Mahindra ROXOR HDUV 2023 Manual

Breathing diesel engine exhaust can expose you to chemicals known to the State of California to cause cancer and birth defects or other
reproductive harm.
• Always start and operate the engine in a well-ventilated area.
• If in an enclosed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system.
• Do not idle the engine except as necessary.
For more information go to www.P65warnings.ca.gov/diesel
Operating, servicing and maintaining a passenger vehicle or off-road vehicle can expose you to chemicals including engine exhaust, carbon
monoxide phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. To
minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your vehicle in a well ventilated area and wear
gloves or wash your hands frequently when servicing your vehicle.
For more information go to www.P65warnings.ca.gov/passenger-vehicle
California Perchlorate Contamination Prevention Act This Off-Road vehicle may contain perchlorate materials-special handling may apply.
For more information go to www.dtsc.ca.gov/hazardous waste/perchlorate/

1 Introduction ...............................................................................1-1
Improvements.................................................................1-1
Engine tampering statement...................................1-1
2 Getting Started .........................................................................2-1
3 Operator’s Guide .....................................................................3-1
4 Safety Alert Symbols..............................................................4-1
5 Safety Information/General Precautions ...................5-1
Avoid Carbon Monoxide Poisoning .....................5-1
Avoid Diesel Fuel Hazards.........................................5-1
Avoid Hot Part Hazards ..............................................5-2
Accessories and Modifications...............................5-2
6 Safe Operations and Responsibilities ..........................6-1
Owner Responsibilities...............................................6-1
Operator's Responsibilities ......................................6-2
Passenger Responsibilities.......................................6-2
Occupant Restraint System......................................6-3
Riding Carefully...............................................................6-3
Terrain Condition...........................................................6-3
Stopping the Engine and Parking..........................6-4
7 Important On-Product Labels ..........................................7-1
ANSI Labels........................................................................7-1
EPA Labels..........................................................................7-4
Manufacturer Labels....................................................7-5
8 Riding Gear .................................................................................8-1
Helmets and Eye Protection ....................................8-1
Additional Riding Gear ................................................8-2
9 Prepare to Ride.........................................................................9-1
Pre-Ride Inspection Checklist..................................9-1
Post-Ride Inspection Checklist ...............................9-3
10 Learning Your Vehicle........................................................10-1
11 Vehicle Controls ....................................................................11-1
Primary Controls .........................................................11-1
Keys ....................................................................................11-1
Ignition Switch ..............................................................11-1
Headlamp Switch........................................................11-3
Multifunction Gauge .................................................11-3
Table of Contents

Additional Controls (as equipped).....................11-6
Steering Wheel .............................................................11-7
Accelerator Pedal........................................................11-7
Brake Pedal ....................................................................11-7
Clutch Pedal...................................................................11-8
Gear Shift Lever ...........................................................11-8
Transfer Case Lever...................................................11-8
12 Equipment................................................................................12-1
Seat Belts.........................................................................12-1
Driver’s Seat...................................................................12-1
Passenger Seat.............................................................12-1
Rollover Protective Structure (ROPS) ...............12-1
Shoulder Guards (as equipped)..........................12-2
Side Nets / Doors ........................................................12-2
Passenger Handhold.................................................12-2
12 Volt Power Outlet.................................................12-3
Storage Compartments...........................................12-3
Cup Bottle Holders.....................................................12-3
Rear Cargo Area...........................................................12-3
Tailgate .............................................................................12-3
Fuel Reservoir Cap .....................................................12-4
13 Electrical Distribution.........................................................13-1
14 Fuel (Diesel) .............................................................................14-1
Fuel Requirements.....................................................14-1
Fueling Procedure ......................................................14-1
15 Break in Period ......................................................................15-1
Operation During Break In ....................................15-1
Tips for Maximizing Durability.............................15-1
16 Avoiding Accidents...............................................................16-1
17 OFF-Road Operation...........................................................17-1
18 General Driving Techniques...........................................18-1
Driving Tips.....................................................................18-1
Driving in Reverse.......................................................18-1
Driving in or on Slippery Surfaces .....................18-2
Driving in or on Sand ................................................18-2
Driving in or on Snow or Ice..................................18-3
Table of Contents

