Chironex motoports Spartan 500 User manual

SPARTAN 500 OWNERS MANUAL

CHIRONEX MOTORSPORTS INC.

TABLE OF CONTENTS

Topic

Pages

Introduction

Technical parameters

III

Parts Breakdown

Safety Instructions

Operating the Spartan UTV

Breaking-in Period

VII

Maintenance and Repair

VIII

Troubleshooting

Torque specifications

Fuel/ Oil / Fluid Specifications

Circuit Diagrams

I. Introduction

Chironex welcomes you to its growing family of new Spartan series Utility Vehicle owners. The Spartan has been designed for the Canadian

outdoors with careful attention paid to every detail. Proper set-up, maintenance and safe operating practices will help you get years of satisfactory

use from this vehicle.

Safety First

Chironex is fully aware of the need for safe operating procedures around all of our equipment. We hope you will make a sincere effort to put

safety above all other priorities. The Spartan Utility Vehicle was designed and built for work, recreation, and enjoyment; however, improper and

irresponsible operation could result in serious injury or death. Since this is an off-road vehicle, operators will seldom see the road safety and

warning signs they are accustomed to seeing on highways and public streets. This places additional responsibility on the driver to operate this

vehicle well within the safe operational limits and capabilities of the unit.

This manual has been prepared to instruct you in the safe and responsible operation of your Spartan Utility Vehicle. Read and abide by all safety

alert information about this vehicle. If you do not understand any part of this manual, contact your local dealer for additional information and

clarification. As the operator of this piece of equipment, you are in complete control. Only you can prevent an accident from happening.

Using This Manual

* Prior to any vehicle operation it is absolutely essential that you read and comprehend each section in this manual to develop an understanding of

your vehicle and for your safety. After reviewing this manual, store it in a dry and easily accessible place for future reference.

* The Operator’s Section is designed to help familiarize you with safety, assembly, operation, adjustments, troubleshooting, and maintenance.

Read this manual and follow the recommendations to help ensure safe and efficient operation.

* The information contained within this manual was current at the time of printing. Some parts may change slightly to assure you of the best

performance.

* To order a new Operator’s or Parts Manual contact your authorized dealer.

www.chironex.ca

Getting Acquainted with your Utility Vehicle

This off-road utility vehicle is a very unique vehicle designed exclusively for off-road use. It is not designed, properly equipped, or licensed to be

safely operated on public streets and highways. This vehicle is designed to carry two people and a limited amount of gear or cargo comfortably

and safely over rough terrain.

Unlike ATVs that have handlebar steering, the Spartan Utility Vehicles have a steering wheel with easy handling rack-and pinion steering. The

steering’s tight turning radius makes this vehicle more maneuverable than most ATV’s. Its four wheeled independent suspension, large diameter

hi-flotation tires and high center-frame ground clearance adds up to excellent stability and a smooth ride over rough terrain. Outstanding traction

is achieved by using premium off-road ATV type tires in tandem with the engine mounted directly in front of the rear differential.

Also unlike an ATV’s one person “straddle saddle” seat, the Spartan UTV sports dual headrest cushioned seats with seat belts mounted in a

highly styled and protective full length body. Two passengers can ride comfortably in this vehicle protected from splashing water and mud. The

Brush Guard Bar mounted to the vehicle’s frame provides protection against low hanging limbs and briars.

The Brush Guard Bar also provides a mounting system for optional windshields, canopy tops and weather enclosures. It also serves as a mounting

base for many other optional cargo racks, gun and bow racks.

The dump box is for transporting materials and accessories such as camping equipment, tree stands, hunting gear, and fishing gear. A standard

hitch mounting plate enables quick installation of a rear hitch for pulling small trailers full of supplies, tools, gear, and game.

The Spartan UTV has some similarities to an ATV. Like an ATV it has a short wheelbase, narrow stance, and high center clearance all which

provide for narrow and difficult trail access. This combination of short wheelbase and narrow stance also enables this vehicle to be loaded in the

back of most full to mid-sized pickups for transport.

The Spartan UTV’s ground compaction and is very gentle on the ground and surrounding vegetation. The highly energized four wheeled

independent suspension system provides an incredibly soft ride and outstanding stability over difficult terrain.

Owner Assistance

The safety information should be viewed by the owner and the Warranty Registration card should be filled out by the dealer at the time of

purchase. The owner, upon purchasing the vehicle, should have participated in a short drivers training course with the dealer. This information is

necessary to provide you with quality customer service.

The parts on your Spartan Utility Vehicle have been specially designed and should only be replaced with genuine Chironex parts.

