Trail Rover Mountaineer 800TX User manual

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Not intended for use by anyone
under 16 years of age
2014
Mountaineer 800TX (2 Door)
Mountaineer 800TXE (4 Door)
Owner’s Manual &
User Information

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The owner must properly use, maintain and care for their TrailRover™ as explained in the Owner’s Manual. Owner must maintain all records of service performed on
their UTV. Only an authorized dealer or approved service enter can perform warranty repairs. Periodic service and inspections are considered regular maintenance
and are not reimbursable. All warranty repairs require prior authorization of TrailRover™. Operator must break in their vehicle before normal use or the vehicle may
be subject to warranty non-approval. The break in period is half throttle or 4,000 maximum rpms for the rst 3 hours of initial use. Warranty starts from the date of
purchase.
TrailRover™ 800 TX/TXE UTV Warranty Summary
Engine and Frame 24 Months (Unlimited Miles)
Transmission 8 Months
Electrical EFI, Fuel and Electrical Components 6 Months
Suspension Shocks 6 Months
Brake Caliper 6 Months
Exhaust Header Pipe, Muer 6 Months
Clutch CVT/Manual Clutch 90 Days
Summary of Items Covered Under the Labor Warranty
Pre-Approved Labor form Authorized Service Provider Up to $65/Hour
Engine/Transmission 90 Days
Mechanical Injector 90 Days
Electrical Harness, CDI, Instrument Center 90 Days
Clutch CVT/Manual Clutch 90 Days
Summary of Items Not Covered Under the Warranty
* Damage from Accidents * Damage from Abuse * Damage from Misuse * Damage from unapproved parts & accessories
* Diagnosis of UTV problems * Battery * Fuses * Spark Plug(s)
* Rubber Parts * Rims and Wheels * Brake Levers and Pedals * Clutch Levers and Pedals
* Floor Boards * Tires * Gas and Engine Oil Caps * Body Parts of Any Kind
* Bushings * Filters of Any Kind * Acts of Nature * Light Bulbs
* Required Routine Maintenance * Lubricants * Steering Wheel * Coolant or Fluids of Any Kind
* Travel Charges * Brake Pads, Brake Shoes, Brake Rotors and Brake Discs
* Any part not purchased with TrailRover™ * Seals, Gaskets, Belts , Cables & Hoses of any kind
* Physical damage caused by corrosion, re or explosion not caused by defective materials or workmanship
* Failures not caused by a defect in material or workmanship
Any alterations that have not been PRE-APPROVED by the MANUFACTURER will void all warranties. If an alteration is approved by the MANUFACTURER, verify
that this alteration is covered under warranty.
For detailed warranty information, refer to the complete manufacturer’s warranty beginning on Page 112 of this owner’s manual.
Ifyou have questIons about your traIlrover™ utv, please call 877-722-4097 to speak to afactory traIned servIce representatIve.

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Congratulations on the purchase of your new TrailRover™.
The TrailRover™ UTV is the result of many years of experience in the nest sporting, touring, and pace setting racing machines. This manual
will provide you with a basic understanding of the features and operation of your new TrailRover™ UTV. This manual includes important safety
information, special techniques and skills necessary to ride the UTV. It also includes basic maintenance and inspection procedures.
READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR TRAILROVER™. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS. PAY CLOSE ATTENTION TO THE WARNING AND
CAUTION LABELS ON YOUR TRAILROVER™. NEVER OPERATE YOUR TRAILROVER™ WITHOUT PROPER TRAINING OR INSTRUCTION. FREE TRAINING IS AVAILABLE TO ANYONE WHO BUYS A NEW
UTV. THIS TRAILROVER™ AND ANY OTHER UTV OVER 90cc, SHOULD NOT BE OPERATED BY ANYONE UNDER 16 YEARS OF AGE. DO NOT ALLOW CHILDREN UNDER THE AGE OF 12 TO RIDE ON YOUR
TRAILROVER™.
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:
When you see this symbol, pay close attention to the important safety information
Warning Failure to follow Warning instructions could result in severe injury or death to the TrailRover™ operator, a
passenger, a bystander, or a person inspecting or repairing the machine.
Caution A Caution indicated special precautions that must be taken to avoid damage to your TrailRover™.
note: A Note provides key information to make procedures easier or clearer.
Caution: USE PREMIUM UNLEADED FUEL FOR HIGH PERFORMANCE ENGINES WITH A MINIMUM OCTANE RATING OF 91.
FUEL CONTAINING ETHANOL WILL CAUSE ENGINE DAMAGE. Never use fuel with more than 10% ethanol. If fuel contains ethanol, fuel
stabilizers must be added to the gasoline following the manufacturer’s instructions on the fuel stabilizer label.

