TrailMaster Challenger4 300 Parts list manual

TrailMaster
Challenger4 300(X)
Set up instruction
Version: 1.0
2020/05/05
This set up instruction is prepared for authorized or trained mechanic only! This instruction will introduce the set-
up of Challenger4 300X step by step to ensure a correct assembly, however all information in this instruction is
for reference only! Before assembly, please make sure you have proper tools and knowledge to do it!

Challenger4 300(X) Set up instruction
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1. Check the components after opening the box.
Pic.1

Challenger4 300(X) Set up instruction
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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)
2.2Assemble 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)

Challenger4 300(X) Set up instruction
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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)

Challenger4 300(X) Set up instruction
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2.4 Assemble the metal bumper. (Note: this is only for Challenger4 300X)
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)

Challenger4 300(X) Set up instruction
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Challenger4 300(X) Set up instruction
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2.6 Assemble the steering wheel
2.7Assemble the top roll cages: front piece—rear piece--- side pieces,
meanwhile install the side mirror brackets (Note: the side mirror is
only for Challenger4 300X)

Challenger4 300(X) Set up instruction
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Challenger4 300(X) Set up instruction
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2.8 Install the 4 seats and the 2nd row bar: Insert the seat back into the
mount holes of seats frame. And install the 2nd row bar.

Challenger4 300(X) Set up instruction
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2.9 Install the seatbelts: Install the seatbelts onto the seat belt mounting
brackets

Challenger4 300(X) Set up instruction
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2.10 Assemble canopy top: Put on the canopy top.

Challenger4 300(X) Set up instruction
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2.11 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).

Challenger4 300(X) Set up instruction
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2.12 Assemble the windshield: (note: this is only for Challenger4 300X)

Challenger4 300(X) Set up instruction
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2.13 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.

Challenger4 300(X) Set up instruction
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2.14 Assemble the side mirrors: (note: this is only for Challenger4 300X)
Before driving please read the user manual of TrailMaster Challenger4
300(X) carefully, you will be given with important safety information and
advices.
Thanks a lot for choosing TrailMaster Challenger4 300(X) carefully, For
more other products of TrailMaster, please
visit www.bvpowersports.com !
BV Powersports, LLC