TrailMaster Challenger 200UTV Parts list manual

TrailMaster
Challenger 200UTV
Set up instruction
Version: 4.0
2023/05/14
!This set up instruction is for authorized or trained mechanic use only.!
Pictures used in the instruction are for reference only

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1. Check the components after opening the box.
1.1 Battery (pic.1): type YTX12-BS (12V10Ah), includes one battery,
one battery liquid, two bolts and nuts for installation.
1.2 Steering wheel (1 pc)
1.3 Owner’s manual (1pc)
1.4 Hardware bag (3pc)

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1.4.1 Bag 1: Hub cover 4pcs, zip tie 10
1.4.2 Bag 2: battery box (1pc), battery strap (1pc), bolt M8X55 (4pc),
bolt M8X60 (2pc), bolt M8X30 (8 pc), bolt M6X16 (6pc), bolt M6X30 (2
pc), screw M6X16 (6 pc), bolt M6X12 (3 pc), washer∮6 (6 pc), cotter
pin 3X40 (2pc), R-washer (12 pc), self-locking nut M8 (18pc), nut M6 (6
pc), bolt M8X16 (10 pc)
1.4.3 Bag 3: Steering wheel cover (1pc), cable for headlight (1pc), clamps
for windshield (10pc), clamp cushion for windshield (4pc), plastic plug
(2pc), self-locking nut M10X1.25 (2pc), bolt M5X25 (1pc), washer∮5
(1pc), rear mirror mount and O-ring (1pc)

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1.6 Rear roll cage bar 1pc
1.7 Front roll cage bar 1pc
1.8 Front light cover (lights are pre-installed) 1pc
1.9 Top headlights mounting bar 1pc

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1.10 Front wheel left and right 1of each
1.11 Front wheel left and right 1of each
1.12 Rear shock 1pc

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1.13 canopy top 1pc, side net door left and right 1 of each, bar cushions
1.14 Top headlight mounting parts 1 set
1.15 Side mirror 1 set (The mirror in the box can be different!)

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1.16 Front metal bumper 1pc
1.17 Windshield 1pc (already installed)
1.18 Front lights mounting bar 1pc

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2. Assembly：
2.1 Assemble the rear shocks: take down the bolts from the shocks; lift
the rear swing arm to let the top of shock into the fixing seats of frame,
use 37-44NM torque to fix the shocks attached the frame. (Note: 1NM =
0.74 lb ft):
2.2 Assemble the rear wheels (pic.18): screw the castle nut M16x1.5
tightly with 98-103NM, then open the cotter pin 3X40 for fixing, cover
the hub cover. (pic shown is for X model)

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2.3 Assemble the front shocks: Take down the bolt on the shocks, attach
the shock to the front lower suspension arm, and fix the bolt with
37-44NM torque:
2.4 Assemble the front wheel: Take down the tire bolts on the hub, set up
the front wheel on the right position of hub, fix the tire bolts with
37-44NM torque, put on the hub cover. (pic. Shown is for X model)

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2.5 Front bumper mounting bracket assembly: assemble the front bumper
mounting bracket on the UTV frame using GB5789 M6x16 bolts,
PLEASE DO NOT TIGHT THE BOLTS AT THIS STEP.
2.6 Set up the top headlights wire: open the right side of front hood cover
as displayed in the picture, put the wire through the hole on the front
hood cover where the front roll cage bar mount rod is, connect the plugs

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2.7 Install the front light cover: attach the front light cover on the frame
and install it on the frame with M6X16 bolts and M6 nuts.
2.8 Plug the headlight and turn lights’ wire: plug the wires with the
connecting sockets; tighten the wires using zip ties.
2.9 Install the steering wheel: Use the M6x12 bolts to install the steering
wheel onto the steering shaft, put on the steering bolt cover
2.10 Adjust the steering wheel angle: loose the adjustment nut as shown
in the picture, adjust the steering wheel to a comfortable height, tighten

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the nut
2.11 Install the front roll cage bar: put the front roll cage bar into the
mount posts on the frame, put in the M8x60 bolt, R-washer, windshield
bracket and tighten the M8 nut to fix.

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2.12 Install the rear roll cage bar: put the rear roll cage bar onto the mount
posts of the frame, fix it using M8x55 bolt, R-washer and M8 nut.
2.13 Joint the front and rear roll cage: joint the roll cages and connect
them with M8x30 bolt and M8 nut. The recommended torque is
22-29NM
2.14 Install the safety belt: find the safety belt mounting plate welded on
the frame near the seats, mount the safety belt on the mounting plates,
and tighten the safety belt nuts.

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2.15 Install the seat back head rest (No this step with new sport seat!)
2.16 Install the canopy top: put the foam padding on the top roll cage,
install the canopy top and tighten it.

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2.18 Install the side net doors
2.19 Install the battery, battery cover: put the battery liquid into the
battery body, close the battery cover. Put the cushion plate into the battery
mount box. Connect the battery wires to the battery poles “+ to +; - to –”,
cover them. Put the wired battery into the battery mount box covered with
the plastic protection cover, put the wires out through the protection cover
slot, fasten the battery with battery strap. (Note: because the battery liquid
and wiring of battery poles are dangerous, only experienced adult can
carry out this carefully with protection measures (protective glove,
Prevent electric screwdriver).

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2.20 Install the side mirrors: install the side mirrors on the
windshield brackets (see. 2.11), fix them with a M10
self-locking nut, and adjust the mirrors. (The mirror in the box can
be different!)
2.21 Install the top light mount bar, top lights and windshield (Only for X
model):
2.21.1 Install the top light mounting piece onto the top light mounting bar,
install the top lights on the mounting piece
2.21.2 Install the top light mounting bar onto the frame, fix it using
M8X55 bolt, R-washer, the torque is 22-29N.m
2.21.3 The windshield has protection on both side, the side with text
protection cover is towards outside, install the windshield on the
windshield mounting brackets and tighten the M6x30 bolt and M6 nut.
2.21.4 Install the windshield top brackets on the roll cage, use the hole in
the middle of the bracket and install it with M8x16 bolt and M8 nut.

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2.21.5 Mount the top part of the windshield onto the windshield top
brackets using M8X30 bolt and M8 nut
2.21.6 Connect the top light wiring with the top lights
2.22 Install the front metal bumper, insert the bar end caps

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Before driving please make sure that all of the hardware on the UTV are
tightened; please read the user manual of TrailMaster Challenger
200UTV carefully, you will be given with important safety information
and advices.
Thanks a lot for choosing TrailMaster Challenger 200UTV.
For more other products of TrailMaster, please visit
www.bvpowersports.com !
BV Powersports, LLC
2023-05-14