Massimo motor 800utv-ec User manual

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INTRODUCTION

Congratulations on your purchase of the 800UTV-EC. It represents the result of many years of

experience in the production of fine sporting, UTVs, and pacesetting racing machines. With the

purchase of this UTV, you can now appreciate the high degree of craftsmanship and reliability.

This manual will provide you with a good basic understanding of the features and operation of

this UTV. This manual includes important safety information. It provides information about special

techniques and skills necessary to ride your UTV. It also includes basic maintenance and inspection

procedures. If you have any questions regarding the operation or maintenance of your UTV, please

consult the dealer.

AN IMPORTANT SAFETY MESSAGE

●READ THIS MANUAL TOGETHER WITH TIPS FOR THE UTV RIDER CAREFULLY AND COMPLETELY

BEFORE OPERATING YOUR UTV. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS.

● PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE UTV.

●NEVER OPERATE A UTV WITHOUT PROPER TRAINING OR INSTRUCTION.

●THIS UTV, AND ANY OTHER UTV OVER 90cc, SHOULD NOT BE RIDDEN BY ANYONE UNDER 16 YEARS

OF AGE.

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IMPORTANT MANUAL INFORMATION

FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS

INJURY OR DEATH.

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

The SafetyAlert Symbol means ATTENTION!

YOUR SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or

death to the machine operator, a bystander or a person inspecting or

repairing the machine.

A CAUTION indicates special precautions that must be taken to avoid

damage to the machine.

A NOTE provides key information to make procedures easier or clearer.

NOTE:

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IMPORTANT NOTICE

Curve speed must be smaller than 30km/h.

This UTV has been passed and the EC certificate, it can run on any public street, road, and

highway.

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

When the temperature is below -20℃(-4°F), please park the UTV in the place where the

temperature is higher than -20℃(-4°F). After the UTV has warmed up, the UTV can be started.

Please see page 6-3 on the warming up process.

When the temperature is higher than 38℃(100°F), and when you park the UTV after it run at

high speed, please keep engine running for 3 minutes at idle mode and make sure that the radiator

fan still work for 3 minutes to prevent cooling water from boiling. Then turn off the power switch to

save the battery.

When you park the UTV and cut off the engine, please turn off the ignition switch to stop meter

displaying. With EFI system use for this UTV, the electric fuel pump in the fuel tank can work when

the meter displays. If the fuel pump work for a long time ,it will result in battery power loss and failure

to electric start.

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CONTENTS

1 LOCATION OF THE WARNING

2AND SPECIFICATION LABELS……1-1

2. SAFETY INFORMATION………………2-1

3. DESCRIPTION AND VEHICLE

IDENTIFICATION………………………3-1

Identification Number Records…………3-3

Vehicle Identification Number…………3-3

4. CONTROL UNCTIONS………………4-1

Ignition Switch……………………………4-1

Switch Lock Assy………………………4-2

Indicator And Warning Lights…………4-3

Multi-Function Display Gauge…………4-6

Odometer And Trip Meter Modes………4-7

Clock Mode………………………………4-8

Fuel Gauge………………………………4-9

Switches………………………………4-10

On-Command Four-Wheel–Drive

And Differential Gear Lock Switches…4-11

1 Accelerator Pedal………………………4-15

Brake Pedal……………………………4-16

Drive Select Lever……………………4-16

Fuel Tank Cap…………………………4-17

Seats……………………………………4-17

Seat Moving ForwardAnd

Backward.

…

………………………………

4-19

Seat Belt………………………………4-19

Cargo Bed………………………………4-21

FrontAnd Rear Shock

Absorber Adjustment…………………4-23

Trailer Hitch Bracket……………………4-25

Auxiliary DC Jack………………………4-25

5PRE-OPERATION CHECKS…………5-1

5. Brakes……………………………………5-2

Front And Rear Brakes…………………5-2

Fuel………………………………………5-5

Gasohol…………………………………5-5

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Engine/Reduction Gear box Oil ………5-6

