TrailMaster Challenger 300UTV-X Parts list manual

TrailMaster Challenger
300UTV-(E)X
Set up instruction
Version: 3.2
2021/05/14
* This set upinstruction is ONLY for authorized or trained mechanic to set up
TrailMaster Challenger 300UTV-(E)X.

CHALLENGER300(E)X P. D. I
2
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)

CHALLENGER300(E)X P. D. I
3
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)

CHALLENGER300(E)X P. D. I
4
1.5 Head rest 2pc (Not on the new sport seat)
1.6 Rear roll cage bar 1pc
1.7 Front roll cage bar 1pc

CHALLENGER300(E)X P. D. I
5
1.8 Front light cover (lights are pre-installed) 1pc
1.9 Front wheel left and right 1of each
1.10 Front wheel left and right 1of each
1.11 Rear shock 1pc

CHALLENGER300(E)X P. D. I
6
1.12 canopy top 1pc, side net door left and right 1 of each, bar cushions
1.13 Top headlight mounting parts 1 set

CHALLENGER300(E)X P. D. I
7
1.14 Side mirror 1 set (The mirror in the box can be different!)
1.15 Front metal bumper 1pc
1.16 Windshield 1pc

CHALLENGER300(E)X P. D. I
8
2. Assembly：
2.1 Assemble the front shocks: Assemble the front shocks to lower
suspension arm, use 37-44NM torque to fix the shocks attached the
frame. (Note: 1NM = 0.74 lb ft)
2.2 Assemble the rear shocks: Assemble the rear shocks to rear swing
arm; use 37-44NM torque to fix the shocks attached the frame.
(Note: 1NM = 0.74 lb ft)

CHALLENGER300(E)X P. D. I
9
2.3 Assemble the front plastic fender. Tighten all bolts and nuts of the
front plastic fender to attach to the main hood. Connect the head light and
turn light wires to the main wire harness (for left and right side)

CHALLENGER300(E)X P. D. I
10
2.4 Assemble the metal bumper.
2.5Assemble the front and rear wheels: screw the tire nuts tightly with
torque 37-44NM, then cover the hub cover. (note: Picture is for
Challenger4 300X which has the aluminum rims, the Challenger4 300
has steel rims)

CHALLENGER300(E)X P. D. I
11

CHALLENGER300(E)X P. D. I
12
2.6 Assemble the steering wheel
2.7 Adjust the steering wheel angle: loose the adjustment nut as shown in
the picture, adjust the steering wheel to a comfortable height, tighten the
nut

CHALLENGER300(E)X P. D. I
13
2.8 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, mirror
bracket and tighten the M8 nut to fix.

CHALLENGER300(E)X P. D. I
14
2.9 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.
2.10 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
2.11 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.

CHALLENGER300(E)X P. D. I
15
2.12 Install the seat back to the seat
2.13 Install the canopy top: put the foam padding on the top roll cage,
install the canopy top and tighten it.

CHALLENGER300X P. D. I
16
2.14 Install the side net doors
2.15 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).

CHALLENGER300(E)X P. D. I
17
2.16 Assemble the side mirrors:
2.17 Assemble the LED light bar: (note: this is only for Challenger4
300X), assemble the LED light bar and connect the light bar wire to
main wire harness, the plug is under dash on passenger side.

CHALLENGER300(E)X P. D. I
18
2.18 Assemble the windshield:

CHALLENGER300(E)X P. D. I
19
Before driving please make sure that all of the hardware on the UTV are
tightened; please read the user manual of TrailMaster Challenger
300UTV-X carefully, you will be given with important safety information
and advices.
Thanks a lot for choosing TrailMaster Challenger 300UTV-(E)X.
For more otherproducts of TrailMaster, please visit
www.bvpowersports.com !
BV Powersports, LLC