If customer service or repair parts are required contact a Chironex dealer. They have trained personnel, genuine repair parts and equipment

specially designed to repair Chironex products.

Record your Chironex Spartan Utility Vehicle serial number here for quick reference:

Model Number:___________________________

Serial Number:____________________________

Your Chironex dealer wants you to be satisfied with your new vehicle. If you do not understand any part of this manual or you’re not satisfied

with the service received, please take the following actions.

Discuss the matter with your dealership service manager. Make sure they are aware of any problems so they can assist you.

If you are still unsatisfied, seek out the owner or general manager of the dealership.

For further assistance Initial breaking-in period for the Spartan 500 4x4 is 1000km, during which extra care must be taken (see Section VI). Upon

expiration of this period, continue to carry out the necessary maintenance procedures.

II、Technical parameters

(I) Common technical data

1Weight parameters (kg)

Dry Weight: 500

2Dimensions (mm)

Length/ Width: 2690×1270

Wheelbase:1820

Tread: front tire: 1036 rear tire: 1040

Approach angle(°)：47

Departure angle(°)：82

(II) Operating data

1Top speed(km/h)：H gear : 70

2Steering radius(m)：4.65

3Braking distance (w/ zero load).

When V０=30km/h：4 m

When V０=40km/h：5.5 m

When V０=50km/h：9 m

4 Gas mileage: 10 km/ L

5 Load capacity: 300Kg

(III) Engine

Type: Single cylinder, 4-stroke, liquid cooled

Valve train: 4 valve, top camshaft, single shaft

Induction: Carburetor

Bore and stroke (mm): 87.5 x 82

Engine displacement: 493 cc

Compression ratio: 10.2：1

Maximum power (kw/r/min): 24/6500

Maximum torque (N·m/r/min): 38.8/5500

Minimum fuel consumption rate (g/Kw·h): 340

Idle speed (r/min): 1300±100

Starting: Electric

Ignition type: touch-less CDI DC

Spark Plug: DPR7EA-9(NGK)

Lubricating oil: SAE 15W—40/SF

Engine # location: Topside surface at rear end of left

crankcase

Ignition angle(°/r/min)：

10/1500 – 32/1500

Lubricating type: Pressurized wet sump

Engine oil pump type：TOTOR

Oil filter: Full-flow mechanical w/ paper element

Fuel Capacity: 20 L

Carburetion type: Vacuum slide

Air filter: Sponge element

Fuel type: RQ-93 or better

Transmission: Automatic CVT (toothed V-belt)

P/R/N/H/L, Electrically controlled 2WD/4WD

Gear change: Hand lever

Clutch type: wet, centrifugal hoof

Primary gear ratio: 0.703—2.88

Gear ratio：Total gear reduction ratio:

H Gear：3.514 2.47—10.12

L Gear：5.857 4.12—16.87

R Gear：3.828 2.69—11.02

Coolant: antifreeze with rust prevention

Dimension: 610 x 568 x 519

Net weight: 70 kg

Final Drive: shaft

Shaft rotation: clockwise (from the back of engine)

(IV)、Chassis

1. Differential：

Tapered arc gear transmission

Transmission rate：33/9

2. Drive type：Shaft, 2WD/4WD/Differential LOCK

Normal drive: Rear wheel drive.

3. Suspension：

Front suspension: Independent double wishbone

with preload adjustment

Rear suspension：Independent double wishbone

with preload adjustment

4. Front Wheel alignment:

Camber angle：0° ±1°

Main pin inner angle：11°50’ ±3°

Main pin back angle：4°±1°

Front toe-in: -3—3mm

5. Tires：

Front Tire: 25×8.—12

Air pressure：250Kpa

Rear Tire: 25×10 —12

Air pressure：300Kpa

6. Steering system：Rack-and-pinion steering

Steering wheel turns, lock to lock: 2.5

Total steering angle: 75°.

Maximum steering angle, right: 37.5°.

Maximum steering angle, left: 37.5°.

7. Brakes:

Front brakes: Dual hydraulic disk

Rear brakes: Dual hydraulic disk

Parking brake: Mechanical disk (rear axle)

8. Electric Dump box：

Dumping angle: 49°

9. Winch:

Rated Single Line Pull: 3000 lbs.