Coolant……………………………………5-7

Final Gear Oil……………………………5-8

Differential Gear Oil……………………5-8

Adjustment of steering…………………5-8

Throttle Pedal……………………………5-9

Throttle Freepaly………………………5-10

Throttle Freeplay Inspection………5-10

Throttle Freeplay Ajustment…………5-10

Steering Wheel Inspection……………5-11

Seat Belts………………………………5-11

Fittings and Fasteners…………………5-11

Lights……………………………………5-11

Switches…………………………………5-11

Tires……………………………………5-12

How To Measure Tire Pressure………5-14

TireWearLimit…………………………5-15

6．OPERATION………………………………6-1

Starting The Engine Under In Low

Temperature……………………………6-1

Starting The Engine……………………6-2

Warming Up………………………………6-3

Drive Select Lever OperationAnd

Reverse Driving…………………………6-4

Parking……………………………………6-6

Parking On A Slope……………………6-7

Vehicle Break-in Period…………………6-8

Engine Break-In…………………6-9

Accessories And Loading……………6-10

7DRIVING YOUR VEHICLE……………7-1

Getting To Know Your Vehicle…………7-1

Learning To Operate Your Vehicle……7-5

Turning Your Vehicle……………………7-6

Operating Improperly in Reverse………7-7

Cab NetsAnd Shoulder

Protection Plate…………………………7-7

Braking……………………………………7-8

Going Uphill………………………………7-8

Going Downhill…………………………7-10

Crossing Through Shallow Water……7-12

Vehicle Immersion……………………7-13

Rear Axle Differential Lock …………7-15

Riding Over Rough Terrain……………7-16

Riding In Brush Or Wooded

Areas……………………………………7-17

Encountering Obstacles On The

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Trail………………………………………7-18

8. PERIODIC MAINTENANCE AND

ADJUSTMENT…………………………8-1

Owner’s Manual And Tool Kit…………8-1

Periodic Maintenance Chart For

The Emission Control System…………8-3

General MaintenanceAnd

Lubrication Chart…………………………8-4

Sundry Box Cover………………………8-6

Engine Cover……………………………8-6

Engine Oil And Oil Filter Cartridge……8-7

To Change the Engine Oil………………8-8

To change the Reduction

Gear Box Oil8-11………………………8-11

Final Gear Oil…………………………8-12

Differential Gear Oil……………………8-14

Coolant…………………………………8-16

Axle Boots………………………………8-18

Spark Plug Inspection…………………8-19

Cleaning The Air Filter Elements……8-21

Cleaning The Spark Arrester…………8-25

Valve Clearance………………………8-27

Front Brake Pad Check………………8-27

Rear Brake Pad Check………………8-28

Checking The Brake Fluid Level……8-28

Brake Fluid Replacement……………8-30

Checking The Brake Pedal……………8-30

Parking brake lever free

play adjustment………………………8-31

Brake Light Switch Adjustment………8-33

Cable Inspection And Lubrication……8-34

Brake PedalAndAccelerator

Pedal Lubrication………………………8-35

Rear Knuckle UpperAnd Lower

Pivot Lubrication………………………8-35

Steering Shaft Lubrication……………8-35

Wheel Removal………………………8-37

Wheel Installation………………………8-37

Battery…………………………………8-38

Battery Maintenance…………………8-40

Fuse Replacement……………………8-40

ReplacingAHeadlight Bulb……………8-43

Tail/Brake Light Bulb

Replacement……………………………8-45

Replacing a Front Turning

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Light Bulb………………………………8-47

Replacing a Rear Turning

Light Bulb………………………………8-48

Troubleshooting………………………8-50

Check and solution to Common

Problems in Vehicle……………………8-51

CLEANING AND STORAGE…………9-1

A. Cleaning……………………………9-1

9

B. Storage………………………………9-3

SPECIFICATIONS……………………10-1

10

FAULT CODE OF ELECLRONIC

11 INJECTION SYSTEM…………………11-1

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LOCATION OF THE WARNING AND SPECIFICATION LABELS

1-1

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Read and understand all of the labels on your vehicle. They contain important information for

safe and proper operation of your vehicle.

Never remove any labels from your vehicle. If a label becomes difficult to read or comes off, a

replacement label is available from your dealer.

1-2

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1-3

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1-4

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1-5

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SAFETY INFORMATION

This utility vehicle handles differently from other vehicles including cars and UTVs.

SEVERE INJURY OR DEATH can result if you do not follow these instructions:

● Read this manual and all labels carefully and follow the operating procedures described.

● This vehicle is designed to carry the driver and one passenger.

NEVER CARRY PASSENGERS IN THE CARGO BED.

● Always be sure the driver and passenger are wearing seat belts.

● Never give a ride to a passenger who is too small to reach and hold the handgrip fixed before

the seat.

● Always avoid operating the vehicle on any paved surfaces, including sidewalks, driveways,

parking lots, and streets.

● Driving in the slimy ground and sands is prohibited.

● Never operate this vehicle without wearing an approved motorcycle helmet that fits properly. You

should also wear eye protection (goggles or a face shield), gloves, over-the-ankle boots,

long-sleeved shirt or jacket, and long pants.

● Never consume alcohol or drugs before or while operating this vehicle.

● Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is

proper for the terrain, visibility, operating conditions, and your experience.

● Never attempt jumps of other stunts.

● Always inspect your vehicle each time you use it to be sure it is in safe operating condition,

2-1

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2-2

● Never operate on hills that are slippery or ones where you will not be able to see far enough

ahead of you. Never go over the top of a hill at speed if you cannot see what is on other side.

Always follow the inspection and maintenance procedures and schedules described in this

manual.

