Mountaineer 800tx

2014
Mountaineer 800TX (2 Door)

Mountaineer 800TXE (4 Door)
Owner’s Manual &
User Information
Not intended for use by anyone
under 16 years of age
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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 first 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, Muffler 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, fire 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.
2 If you have questions about your TrailRover™ UTV, please call 877-722-4097 to speak to a factory trained service representative.

Congratulations on the purchase of your new TrailRover™.
The TrailRover™ UTV is the result of many years of experience in the finest 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. 3

YOUR NEW TRAILROVER™ IS DESIGNED AND MANUFACTURED FOR
OFF-ROAD USE ONLY!!
It is illegal and unsafe to operate your TrailRover™

on any public street, road or highway.
Please check your local riding laws and regulations before operating your TrailRover™.
This TrailRover™ complies with all applicable OFF-ROAD noise level and spark arrester laws and
regulations in effect 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™.

TABLE OF CONTENTS
Introduction & Warnings................................................................................................................................................................................................2-4
Operate Safely to Prevent Injury.......................................................................................................................................................................................9
VIN & Engine ID Location..................................................................................................................................................................................................10
Modification 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 Differential ......................................................................................................................................................................... 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 5

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 Off .....................................................................................................................................................................................................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
6 Driving on the sides of hills ...........................................................................................................................................................................................54

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 Definition .......................................................................................................................................................................................................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

7

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

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 differently than cars, trucks or other off-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.

IDENTIFICATION NUMBER RECORDS
Record the vehicle identification 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.
10

Equipment Modifications
Your TrailRover™ is designed to provide safe operation when used as directed. Modifications to your TrailRover™ may
negatively impact vehicle stability. Failure of critical machine components may result from operation with any modifications,
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 modifications to your TrailRover™ for these purposes. Any
modifications 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 modifications 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
effect on the vehicle.
11

SAFETY
Safe Riding Gear
Always wear appropriate clothing when riding this vehicle. Wear protective clothing for comfort and to reduce the chance of
injury.
12

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.
13

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 different
situations and on different 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 floor.
14

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 affect 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.
15

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 fits 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 affect operator judgment, reaction time,
balance and perception. Never consume alcohol or drugs
before or while operating or riding in this vehicle.
16

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 affect 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 affect handling and control of the vehicle, and may cause the vehicle to go out of
control. This vehicle’s tires are designed for off-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.
17

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 floor 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 floor and with both hands securely grasping the
hand holds. Always keep hands and feet inside the vehicle at all times.
18

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.
19

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.
20

Safety Warnings
Operating in Unfamiliar Terrain
Failure to use extra caution when operating on unfamiliar terrain
could result in an accident or overturn.
Unfamiliar terrain may contain hidden rocks, bumps, or holes that
could cause loss of control or overturn.
Travel slowly and use extra caution when operating on unfamiliar
terrain. Always be alert to changing terrain conditions.
Operating on Sand or Slippery Terrain
Operating on sand or on excessively rough, slippery or loose
terrain could cause loss of traction, loss of control, accident
or overturn. Always use extra caution when operating on
sand or on rough, slippery or loose terrain.
Do not operate on excessively rough, slippery or loose terrain.
21

Safety Warnings
Operating Improperly in Reverse
Improperly operating in reverse could result in a collision with
an obstacle or person. Always follow proper operating procedures
as outlined in this manual. Before shifting into reverse gear, always
check for obstacles or people behind the vehicle. When it’s safe to
proceed, back slowly.
Operating Over Obstacles
Improperly operating over obstacles could cause loss of control or
overturn. Before operating in a new area, check for obstacles. Never
attempt to operate over large obstacles such as rocks or fallen trees.
Always follow the proper procedures outlined in this manual when
operating over obstacles.
Skidding or Sliding
Skidding or sliding can cause loss of control or overturn (if tires regain traction unexpectedly). Always follow proper
procedures for operating on slippery surfaces as described in the owner’s manual. When operating on slippery surfaces such as
ice or loose gravel, reduce speed and use extra caution to reduce the chance of skidding or sliding. Do not operate on excessively
slippery surfaces.
22