(V)、Electrical components

1. Pipeline voltage: 12V。

2. Alternator power rating: 325W。

3. Battery：12V - 36A·h。

4. Starter motor：12V DC motor

III Parts Breakdown

1. Safety belt

2. Frame

3. Steering wheel

4. Rear view mirror

5. Engine hood

6. Indicator

7. Bumper

8. Headlight

9. Winch

10. Wheel

11. Seat

12. Side cover

13. Rear mudguard

14. Cargo bed

15. Headrest bar

16. Head rest

Engine Parts Breakdown

1. Carburetor

2. Starter

3. Water temperature sensor

4. Starting handle

5. Left cover

6. Rear shaft flange

7. Front shaft flange

8. Oil filter

9. Thermostat

10. CVT case

11. CVT inlet

12. CVT inlet

13. Plug

VIN number Rear suspension

（on the frame above right rear wheel）

Oil Intake Oil Dipstick

Oil drain plug（bottom of engine）

Warning：Oil drain plugs of engine and gear box

should be tightened

，otherwise engine would

burned for oil leakage. Should use the correct gear

box oil and quantity. More or less oil can cause the

gear box burned out..

警告：发动机机放机油塞应拧紧，否则会因漏油而烧

毁发动机。

WARNING

：

ENGINE OIL LEVEL SHOULD BE

BETWEEN UPPER AND LOWER MARKINGS. ELSE

YOU RISK ENGINE DAMAGE.

Fuel tank intake（left side）Coolant, Brake fluid intake

Rear differential Front differential

WARNING：Use only TC / DOT approved brake fluid. Do not mix

different types of brake fluids. Always maintain brake fluid level to

ensure proper functioning of the brakes.

WARNING：Do not unscrew radiator cap when engine is hot;

contents are at a high temperature and pressure.

WARNING：Use TC / DOT approved gear oil in the front and rear

differentials. Fill up to just below intake. Filling too much will result

in leakage and too little burn damage to the differential

IV、Safety Instructions:

1. Check for leaks of engine oil, coolant, fuel, lubricant.

2. Check the levels of engine oil, brake fluid and coolant. If

necessary, add more.

3. Check the air pressure in tires.

4. Check the functioning of the safety belt.

5. Check steering play.

6. Check engine support frame, bolts, transmission system

and running system.

7. After starting engine, listen for any abnormal noises and

confirm whether all meter readings are normal.

8. Check brake pedal movement and functionality of brakes

(including the hand brake).

9. Check whether the lights (steering light, brake light,

warning light, running lights, headlight – low and high

beams) are working.

10. Check whether the winch and dump box are in good

working order

11. Check fuel level.

V、Operating the Spartan UTV

(1)Key

The same key is used for ignition and to open fuel tank

cover. You are given two copies of your Spartan UTV

key; remember to put aside one copy.

Warning：

(1) Driver must be of legal age to operate the UTV.

(2) Fasten the safety belt before riding the UTV.

(3) Driver should be adequately insured.

(4) Driver should operate UTV at speeds of 35—45km/h. Speeding will cause an

accident.

(5) Driver should limit speed to 20 km/h when turning.

(6) Do not over load the dump box. If cargo height exceeds height of dump box, it

must be fastened down. This will prevent cargo from falling forward and hurting

the driver.

(7) The antifreeze in radiator is only suitable for use in temperatures above -35 C.

Please use antifreeze with the appropriate temperature rating for temperatures

below -35 C.

(8) Do not use the hand brake at speeds over 50km/h (except in case of

emergency); it may damage the vehicle and cause it to slip or over turn.

(9) Use the two wheel drive for on road driving. Unnecessary use of four wheel

drive may increase wear and tear.

(10) Ensure the vehicle is stopped before switching gears.

(2)Ignition switch

Ignition switch has four positions：

“OFF”（close）position：All circuits are turned off

except for the emergency light, electric fan and

cigarette lighter.

“ON”（open）position：All circuits except starter

and ignition are connected, keeps an engine running

“START”（start）position：Connects starter and

ignition circuit to start engine; automatically returns to

“ON” position after engine starts

“LOCK”（lock）position: The steering wheel is

locked at this position and the key can be pulled out.

(3) Instruments

Note: You only can start the engine when gear is in “N”

position. The engine can not be started up when gear is in “H”,

“L” or “R” positions.

WARNING: Ignition key can not be turned to “LOCK”

position and pull out before vehicle is stopped stably. This

could causes the vehicle lost control when the steering wheel is

locked.

1、Temperature Gauge 2.3.、L/R Indicators 4、Fuel Gauge

5、High beam 6、Odometer 7、Speedometer 8、2WD/ 4WD

（

）

Temperature Gauge: Displays the temperature

of engine coolant.

（

2, 3

）

Indicators: Left or Right indicator blinks

corresponding to turning signal switched on.

Both indicators blink if hazard light is switched

on.

