAN HAPPENOperating or riding without an approved helmetincreases your chances of a serious head injury ordeath in the event of an accident.Operating or riding without eye protection can result inan accident and increases your chances of a seriousinjury in the event of an accident.Operating or riding without protective clothingincreases your chances of serious injury in the eventof an accident.

HOW TO AVOID THE HAZARDAlways wear an approved helmet that fits properly.You should also wear: Eye protection (goggles or face shield)

GlovesBootsLong sleeved shirt or jacketLong pants

! WARNINGPOTENTIAL HAZARDOperating this vehicle after or while consuming alcohol or drugs.

WHAT CAN HAPPENCould seriously affect your judgment.Could cause you to react more slowly.Could affect your balance and perception.Could result in an accident.

HOW TO AVOID THE HAZARDNever consume alcohol or drugs before or while driving this vehicle.

! WARNINGPOTENTIAL HAZARDAllowing passengers to ride in the cargo box.

WHAT CAN HAPPENSerious injury or death. This vehicle is not designed to carry passengers in thecargo box. Passengers in the cargo box can be thrown around or from the vehicleduring operation or in an accident.

HOW TO AVOID THE HAZARDDo not permit passengers to ride in the cargo box. Do not install any seating in thecargo box.


! WARNINGPOTENTIAL HAZARDOperating or riding in the vehicle without occupant side restraints properlysecured.

WHAT CAN HAPPENSerious injury or death. Occupants or their body parts can strike objects outsidethe vehicle, be crushed by the vehicle, or fall out of the vehicle during maneuversor in the event of an accident.

HOW TO AVOID THE HAZARDDo not remove the occupant side restraints. Make sure both driver and passengeroccupant side restraints are secure before operating or riding in the vehicle. Stayseated with your seat belt and helmet on and keep your body completely inside thevehicle during operation. See the Operation/Maintenance section of this manualfor more information.

! WARNINGPOTENTIAL HAZARDFailing to keep all parts of your body inside the passenger compartment duringoperation.

WHAT CAN HAPPENSerious injury or death. Body parts could strike objects outside of vehicle or becrushed in the event of a rollover or accident.

HOW TO AVOID THE HAZARDDo not place your head, arms, hands, legs, or feet outside of the passenger com-partment during operation. Stay seated with your seat belt and helmet on andoccupant side restraints properly secured. Keep your feet and legs inboard of thefoot restraints at all times. Do not attempt to stop movement or tipping of the vehi-cle with your hands or feet. If you feel the vehicle tipping, brace your feet flat on thefloor, keep hands firmly gripping the steering wheel and handholds, and keep allbody parts inside the passenger compartment.

! WARNINGPOTENTIAL HAZARDOperating this vehicle at excessive speeds.

WHAT CAN HAPPENIncreases your chances of losing control of the vehicle, which can result in an acci-dent.

HOW TO AVOID THE HAZARDAlways ride at a speed that is proper for the terrain, visibility, load, and operatingconditions.


! WARNINGPOTENTIAL HAZARDAttempting abrupt maneuvers, sideways sliding, skidding, fishtailing, or donuts.

WHAT CAN HAPPENIncreases the chance of an accident including a rollover.

HOW TO AVOID THE HAZARDNever attempt abrupt maneuvers, sideways sliding, skidding, fishtailing, or donuts.Don’t try to show off.

! WARNINGPOTENTIAL HAZARDFailure to inspect this vehicle before operating.Failure to properly maintain this vehicle.

WHAT CAN HAPPENIncreases the possibility of an accident or equipment damage.

HOW TO AVOID THE HAZARDAlways inspect this vehicle each time you use it to make sure it is in safe operatingcondition.Always follow the inspection and maintenance procedures and schedulesdescribed in this Operator’s Manual.

! WARNINGPOTENTIAL HAZARDFailure to use extra care when operating this vehicle on unfamiliar terrain.

WHAT CAN HAPPENYou can come upon hidden rocks, bumps, or holes without enough time to react.Could result in the vehicle overturning or going out of control.

HOW TO AVOID THE HAZARDGo slowly and be extra careful when operating on unfamiliar terrain.Always be alert to changing terrain conditions when operating this vehicle.

! WARNINGPOTENTIAL HAZARDFailure to use extra care when operating on rough, slippery, or loose terrain.

WHAT CAN HAPPENCould cause loss of traction or control, which could result in an accident includinga rollover.

HOW TO AVOID THE HAZARDDo not operate on rough, slippery, or loose terrain until you have learned and prac-ticed the skills necessary to control this vehicle on such terrain.Always be especially cautious on these kinds of terrain.


! WARNINGPOTENTIAL HAZARDFailing to use care in turns; turning too sharply or aggressively.

WHAT CAN HAPPENThe vehicle could go out of control causing a collision, tip over, or rollover.

HOW TO AVOID THE HAZARDAlways follow proper procedures for turning as described in this Operator’s Man-ual. Practice turning at slow speeds before attempting to turn at faster speeds. Donot turn at excessive speed or too sharply for the conditions and for your experi-ence level. See the Operation/Maintenance section of this manual for more infor-mation on turning on flat ground, hills, sand, ice, mud, or water.

! WARNINGPOTENTIAL HAZARDOperating on steep hills.

WHAT CAN HAPPENThis vehicle can overturn more easily on steep hills than on level surfaces or smallhills.

HOW TO AVOID THE HAZARDNever operate the vehicle on hills too steep for the vehicle or for your abilities.Practice on smaller hills before attempting larger hills.

! WARNINGPOTENTIAL HAZARDOperating with the ROPS removed.

WHAT CAN HAPPENCould lead to serious injury or death.

HOW TO AVOID THE HAZARDNever operate this vehicle with the ROPS removed.

! WARNINGPOTENTIAL HAZARDGoing down a hill improperly.

WHAT CAN HAPPENCould cause loss of control or cause the vehicle to overturn.

HOW TO AVOID THE HAZARDAlways follow proper procedures for going down hills as described in this Opera-tor’s Manual.Always check the terrain carefully before you start down any hill.Never go down a hill at high speed.Avoid going down a hill at an angle that would cause the vehicle to lean sharply toone side. Go straight down the hill where possible.


! WARNINGPOTENTIAL HAZARDClimbing hills improperly.

WHAT CAN HAPPENCould cause loss of control or cause the vehicleto overturn.

HOW TO AVOID THE HAZARDAlways follow proper procedures for climbing hills as described in this Operator’sManual.Always check the terrain carefully before you start up any hill.Never climb hills with slippery or loose surfaces.Never open the throttle suddenly or make sudden gear changes. The vehicle couldflip over backwards.Never go over the top of any hill at high speed. An obstacle, a sharp drop, oranother vehicle or person could be on the other side of the hill.

! WARNINGPOTENTIAL HAZARDCrossing hills or turning on hills.

WHAT CAN HAPPENCould cause loss of control or cause the vehicle to overturn.

HOW TO AVOID THE HAZARDAvoid crossing the side of a hill or turning on a hill whenever possible. Neverattempt to turn the vehicle around on any hill. If you must cross the side of a hill,drive slowly and stop or turn downhill if you feel the vehicle may tip.

! WARNINGPOTENTIAL HAZARDStalling, rolling backwards, or improperly dismounting while climbing a hill.

WHAT CAN HAPPENCould result in the vehicle overturning.

HOW TO AVOID THE HAZARDUse proper gear and maintain steady speed when climbing a hill.If you lose all forward speed:

Apply the brakes. Place the transmission in park after you are stopped.If you begin rolling backwards:

Gradually apply the brakes while rolling backwards.When fully stopped, place the transmission in park.


! WARNINGPOTENTIAL HAZARDImproperly operating over obstacles.

WHAT CAN HAPPENCould cause loss of control or a collision. Could cause the vehicle to overturn.

HOW TO AVOID THE HAZARDBefore operating in a new area, check for obstacles.Never attempt to ride over large obstacles, such as large rocks or fallen trees.When you go over obstacles, always follow proper procedures as described in thisOperator’s Manual.

! WARNINGPOTENTIAL HAZARDImproperly operating in reverse.

WHAT CAN HAPPENYou could hit an obstacle or person behind you, resulting in serious injury or death.

HOW TO AVOID THE HAZARDBefore you engage reverse gear, make sure there are no obstacles or peoplebehind you. When it is safe to proceed, go slowly.

! WARNINGPOTENTIAL HAZARDSkidding or sliding.

WHAT CAN HAPPENYou could lose control of the vehicle.You could also regain traction unexpectedly, which may cause the vehicle to over-turn.

HOW TO AVOID THE HAZARDLearn to safely control skidding or sliding by practicing at slow speeds and on level,smooth terrain.On extremely slippery surfaces, such as ice, go slowly and be very cautious inorder to reduce the chance of skidding or sliding out of control.

! WARNINGPOTENTIAL HAZARDOverloading the vehicle or carrying or towing improperly.

WHAT CAN HAPPENCould cause changes in handling, which could lead to an accident.

HOW TO AVOID THE HAZARDNever exceed the stated load capacity for this vehicle.Cargo should be properly distributed and securely attached.Reduce speed when carrying cargo or pulling a trailer. Allow greater distance forbraking. Always follow the instructions in this Operator’s Manual for carrying cargoor pulling a trailer.


! WARNINGPOTENTIAL HAZARDOperating this vehicle through deep or fast flowing water.

WHAT CAN HAPPENTires may float, causing loss of traction and loss of control, which could lead to anaccident.

HOW TO AVOID THE HAZARDNever operate this vehicle in fast flowing water or in water deeper than the floor-board.Remember that wet brakes may have reduced stopping capability.Test the brakes after leaving water. If necessary, apply them several times to dryout the pads.

! WARNINGPOTENTIAL HAZARDOperating the vehicle with improper tires or with improper or uneven tire pressure.

WHAT CAN HAPPENUse of improper tires on the vehicle, or operating the vehicle with improper oruneven tire pressure, could cause loss of control increasing your risk of accident.

HOW TO AVOID THE HAZARDAlways use the size and type tires specified in this Operator’s Manual for this vehi-cle.Always maintain proper tire pressure as described in this Operator’s Manual.

! WARNINGPOTENTIAL HAZARDOperating this vehicle with improper modifications.

WHAT CAN HAPPENImproper installation of accessories or modification of the vehicle may causechanges in handling which could lead to an accident.

HOW TO AVOID THE HAZARDNever modify this vehicle through improper installation or improper use of accesso-ries. All parts and accessories added to this vehicle should be approved compo-nents designed for use on this vehicle and should be installed and used accordingto instructions. If you have questions, consult an authorized dealer.

! WARNINGPOTENTIAL HAZARDFailing to avoid pinch-points when lowering the cargo box.

WHAT CAN HAPPENFingers, hands, or arms could be seriously injured when lowering the cargo box.

HOW TO AVOID THE HAZARDAlways be aware of and avoid lowering cargo box until everyone is clear of pinch-points.


California Proposition 65

! WARNINGPOTENTIAL HAZARDOperating through or over thick or sharp brush, timber, debris, or rocks.