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YOUR NEW TRAILROVER™ IS DESIGNED AND MANUFACTURED FOR
OFF-ROAD USE ONLY!!
I        TR™
   ,   .
Please check your local riding laws and regulations before operating your TrailRover™.
is TrailRover™ complies with all applicable OFF-ROAD noise level and spark arrester laws and
regulations in eect at the time of manufacture.
ENGAGE PARKING BRAKE AND REMOVE KEYS WHEN YOUR
TRAILROVER™ IS NOT IN USE
Provide adequate supervision when children are present.
Never leave children unattended near your TrailRover™.

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TABLE OF CONTENTS
Introduction & Warnings................................................................................................................................................................................................2-4
Operate Safely to Prevent Injury.......................................................................................................................................................................................9
VIN & Engine ID Location..................................................................................................................................................................................................10
Modication Warning .......................................................................................................................................................................................................11
SAFETY WARNINGS.......................................................................................................................................................................................................12-28
FEATURES AND CONTROLS
Overview .......................................................................................................................................................................................................................29,30
Dashboard Display ..................................................................................................................................................................................................... 31,32
Light & Turn Signal Operation .......................................................................................................................................................................................33
Dump Bed and Winch .....................................................................................................................................................................................................34
4×2,4×4WD and Locking Dierential ......................................................................................................................................................................... 35
Windshield Wiper & Auxiliary Power ...........................................................................................................................................................................36
Choke, Reverse Speed Warning & Mp3 .......................................................................................................................................................................37
SEATS
Adjusting Drivers Seat .................................................................................................................................................................................................... 38
Seat Belt Use and Inspection ...................................................................................................................................................................................38, 39
Adding Fuel ............... ........................................................................................................................................................................................................39
Fuel Requirements ............................................................................................................................................................................................................39
Ignition Switch .................................................................................................................................................................................................................. 40
Gear Shift .............................................................................................................................................................................................................................41

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Parking Brake .....................................................................................................................................................................................................................41
Brake Pedal .........................................................................................................................................................................................................................42
Throttle Pedal ....................................................................................................................................................................................................................42
OPERATION
Break-In Period & Instructions ..................................................................................................................................................................................43,44
Pre-ride inspection ..........................................................................................................................................................................................................45
Safe Operating Instructions............................................................................................................................................................................................46
Starting the Engine ..........................................................................................................................................................................................................47
Turning the Engine O .....................................................................................................................................................................................................48
Braking Instructions .........................................................................................................................................................................................................48
Parking .................................................................................................................................................................................................................................48
New Operator Driving Practices ...................................................................................................................................................................................49
Driving with a passenger ...............................................................................................................................................................................................50
Driving on slippery surface .....................................................................................................................................................................................51, 52
Driving uphill..................................................................................................................................................................................................................... 53
Driving on the sides of hills ...........................................................................................................................................................................................54

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Driving downhill .............................................................................................................................................................................................................54
Driving through water ..................................................................................................................................................................................................55
Driving over obstacles ...................................................................................................................................................................................................56
Driving in reverse ..............................................................................................................................................................................................................57
Parking on an incline .......................................................................................................................................................................................................58
MAINTENANCE
Periodic Maintenance ......................................................................................................................................................................................................59
Severe Use Denition .......................................................................................................................................................................................................59
Periodic maintenance chart .....................................................................................................................................................................................60, 61
Engine oil .....................................................................................................................................................................................................................62 - 65
Gear Box ...............................................................................................................................................................................................................................66
Spark plugs ..........................................................................................................................................................................................................................67
Constant variable transmission (CVT )system ....................................................................................................................................................68, 69
Filter system ........................................................................................................................................................................................................................70
Cooling system ...........................................................................................................................................................................................................71 - 73