● Always keep both hands, arms, feet, and legs inside the vehicle at all times during operation.

Keep your feet on the floorboard. Never hold onto the enclosure. Otherwise, your hand could be

injured if it is caught between the enclosure and an obstacle outside the vehicle.

● Always keep both hands on the steering wheel when driving.

● Never wrap your thumbs and fingers around the steering wheel. This is particularly important

when driving in rough terrain. The front wheels will move right and left as they respond to the

terrain, and this movement will be felt in the steering wheel. A sudden jolt could wrench the

steering wheel around, and your thumbs or fingers could be injured if they are in the way of the

steering wheel spokes.

● Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to

changing terrain conditions when driving the vehicle.

● Never operate on excessively rough, slippery, or loose terrain until you have learned and

practiced the skills necessary to control the vehicle on such terrain. Always be especially

cautious on these kinds of terrain.

● Never turn at excessive speed. Practice turning at slow speeds before attempting to turn at

faster speeds. Do not attempt turns on steep inclines.

● Never operate the vehicle on hills that are too steep for it or for your abilities. Go straight up and

down hills where possible. Maximum slope angle: 15°.

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2-3

● Always follow proper procedures for going uphill. If you lose control and cannot continue up a hill,

back down the hill with the engine in reverse gear. Use engine braking to help you go slowly. If

necessary, use the brakes gradually to help you go slowly.

● Always check terrain before going down hills. Go as slowly as possible. Never go down a hill at

high speed.

● Always check for obstacles before operating in a new area.

● Never operate the vehicle in fast flowing water or water deeper than the floorboards on this

model. Remember that wet brakes may have reduced stopping ability. Test your brakes after

leaving water. If necessary, apply the brake several times to let friction dry out the linings.

● Always be sure there are no obstacles or people behind you when you operate in reverse.

When it is safe to proceed in reverse, go slowly.

● Do not brake abruptly when carrying loads in the cargo bed.

● Always use the size and type of tires specified in this manual.

● Always maintain proper tire pressure as described in this manual.

● Never exceed the stated load capacity. Cargo should be as far forward in the bed as possible,

and distributed evenly from side to side. Be sure cargo is secured so that it cannot move around

during operation. Reduce speed and follow instructions in this manual for carrying cargo or

pulling a trailer. Allow greater distance for braking.

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WARNING

POTENTIAL HAZARD

Improper handling of gasoline.

WHAT CAN HAPPEN

Gasoline can catch fire and you could be burned.

HOW TO AVOID THE HAZARD

Always turn off the engine when refueling. Do not refuel right after the engine has been

running and is still very hot. Do not spill gasoline on the engine or exhaust pipe（or muffler）

when refueling. Never refuel while smoking, or while in the vicinity of sparks, open flames,

or other sources of ignition such as the pilot light of water heaters and clothes dryers.

When transporting the vehicle in another vehicle, be sure it is kept in an upright

position. Otherwise, fuel may leak out of the carburetor or fuel tank.

WHAT CAN HAPPEN

Gasoline is poisonous and can cause injuries.

HOW TO AVOID THE HAZARD

If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline

in your eyes, see your doctor immediately. If gasoline spills on your skin, wash with soap

and water. If gasoline spills on your clothing, change your clothes.

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WARNING

POTENTIAL HAZARD

Starting or running the engine in a closed area.

WHAT CAN HAPPEN

Exhaust fumes are poisonous and may cause loss of consciousness and death within a

short time.

HOW TO AVOID THE HAZARD

Always operate your vehicle in an area with adequate ventilation.

2-5

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DESCRIPTION AND VEHICLE IDENTIFICATION

1. Headlights

2. Front shock absorber assembly

3. Brake fluid reservoir

4. Rear mirror

5. Driver seat

6. Battery

7. Fuses

8. Left shoulder protection plate

9. Driver seat belt

10. Air filter element

11. Cargo bed

12. Tail/brake lights/rearturning light

13.

R

ear

r

eflecto

r

14. License light

15. Rear shock absorber assembly

16. Spark arrester

17. CVT-belt case

18. Passengerseat belt

19. Right shoulder protection plate

20. Spark plug

21. Oil filter cartridge

22. Fuel tank cap

23. Switch lock assy

24. Passenger seat

25. Coolant reservoir

26. Radiator cap

3-1

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27. Steering wheel

28. On-Command four-wheel-drive and differential lock switches

29. Multi-function display gauge

30. Auxiliary DC jack

31. Passenger handrail

32. Drive select lever

33. Accelerator pedal

34. Brake pedal

3-2

35. Cab nets.

36. Front turning light

NOTE:

The vehicle you have purchased may differ slightly from

those in the figures of this manual.

WARNING

To protect drivers and passengers’ arm, leg

and feet, make sure the cab nets is in

function before driving.

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Massimo Motor 800UTV-EC User manual

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