WHAT CAN HAPPENSerious injury or death. Brush, branches, debris, and rocks can enter or penetratethe passenger compartment and strike occupants. Running over sharp branches,rocks, or other large objects can also cause loss of control.

HOW TO AVOID THE HAZARDBe alert. Slow down. Wear all recommended protective gear specified in this Oper-ator’s Manual. Avoid operating through or over thick brush, timber, debris, or largerocks whenever possible. Watch for and avoid sharp branches, rocks, or otherlarge objects that could impede or impact the vehicle or enter the passenger com-partment.

! WARNINGPOTENTIAL HAZARDSecuring a person improperly in the vehicle due to physical size.

WHAT CAN HAPPENSerious injury or death. Occupant could strike objects in the passenger compart-ment, fall out of the vehicle during maneuvers, or be ejected and crushed in theevent of an accident.

HOW TO AVOID THE HAZARDAlways make sure a passenger can sit with both feet flat on the floor and their backagainst the seat while being able to reach any provided handholds.

! WARNINGPOTENTIAL HAZARDOperating this vehicle on paved surfaces.

WHAT CAN HAPPENThe vehicle’s tires are designed for off-road use only, not for use on pavement.Paved surfaces may seriously affect handling and control of the vehicle and maycause the vehicle to go out of control.

HOW TO AVOID THE HAZARDWhenever possible, avoid operating the vehicle on any paved surfaces includingsidewalks, driveways, parking lots, and streets. If operating on paved surfaces isunavoidable, travel slowly (less than 10 mph) and avoid sudden turns and stops.

! WARNINGThe Engine Exhaust from this product contains chemicalsknown to the State of California to cause cancer, birthdefects or other reproductive harm.


Division II — Operation/MaintenanceSpecifications

Specifications subject to change without notice.

ENGINE

Type Four-Cycle/Liquid Cooled

Bore x Stroke 89 mm x 71.2 mm (3.5 x 2.8 in.)

Displacement 443 cc (27.0 cu in.)

Spark Plug Type NGK CR6E

Spark Plug Gap 0.7-0.8 mm (0.028-0.031 in.)

Brake Type Hydraulic Disc (front); Shaft-Mounted Hydraulic Disc (rear)

CHASSISLength (Overall) 270.3 cm (106.4 in.)

Height (Overall) 194.8 cm (76.7 in.)

Width (Overall) 143.3 cm (56.4 in.)

Suspension Travel (Front/Rear) 19 cm (7.5 in.)

Tire Size (Front) 25 x 8-12

Tire Size (Rear) 25 x 10-12

Tire Inflation Pressure 82.7 kPa (12 psi)

MISCELLANEOUSDry Weight (Approx) 497 kg (1095 lb)

ROPS Tested Curb Weight 997.9 kg (2200 lb)

Gas Tank Capacity 32.2 L (8.5 U.S. gal.)

Coolant Capacity 2.5 L (2.64 U.S. qt)

Differential Capacity 250 ml (8.5 fl oz)

Rear Drive Capacity 230 ml (7.8 fl oz)

Engine Oil Capacity (Approx) (Change w/filter) 2.4 L (2.5 U.S. qt)

Gasoline (Recommended) 87 Octane Regular Unleaded

Engine Oil (Recommended) ACX All Weather (Synthetic)

Front Differential/Rear Drive Lubricant SAE-Approved 80W-90 Hypoid

Taillight/Brake Light 12V/5W/21W

Headlight 12V/55W/60W

Starting System Electric

20

Vehicle Operation

Pre-Start/Pre-Operation ChecklistItem Remarks

Brake System Pedal firm — near top of travel.Fluid at proper level.Check for fluid leaks.

Controls Steering free — no binding — no excessive free-play.Shift lever in park.Accelerator free — no binding — returns to idle position.

Fluids Coolant level to bottom of radiator neck and reservoir at least half fill.Check oil level.Gas tank full of recommended gasoline.Differential/rear drive at proper level.Check for fluid leaks.

Suspension Ball joints/tie rod ends free — secure.Shocks not leaking — mountings secure.Shock spring preload equal on left and right.Components free of all debris.

Lights/Switches Check headlight HI/LO beam — light switch to OFF.Check taillight/brake light — light switch to OFF.Check drive select switch — set to 2WD.

Air Filter Drain caps clear of all debris.Ducting secure — no holes or tears.

Tires/Wheels Properly inflated — tread adequate.Check tires for cuts or tears.Wheels secure to hubs — hubs secure to axles.Check wheels for cracked or bent rims.

Seat Belts/Restraints Check condition — proper operation — proper adjustment.

Nuts/Bolts/Fasteners Check for loose nuts — bolts — tighten as necessary.Check fasteners — latches — ROPS.Secure hood, cargo box, seats.

21

Vehicle OperationStarting the VehicleAlways start with the vehicle on a flat,level surface. Carbon monoxide poison-ing can kill you, so keep the vehicle out-side while it’s running. Follow thesesteps to start it up:NOTE: This vehicle is equippedwith a driver’s seat belt sensor. If thedriver’s seat belt is not fastened, thevehicle speed is limited to 15 mphand the seat belt indicator on thedigital gauge will illuminate. The seatbelt indicator will remain illuminateduntil the driver’s seat belt is fas-tened.

HDX323A

1. Step into the vehicle and sit down;then fasten the operator seat belt andthe passenger seat belt (if applica-ble) and strap on your approved hel-met and require your passenger to dothe same (if applicable). Check thatthe occupant side restraints aresecured in place.

2. Place the transmission in park; thendepress the brake pedal.

3. Turn the ignition switch clockwiseto the START position; then whenthe engine starts, release to the RUNposition. Do not increase engineRPM above idle.

4. Let the engine warm up.ShiftingNOTE: The CVT is fully automaticand shifts as a function of engineRPM and vehicle loading.

PK059A

1. To select reverse gear from park,move the shift lever forward oneposition until the letter “R” is dis-played on the digital gauge.

2. To select neutral from reverse, movethe shift lever forward one positionuntil the letter “N” is displayed onthe digital gauge.

3. To select high range from neutral,move the shift lever forward oneposition until the letter “H” is dis-played on the digital gauge.

! WARNINGFalling from a moving vehicle couldresult in serious injury or death.Always fasten your seat belt securelyand ensure the passenger seat belt isproperly and securely fastened priorto operating or riding in this vehicle.

CAUTIONIncreasing engine RPM above idlewhile in Park will cause belt damage.

CAUTIONDo not run the starter motor for morethan eight seconds per startingattempt. The starter motor may over-heat causing severe starter motordamage. Allow 15 seconds betweenstarting attempts to allow the startermotor to cool.

CAUTIONAlways come to a complete stopbefore attempting to shift from onerange to the other or into reverse.Always shift on level ground.

22

4. To select low range from high range,move the shift lever forward oneposition until the letter “L” is dis-played on the digital gauge.

NOTE: The high range is for nor-mal driving with light loads. The lowrange is for carrying heavy loads ortrailer towing. Compared to HIGHrange, the LOW range position pro-vides slower speed and greatertorque to the wheels.

5. To select park, move the shift levercompletely down until the letter “P”is displayed on the digital gauge.

Driving the VehicleOnce the engine is warm, the vehicle isready to be driven.

1. With the engine idling, press the footbrake pedal to apply the brake; thenselect the appropriate operating rangeand/or direction with the shift lever.

2. Release the foot brake pedal andpress the accelerator to slowly addpower to start moving.

3. To slow down or stop, release theaccelerator and press the foot brakepedal as necessary to slow or stopthe vehicle.

Braking/StoppingAlways allow plenty of room and time tostop smoothly. Sometimes quick stopsare inevitable, so always be prepared.Whether you’re stopping slowly or stop-ping quickly, do this:

1. Release the accelerator; then pressthe foot brake pedal to apply thebrake.

2. If the wheels lock, release them for asecond; then apply them again. Onsurfaces such as ice, mud, or loosegravel, pump the brake pedal rapidly.

3. Never “ride” the brake. Even main-taining minimal pressure on thebrake pedal will cause the brakepads to drag on the disc and mayoverheat the brake fluid.

ParkingParking involves following the previousrules for braking; then:

1. After the vehicle stops, shift intopark.

2. Turn off the ignition.3. If you have to park on a hill, block

the wheels on the downhill side.Basic TurnsSteering effort is at its lowest in two-wheel drive (2WD). Greater effort isneeded when in four-wheel drive (4WD).The greatest effort is needed when infour-wheel drive and the differential (ifequipped) is locked.Slow down before entering a turn. Thebasic turning technique is to drive at lowspeed and gradually adjust the amount ofsteering to suit the driving surface. Donot make sudden sharp turns on any sur-face. Refer to the sub-sections DrivingUphill, Driving Downhill, CrossingObstacles, Driving in Reverse, Skiddingor Sliding, Crossing Water, or CrossingRoads for more information.

CAUTIONAlways shift into low range whenoperating on wet or uneven terrain,when towing or pushing heavy loads,and when using a plow. Failure to fol-low this caution may result in prema-ture V-belt failure or in damage torelated drive system components.

CAUTIONNever increase engine speed aboveidle RPM when in park or belt damagewill occur.

! WARNINGExcessive repetitive use of thehydraulic brake for high speed stopswill cause overheating of the brakefluid and premature brake pad wearwhich will result in an unexpectedloss of brakes.

! WARNINGUse only manufacturer-approvedbrake fluid. Never substitute or mixdifferent types or grades of brakefluid. Brake loss can result. Checkbrake fluid level and pad wear beforeeach use. Brake loss can result inserious injury or death.

23

If your vehicle ever skids sidewaysduring a turn, steer in the direction of theskid. Also, avoid hard braking or acceler-ating until you have regained directionalcontrol.

Driving UphillAlways drive straight up the hill andalways avoid hills steeper than 15°.

1. Keep both hands on the wheel.2. Prior to starting the climb, shift into

low range, select four-wheel drivefor traction, and gradually press theaccelerator; then maintain a constantspeed.

3. If the vehicle stalls on a hill, pressthe foot brake pedal to apply thebrake, shift into reverse, and slowlyback down the hill. Do not attemptto turn around on a hill.

NEVER OPERATE UP OR DOWN HILLS STEEPER THAN 15°

Driving DownhillAlways drive straight down the hill andalways avoid hills steeper than 15°.

1. Keep both hands on the wheel.2. Prior to descending the hill, shift

into low range and release the accel-erator to allow maximum enginebraking. Do not use four-wheel drivewhen descending a hill. Enginebraking can cause the front wheelsto slide reducing steering control.

NOTE: Use minimum braking (asnecessary) to maintain a slow speed.

Crossing ObstaclesCrossing obstacles can be hazardous.There is always the possibility of thevehicle tipping. If you cannot go aroundan obstacle, follow these guidelines:

1. Stop the vehicle and place the trans-mission in park. Go out to inspectthe obstacle thoroughly from bothyour approach side and the exit side.If you believe you can cross theobstacle safely, select four-wheeldrive (4WD).

NOTE: Selecting the LOCK posi-tion on the differential lock controlmay be beneficial; however, steeringeffort will be increased.