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Throttle system ...........................................................................................................................................................................................................74, 75
Carburetor ..........................................................................................................................................................................................................................76
Throttle body ....................................................................................................................................................................................................................77
Brakes ...........................................................................................................................................................................................................................78, 79
Steering wheel inspection ............................................................................................................................................................................................80
Shock spring adjustment ...............................................................................................................................................................................................80
Tires ......................................................................................................................................................................................................................................81
Caring for an Immersed Vehicle ....................................................................................................................................................................................82
Clearing and storage................................................................................................................................................................................................. 86, 87
Troubleshooting .....................................................................................................................................................................................................88 - 105
SPECIFICATIONS ............................................................................................................................................................................................................106 - 111
WARRANTy ...................................................................................................................................................................................................................112 - 117

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Warning:
Failure to follow the warnings and safety precautions contained in this manual can result in severe injury or death. Your
TrailRover™ is not a toy and can be hazardous to operate. TrailRover™s handle dierently than cars, trucks or other o-road
vehicles. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over
obstacles, if you fail to take proper precautions.
Read this owner’s manual. Understand all safety warnings, precautions and operating procedures
before driving the vehicle. Keep this manual with the vehicle.
Never operate this vehicle without proper instruction.
Always follow the age guidelines for your vehicle. Operation is prohibited for anyone age 16 and
under. Never operate with a passenger age 12 and under.

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IDENTIFICATION NUMBER RECORDS
Record the vehicle identication number and engine number and keep it in a safe place for assistance when ordering spare
parts from your dealer or for reference in case the vehicle is stolen.
NOTE: THE vEHICLE IDENTIFICATION NUMbER IS USED TO IDENTIFy yOUR MACHINE.

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Equipment Modications
Your TrailRover™ is designed to provide safe operation when used as directed. Modications to your TrailRover™ may
negatively impact vehicle stability. Failure of critical machine components may result from operation with any modications,
especially those that increase speed or power. Your TrailRover™ may become less stable at speeds higher than those for
which it is designed. Loss of control may occur at higher speeds. Do not install on any equipment on your TrailRover™ that
may increase the speed or power of the vehicle, or make any other modications to your TrailRover™ for these purposes. Any
modications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury.
The warranty on your TrailRover™ is terminated if any equipment has been added to the vehicle, or if any modications have
been made to the vehicle, that increase its speed or power. The addition of certain accessories may change the handling
characteristics of your TrailRover™. Use only our company approved accessories, and familiarize yourself with their function and
eect on the vehicle.

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SAFETY
Safe Riding Gear
Always wear appropriate clothing when riding this vehicle. Wear protective clothing for comfort and to reduce the chance of
injury.

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SAFETY
Safe Riding Gear
Helmet
Wearing a helmet can prevent a severe head injury. Whenever riding this vehicle, always wear a helmet that meets or exceeds
established safety standards.
Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.
Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a vehicle, always wear shatterproof goggles or
use a shatterproof helmet face shield.
Gloves
Wear gloves for comfort and for protection from sun, cold weather and other elements.
Boots
Wear sturdy footwear. Do not ride a vehicle with bare feet.
Clothing
Wear long sleeves and long pants to protect arms and legs.

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Safety WarningS
Failure to operate this vehicle properly can result in a collision, loss of control, accident or overturn, which may result in serious
injury or death. Be sure to read all of the following warnings about driving hazards and how to avoid them. These warnings are
provided for your safety.
Operating Without Instruction
Operating this vehicle without proper instruction increases the risk of an accident.
The operator must understand how to operate the vehicle properly in dierent
situations and on dierent types of terrain.
Age Restrictions
Operation is prohibited for anyone age 16 and under. Never
operate with a passenger age 12 and under. Make sure any
passenger is tall enough to comfortably and safely reach the
hand holds and place both feet on the oor.

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Safety WarningS
Failure to Inspect Before Operating
Failure to inspect and verify that your TrailRover™ is in safe operating condition
before operating increases the risk of an accident. Always inspect the
vehicle before each use to make sure it’s in safe operating condition. Always
follow the inspection and maintenance procedures and schedules described
in the owner’s manual.
Accessories
Installing non-approved accessories may seriously aect vehicle handling
and stability, which could result in loss of control or an accident.
Never install accessories not approved by TrailRover™ for use on this vehicle.