Safety Warnings
Operating Through Water
Operating through deep or fast-flowing water can cause loss
of traction, loss of control, overturn or accident. Never operate
in fast-flowing water or in water that exceeds the floor level.
Always follow proper procedures for operating in water as
described in the owner’s manual. Wet brakes may have reduced
stopping ability. After leaving water, test the brakes. Apply them
lightly several times while driving slowly. The friction will help
dry out the pads.
Overloading the Vehicle
Overloading the vehicle may cause changes in stability and handling, which could cause loss of control or an accident.
Never exceed the maximum weight capacity for this vehicle.
23

Safety Warnings
Operating a Damaged Vehicle
Operating a damaged TrailRover™ can result in an accident with serious injury or death. After any overturn or accident,
have a qualified service dealer inspect the entire vehicle for possible damage, including (but not limited to) brakes, throttle and
steering systems.
Operating on Frozen Bodies of Water
Operating on frozen bodies of water can result in the vehicle
and/or riders falling through the ice. Never operate this
vehicle on a frozen body of water.
24

Safety Warnings
Handling Gasoline
Gasoline is highly flammable and is explosive under certain conditions. Always exercise extreme caution whenever handling
gasoline.
Never allow a child to refuel or handle gasoline.
Always stop the engine when refueling.
Always refuel outdoors or in a well ventilated area.
Do not smoke or allow open flames or sparks in or near the refueling area or where gasoline is stored.
Never refuel while a person is in the vehicle.
Do not over fill the tank. Do not fill the tank neck.
If gasoline spills on your skin or clothing, immediately wash it off with soap and water and change clothing.
Turn the fuel valve off whenever the vehicle is stored or parked.
Exposure to Exhaust
Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time. Never start the engine
or let it run in an enclosed area. Operate this vehicle only outdoors or in well-ventilated areas.
Caution: USE PREMIUM UNLEADED FUEL FOR HIGH PERFORMANCE ENGINES WITH A MINIMUM OCTANE RATING OF 91.
Fuel containing Ethanol will cause engine damage. If fuel contains Ethanol, it cannot contain more than 10%. Fuel
stabilizers must be added to the gasoline following the manufacturer’s instructions on the fuel stabilizer label.
Engine damage caused by low octane fuel is not covered under the warranty.
Engine damage caused by fuel with high ethanol levels is not covered under the warranty. 25

Safety Warnings
Hot Exhaust Systems
Exhaust system components are very hot during and after use of the vehicle. Hot components can cause burns and fire. Do
not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.
Use caution when traveling through tall grass, especially dry grass. Always inspect the underside of the vehicle and areas
near the exhaust system after driving through tall grass, weeds, brush and other tall ground cover. Promptly remove any grass or
debris clinging to the vehicle.
Unauthorized Use of the Vehicle
Leaving the keys in the ignition can lead to unauthorized use of the vehicle, which could result in an accident or overturn.
Always remove the ignition key when the vehicle is not in use.
Safety Labels and Locations
Warning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully.
If any of the labels shown in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels
on the vehicle. If an informational or graphic label becomes illegible or comes off, contact your dealer to purchase a replacement.
26

Warning!
Improper vehicle use can result in SEVERE INJURY or DEATH
NEVER allow vehicle to be operated:
Without all occupants first viewing and understanding safety warning labels.
With more than stipulate passenger.
On hills steeper than 15 degrees.
On paved surfaces - pavement may seriously affect handling and control.
With non-approved accessories, they may seriously affect stability.
At speeds that are too fast for the operator’s skills, the conditions and/or the terrain.
ALWAYS require operator and passenger to:
Wear seat belts, grab hand holds (passenger) and plant feet firmly on the floor.
Keep hands and feet inside vehicle.
Avoid quick turns of the steering wheel and driving stunts such as jumps, donuts or power slides.
Reduce speed and use extra caution when carrying a passenger.
Watch for branches or other hazards that could enter vehicle.
27

WARNING
Operation of this vehicle by children age 16 and under increases the risk of severe injury or death.
NEVER permit children age 16 and under to operate or ride in this vehicle.
WARNING
VEHICLE OVERTURN could cause severe injury or death. The cab frame is not designed or intended to provide rollover
protection.
TIRE PRESSURE IN PSI (KPa):

Front: 21±1(145±6.9)
Rear: 28±1(193±6.9)
LOADING CAPACITY 660 lbs. INCLUDES WEIGHT OF OPERATOR, PASSENGERS, CARGO LOAD AND ACCESSORIES.
READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. IF OWNER’S MANUAL IS MISSING, CONTACT YOUR
DEALER FOR A REPLACEMENT.
28