! WARNINGUse care in turns — turning the steer-ing wheel too far or too fast can resultin loss of control or a rollover. Exces-sive speed, driving aggressively, ormaking abrupt maneuvers, even onflat, open areas, can cause loss ofcontrol, tipping, or rollover. Uneventerrain, rough terrain, soft surfaces,slippery surfaces, and paved surfacescan also cause a loss of control orrollover in a turn. On loose or soft sur-faces, allow yourself more time anddistance to turn and slow down.

! WARNINGDo not attempt to turn around on a hill.

! WARNINGDriving up hills improperly can causeloss of control of the vehicle resultingin serious injury or death. Useextreme care when driving in hilly ter-rain.

! WARNINGDo not attempt to turn around on ahill.

! WARNINGDriving down hills improperly cancause loss of control of the vehicleresulting in serious injury or death.Never drive downhill at a high rate ofspeed. Use extreme care when drivingin hilly terrain.

24

2. Approach the obstacle as close aspossible to 90° to minimize vehicletipping.

3. Keep speed slow enough to maintaincontrol but fast enough to maintainmomentum.

4. Use only enough power to cross theobstacle but still give yourself plentyof time to react to changes in condi-tions. Crawl over the obstacle.

NOTE: If there is any questionabout your ability to cross the obsta-cle safely, you should turn around ifthe ground is flat and you have roomor back up until you find a less diffi-cult path.

Driving in ReverseWhen operating in reverse, avoid sharpturns and backing down a hill. Whenusing reverse, follow these guidelines:

1. Back up slowly. It’s hard to seebehind you.

NOTE: Avoid sudden braking whilebacking up.

2. If possible, it is advisable to havesomeone “spotting” for you whilebacking up.

3. If you are unsure of what is behind thevehicle, place the transmission in parkand get out and inspect the areabehind.

Skidding or SlidingIf you lose control after hitting sand, ice,mud, or water, follow these guidelines:

1. Turn the steering wheel into thedirection of the slide.

2. Keep your foot off the brake untilyou’re out of the skid.

3. Stop and shift into four-wheel drive.Crossing WaterThis vehicle can only operate in water up toits floorboard. Stay away from fast movingrivers. This vehicle’s tires can be buoyant. Indeep water, the vehicle may lose traction dueto floating.

1. Physically check the depth and currentof the water, especially if you can’t seethe bottom. Also, check for boulders,logs, or any other hidden obstacles.

2. Keep speed slow while maintainingmomentum.

3. Make sure you have a way out on theother side of the water.

4. Once you’ve cleared the water, brieflyapply the brakes to make sure theywork.

NOTE: Light pedal pressure orpumping the brakes for a short dis-tance will aid in drying the brakes.

Crossing RoadsIt may be necessary to cross a road or high-way. If so, note the following guidelines.

1. Stop completely on the shoulder of theroad.

2. Check both directions for traffic.3. Crossing near a blind corner or inter-

section is dangerous; avoid it if at allpossible.

4. Drive straight across to the oppositeshoulder.

5. Take into account that this vehiclecould stall while crossing; give yourselfenough time to get off the road.

6. You have to assume that oncoming carsdon’t see you, and if they do, theywon’t be able to predict your actions.

7. It’s illegal to cross public roads in someplaces. Know your local laws.

! WARNINGStriking hidden obstacles can causeserious injury or death. Reduce speedand proceed with care in unfamiliarterrain.

! WARNINGNever activate the override while thethrottle is open as a loss of controlmay result. Use caution when usingthe override switch as reverse speedcan greatly increase.

! WARNINGDo not operate this vehicle on a frozenbody of water unless you have firstverified the ice is sufficiently thick tosupport the vehicle, cargo, and partic-ipants. The vehicle could breakthrough the ice causing serious injuryor death.

25

General InformationControl Locations and FunctionsIgnition Switch Key

Two keys come with this vehicle. Keepthe spare key in a safe place. An identify-ing number is stamped on each key. Usethis number when ordering a replacementkey.Ignition Switch

The ignition switch has three positions.

PK049

OFF position — All electrical circuitsexcept the accessory are off. The enginewill not start. The key can be removed inthis position.NOTE: The accessory plugs arepowered by the battery at all times.

RUN position — The ignition circuit iscomplete and the engine can run. The keycannot be removed in this position.START position — The ignition circuitis complete and the starter is engaged.When the key is released, the switch willreturn to the RUN position. The key can-not be removed in this position.NOTE: This vehicle has safetyinterlock switches which prevent thestarter motor from activating whenthe transmission is not in neutral.Depress and hold the brake pedal toengage starter when the transmis-sion is not in neutral.

Shift Lever

This vehicle has a dual-range ConstantVariable Transmission (CVT) withreverse and park.

PK059A

Drive Select Switch

PK019

This switch allows the operator to oper-ate the vehicle in either two-wheel drive(rear wheels) or four-wheel drive (allwheels) as well as mechanically lock thedifferential (if equipped) to apply equalpower to both front wheels. For normalriding on flat, dry, hard surfaces, two-wheel drive should be sufficient. In situa-tions when additional traction is neces-sary, four-wheel drive would be thedesired choice.To select 2WD, depress the bottom of theswitch. To select 4WD, move the switchto the middle position. To engage the dif-ferential lock, slide the switch latchslightly downward while pressing the topof the switch forward.

NOTE: When the differential lock isengaged on equipped models, theindicator light will be illuminated.

CAUTIONDo not attempt to either engage ordisengage the front differential whilethe vehicle is moving.

26

NOTE: The differential lock isintended for use where minimumtraction is available. Steering effortwill increase with the front differen-tial lock engaged. Maneuverabilityand handling characteristics will dif-fer with the differential lock engaged.

Foot Brake

The foot brake should be applied when-ever braking is needed.Apply the brake by pressing the brakepedal down.Steering Wheel Tilt Latch

Pull on the lever located on the bottom ofthe steering column and move the steer-ing wheel to the desired position; thenrelease the lever and make sure the steer-ing wheel locks securely.

PK020

Headlight Switch

PK021

With the ignition switch in the ON posi-tion, use the headlight switch to selectoff, running, low, or high beam.

Reverse Override Switch

This vehicle is equipped with a reversespeed limiter system. When additionalRPM is needed in reverse, depress andhold the override switch located on thecenter console. NOTE: The vehicle must be in 4WDto activate the reverse override.

Accelerator Pedal

Press down on the pedal to increaseengine RPM and vehicle speed; releasethe pedal to decrease engine RPM andvehicle speed.NOTE: This vehicle is equippedwith an RPM limiter that retards igni-tion timing when maximum RPM isapproached. When the RPM limiter isactivated, it could be misinterpretedas a high-speed misfire.

Seat Latches

1. To remove the seat, raise the front ofthe seat and slide it forward.

2. To install the seat, slide the seatbrackets under the frame rails; thenpress firmly on the front of the seatto engage both front seat studs intothe receivers.

Seat Belts

This vehicle is equipped with seat beltsfor the operator and the passenger. Tofasten and release the seat belt properly,use the following procedure.

! WARNINGMake sure the steering wheel islocked securely in place before mov-ing the vehicle, or steering wheelmovement could occur causing lossof control.

! WARNINGNever activate the override switchwhile the throttle is open as a loss ofcontrol could result. Use cautionwhen using the override switch asreverse speed can greatly increase.

! WARNINGMake sure the seat is secure beforedriving the vehicle. Serious injury ordeath could result if the seat is notproperly secured.

27

1. Place the seat belt across your lap aslow as possible without twisting thebelt making sure the shoulder strapis below the neck and across thechest.

2. Push the latch-plate into the buckleslot until it “clicks” and latchessecurely. The belt will retract whenthe buckle is released.

Occupant Side Restraints

In addition to the seat belts, there are left-and right-side restraints to restrict armsor legs from extending outside the vehi-cle. The restraints should always besecured when the vehicle is moving.To secure the restraint, connect therestraint buckle to the receiving latch onthe front ROPS tube. To release therestraint, squeeze the locking tabs of therestraint buckle.

PK013A

Tailgate Latch

PK022A

1. To open the tailgate, pivot the latchlevers outward.

2. To close the tailgate, lift up and pushforward firmly; then pivot the latchlevers inward

Cargo Box Latch Handles

PK023

1. To raise the cargo box, pivot thelatch forward; then raise the cargobox.

2. To lower the cargo box, push downfirmly on the front of the box. Thebox will automatically lock intoposition.

Digital Gauge

WT103D

1. Left Button — Shifts top displaythrough speedometer, RPM, andclock.

! WARNINGOnly appropriate-sized passengersmay ride in this vehicle. Passengersmust be able to place both feet flat onthe floor while keeping their backagainst the back of the seat and hold-ing on to the handholds.

! WARNINGFalling outside a moving vehicle couldresult in serious injury or death.Always fasten your seat belt securelyand ensure the passenger seat belt isproperly and securely fastened priorto operating or riding in this vehicle.

28

2. Middle Button — Shifts middle dis-play through speedometer, RPM,clock, odometer, trip 1, trip 2, andengine hours.

3. Right Button — Shifts bottom dis-play through coolant temperature,battery voltage, intake air tempera-ture, and fuel level.

4. Speedometer/Tachometer/ClockDisplay — Indicates approximatevehicle speed in MPH or KM/Hwhen speedometer function isselected, RPM when tachometerfunction is selected, or time whenclock is selected. Press the Left But-ton to change which parameter isbeing displayed. With speedometerselected, press and hold the LeftButton to shift between standard(mph/miles/Fahrenheit) and metric(km/h-kilometers/Celsius).With the clock mode selected, pressand hold the Left Button to set theclock. The option of selecting the12-hour or 24-hour clock is avail-able; press the Left Button to alter-nate between the two modes. Next,press the Middle Button to set theclock. Press the Left or Right to setthe hours; then press the MiddleButton to set the minutes. Press theLeft or Right Button to set the min-utes. When the proper time has beenset, press the Middle Button toreturn to the main digital gauge dis-play.

5. Engine Hour Meter/Odometer/TripMeter/Speedometer/Tachometer/Clock Display — Displays enginehours, odometer, trip meter, speed-ometer, tachometer, or clock. Pressthe Middle Button to change whichparameter is being displayed. TheEngine Hour Meter and Odometercannot be reset. To reset the tripmeter, select the Trip Meter; thenpress and hold the Middle Buttonuntil the trip meter display reads 0.

NOTE: The engine hour meter willnot activate until engine speedexceeds 500 RPM.

NOTE: An item can only be dis-played in this position if it is notalready being displayed in the topdisplay. To set the clock when theclock is in this position, press andhold the Middle Button; then use theprocedure found in step 4.

6. Coolant Temperature/Battery Volt-age/Intake Air Temperature/FuelLevel Display — Displays coolanttemperature, battery voltage, intakeair temperature, and fuel quantity.Press the Right Button to changewhich parameter is being displayed.Press and hold the Right Button tosee the actual values associated withthe mode selected.

NOTE: High engine RPM, low vehi-cle speed, or heavy load can raiseengine temperature. Decreasingengine RPM, reducing load, andselecting an appropriate transmis-sion gear can lower the temperature.

