Massimo ALLIGATOR 500 User manual

MASSIMO ALLIGATOR 500 & MSU 500
Owner’s Manual

INTRODUCTION
Congratulations on your purchase of the Massimo Alligator 500 or MSU 500
UTV. With the purchase of this vehicle, you can now appreciate the high degree
of craftsmanship. This manual will provide you with a good basic understanding
of the features and operation of this vehicle. This manual includes important
safety information. It provides information about special techniques and skills nec-
essary to ride your vehicle. It also includes basic maintenance and inspection pro-
cedures. If you have any questions regarding the operation or maintenance of
your vehicle, please consult you dealer.
AN IMPORTANT SAFETY MESSAGE:
● READ THIS MANUAL FOR THE VEHICLE RIDER CAREFULLY AND COMPLETELY
BEFORE OPERATING YOUR VEHICLE. MAKE SURE YOU UNDERSTAND ALL
INSTRUCTIONS.
● PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE
VEHICLE.
● NEVER OPERATE A VEHICLE WITHOUT PROPER TRAINING OR INSTRUCTION.
FREE TRAINING IS AVAILABLE TO ANYONE WHO BUYS A NEW VEHICLE.
● THIS VEHICLE, AND ANY OTHER VEHICLE OVER 90cc, SHOULD NOT BE RIDDEN
BY ANYONE UNDER 16 YEARS OF AGE.

Owner Manual
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 Safety Alert Symbol means ATTENTION!
YOUR SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to
the machine operator, 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:

Owner Manual
IMPORTANT NOTICE
This UTV is designed and manufactured for OFF - ROAD use only. It is illegal and unsafe to operate this
UTV on any public street, road or highway.
This UTV complies with all applicable OFF - ROAD noise level and spark arrester laws and regulations in
effect at the time of manufacture.
Please check your local riding laws and regulations before operating this UTV.
When the temperature is below -4°F (-20°C), park the UTV in a place where the temperature is higher
than -4°F (-20°C). Start the UTV after the UTV has warmed up. Please see page 6-3 on the warming up
process.
Follow the proper parking procedures when the temperature is higher than 100°F (38°C): turn off the
engine; make sure the radiator fan is on for 3 minutes before turning off the power switch.
Starting the UTV for the first time will take longer because the fuel will need reach the fuel injectors. To
start the UTV the first time, hold the ignition key on at 5-second intervals. Allow the starter to rest 15
seconds between each start attempt.

Owner Manual
Location of the Warning and
Specification Labels 1-1
Safety Information 2-1
Description and Vehicle
Identification 3-1
Identification Number Records 3-3
Vehicle Identification Number 3-3
Control Functions 4-1
Main Switch 4-1
Indicator and Warning Lights 4-2
Use of EPS system 4-4
Speedometer Unit 4-6
Odometer and Trip Meter Modes 4-6
Clock time adjustment 4-7
Fault code indicator 4-8
Fuel level indicator 4-9
Switches 4-9
Accelerator Pedal 4-14
Brake Pedal 4-15
Parking Brake Lever 4-15
Drive Select Lever 4-16
Fuel Tank Cap 4-17
Seats 4-17
Seat Belts 4-18
Glove Compartment 4-21
Cargo Bed 4-21
Opening and Closing the Tailgate 4-22
Lifting and Lowering the Cargo Bed
4-22
Front and Rear Shock Absorber
Adjustment 4-24
Trailer Hitch Bracket 4-26
Auxiliary DC Jack 4-27
Pre Operation Checks 5-1
Brakes 5-2
2
3
4
1
5

Owner Manual
Brake Fluid Level 5-2
Brake Fluid Leakage 5-3
Brake Operation 5-3
Fuel 5-4
Gasohol 5-4
Engine Oil 5-5
Coolant 5-6
Final Gear Oil 5-7
Differential Gear Oil 5-7
Throttle Pedal 5-8
Throttle Freeplay 5-9
Throttle Freeplay Inspection 5-9
Throttle Freeplay Adjustment 5-9
Steering Wheel Inspection 5-10
Seat Belts 5-10
Fittings and Fasteners 5-10
Lights 5-10
Switches 5-11
Tires 5-11
How to Measure Tire Pressure 5-12
Tire Wear Limit 5-13
Operation 6-1
Starting the Engine in Low
Temperatures 6-1
Starting the Engine 6-2
Warming Up 6-3
Drive Select Lever Operation and
Driving In Reverse 6-4
Parking 6-8
Parking on a Slope 6-8
Vehicle Break-in Period 6-9
Engine Break-In 6-10
Accessories 6-11
Loading 6-12
Driving Your Vehicle 7-1
Getting to Know Your Vehicle 7-1
6
7

Owner Manual
Learning to Operate Your Vehicle 7-5
Turning your Vehicle 7-6
Braking 7-8
Going Uphill 7-8
Going Downhill 7-10
Crossing Through Shallow Water 7-12
Riding Over Rough Terrain 7-15
Riding in Brush or Wooded Areas 7-17
Encountering Obstacles on the
Trail 7-17
Periodic Maintenance and
Adjustment 8-1
Periodic Maintenance Chart for the
Emission Control System 8-3
General Maintenance and
Lubrication Chart 8-4
Hood 8-7
Console 8-8
Engine Oil and Oil Filter Cartridge 8-9
To Check the Engine Oil Level 8-9
To Change the Engine Oil 8-10
Final Gear Oil 8-13
Changing the Final Gear Oil 8-15
Differential Gear Oil 8-16
Changing The Differential Gear Oil 8-17
Coolant 8-18
Axle Boots 8-19
Spark Plug Inspection 8-20
Inspection 8-21
Installation 8-21
Cleaning the Air Filter Elements 8-22
V-belt Cooling Duct Check Hose 8-26
V-belt Case Drain Plug 8-27
Cleaning the Spark Arrester 8-27
Valve Clearance 8-29
Front Brake Pad Check 8-29
Rear Brake Pad Check 8-30
Checking the Brake Fluid Level 8-31
8

Owner Manual
Brake Fluid Replacement 8-32
Checking the Brake Pedal 8-32
Parking Brake Lever Free Play
Adjustment 8-33
Brake Light Switch Adjustment 8-35
Cable Inspection and Lubrication 8-35
Brake Pedal and Accelerator Pedal
Lubrication 8-36
Rear Knuckle Upper and Lower
Pivot Lubrication 8-37
Steering Shaft Lubrication 8-37
Wheel Removal 8-37
Wheel Installation 8-38
Battery 8-39
Battery Maintenance 8-41
Fuse Replacement 8-41
Replacing Headlight Bulb 8-43
Headlight Beam Adjustment 8-46
Tail/brake Light Bulb Replacement 8-47
Troubleshooting 8-49
Solution to Common Problems in
the Vehicle 8-50
Cleaning and Storage 9-1
Cleaning 9-1
Storage 9-3
Specifications 10-1
Faultcode of Electronic Injection
System 11-1
USA EPA Emissions Limited
Warranty
12-1
12
9
10
11

Location of the Warning and Safety Labels 1-1
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