FEATURES AND CONTROLS
TrailRover™ Overview
29

Component Locations
30

Dashboard Display
16
16
1. Temperature Gauge 2. & 3. Turn Signals & Hazard Light Indicator 4. Fuel Gauge 5. High Beam Indicator
6. Odometer* 7. Speedometer 8. 2 & 4 Wheel Drive. 9. Brake Fluid Warning Light.
10. Excess Speed in Reverse Alarm Light 11. Parking Brake Light 12. Engine Oil Warning Light
13. Engine Warning Light 14. Battery Warning Light 15. Tachometer 16. Gear Indicator Light
(7) Speedometer: Displays the speed of vehicle.
(6) Odometer: Displays the accumulated mileage.
(5) High Beam Indicator: Light: Light on when high beam is on.
(11) Parking Brake Light: Light on when parking brake is engaged 31

(2 & 3) Turn Signals & Hazard Light Indicator: Blinks relative to the direction. Both blink at the same time when hazard light is on.
(4) Fuel Gauge: Displays amount of fuel in tank.
(16) Gear display: Back Lit relative to the gear
(L) - Low Speed
(H) - High Speed
(N) - Neutral
(R) - Reverse
(1) Temperature Gague: Displays the temperature of engine coolant..
(8) 2WD/4WD transfer and differential lock display:
When one axle indicator light is on, only the rear axle is in drive.
When two axle indicator lights are on, both front and rear axles are in drive.
When “X” is displayed in the middle, both front and rear axles are in drive and the front differential is locked.
(9) Brake Fluid Alarm Light: The alarm light will turn on when the level of brake fluid level is low. Add brake fluid.
(10) Low Range Override Alarm Light (10): - The light will be on when you press down the over speed override button.
32

Light and Turn Signal Operation
(a). When ignition switch is at “ACC” or “ON” position, press down halfway to turn on front and rear parking lights and
dashboard control lights. Press down all the way to turn on headlights, park lights tail lights and dashboard control
lights.
(b). When ignition switch is at “ACC” or “ON” position, press down all the way and at the same time press “ ” up and the
headlight will go to high beam. Park lights, tail lights and dashboard controls are on.
Press down“ ”, to turn on headlights back to low beam.
(c). With ignition switch turned to the “ACC”or“ON”position, press down“ ”, to turn hazard light on. Indicator light will flash.
(d). With ignition switch turned to the “ACC” or “ON” position, press down“ ”or“ ”,The left or right turn signals and indicator
lights will flash.
33

Dump Bed and Winch
To use the dump bed, open the rear door of cargo box, then press
main switch to“ON” position, and press “DUMP” button to the “UP”
position. Keep your finger on the switch until the dump bed reaches
the desired position. Release the”UP” switch. To lower the cargo bed,
follow the same procedure using the “DOWN” switch until the cargo box
Main Winch Dump Bed
returns to its original position.
Switch Switch Switch
Warning
When you have finished using the dump option, make sure you return the main switch to the “OFF” position to ensure the
battery is not drained of power.
If your TrailRover™ gets stuck in the mud, the winch can be used to help remove it. Turn the main power switch to the “ON”
position, and then press and hold “WINCH” to “OUT” or “IN”, allowing the winch cable can be stretched out and in.
Warning
When the cargo box reaches the top or bottom, or the winch cable has been extended or recoiled to the maximum allowable
position, release the switch to avoid damaging the motor.
34

4×2, 4×4, and Locking Differential
“4x2” is the normal driving mode with your TrailRover™ in Rear Wheel Drive.
“4x4” is the mode you should select when driving on rugged or muddy terrain.
When 4x4 is selected, both the front and rear wheels will be in drive at the same time.
“LOCK 4WD” is the mode you should select only when driving on very rough
terrain or when your TrailRover™ is stuck. This allows 4 wheel drive mode with the front
differential locked.
Warning
Your TrailRover™ must be completely stopped when changing between 2WD and 4WD.
The corresponding gear position is displayed on the meter when changing gears. To engage the new gear, step on the
accelerator pedal lightly after each shift, locking the gear into the new position. Use light pressure on the accelerator to avoid
damage to the transmission.
Note
Using your TrailRover™ in 4 WD under normal driving conditions will increase wear and tear. Please use 2 wheel
drive when operating your trail rover in normal conditions. Use of 4 Wheel drive is only recommended on muddy,
slippery, snowy or upward sloping conditions.
35