NOTE: Debris in the engine com-partment (or packed between thecooling fins of the radiator) canreduce cooling capacity. Using a gar-den hose, wash the radiator and theengine to remove any debris pre-venting air flow.

7. Gear Position Indicator — Indicateswhich gear is selected.

CAUTIONContinued operation with high enginetemperature may result in enginedamage or premature wear.

CAUTIONDo not use a pressure washer toclean the radiator core. The pressuremay bend or flatten the fins causingrestricted air flow, and electrical com-ponents on the radiator could bedamaged. Use only a garden hosewith spray nozzle at normal tap pres-sure.

29

8. EFI Malfunction Indicator — Adiagnostic code (see list below) andengine icon will be displayed on theLCD whenever an EFI error isdetected. The LCD will be normal,but the code and engine icon willcontinue to be displayed on the LCDuntil the error is corrected.

WT114C

NOTE: Take the vehicle to anauthorized dealer to have the errorcorrected and the system error resetas soon as possible.

9. Drive Select Indicator — Displays4WD when selected by the driveselect switch.

10. Seat Belt Reminder Indicator —Each time the ignition switch isturned ON, the indicator will illumi-nate until the driver’s seat belt is fas-tened.

! WARNINGThe seat belt indicator does not indi-cate that all seat belts are properlysecured. It is the operator’s responsi-bility to ensure all vehicle occupantsare properly seated with seat beltssecure and side restraints are prop-erly latched. Serious injury or deathcould occur as a result of falling out-side a moving vehicle.

30

Diagnostic Trouble Codes

Display Fault DescriptionC0063 Tilt Sensor Circuit HighC0064 Tilt Sensor Circuit Low/SG/OpenC1263 Backup/Reverse-Light Circuit OpenC1264 Backup/Reverse-Light Circuit HighC1265 Backup/Reverse-Light Circuit Low/SGC1400 Fuel Level Sender OpenC1418 Memory Power FailureP0030 O2 Heater Intermittent/OpenP0031 O2 Heater Low/SGP0032 O2 Heater High/SPP0107 MAP Sensor Circuit Low/SG/OpenP0108 MAP Sensor Circuit High/SPP0112 Intake Air Temp Sensor Circuit Low/

SGP0113 Intake Air Temp Sensor Circuit High/

OpenP0114 Intake Air Temp Sensor Circuit Inter-

mittentP0116 Engine Coolant Temp Sensor Circuit

Range/PerformanceP0117 Engine Coolant Temp Sensor Circuit

Low/SGP0118 Engine Coolant Temp Sensor Circuit

High/Open/SPP0119 Engine Coolant Temp Sensor Circuit

IntermittentP0121 Throttle Position Sensor Range/Per-

formanceP0122 Throttle Position Sensor Circuit Low/

SGP0123 Throttle Position Sensor Circuit HighP0130 O2 Sensor Intermittent/OpenP0131 O2 Sensor Low/SG or Air-LeakP0132 O2 Sensor High/SPP0171 O2 Feedback Below Minimum Correc-

tionP0172 O2 Feedback Exceeds Maximum Cor-

rectionP0219 Engine Over-Speed ConditionP0231 Fuel Pump Relay Circuit Low/SG/

OpenP0232 Fuel Pump Relay Circuit HighP0233 Fuel Pump Relay CircuitP0261 Cylinder #1 Fuel injector Circuit Low/

SGP0262 Cylinder #1 Fuel injector Circuit HighP0263 Cylinder #1 Fuel injector Balance/

OpenP0264 Cylinder #2 Fuel injector Circuit Low/

SGP0265 Cylinder #2 Fuel injector Circuit High

P0266 Cylinder #2 Fuel injector Balance/Open

P0336 Crankshaft Angle Sensor Synchroni-zation

P0337 Crankshaft Angle Sensor Circuit/SGP0339 Crankshaft Angle Sensor Intermittent/

ErraticP0340 Camshaft Angle Sensor Synchroniza-

tionP0341 Camshaft Angle Sensor Circuit/SGP0342 Camshaft Angle Sensor Intermittent/

ErraticP0480 Fan-Primary/Right Relay Control Cir-

cuitP0481 Fan-Secondary/Left Relay Control Cir-

cuit HighP0482 Fan-Secondary/Left Relay Control Cir-

cuit Low/SG/OpenP0483 Fan-Secondary/Left Relay Control Cir-

cuitP0484 Fan-Primary/Right Relay Control Cir-

cuit HighP0485 Fan-Primary/Right Relay Control Cir-

cuit Low/SG/OpenP0500 Vehicle Speed-SensorP0508 Idle Air Control System Circuit Low/

SGP0509 Idle Air Control System Circuit High/

OpenP0520 Engine Oil Sensor/SwitchP0562 System Voltage LowP0563 System Voltage HighP0601 ECM CAN Communication ShutdownP0615 Starter Relay CircuitP0616 Starter Relay Circuit LowP0617 Starter Relay Circuit HighP0630 VIN Not Programmed or IncompatibleP0642 Sensor Power Circuit LowP0643 Sensor Power Circuit HighP2300 Ignition Coil #1 Primary Circuit Low/

SG/OpenP2301 Ignition Coil #1 Primary Circuit HighP2303 Ignition Coil #2 Primary Circuit Low/

OpenP2304 Ignition Coil #2 Primary Circuit HighP2531 Ignition Switch Circuit LowP2532 Ignition Switch Circuit HighFUEL OFF

Tilt Sensor Activation Code

Display Fault Description

31

Oil Level StickThere is an oil level stick for checkingthe engine oil level. To check the oillevel, use the following procedure.NOTE: The vehicle should be onlevel ground when checking theengine oil level.

1. Remove the seat.2. Unscrew the oil level stick (located

on the right-side of the engine) andwipe it with a clean cloth.

PK024A

3. Install the oil level stick.NOTE: The oil level stick should bethreaded in for checking purposes.

4. Remove the oil level stick; theengine oil level should be within theoperating range.

GZ461A

5. Add oil to the oil level stick openinguntil proper operating level isachieved.

6. Install the seat making sure it issecurely latched.

Load Capacity Ratings Chart This vehicle must always be loaded inaccordance with the Load Capacity Rat-ings chart. Under no circumstancesshould the Vehicle Load Capacity ratingever be exceeded.

Vehicle Load Capacity — Total weightof operator, passenger, trailer tongueweight, accessories, cargo, and storagecompartments.Tongue Weight — Weight on trailertongue.Accessory Weight — Winch, gun scab-bard brackets, snow plow, etc.Rear Tongue and Cargo Weight —Total weight on trailer tongue and cargobox.Towing Capacity — Total weight oftrailer and all cargo in the trailer.

CAUTIONDo not overfill the engine with oil.Always make sure the oil level iswithin the operating range but notabove the FULL mark.

! WARNINGOverloading this vehicle could resultin loss of control resulting in seriousinjury or death.

Item Specifications(lb) (kg)

Vehicle Load Capacity 1000 454Front Storage Compartment (max)

25 11

Tongue Weight 150 68Cargo Weight (max) 500 227Rear Tongue and Cargo Weight (max)

650 295

Towing Capacity 1500 680

32

Trailering and Towing

PK327A

This vehicle is equipped with a rearframe-mounted receiver for a standard5.1 cm (2 in.) receiver hitch. The stan-dard receiver hitch must be purchasedseparately.

When loading a trailer properly, twoitems are critical: Gross Trailer Weight(the weight of the trailer plus cargo) andTrailer Tongue Weight.

Trailer Tongue Weight is the downwardforce exerted on the hitch by the trailercoupler when the trailer is fully loadedand the coupler is at its normal towingheight. Refer to the Load Capacity Rat-ings chart for tongue weight information.

Always maintain a slow speed whentrailering and towing and avoid suddenaccelerations, quick maneuvers, and sud-den stops. Braking distance will beaffected when towing a trailer. Whentowing a trailer, always maintain slowspeed and allow more stopping distancethan when not towing a trailer.

TransportingWhen transporting, the vehicle must bein its normal operating position (on allfour wheels) and the following proceduremust be used.

1. Place the transmission in park.

2. Secure the vehicle with load ratedhold-down straps.

PK083A

! WARNINGMake sure that the load in the trailer isproperly secured and will not shiftwhile moving. Also, do not overloadthe trailer.

! WARNINGNever exceed any of the vehicleweight restrictions.

! WARNINGDriving this vehicle without extra cau-tion when towing a trailer will be haz-ardous. Trailer towing can affect thehandling and braking of the vehicle.Tow only at low speeds and neverexceed 10 mph. Avoid sudden accel-erations and stopping of the vehicle.Do not make quick maneuvers. Avoiduneven surfaces and do not tow onhills.

! WARNINGNever tow people in or on any deviceexcept when towing a disabled vehiclewith operable brakes and steering oron a trailer designed for passengersthat has a rigid tow bar.

CAUTIONFailure to place the transmission inpark could allow the vehicle to roll offthe trailer in the event of tie-downstrap failure.

33

PK327

NOTE: Suitable hold-down strapsare available from your authorizeddealer. Ordinary rope is not recom-mended because it can stretch underload.

Gasoline—Oil—LubricantFilling Gas Tank

Since gasoline expands as its temperatureincreases, the gas tank must be filled toits rated capacity only. Expansion roommust be maintained in the tank particu-larly if the tank is filled with cold gaso-line and then moved to a warm area. Allow the engine to cool before fillingthe gas tank. Care must be taken not tooverfill the tank. If overfilled, gas mayleak onto the engine creating a fire haz-ard.

1. To remove the gas tank cap, flip thelid down; then rotate the cap coun-terclockwise 1/4 turn.

PK061

2. After filling the tank, position the lidtoward the right side of the fillerneck and rotate the lid 1/4 turnclockwise to secure. Flip the lid up.

Recommended Gasoline

The recommended gasoline to use in thisvehicle is 87 minimum octane regularunleaded. In many areas, oxygenates areadded to the gasoline. Oxygenated gaso-lines containing up to 10% ethanol or 5%methanol are acceptable gasolines.When using ethanol-blended gasoline, itis not necessary to add a gasoline anti-freeze since ethanol will prevent theaccumulation of moisture in the fuel sys-tem.

CAUTIONIf using additional hold-down strapsin any other areas, care must be takennot to damage the vehicle.

CAUTIONAlways buckle the side restraintswhen transporting to prevent buckledamage to body panels.

! WARNINGAlways fill the gas tank in a well-venti-lated area. Never add gasoline to thegas tank near any open flames or withthe engine running or hot. DO NOTSMOKE while filling the gas tank.

! WARNINGDo not over-flow gasoline when fillingthe gas tank. A fire hazard could mate-rialize. Always allow the engine tocool before filling the gas tank.

! WARNINGDo not overfill the gas tank.

CAUTIONDo not use white gas. Only approvedgasoline additives should be used.

34

Recommended Engine/Transmission Oil

The recommended oil to use is ACX AllWeather Synthetic engine oil, which hasbeen specifically formulated for use inthis engine. Although ACX All WeatherSynthetic engine oil is the only oil rec-ommended for use in this engine, use ofany API-certified SM 0W-40 oil isacceptable.