Driving on Hills and Slopes....................................18-3
Side Hilling......................................................................18-4
Drop Offs.........................................................................18-4
Crossing Obstacles.....................................................18-4
Crossing Shallow Water...........................................18-5
Crossing Public Streets, Roads, or
Highways .........................................................................18-5
Driving on Pavement ................................................18-5
Group and Distance Riding ...................................18-6
Environment..................................................................18-6
19 Moving Loads and Doing Work.....................................19-1
Working with Your ROXOR.....................................19-1
Weight and Load Limits...........................................19-1
Loading the Rear Cargo Area ...............................19-1
Carrying Loads .............................................................19-2
Hauling and Pulling Loads .....................................19-2
20 Transporting ...........................................................................20-1
Trailering..........................................................................20-1
Towing...............................................................................20-2
21 Lifting and Supporting.......................................................21-1
22 Maintenance ...........................................................................22-1
Severe Dusty Conditions.........................................22-1
Scheduled Maintenance Chart............................22-2
23 Maintenance Procedures.................................................23-1
Maintenance Tips and Precautions ..................23-1
Clean Spark Arrester.................................................23-1
Clean and Inspect Brakes.......................................23-2
Check Brake Fluid Level and Leak Check .......23-3
Check Differential Oil Levels and Leak
Check .................................................................................23-4
Check Engine Coolant Level and Leak
Check .................................................................................23-4
Check Engine Oil Level and Leak Check..........23-5
Check Power Steering Oil Level and Leak
Check .................................................................................23-6
Check Tire Pressure...................................................23-7
Table of Contents

Check Transfer Case Oil Level and Leak
Check .................................................................................23-8
Drain Fuel/ Water Separator.................................23-8
Lubricate Shift Linkage ............................................23-9
Accessory Drive Belt Tension/
Replacement .................................................................23-9
Replace Engine Air Filter ...................................... 23-11
Replace Engine Oil and Oil Filter ..................... 23-12
Replace Transfer Case Oil ................................... 23-13
Rotate Wheels and Tires ...................................... 23-14
24 Vehicle Care.............................................................................24-1
Post Operation Care..................................................24-1
Vehicle Cleaning and Protection.........................24-1
Metal and Rust Prevention ....................................24-1
Storage and Preseason Preparation ................24-1
25 Technical Information........................................................25-1
Product Identification Number ...........................25-1
Engine Identification Number..............................25-1
Noise Emission Control System..........................25-1
Acts Presumed to Constitute Tampering.......25-2
26 Specifications..........................................................................26-1
Fluid Specifications and Quantities...................26-1
Vehicle Specifications ...............................................26-2
27 Troubleshooting....................................................................27-1
28 Limited and EPA Warranties U.S. and Canada .....28-1
Mahindra Emissions Control Warranty
Policy ................................................................................28-1
29 Contact Us................................................................................29-1
30 Privacy Information.............................................................30-1
31 Change of Address/Ownership ....................................31-1
32 Stolen Units .............................................................................32-1
Table of Contents

Mahindra USA, Inc. All Rights Reserved. 1-1
1 Introduction
Congratulations on the purchase of your new Mahindra ROXOR
Offroad Side x Side. Please know that Mahindra USA, Inc d/b/a
“MAgNA” (sometimes referred to as "Mahindra" here in after)
backs this unit with limited and EPA warranties. A network of
ROXOR authorized dealers are ready to provide the parts,
accessories and services to support your needs.
Upon delivery, you were informed of these limited and EPA
warranty coverages and signed the Pre-Delivery Checklist to
ensure your new ROXOR was prepared to your entire satisfaction.
Please make sure you have a copy of the Pre-Delivery Checklist and
retain it for your records. If you have questions or need more
information, please contact your ROXOR authorized dealer or visit
our website WWW.ROXOROFFROAD.COM.
1.1 Improvements
MAgNA’s policy is one of continuous improvement, and the right to
change prices, specifications or equipment at any time without
notice is reserved.
All data given in this book is subject to production variations.
Dimensions and weight are approximate only and illustrations do
not necessarily show vehicles in standard conditions. For exact
information about your particular ROXOR, Please consult your
Mahindra Dealer.
1.2 Engine tampering statement
The fuel system and engine on your machine are designed and
built to government emissions standard.
Tampering by dealers, customers, operators and users is strictly
prohibited by law. Failure to comply could result in government
fines, rework charges, invalid warranty, legal action and possible
confiscation of the machine until rework to original condition is
completed. Engine service and/or repairs must be done by a
certified technician only.
Introduction