（

）

Fuel Gauge: Displays quantity of fuel left in the

fuel tank.

（

）

High-beam: Lit when high-beam is switched on.

（

）

Odometer: Displays the total distance travelled

（

）

Speedometer: Display the current speed

（

）

.2WD/4WD and differential lock

Single axle indicator being lit corresponds to

2WD. In 4WD mode both axles indicator are

lit. When an “X” in displayed, it indicates 4WD

with the front differential locked.

（

L/H/N/R

）

Gear Indicator：Displays the currently

operational gear corresponding to Low, High,

Neutral and Rear.

(4) Lights

Press light switch to center position to turn on

the dashboard as well as the running lights of the

UTV. Press switch to “on” position to turn on the

headlight.

With the light switch in the “on” position, press

the headlight switch to turn on high beam.

Hazard light: switches on the front and rear

flashers in case of emergency.

Use the turn signal button to switch on left

and right signal lights corresponding to the left and

right arrows marked. To turn off both signal lights keep

button in the center position.

(5) Horn

Press button located at the center of the steering wheel to

blow horn.

(6) Accelerator and brake pedals

The accelerator pedal (left) and brake pedal (right) are

located at the floor board on the driver side of the

UTV. Step on the brake pedal before switching into

L/H/R gear as required, then step on the accelerator

pedal to move.

(7) Hand brake (Parking brake)

Remember to pull up the hand brake when the UTV is

parked to prevent vehicle from rolling.

(8) Dump box

To dump contents of the dump box, open the rear gate.

Switch on (“O” position) the red “MAIN” button on the

dash. Now keep the “TRAILER” button pressed in the

“UP”position to lift the dump box, release the button

once box is at desired angle and contents are emptied. To

lower the dump box, keep the “TRAILER” button pressed

in the “DOWN”till the box is completely lowered.

(9) Winch

Keep the winch button pressed in the “OUT”position to

extend the winch cable to the required length. To retract

keep the button pressed in the “IN” position.

(10) 2WD/ 4WD/LOCK

To select normal rear wheel drive switch button to 2WD

position; this mode is for on road driving. Switch to 4WD

position to select all wheel drive; use this mode for off-

roading. If the UTV gets stuck or you are driving in extreme

terrain and/or weather conditions switch to LOCK position;

this locks the front differential.

WARNING：After parking the vehicle, pull up the hand

brake lever. Push down the hand brake lever before stepping

on the accelerator. Do not use the hand brake to stop vehicle

when moving (except in case of emergency). WARNING: Always switch the “MAIN” button to the OFF

position when done using the winch or dump box to conserve

battery power. Once the dump box has been lifted to the

maximum inclination or lowered completely, do not continue

to press the “TRAILER” button.

(11)Windshield and wiper (optional)

Turn knob in clockwise direction to the preferred “Low” or

“High” setting. To switch off the wiper, turn knob in anti-

clockwise direction to the “Off” position.

(12)Reverse speed over ride button (installation optional)

Under normal circumstances do not use the reverse over ride.

Use the over ride only when you are stuck or need to reverse in

rough terrain.

WARNING

: Do not change from 2WD to 4WD when the UTV is

in motion. Selected gear is displayed on the dash. At times the

gear is selected only after stepping on the accelerator. In order

to prevent damage to the transmission, step lightly on the

accelerator pedal momentarily, to ensure that the gear is in the

right position.

NOTE：

Using the 4WD mode increases wear and tear on the

UTV. In order to prolong the life of UTV components use 4WD

only when the terrain is muddy, slippery, covered with snow

and/or steep terrain.

(13) Choke

When operating the UTV in cold weather, if you

experience difficulty in starting the engine, pull out the choke.

After the UTV starts push down the choke to restore the

carburetor to normal operation.

VI、Breaking-in period

The operating quality and longevity of the UTV depends on

taking proper care during the breaking-in period. During the

initial 1600 km of driving the various components of the UTV

should be allowed to wear into each other. Adhere to the

speed limit, keep total UTV payload to a minimum and carry

out periodic maintenance as per the guidelines in this manual.

1. Maximum permissible speed:

Mileage

Maximum permissible speed

< 800Km 40Km/h

800 - 1600Km 50Km/h

> 1600Km 60Km/h

Avoid full throttle starts, sudden acceleration or

deceleration during the breaking-in period.

2. Warming up engine

During the breaking-in period, it is necessary idle the

engine for 3-5 minutes after starting and warm it up.

This gives time for the engine oil and lubricants to

flow over surfaces in contact.

3. Coolant Temperature Monitoring

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