OILCHARTJ

Recommended Front Differential/Rear Drive Lubricant

NOTE: The manufacturer recom-mends the use of genuine lubri-cants.

The recommended front differential/reardrive lubricant is SAE-approved 80W-90hypoid. This lubricant meets all of thelubrication requirements of this vehicle.

Engine Break-In After the completion of the break-inperiod, the engine oil and oil filter shouldbe changed. Other maintenance afterbreak-in should include checking of allprescribed adjustments and tightening ofall fasteners. At the discretion andexpense of the owner/operator, the vehi-cle may be taken to an authorized dealerfor this initial service.New vehicles and engines require a“break-in” period. The first month ismost critical to the life of this vehicle.Proper operation during this break-inperiod will help ensure maximum lifeand performance from this vehicle.During the first 10 hours of operation,always use less than 1/2 throttle. Varyingthe engine RPM during the break-inperiod allows the components to “load”(aiding the engine/transmission compo-nent mating process) and then “unload”(allowing components to cool). Althoughit is essential to place some stress on theengine components during break-in, careshould be taken not to overload theengine too often. Do not pull a trailerduring the break-in period.When the engine starts, allow it to warmup properly. Idle the engine several min-utes until the engine has reached normaloperating temperature. Do not idle theengine for excessively long periods oftime.Burnishing Brake PadsBrake pads must be burnished to achievefull braking effectiveness. Braking dis-tance will be extended until brake padsare properly burnished.

1. Choose an area sufficiently large tosafely accelerate to 30 mph and tobrake to a stop.

2. Accelerate to 30 mph; then releasethe accelerator pedal and press brakepedal to decelerate to 0-5 mph.

3. Repeat procedure 20 times.

CAUTIONAny oil used in place of the recom-mended oil could cause seriousengine damage. Do not use oils whichcontain graphite or molybdenumadditives. These oils can adverselyaffect clutch operation. Also, not rec-ommended are racing, vegetable,non-detergent, and castor-based oils.

CAUTIONAny lubricant used in place of the rec-ommended lubricant could causeserious front differential/rear drivedamage.

! WARNINGDo not attempt sudden stops or putyourself into a situation where a sud-den stop will be required until thebrake pads are properly burnished.

35

General MaintenanceNOTE: Proper maintenance of thisvehicle is important for optimum per-formance. Follow the MaintenanceSchedule and all ensuing mainte-nance instructions/information.

If, at any time, abnormal noises, vibra-tions, or improper functioning of anycomponent of this vehicle is detected,DO NOT OPERATE THE VEHICLE.Take the vehicle to an authorized dealerfor inspection and adjustment or repair.

A repair shop or person of the owner'schoosing may maintain, replace, or repairemission-control devices and systems.If the owner/operator does not feel quali-fied to perform any of these maintenanceprocedures or checks, take the vehicle toan authorized dealer for professional ser-vice.NOTE: The following instructionsand information refer to specificitems in the maintenance and care ofthis vehicle.

I = Inspect and clean, adjust, lubricate, replace as necessary; T = Tighten; R = Replace; C = Clean* Dealer maintenance** When using ACX All Weather Synthetic oil, oil change interval can be increased to every 1,000 miles or

every 12 months.

Maintenance Schedule

Item Page Initial 100 miles

Every 100 miles

Every 300 miles

Every 500 miles

Battery 41 I I

* Engine nuts and bolts — I I

* Valve clearance — I I

Spark plug 44 I I

44 Replace every 4000 miles (6436 km) or 18 months

Liquid cooling system 37 I Inspect every time before operating

Gas hoses 40 I Inspect every time before operating

Engine/transmission oil and filter 38 R R**

Air filter 44 I I

Gear lubricant(front differential/rear drive)

38 R I I

V-belt 45 I I

Spark arrester/muffler 46 C

Tires/air pressure 46/20 I Inspect every time before operating

* Brake components 39 I Inspect every time before operating

Brake fluid 39 I Inspect every time before operating

Brake hoses 39 I Inspect every time before operating

* Steering — I Inspect every time before operating

* Suspension (Ball joint boots, drive axle boots front and rear, tie rods, differential and rear drive bellows)

— I Inspect every time before operating

* Chassis nuts and bolts — I T

Wheel lug nuts 46 T I T

Frame/welds/racks — I I

Electrical connections — I I

Headlight/taillight/brake light 47 I Inspect every time before operating

Air filter drains — I Inspect every time before operating

Accelerator pedal 27 I Inspect every time before operating

ROPS 50 Inspect every time before operating

Occupant side restraints 50 Inspect every time before operating

36

Liquid Cooling SystemNOTE: Debris in the engine com-partment or packed between thecooling fins of the radiator canreduce cooling capability. Using agarden hose, wash the radiator toremove any debris preventing airflow.

The cooling system capacity can be foundin the specification chart. The cooling sys-tem should be inspected daily for leakageand damage. If leakage or damage isdetected, take the vehicle to an authorizeddealer for service. Also, the coolant levelshould be checked periodically.

NOTE: High engine RPM, low vehi-cle speed, or heavy load can raiseengine temperature. Decreasingengine RPM, reducing load, andselecting an appropriate transmis-sion gear can lower the temperature.

When filling the cooling system, use acoolant/water mixture which will satisfythe coldest anticipated weather conditionsof the area in accordance with the coolantmanufacturer’s recommendations. While the cooling system is being filled,air pockets may develop; therefore,remove the bleed plug on the coolantpipe at the front of the engine allowingtrapped air to escape. When pure coolant(no air) flows from the bleed hole, installthe bleed plug, tighten securely, and thenfill the cooling system to the bottom ofthe stand pipe in the radiator neck. Runthe engine for five minutes after the ini-tial fill; then shut off the engine andrecheck coolant level.

NOTE: Use a good quality, biode-gradable glycol-based, automotive-type antifreeze.

Shock AbsorbersEach shock absorber should be visiblychecked weekly for excessive fluid leak-age (some seal leakage may be observedbut it does not indicate the shock is inneed of replacement), cracks or breaks inthe lower case, or a bent shock rod. If anyone of these conditions is detected,replacement is necessary.NOTE: When the vehicle isoperated in extremely coldweather (-23° C/-10° F or colder), asmall amount of leakage may bepresent. Unless the leakage is exces-sive, replacement is not necessary.

This vehicle is equipped with adjustableshock absorbers to allow for differentdriving and loading conditions. Adjustments can be made with a specialspanner wrench to increase or decreasecoil spring tension.To adjust the spring force, loosen thelock collar; then rotate the preload adjust-ment sleeve with a suitable spannerwrench until desired spring tension isachieved.NOTE: For normal operating con-ditions, we recommend the preloadsettings be set to full-soft on all fourshock absorbers.

CAUTIONDo not use a pressure washer toclean the radiator core. The pressuremay bend or flatten the fins causingrestricted air flow, and electrical com-ponents on the radiator could bedamaged. Use only a garden hosewith spray nozzle at normal tap pres-sure.

CAUTIONContinued operation of the vehiclewith high engine temperature mayresult in engine damage or prematurewear.

! WARNINGNever check the coolant level whenthe engine is hot or the cooling sys-tem is under pressure.

CAUTIONAfter operating the vehicle for the ini-tial 5-10 minutes, stop the engine,allow the engine to cool down, andcheck the coolant level. Add coolantas necessary.

37

PK082

NOTE: Before attempting to adjustsuspension, clean dirt and debrisfrom the threads and remove loadfrom the suspension; then use thespanner wrench to adjust the pre-load.

General LubricationCables

None of the cables require lubrication;however, it is advisable to lubricate theends of the cables periodically with agood cable lubricant.Engine/Transmission Oil and Filter

NOTE: Refer to the recommendedoil viscosity chart (on page 35) inthis manual for the proper engine oil.

Change the engine oil and oil filter at thescheduled intervals. The engine shouldalways be warm when the oil is changedso the oil will drain easily and com-pletely.

1. Park the vehicle on level ground.2. Remove the seat.3. Loosen the oil level stick. Be careful

not to allow contaminants to enterthe opening.

PK024A

4. Remove the drain plug from the bot-tom of the engine and drain the oilinto a drain pan.

5. Using the oil filter wrench and aratchet handle (or a socket or box-end wrench), remove the old oil fil-ter and dispose of properly. Do notre-use oil filter.

NOTE: Clean up any excess oilafter removing the filter.

6. Apply oil to the new filter O-ringand check to make sure it is posi-tioned correctly; then install the newoil filter. Tighten securely.

7. Install the engine drain plug andtighten it securely. Pour the recom-mended oil into the level stick open-ing. Install the level stick.

8. Start the engine (while the vehicle isoutside on level ground) and allow itto idle for a few minutes.

9. Turn the engine off and wait approx-imately one minute. Recheck the oillevel.

10. Inspect the area around the drainplug and oil filter for leaks.

11. Install the seat making sure it issecurely latched.

Front Differential/Rear Drive Gear Lubricant (Inspecting/Changing)

Inspect and change the gear lubricant ineach according to the MaintenanceSchedule. When changing the lubricant,use the appropriate hypoid oil and use thefollowing procedure.

1. Place the vehicle on level ground.2. Remove each check plug.

PK027A

Front

38

PK028A

NOTE: The lubricant level shouldbe visible at the check plug threads.

3. Drain the oil into a drain pan byremoving the drain plug from eachgear case.

PK029A

4. After all the oil has been drained,install the drain plugs and tighten to45 in.-lb.

5. Pour recommended oil into each fillhole.

6. Install the fill plugs and tighten to 16ft-lb.

Hydraulic Brake

Brake Fluid

PK030A

1. Check the brake fluid level in thebrake fluid reservoir. The fluid levelmust be maintained between theMAX and MIN level marks. If thelevel in the reservoir is low, addDOT 4 brake fluid.

NOTE: The brake fluid reservoir islocated on top of the master cylinderunder the front body panel.

2. Press the brake pedal several timesto check for firmness.

3. If the pedal is not firm, the systemmust be bled.

NOTE: Take the vehicle to anauthorized dealer for this service.

Brake Hoses

Carefully inspect the hydraulic brakehoses for cracks or other damage. Iffound, take the vehicle to an authorizeddealer to have the brake hoses replaced.Brake Pads

The clearance between the brake padsand brake discs is adjusted automaticallyas the brake pads wear. The only mainte-nance that is required is replacement ofthe brake pads when they show excessivewear. Check the thickness of each of thebrake pads as follows:

1. Remove a front wheel.2. Measure the thickness of each brake

pad.

CAUTIONInspect the oil for any signs of metalfilings or water. If found, take thevehicle to an authorized dealer forservicing.

! WARNINGBe sure to inspect the hydraulic brakesystem before each use. Always main-tain brakes according to the Mainte-nance Schedule.

Rear

Front

CAUTIONBe careful not to spill any fluid whenfilling the brake fluid reservoir. Wipeaway spilled fluid immediately.

39

3. If thickness of either brake pad fric-tion material is less than 1.0 mm(0.039 in.), take the vehicle to anauthorized dealer to have brake padsreplaced.