Mahindra USA, Inc. All Rights Reserved. 2-1
2 Getting Started
Start by learning how to help reduce the risk of an accident
affecting you, your passengers or bystanders. Read and make sure
you fully comprehend and abide by the content of this Operator’s
Guide before you operate the Mahindra ROXOR Offroad Side x
Side.
Also, read and become familiar with all safety labels on your
ROXOR. Failure to follow all on-product safety label warnings, and
the warnings contained in this Operator’s Guide may result in
severe injury or death of the operator, passengers and bystanders.
Getting Started

Mahindra USA, Inc. All Rights Reserved. 3-1
3 Operator’s Guide
This Operator’s Guide has been prepared to familiarize the owner
and any operator with the various controls, maintenance and safe
operating instructions. It is essential for the proper use of the
product.
The information contained in this Operator’s Guide is correct at the
time of publication. MAgNA, however, maintains a policy of
continuous improvement of its products without imposing upon
itself any obligation to install them on products previously
manufactured. We reserve the right to change, modify, or cancel
specifications, designs, features, and colors without notice or
obligation. Some differences between the manufactured product
and the descriptions and/or specifications may exist.
Keep this Operator’s Guide with the vehicle so you and any other
operator can refer to it for things such as maintenance,
troubleshooting and instructing others. To view and/or print extra
copies of the Operator’s Guide, simply visit WWW.
ROXOROFFROAD.COM.
Operator’s Guide

Mahindra USA, Inc. All Rights Reserved. 4-1
4 Safety Alert Symbols
This safety alert symbol indicates a potential for injury hazard. The
categories of safety and informational labels provided on the
ROXOR and in this Operator’s Guide are defined as follows:
potential for an immediate hazard resulting in severe injury or
death to occupants and/or the general public if not avoided.
potential for a hazardous condition exists that could result in
severe injury or death of occupants and/or the general public if
not avoided.
potential for a non-immediate hazard presenting a lesser threat of
injury, resulting in minor or moderate injuries to occupants and/or
general public if not avoided.
potential for a non-immediate hazard presenting a risk to
property and/or equipment damage.
The entire contents of this Operator’s Guide should be treated as
safety instructions. They should be scrupulously adhered to, and
where specifically warranted, we have called out instructions with
the symbols above. However, failure to use proper care and abide
by the contents of this Operator’s Guide, as well as the applicable
laws and regulations in your area, could result in severe injury,
including death.
Safety Alert Symbols

