Massimo MSU 800 User manual

MASSIMO MSU 800
Owner’s Manual

INTRODUCTION
Congratulations on your purchase of the MASSIMO MSU 800 UTV. 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 in-
cludes important safety information. It provides information about special techniques
and skills necessary to ride your UTV. It also includes basic maintenance and inspec-
tion 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 CARE-
FULLY AND COMPLETELY
BEFORE OPERATING YOUR UTV. MAKE SURE YOU UNDERSTAND ALL IN-
STRUCTIONS.
● 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.

IMPORTANT MANUAL INFORMATION
FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS
INJURY OR DEATH.
Particularlyimportant 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 themachine.
ANOTEprovides key information to makeprocedures easier or clearer.
NOTE:

IMPORTANT NOTICE
Curve speed must be smallerthan 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 thebattery.
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.

CONTENTS
1 LOCATION OF THE WARNING
2AND SPECIFICATION LABELS……1-1
2. SAFETY INFORMATION………………2-1
3. DESCRIPTIONAND 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
OdometerAnd 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
Accelerator Pedal………………………4-15
Brake Pedal……………………………4-16
Drive Select Lever……………………4-16
Fuel Tank Cap…………………………4-17
Seats……………………………………4-17
SeatMovingForwardAnd
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
1

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
Tire Wear Limit…………………………5-15
6．OPERATION………………………………6-1
StartingThe 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 OnThe

Trail………………………………………7-18
8. PERIODIC MAINTENANCEAND
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
Checking The Brake Pedal……………8-30
Parkingbrake 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
ReplacingAHeadlightBulb……………8-43
Tail/BrakeLightBulb
Replacement……………………………8-45
Replacing a FrontTurning

Light Bulb………………………………8-47
Replacing a RearTurning
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
B. Storage………………………………9-3
SPECIFICATIONS……………………10-1
FAULT CODE OF ELECLRONIC
INJECTION SYSTEM…………………11-1
9
10
11

1-1
LOCATION OF THE WARNING AND SPECIFICATION LABELS

1-2
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.

1-3

1-4

1-5

2-1
This utility vehicle handles differently from other vehicles including cars and UTVs.
SEVERE INJURY OR DEATH can result if you do notfollow these instructions:
● Read this manual and all labels carefully and followtheoperating 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.
● Drivingin the slimyground and sands is prohibited.
● Neveroperate 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,
SAFETY INFORMATION

2-2
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 yourfeeton the floorboard.Neverhold onto theenclosure. Otherwise, your hand could be
injured if it is caught between the enclosure and an obstacle outside the vehicle.
● Always keepboth 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 conditionswhen 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 kindsof 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 itor for your abilities. Go straight up and
down hills where possible. Maximum slope angle: 15°.
● 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 onother side.

2-3
● Always followproperprocedures 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 anew 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. Besure cargois 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.

2-4
WARNING
POTENTIAL HAZARD
Improper handling of gasoline.
WHAT CAN HAPPEN
Gasoline can catch fire and you could be burned.
HOW TOAVOID 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 TOAVOID THE HAZARD
If you should swallow some gasoline or inhale a lot of gasoline vapor, orget some gasoline
in your eyes, see your doctor immediately. If gasoline spills on your skin, wash with soap
andwater. If gasoline spills on your clothing, change your clothes.

2-5
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 TOAVOID THE HAZARD
Always operate your vehicle in an area with adequate ventilation.

3-1
DESCRIPTIONAND VEHICLE IDENTIFICATION
1.
Headlights
2. Frontshockabsorber assembly
3. Brake fluid reservoir
4. Rear mirror
5. Driver seat
6. Battery
7. Fuses
8. Left shoulderprotectionplate
9. Driver seat belt
10. Airfilterelement
11. Cargobed
12. Tail/brakelights/rearturninglight
13. Rear reflector
14. Licensel
ight
15. Rear shockabsorberassembly
16. Spark arrester
17. CVT-belt case
18. Passengerseatbelt
19. Rightshoulderprotectionplate
20. Spark plug
21. Oilfiltercartridge
22. Fuel tankcap
23. Switchlockassy
24. Passengerseat
25. Coolant reservoir
26. Radiator cap

3-2
27. Steering wheel
28. On-Commandfour-wheel-driveand differentiallockswitches
29. Multi-functiondisplaygauge
30. AuxiliaryDCjack
31. Passengerhandrail
32. Driveselectlever
33. Acceleratorpedal
34. Brake pedal
35. Cabnets.
36. Frontturning light
NOTE:
The vehicle you have purchased may differ slightly from
those in the figures of thismanual.
WARNING
To protect drivers and passengers’ arm, leg
and feet, make sure the cab nets is in
function before driving.