PK004A

4. Install the wheel and tighten thewheel nuts in 20 ft-lb increments toa final torque of 45 ft-lb (steelwheel), 60 ft-lb (aluminum wheel w/black nuts), or 80 ft-lb (aluminumwheel w/chrome nuts).

Gas HosesInspect the gas hoses. Damage fromaging may not always be visible.Protective Rubber BootsThe protective boots should be inspectedperiodically according to the Mainte-nance Schedule.Ball Joint Boots (Upper and Lower/Right and Left)

PK005A

1. Secure the vehicle on a supportstand to elevate the front wheels.

2. Remove both front wheels.3. Inspect the four ball joint boots for

cracks, tears, or perforations.

4. Check the ball joint for free-play bygrasping the steering knuckle andturning it from side to side and upand down.

5. If boot damage is present or balljoint free-play seems excessive, con-tact an authorized dealer for service.

Tie Rod Boots (Inner and Outer/Right and Left)

1. Secure the vehicle on a supportstand to elevate the front wheels.

2. Remove both front wheels.3. Inspect the tie rod boots for cracks,

tears, or perforations.4. Check the tie rod end free-play by

grasping the tie rod near the end andattempting to move it up and down.

PK006A

5. If boot damage is present or tie rodend free-play seems excessive, con-tact an authorized dealer for service.

Drive Axle Boots

PK006B

1. Inspect all drive axle boots forcracks, tears, or perforations.

2. If boot damage is present, contact anauthorized dealer for service.

40

BatteryThe battery is located under the seat onthe driver’s side.

PK050A

After being in service, batteries requireregular cleaning and recharging in orderto deliver peak performance and maxi-mum service life. The following proce-dures are recommended for cleaning andmaintaining lead-acid batteries. Alwaysread and follow instructions providedwith battery chargers and battery prod-ucts.NOTE: Refer to all warnings andcautions provided with the battery orbattery maintainer/charger.

Loss of battery charge may be caused byambient temperature, ignition OFF cur-rent draw, corroded terminals, self dis-charge, frequent start/stops, and shortengine run times. Frequent winch usage,snowplowing, extended low RPM opera-tion, short trips, and high amperageaccessory usage are also reasons for bat-tery discharge.Maintenance Charging

NOTE: Use of the CTEK Multi US800 or the CTEK Multi US 3300 formaintenance charging is recom-mended. Maintenance charging isrequired on all batteries not used formore than two weeks or as requiredby battery drain.

1. When charging a battery in the vehi-cle, be sure the ignition switch is inthe OFF position.

NOTE: Be sure to maintain thefluid of the battery at the UPPERLEVEL. Use only distilled waterwhen adding fluid to these batteries.

2. Clean the battery terminals with asolution of baking soda and water.

3. Be sure the charger and battery arein a well-ventilated area and ensurethe battery charger cables will notcontact any battery acid. Be sure thecharger is unplugged from the 110-volt electrical outlet.

4. Connect the red terminal lead fromthe charger to the positive terminalof the battery; then connect the blackterminal lead of the charger to thenegative terminal of the battery.

NOTE: Optional battery chargingadapters are available from yourauthorized dealer to connect directlyto your vehicle from the recom-mended chargers to simplify themaintenance charging process.Check with your authorized dealerfor proper installation of thesecharging adapter connectors.

5. Plug the battery charger into a 110-volt electrical outlet.

6. If using the CTEK Multi US 800,there are no further buttons to push.If using the CTEK Multi US 3300,press the Mode button (A) at the leftof the charger until the MaintenanceCharge Icon (B) at the bottom illu-minates. The Normal Charge Indica-tor (C) should illuminate on theupper portion of the battery charger.

800A

NOTE: The maintainer/charger willcharge the battery to 95% capacity atwhich time the Maintenance ChargeIndicator (D) will illuminate and themaintainer/charger will change topulse/float maintenance. If the bat-tery falls below 12.9 DC volts, thecharger will automatically start againat the first step of the chargesequence.

41

3300C

NOTE: Not using a battery chargerwith the proper float maintenancewill damage the battery if connectedover extended periods.

Charging

NOTE: Use of the CTEK Multi US800 or the CTEK Multi US 3300 forbattery maintenance charging is rec-ommended.

1. Be sure the battery and terminalshave been cleaned with a bakingsoda and water solution.

2. Be sure the charger and battery arein a well-ventilated area and ensurethe battery charger cables will notcontact any battery acid. Be sure thecharger is unplugged from the 110-volt electrical outlet.

3. Connect the red terminal lead fromthe charger to the positive terminalof the battery; then connect the blackterminal lead of the charger to thenegative terminal of the battery.

4. Plug the charger into a 110-volt elec-trical outlet.

5. By pushing the Mode button (A) onthe left side of the charger, select theNormal Charge Icon (E). The Nor-mal Charge Indicator (C) shouldilluminate on the upper left portionof the charger.

6. The battery will charge to 95% of itscapacity at which time the Mainte-nance Charge Indicator (D) will illu-minate.

NOTE: For optimal charge and per-formance, leave the charger con-nected to the battery for a minimum1 hour after the Maintenance ChargeIndicator (D) illuminates. If the bat-tery becomes hot to the touch, stopcharging. Resume after it hascooled.

7. Once the battery has reached fullcharge, unplug the charger from the110-volt electrical outlet.

NOTE: If, after charging, the bat-tery does not perform to operatorexpectations, bring the battery to anauthorized dealer for further trouble-shooting.

Jump-Starting

NOTE: Jump-starting a vehiclewith a dead battery is not recom-mended but rather removing the bat-tery, servicing it, and correctlycharging it; however, in an emer-gency, it may be necessary to jump-start a vehicle. If so, use the follow-ing procedure to carefully and safelycomplete this procedure.

1. On the vehicle to be jump-started,remove the battery cover and anyterminal boots.

2. Inspect the battery for any signs ofelectrolyte leaks, loose terminals, orbulging sides. Leaking or bulgingbattery cases may indicate a frozenor shorted battery.

! WARNINGImproper handling or connecting of abattery may result in serious injuryincluding acid burns, electrical burns,or blindness as a result of an explo-sion. Always remove rings andwatches.

! WARNINGAny time service is performed on abattery, the following must beobserved: keep sparks, open flame,cigarettes, or any other flame away.Always wear safety glasses. Protectskin and clothing when handling abattery. When servicing battery inenclosed space, keep the area well-ventilated. Make sure battery ventingis not obstructed.

42

3. Inspect the vehicle to be used forjump-starting to determine if voltageand ground polarity are compatible.The vehicle must have a 12-volt DC,negative ground electrical system.

4. Move the vehicle to be used for thejump-start close enough to ensurethe jumper cables easily reach; thenshift into neutral, set and lock thebrakes, shut off all electrical acces-sories, and turn the ignition switchOFF.

NOTE: Make sure all switches onthe vehicle to be jump-started areturned OFF.

5. Disconnect all external accessoriessuch as cell phones, GPS units, andradios on both vehicles.

6. Attach one clamp of the positive(red) jumper cable to the positive (+)terminal (1) of the dead battery (C)being careful not to touch any metalwith the other clamp; then attach theother clamp of the positive (red)jumper cable to the positive (+) ter-minal (2) of the good battery (B).

0744-527

NOTE: Some jumper cables maybe the same color but the clamps orends will be color-coded red andblack.

7. Attach one clamp of the negative(black) jumper cable to the negative(-) terminal (3) of the good battery(B); then attach the other clamp ofthe negative (black) jumper cable (4)to an unpainted metal surface (A) onthe engine or frame well away fromthe dead battery and fuel systemcomponents.

8. Stand well away from the dead bat-tery and start the vehicle with thegood battery. Allow the vehicle torun for several minutes applyingsome charge to the dead battery.

9. Start the vehicle with the dead bat-tery and allow it to run for severalminutes before disconnecting thejumper cables.

10. Remove the jumper cables in oppo-site order of hook-up (4, 3, 2, 1). Becareful not to short cables againstbare metal.

NOTE: Have the battery and elec-trical system checked prior to oper-ating the vehicle again.

! WARNINGIf any of these conditions exist, DONOT attempt a jump-start, boost, orcharge the battery. An explosioncould occur causing serious injury ordeath.

CAUTIONAlways make sure the electrical sys-tems are of the same voltage andground polarity prior to connectingjumper cables. If not, severe electricaldamage could occur.

CAUTIONFailure to disconnect electronicaccessories during jump-starting maycause system damage due to powerspikes.

! WARNINGNever make the final connection to abattery as a spark could ignite hydro-gen gases causing an explosion of thebattery resulting in acid burns orblindness.

43

Spark PlugThis vehicle comes equipped with a spec-ified spark plug. See the specificationschart for the correct spark plug. A lightbrown insulator indicates that the plug iscorrect. A white or dark insulator indi-cates that the engine may need to be ser-viced. Consult an authorized dealer if theplug insulator is not a light brown color.To help prevent cold weather fouling,make sure to thoroughly warm up theengine before operating.To maintain a hot, strong spark, keep theplug free of carbon.

ATV-0051

Before removing the spark plug, be sureto clean the area around the spark plug. Ifyou do not, dirt could enter engine whenremoving or installing the spark plug.Adjust the gap (see specifications chart)for proper ignition. Use a feeler gauge tocheck the gap.

ATV-0052

A new spark plug should be tightened 1/2turn once the washer contacts the cylin-der head. A used spark plug should betightened 1/8-1/4 turn once the washercontacts the cylinder head.

Air Filter/Housing DrainThe air filter inside the air filter housingmust be kept clean to provide goodengine power and gas mileage. If thevehicle is used under normal conditions,service the filter at the intervals speci-fied. If operated in dusty, wet, or muddyconditions, inspect and service the filtermore frequently. Use the following pro-cedure to remove the filter and inspectand/or clean it.

NOTE: To access the air filter, theseat must be removed.

1. Remove dirt and debris from aroundthe filter housing.

2. Unsnap the seven spring-clips andremove the air filter cover; then loosenthe clamp securing the air filter.

PK008A

3. Remove the Phillips screw to sepa-rate the air filter holders from the airfilter.

PK321

4. Slide out the air filter screen; thenseparate the inner and outer air filterelements to thoroughly clean.

CAUTIONFailure to inspect the air filter fre-quently if the vehicle is used in dusty,wet, or muddy conditions can dam-age the engine.

44

PK322

5. Place each element in a pan largerthan the elements and spray all sidesgenerously with cleaning solvent.Let sit approximately three minutes.

6. In a pan larger than each element,with a mild detergent (dish soap)and water, wash all the dirt and oiloff by squeezing the element nottwisting it (wringing out or twistingthe filter can cause damage).

NOTE: Foam Filter Cleaner andFoam Air Filter Oil Aerosol are avail-able.

7. Rinse off any remaining soap.8. Remove any excess water from the

element by matting with a towel.9. Allow each element to dry com-

pletely. Place the outer element overthe inner air filter element.