Mahindra USA, Inc. All Rights Reserved. 5-1
5 Safety Information/General Precautions
5.1 Avoid Carbon Monoxide Poisoning
All engine exhaust contains a deadly gas known as carbon
monoxide. Carbon monoxide is a colorless, odorless, tasteless gas
that may exist even though you may not see or smell engine
exhaust. Breathing carbon monoxide can result in headaches,
dizziness, drowsiness, nausea, confusion and could eventually lead
to death. Lethal levels of carbon monoxide can collect quickly and
exist for long periods of time when not properly ventilated. Always
run the ROXOR in a well ventilated or open area.
If you have symptoms that you think could be a result of carbon
monoxide poisoning, leave the area right away, and call or go to
the emergency room. If you keep breathing carbon monoxide
fumes, you may pass out and die.
Avoid running the engine in garages, carports or barns that do not
have proper ventilation. Avoid running the engine anywhere that
may allow exhaust gases to be drawn into a building through open
doors, windows or vents resulting in the carbon monoxide
poisoning of yourself or others.
5.2 Avoid Diesel Fuel Hazards
Diesel fuel is widely regarded as safe to handle and store in its
liquid form. However, diesel fuel in its vapor form can be
dangerous, especially at temperatures above 100° F (38° C). The
vaporization rate of diesel fuel increases as the temperature
increases. In the presence of a vapor accelerant such as fan forced
air or oxygen, the diesel fuel can begin to vaporize even faster.
Help reduce the risk of diesel fuel hazards by following these
instructions.
• Strictly adhere to the fueling instructions in section 14.2 Fueling
Procedure
• Never start or operate the engine if the fuel cap is not properly
installed
• Use only an approved (yellow) diesel fuel container to store and
transfer diesel fuel
All fuel handling must take place in a well-ventilated area. Avoid
heat, flames and other sources of ignition, avoid inhalation of
vapors and contact with skin and eyes, do not siphon diesel fuel by
mouth, never fill a fuel container inside the ROXOR as the interior
surfaces are coated, acting as an insulator and allowing static
electricity to build up, help guard against static discharges by
always filling approved containers on the ground, do not allow
anyone to remain in the ROXOR while fueling, an occupant may
not be able to leave the area quickly in an emergency, failure to
follow these warnings may result in severe injury or death.
Safety Information/General Precautions

5-2 Mahindra USA, Inc. All Rights Reserved.
5.3 Avoid Hot Part Hazards
The engine, exhaust, transmission, cooling system and other
ancillary parts on the ROXOR become very hot during operation.
Burns from touching these parts can happen in less than one
second, but can be very serious. Help reduce the risk of burns by
avoiding contact with these areas and other very hot parts, during
and shortly after operation. If a burn occurs from contact with
these areas follow these instructions:
• Use cool water on the burned areas. Avoid ice and cold water
• Clean the burn area immediately, and keep the area clean
• Cover or wrap the burn with a clean dry gauze pad
• For severe burns, call 911 and get medical attention right away
Avoid contact with the engine, exhaust, transmission, cooling
system and other very hot parts, during and shortly after
operation to prevent burns and any other severe injury.
5.4 Accessories and Modifications
It is important to take the time to get familiar with the ROXOR once
authorized and approved modifications are made, to help
understand how to adapt your driving behavior accordingly.
MAgNA parts and accessories have been specifically designed for
use on the Mahindra ROXOR Offroad Side x Side. We strongly
recommend that all parts and accessories you add to your ROXOR
be genuine Mahindra parts and accessories, so as not to affect
your safety, EPA compliance or factory limited warranty.
MAgNA warrants that the Accessories, as further defined below,
are free from defects in material and workmanship:
for ninety (90) days from the date of purchase, if purchased by
consumer without installation by a ROXOR authorized dealer; or
For the period and under the conditions described in section 28.1
Limited Warranty U. S. and Canada if factory installed, or
installed by a ROXOR authorized dealer.
Do not tamper with unauthorized modifications or install
equipment not specifically certified by MAgNA for the ROXOR.
These modifications have not been tested by MAgNA and they may
increase emissions, risk of injury, loss of control or render the
ROXOR illegal to use or operate.
As an example, tampering with tire specifications or ride height (lift
kit) may affect the behavior of the ROXOR and increase the risk of
roll over and loss of control. If you have questions, consult your
local authorized dealer for suitable, available accessories for your
ROXOR.
Safety Information/General Precautions

Mahindra USA, Inc. All Rights Reserved. 5-3
The ROXOR was certified to EPA emissions and voluntary safety
standards; Any unapproved modifications or addition of
accessories may affect the certifications, emissions, safety and
handling resulting in injury or death.
Any changes to factory installed wheel and tire size will adversely
affect the operation of this unit's Dash Cluster and Engine Control
Unit (ECU). Altering the Dash Cluster and/or ECU may cause
driveability issues and potentially void the unit's warranty. Consult
an authorized ROXOR Dealer for more information.
Safety Information/General Precautions