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Safety WarningS
Protective Apparel
Operating or riding in this vehicle without wearing an approved
helmet and protective eyewear increases the risk of
serious injury in the event of an accident. Operator
and passenger must always wear an approved helmet
that ts properly and eye protection (goggles or face
shield).
Seat Belts
Operating or riding in this vehicle without wearing the seat belt increases the risk of serious injury in the event of an
accident or sudden stop. Riders must wear seat belts at all times. Seat belts reduce the severity of injury in the event of a sudden
stop or accident. Always make sure the seat belts are secured for both the operator and passenger before riding.
Using Alcohol or Drugs
Operating or riding in this vehicle after consuming alcohol or drugs
could adversely aect operator judgment, reaction time,
balance and perception. Never consume alcohol or drugs
before or while operating or riding in this vehicle.

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Safety WarningS
Carrying a Passenger
Never carry a passenger until you have operated this vehicle for at least four hours.
Carrying Multiple Passengers
Carrying more than one passenger in the 500/800TX or carrying
more than three passengers in the 800TXE can aect the
operator’s ability to steer and operate the controls, which
increases the risk of loss of control and accident or overturn.
Never carry more than stipulate passenger in this vehicle.
Operating on Pavement
Operating your TrailRover™ on paved surfaces (including sidewalks, paths,
parking lots and driveways) may seriously aect handling and control of the vehicle, and may cause the vehicle to go out of
control. This vehicle’s tires are designed for o-road use only, not for use on pavement. Avoid operating the vehicle on pavement.
If you must operate on a paved surface, travel slowly and do not make sudden turns or stops.
Operating on Public Roads
Operating this vehicle on public streets, roads or highways
could result in a collision with another vehicle. Never
operate this vehicle on any public street, road or highway,
including dirt and gravel roads. In many areas it’s unlawful
to operate vehicles of this type on public streets, roads and
highways.

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Safety WarningS
Operating at Excessive Speeds
Operating this vehicle at excessive speeds increases the operator’s risk
of losing control. Always operate at a speed that’s appropriate for the terrain,
the visibility and operating conditions, your skills and your passenger’s skills.
Turning Improperly
Turning improperly could cause loss of traction, loss of control,
accident or overturn. Never turn abruptly or at sharp angles. Never turn at high speeds. Practice turning at slow speeds before
attempting to turn at faster speeds.
Physical Control of the Vehicle
Removing hands from the steering wheel or hand holds or removing feet from the oor while riding increases the risk of
loss of control and accident or overturn. The operator should always keep both hands on the steering wheel during operation. A
passenger should always be seated in the passenger seat with both feet on the oor and with both hands securely grasping the
hand holds. Always keep hands and feet inside the vehicle at all times.

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Safety WarningS
Jumps and Stunts
Exhibition driving increases the risk of an accident or overturn.
DO NOT do power slides, “donuts”, jumps or other driving stunts.
Avoid exhibition driving.
Driving Downhill Improperly
Driving down a hill improperly could cause loss of control or overturn.
Always follow proper procedures for driving down a hill as described in the owner’s manual.
Always drive down a hill with the transmission in forward gear.
Never drive down a hill with the transmission in neutral.
Never operate the vehicle on hills steeper than 15 degrees.
Always check the terrain carefully before driving down a hill.
Never travel down a hill at high speed.
Avoid traveling down a hill at an angle, which would cause the
vehicle to lean sharply to one side.
Travel straight downhill.

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Safety WarningS
Improper Hill Climbing
Improper hill climbing could cause loss of control or overturn.
Use extreme caution when operating on hills. Always follow
proper procedures for hill climbing as described in the owner’s
manual.
Stalling While Climbing a Hill
Stalling or rolling backwards while climbing a hill could cause
an overturn. Maintain a steady speed when climbing a hill.
If you lose all forward speed:
Apply the brakes gradually until the vehicle is fully stopped.
Place the transmission in reverse and slowly allow the vehicle
to roll straight downhill while applying light brake pressure to
control speed.
Crossing Hillsides
Driving on the side of a hill is not recommended. Improper procedure
could cause loss of control or overturn. Avoid crossing the side
of any hill unless absolutely necessary.