10. Spray oil generously onto air filterand work the oil into the element.

11. Squeeze the element to removeexcess oil.

12. Clean any dirt or debris from insidethe filter housing.

13. Inspect the drain cap beneath themain housing for debris and forproper sealing.

PK009

14. Insert the air filter screen into theinner element; then secure the air fil-ter holders with the Phillips screw.

15. Install the air filter cover and securewith the clamp. Install the air filtercover and secure with the spring-clips. Install the seat and make sureit is securely latched.

Draining V-Belt CoverNOTE: If the vehicle has beendriven through water, the V-beltcover must be drained of any water.

1. Place the vehicle on a level surface.2. Remove the drain bolt from the

cover (located on the bottom of theV-belt cover) and allow the water todrain out.

NOTE: The drain bolt can beaccessed through the bottom of theskid plate.

3. Shift the range lever to the neutralposition; then start the engine.

4. Increase and decrease engine RPMseveral times to “blow out” anywater; then stop the engine.

5. Install the drain bolt and tightensecurely.

NOTE: The V-belt and clutchesshould be inspected every 500 milesand the belt replaced (if necessary).

CAUTIONA torn air filter can cause damage tothe engine. Dirt and dust may getinside the engine if the element istorn. Carefully examine the elementfor tears before and after cleaning it.Replace the element with a new one ifit is torn.

CAUTIONDo not attempt to clear water with thevehicle in park. The transmission islocked and belt or clutch damagecould occur.

45

Tires

Tire Tread Condition

0732-649

The use of worn-out tires on this vehicleis very dangerous. A tire is considered tobe worn out when the depth of the treadis less than 3 mm (1/8 in.). Be sure toreplace the tires before reaching this min-imum specification.

Tire Replacement

This vehicle has low-pressure tubelesstires. Air is sealed by the contact surfacesof the inner wheel rim and the tire bead.If either the inner wheel rim or tire beadis damaged, air may leak. Be extremelycareful not to damage these areas whenreplacing tires.It is very important to use the propertools when repairing or replacing tires toprevent damage to the tire bead or wheelrims. If proper tools and related items arenot available, have this maintenance per-formed by an authorized dealer or a qual-ified tire repair shop.

Tubeless Tire Repair

Should a leak or flat tire occur due to apuncture, the tire may be repairedusing a plug-type repair. If the dam-age is from a cut or if the puncturecannot be repaired using a plug, thetire must be replaced. When operat-ing the vehicle in areas where trans-portation or service facilities are notreadily available, it is strongly rec-ommended to carry a plug-typerepair kit and a tire pump along.

Wheels1. Park the vehicle on level ground and

engage the differential lock.2. Loosen the lug nuts on the wheel to

be removed.3. Elevate the vehicle.4. Remove the lug nuts.5. Remove the wheel.6. Install the wheel and install the lug

nuts.7. Install the wheel and tighten the

wheel nuts in 20 ft-lb increments toa final torque of 45 ft-lb (steelwheel), 60 ft-lb (aluminum wheel w/black nuts), or 80 ft-lb (aluminumwheel w/chrome nuts).

8. Remove the jack.Muffler/Spark ArresterThe muffler has a spark arrester whichmust be periodically cleaned. At theintervals shown in the MaintenanceSchedule, clean the spark arrester usingthe following procedure.

1. Remove the cap screws securing thespark arrester assembly to the muffler.

! WARNINGAlways use the size and type of tiresas specified. Refer to the specifica-tions chart for proper tire inflationpressure, and always maintain propertire inflation pressure.

! WARNINGThe use of worn-out tires is danger-ous and can increase the risk of anaccident.

CAUTIONWhen breaking the tire bead loosefrom the wheel, be extremely carefulnot to damage the inner wheel sur-face or the tire bead.

! WARNINGUse only approved tires when replac-ing tires. Failure to do so could resultin unstable operation.

! WARNINGWait until the muffler cools to avoidburns.

46

PK010

2. Using a suitable brush, clean the car-bon deposits from the screen takingcare not to damage the screen.

NOTE: If the screen or gasket isdamaged in any way, it must bereplaced.

3. Install the spark arrester assemblyand secure with the cap screws.Tighten to 50 in.-lb.

Light Bulb Replacement

NOTE: The bulb portion of the head-light is fragile. HANDLE WITH CARE.When replacing the headlight bulb, donot touch the glass portion of the bulb.If the glass is touched, it must becleaned with a dry cloth before install-ing. Skin oil residue on the bulb willshorten the life of the bulb.

To replace the headlight bulb, use the fol-lowing procedure.

1. Rotate the back of the headlight bulbcounterclockwise, disconnect thewiring harness, and discard the bulb.

PK062A

2. Connect the new headlight bulb tothe wiring harness and insert intoheadlight assembly. Turn clockwiseto secure the bulb.

3. Adjust the headlight (see Checking/Adjusting Headlight Aim in thissub-section.

To replace the taillight/brake light, usethe following procedure:

1. Disconnect the taillight/brake lightconnector.

2. Remove the two nuts and cap screwssecuring the steel tie-down to thecargo box.

PK063A

3. Remove the six plastic screws secur-ing the rear fender to the cargo box.Remove the rear fender.

TXR004A

4. Remove the taillight/brake lightsocket by rotating the socket coun-terclockwise. Rotate the bulb coun-terclockwise to remove from socket.

CAUTIONUse only specified bulbs indicated inthe Specifications chart as replace-ment bulbs.

CAUTIONWhen replacing the headlight bulb, becareful not to touch the glass portionof the bulb. Grasp the new bulb with aclean cloth.

47

PK328

5. To install the taillight/brake light,insert the bulb into the socket andturn clockwise. Insert the socket intothe taillight assembly and turnclockwise.

6. Place the rear fender onto the cargobox and secure with the six plasticscrews. Secure the tie-down with thetwo nuts and cap screws.

7. Connect the taillight/brake light con-nector.

Checking/Adjusting Headlight AimThe headlights can be adjusted vertically.The geometric center of the HIGH beamlight zone is to be used for aiming.

1. Position the vehicle on a level floorso the headlights are approximately6.1 m (20 ft) from an aiming surface(wall or similar aiming surface).

0748-733

NOTE: There should be an averageoperating load on the vehicle whenadjusting the headlight aim.

2. Measure the distance from the floorto the midpoint of each headlight.

3. Using the measurements obtained instep 2, make horizontal marks on theaiming surface.

4. Make vertical marks which intersectthe horizontal marks on the aimingsurface directly in front of the head-lights.

5. Switch on the lights. Make sure theHIGH beam is on. DO NOT USELOW BEAM.

6. Observe each headlight beam aim.Proper aim is when the most intensebeam is centered on the verticalmark 5 cm (2 in.) below the horizon-tal mark on the aiming surface.

7. Loosen the headlight adjustmentscrew; then adjust the headlight upor down as required. Tighten theheadlight adjustment screw.

PK081A

FusesThe fuses are located under the frontaccess panel. If there is any type of elec-trical system failure, always check thefuses first.

PK012

NOTE: To remove the fuse, com-press the locking tabs on either sideof the fuse cover and lift out.

48

UTV-253

Electrical Output TerminalsThree output terminals for electricalaccessories are located on the wiring har-ness. An accessory plug is located on thedash board.NOTE: The rear output terminal islocated above the bottom frame railbehind the right rear tire. The frontoutput terminal is located behind theleft front fender well. A third outputterminal is located under the seat.

PK067A

Storage Compartments/ToolsA basic tool kit (located in the glove box)is provided with this vehicle. Maintainthe tool kit with the vehicle at all times.NOTE: There are a total of threestorage compartments.

1. To access the front storage compart-ment, lift up firmly on the front ofthe cover to remove. To install, alignthe tabs of the storage cover into thefront panel slots.

PK084

2. To open the glove box (if unlocked),squeeze the locking tabs togetherand pivot the lid downward or insertthe key and rotate 1/8 turn counter-clockwise and pivot the lid down-ward. To lock the glove box, closethe lid, insert the key, and rotate it1/4 turn clockwise. Remove the key.

PK085

3. To open the tailgate compartment,pull outward on the locking leverand allow the tailgate storage coverto pivot downward. To secure thetailgate storage cover, pivot thecover upward and press firmly onboth left and right hands sides.

TXR005

CAUTIONAlways replace a blown fuse with afuse of the same type and rating. Ifthe new fuse blows after a shortperiod of use, consult an authorizeddealer immediately.

CAUTIONAlways use electrical accessoriesless than 180W.

49

Seat BeltsInspect the seat belts for frayed or tornedges. Check that the belts extend andretract smoothly and fully without bind-ing or catching. Check that the latch platelocks securely in place in the buckle andreleases when the button is pressed.Wash off any dirt and make sure theretractors are free of debris. Do notgrease or oil the retractors.Occupant Side RestraintsInspect the occupant side restraints forfrayed edges, cuts, or separation ofseams. Wash off any dirt and make surethe latch straps lock securely into thereceiver located on the front ROPS tube.

PK013A

ROPSInspect the Rollover Protection Structure(ROPS) for any deformation, twisting,cracking, missing or damaged fasteners,loose fasteners, modification to the pro-duction form, missing ROPS label, unau-thorized repair or welding, and/orimproper installation. If any of these cir-cumstances are discovered, do not oper-ate and immediately bring the vehicle toan authorized dealer for service.

50

Preparation for StorageUse the following procedure to preparethe vehicle for storage:

1. Clean the seat cushion with a dampcloth and allow to dry.

2. Clean the vehicle thoroughly bywashing dirt, oil, grass, and otherforeign matter from the entire vehi-cle. Allow the vehicle to dry thor-oughly. DO NOT get water into anypart of the engine or air intake.

3. Either drain the gas tank or add afuel stabilizer to the gas in the gastank.

4. Clean the interior of the air filterhousing.

5. Plug the hole in the exhaust systemwith a clean cloth.

6. Apply light oil to the plungers of theshock absorbers.

7. Tighten all nuts, bolts, cap screws,and screws. Care must be taken thatall calibrated nuts, cap screws, andbolts are tightened to specifications.

8. Fill the cooling system to the bottomof the stand pipe in the radiator neckwith properly mixed coolant.

9. Disconnect the battery cables (nega-tive cable first); then remove the bat-tery, clean the battery posts andcables, and store in a clean, dry area.

NOTE: For storage, use a batterymaintainer or make sure the batteryis fully charged (see Battery sectionin this manual).

10. Store the vehicle indoors in a levelposition.

CAUTIONPrior to storing this vehicle, it mustbe properly serviced to prevent rust-ing and component deterioration.

CAUTIONAvoid storing outside in direct sun-light and avoid using a plastic coveras moisture will collect on the vehiclecausing rusting.

51

Preparation after Storage Taking this vehicle out of storage andcorrectly preparing it will ensure manymiles and hours of trouble-free riding.Use the following procedure:

1. Clean the vehicle thoroughly.2. Clean the engine. Remove the cloth

from the exhaust system.3. Check all control wires and cables

for signs of wear or fraying. Replaceif necessary.

4. Change the engine/transmission oiland filter.

5. Check the coolant level and addproperly mixed coolant as necessary.

6. Charge the battery; then install. Con-nect the battery cables making sureto connect the positive cable first.

7. Check the entire brake systems(fluid level, pads, etc.), all controls,headlights, taillights, brake lights,and headlight aim; adjust or replaceif necessary.

8. Check the tire pressure. Inflate torecommended pressure as necessary.

9. Tighten all nuts, bolts, cap screws,and screws making sure all cali-brated nuts, cap screws, and boltsare tightened to specifications.

10. Make sure the steering moves freelyand does not bind.

11. Check the spark plug. Clean orreplace as necessary.

12. Check the air filter and the air filterhousing. Clean or replace as neces-sary.

CAUTIONBefore installing the battery, makesure the ignition switch is in the OFFposition.

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Maintenance RecordDATE MILEAGE SERVICE PERFORMED/NOTES

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Limited WarrantyTracker Off Road (the Company) extends a limited warranty as described below on each new vehicle itassembles and on each genuine part and accessory assembled and sold by an authorized dealer. The limitedwarranty on the vehicle is extended to the original retail purchaser for the time periods described below;however, the balance of the remaining warranty may be transferred to another party unless the purchase is forcommercial use (see below). Warranty coverage is only available in the country in which the original retailpurchase occurs to the original retail purchaser resident in that country or to a transferee resident in thatcountry of the balance of the remaining warranty.

We warrant only the products we assemble and/or sell and do not warrant that other products will functionproperly when used with the vehicle or will not damage the vehicle. The Company does not assume anyliability for incidental or consequential damages.

The Company will repair or replace, at its option, free of charge (including any related labor charges), anyparts that are found to be warrantable in material or workmanship. This repair work MUST be done by anauthorized dealer. No transportation charges, rental charges, or inconvenience costs will be paid by theCompany. The warranty is validated upon examination of said parts by us or an authorized dealer. TheCompany reserves the right to inspect such parts at its factory for final determination if warranty should apply.

The warranty periods are as follows:

1. Twelve months from the date of sale — for a vehicle used for recreational purposes.2. Ninety days from date of invoice — for a vehicle used for commercial purposes, including rental

operations (non-transferable).3. Thirty days from date of sale of vehicle on Company-supplied batteries.

Exclusions to this warranty include normal wear, abuse, or corrosion and the following parts anditems:

Tires CV Boots Torn or Punctured UpholsteryOil Filter Drive Belt Cracks or Gouges in Body PanelsAir Filter Brake Pads Drive/Driven Clutch Wear PartsLight Bulbs Spark Plug(s) WindshieldShock Absorber(s)** Limited to one (1) year of “normal” riding conditions — replace for defective or leaking shock, corroded

or pitted shaft, peeling chrome.NOTE: Vehicles that are factory equipped with FOX, Elka, or JRi shocks and experience a shock failure ofworkmanship or material within the factory warranty period must not be tampered with. Only the airpressure valve (p/n 2603-511 — FOX shocks only) is serviceable during the warranty period. Any othertampering with the shock will void warranty.

The following will VOID the warranty:

1. Failure to perform the proper break-in procedure and all related maintenance, storage procedures(if stored for extended periods), and/or service as recommended in the Operator’s Manual.

2. Repairs and/or adjustments by anyone other than an authorized dealer.3. Use of improper carburetor jets.4. Use of improper gasoline/fuel, lubricating oils, or spark plug(s).5. An accident or subjecting the vehicle to misuse, abuse, or negligent operation.6. Any modification, addition, or removal of parts unless instructed to do so by the Company.7. Use of the vehicle in any way for racing purposes.8. Removal of the engine for use in another vehicle.9. Removal or mutilation of the Vehicle Identification Number or Engine Serial Number.

10. Use of parts not sold or approved by the Company.11. Damage due to improper transportation.12. Use of starting fuel (ether) for cold starts.

The Company shall not be responsible for and this limited warranty excludes recovery of economic,punitive, consequential and incidental damages, lost profits, and loss of use. Some states or provincesdo not allow the exclusion or limitation of incidental or consequential damages, so the above limitationmay not apply to you. Our aggregate liability may not exceed the price of the product. The law of theState of Minnesota shall apply to all claims or disputes, exclusive of its conflicts of law provisions.

IMPLIED WARRANTY EXCLUSION AND DISCLAIMERTo the fullest extent permitted by law, the Company excludes and disclaims all implied warranties ofmerchantability and fitness for a particular purpose. If you are not satisfied with warranty service orrepairs, contact us at 877-394-6727.

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Warranty Procedure/Owner ResponsibilityAt the time of sale, an ROV Rider Training Certificate and Owner Registration form is to be com-pleted by the selling dealer and consumer. The receipt of the form by the Company is a condi-tion precedent to warranty coverage. It is the selling dealer’s responsibility to retain and/orsubmit appropriate copies of the form to the appropriate place(s) to initiate warranty coverage.The dealer will furnish to the consumer a signed copy of the form which must be presented tothe dealer when requesting warranty service. The registration form is the consumer’s proof ofownership and warranty eligibility. The form is used by the dealer to validate the warranty claim.Retain your copy of the form and keep it in a safe place.When warranty repair is suspected, the vehicle should be taken to the selling dealer, who hasthe primary responsibility to perform warranty repairs. Subject to the limitations set forth in theLimited Warranty, in the event the selling dealer has ceased to do business, you have moved, oryou are in a location away from your selling dealer, warranty may be performed by any autho-rized dealer.The authorized dealer will examine the vehicle or part to determine if, in the dealer’s opinion, awarrantable condition exists. If a warrantable condition appears to exist, the dealer will repair orreplace, at the Company’s option, free of charge, including any related labor costs, all parts thatare found to be warrantable and any other parts which the warrantable part caused to be dam-aged. You, the owner, will then be asked to sign a warranty form to ensure the Company that thewarranty work was actually performed.It is the owner’s responsibility to maintain and service the vehicle in accordance with this Oper-ator’s Manual. To protect yourself and your vehicle, follow all safety and service tips. The Com-pany will NOT warrant repairs required as a result of not performing standard operatormaintenance, storage procedures, and service as outlined in the Operator’s Manual.Should you have any questions concerning the warranty, contact an authorized dealer.

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U.S. EPA Emission ControlStatement/Warranty Coverage — ROV

(U.S. Only)STATEMENT/WARRANTYTracker Off Road warrants to the original retail purchaser, and each subsequent purchaser, that all U.S. EPA-certified Tracker Off Road vehicles are designed, built, and equipped to conform to all U.S. EPA EmissionControl Regulations. Please read the following information completely.

Your authorized dealer will repair or replace any defective emission-related component at no cost to youduring the warranty period. You may have non-warranty service performed by any repair establishment thatuses equivalent components. The regulations provide significant civil penalties for tampering that causesyour vehicle to no longer meet U.S. EPA emission standards.

Tracker Off Road further warrants that the engine and its emission-related components are free from defectsin materials or workmanship that could cause the engine to fail to comply with applicable regulations duringthe warranty period.

If you have any questions about this information, or the emission warranty coverage statement, contact yourauthorized dealer.

WARRANTY PERIODThe emission warranty period for this vehicle begins on the same date as the standard warranty coverageand continues for 30 months, 5000 kilometers (3107 miles), or 500 hours, whichever comes first.

COMPONENTS COVEREDI. For exhaust emissions, emission-related components include any engine parts related to the followingsystems:

Air-induction system. Fuel system.

Ignition system. Exhaust gas recirculation systems.

II. The following parts are also considered emission-related components for exhaust emissions:

Aftertreatment devices. Crankcase ventilation valves.

Sensors. Electronic control units.

III. The following parts are considered emission-related components for evaporative emissions:

Fuel Tank. Fuel Cap.

Fuel Line. Fuel Line Fittings.

Clamps*. Pressure Relief Valves*.

Control Valves*. Control Solenoids*.

Electronic Controls*. Vacuum Control Diaphragms*.

Control Cables*. Control Linkages*.

Purge Valves. Vapor Hoses.

Liquid/Vapor Separator. Carbon Canister.

Canister Mounting Brackets. Carburetor Purge Port Connector.

*As related to the evaporative emission control system.

For U.S. EPA Emission Control Warranty coverage questions, contact us at877-394-6727.OWNER’S RESPONSIBILITIESThe owner of any vehicle warranted under this Emission Control Statement is responsible for the propermaintenance and use of the vehicle as stated in the Operator’s Manual. Proper maintenance generallyincludes replacement and service, at the owner’s choosing, such items as air filter, oil and oil filter, or anyother part, item, or device related to emissions control as specified in the Operator’s Manual. It is the owner’sresponsibility to ensure that the vehicle is used in a manner for which it was designed.

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Change of Address, Ownership, or Warranty Transfer

Tracker Off Road keeps on file the current name and address of theowner of this vehicle. This allows us to reach the current owner with anyimportant safety information which may be necessary to protectcustomers from personal injury or property damage. Please make surea copy of this form is completed and returned to us. if you move or if thevehicle is sold to another party.

This form may also be used to transfer the unused portion of theoriginal warranty to a second party. In order to transfer warranty, fill outthis form completely; then return a copy of this form to us. We will thenprocess the application and issue warranty for the balance of the timeremaining of the original warranty. Warranty coverage is only availablein the country in which the original retail purchase occurs to the originalretail purchaser resident in that country or to a transferee resident inthat country of the balance of the remaining warranty.

Address Change

Ownership Change

Warranty Transfer

CHANGE OF ADDRESS/OWNERSHIP/WARRANTY TRANSFER TO:

Name ________________________________________

Address ______________________________________

City/State (Province) ____________________________

Zip Code (Postal Code)___________________________

Phone ( ) ___________________________________

Email ________________________________________

Year and Model ________________________________

Vehicle Identification Number (VIN) _________________

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CHANGE OF ADDRESS/OWNERSHIP

TRACKER OFF ROAD1451 MARVIN GRIFFIN RDAUGUSTA GA 30906-3852 USA

PlaceStampHere

NOTES

59

NOTES

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Identification Numbers RecordThis vehicle has two identification numbers: Vehicle Identification Number (VIN)and Engine Serial Number (ESN). These numbers are required by the dealer to com-plete warranty claims properly. No warranty will be allowed if the VIN or ESN isremoved or mutilated in any way.Always provide the name, VIN, and ESN when contacting an authorized dealer forparts, service, accessories, or warranty. If a complete engine must be replaced, ask thedealer to notify the manufacturer for correct registration information.Record the Vehicle Identification Number and Engine Serial Number in the spacesprovided to assist you in ordering parts from your authorized dealer or for referencein case this vehicle is stolen.

1. KEY IDENTIFICATION NUMBER:

The key identification number is stampedon the key. Record this number in thespace provided for reference if you everneed a new key.

2. VEHICLE IDENTIFICATION NUMBER:

The VIN is located behind the front righttire.

3. ENGINE SERIAL NUMBER:

The ESN is located on the front-right sideof the crankcase.

ATV-0055B

PK047

PK048

MANUFACTURER INFORMATION:Textron Specialized Vehicles, Inc.1451 Marvin Griffin RoadAugusta, Georgia 30906-3852 USADealer: 800-296-4804Consumer: 877-394-6727www.trackeroffroad.com

Date post:	09-Jul-2020
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