Auxiliary Power Source / Cigarette Lighter

There is an auxiliary power source/cigarette lighter installed on your TrailRover™ that can also be used for phone charging and as
an external power supply.
Note:
The voltage of the socket is 12V, DC. Please make sure the external device is compatible with the power source to avoid damage
to either the TrailRover™ or the device.
Windshield Wiper
With the main switch in either the “ACC” or “ON” position, press down
halfway to turn the wipers on “low”. Press down all the way to turn the wipers on ‘high”.
To turn the wipers off, return the rocker switch to the original position.
36

CHOKE
When starting your TrailRover™ in cold weather, pull out the “CHOKE SWITCH”
a little bit. Push it back in after successfully starting the engine.
Warning
Once the engine has started, push the choke switch back to the original Choke
CHOKE SWITCH
position. Do Not operate your TrailRover™ with the choke out while driving
to avoid increased fuel consumption, pollution and decreased power.
EXCESSIVE SPEED IN REVERSE INDICATOR

The engine has the speed limiter for the safety when in Reverse
(“R” ) and/or the differential is locked. After coming to a complete stop,
press the button to release the restrictor.
Note
Under normal driving conditions, do not operate your TrailRover™
with the speed restrictor “OFF”.
MP3 PLAYER
With the ignition switch turned to the “ON” or “ACC” position, also press the button
in the middle of MP3 player, to listen to music on your Mp3 player.
There is a USB interface under the passenger seat.
37

Seat
Seats Adjustment
Driver’s Seat Adjustment Dial
If you want to adjust the backrest of the seat forward or backward, rotate the dial
located on the inner edge of the seat clockwise or counter clockwise.
Seat Belts
This vehicle is equipped with three-point lap seat belts for the operator and
passengers. Always make sure the seat belts are secured for both the operator and passengers before riding. To wear the seat belt
properly, follow this procedure:
1. Pull the seat belt latch downward and across your chest toward the buckle at the inner edge of the seat. The belt should fits
snugly across your hips and diagonally across your chest. Make sure the belt is not twisted.
2. Push the latch plate into the buckle until it clicks.
3. Press the red release latch on the buckle to release the seat belt.
Seat Belt Inspection
Inspect all seat belts for proper operation before each use of the vehicle.
1. Push the latch plate into the buckle until it clicks. The latch plate must slide smoothly into the
buckle. A click indicates that it’s securely latched.
38

2. Push the red release latch in the middle of the buckle to make sure it releases freely.
3. Inspect the full length for any damage, including cuts, wear, fraying or stiffness. If any damage is found, or if the seat belt does
not operate properly, have the seat belt system checked and/or replaced by an authorized dealer.
4. To clean dirt or debris from the seat belts, sponge the straps with mild soap and water. Do not use bleach, dye or household
detergents.
Adding Fuel
Fuel
Tank
Warning: Cap
Never allow a child to refuel or handle gasoline.
The fuel tank cap is located on the left-hand side of the vehicle behind the driver’s seat.
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 that contains 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.
Engine damage caused by low octane fuel is not covered under the warranty.
Engine damage caused by fuel with high ethanol levels is not covered under the warranty. 39

Ignition Switch
The ignition switch has four positions.
OFF: All circuits except brake light are off
ACC: Auxiliary components Lights, Mp3 and horn only “ON”
ON: All circuits, except engine are on. Engine will operate in “ON” position.
START: With transmission in NEUTRAL, parking brake engaged and foot on brake pedal, turn the key to “START” and release the
key when the engine starts. Key automatically goes to “ON” position.
NOTE: The brake must be engaged when starting the engine with the gear set to “H”, “L”, and “R” positions. It is not necessary
to engage the brake when starting the engine in “N”.
Ignition
Switch
40

Gear Shift
L: Low gear
H: High gear
N: Neutral
R: Reverse
The gear shift is located between the seats. To change gears, stop the vehicle,
and with the engine idling, move the lever to the desired gear. Do not attempt to
shift gears with engine speed above idle or while the vehicle is moving.
Tip: Maintaining shift linkage adjustment is important to ensure proper care and Parking Gear
Brake Shift
operation of the transmission. See your dealer if you experience any shifting problems.
Always shift when the vehicle is stationary and the engine is at idle. Do not attempt to shift the transmission while the vehicle
is moving or damage to the transmission could result.
Parking Brake
1. Apply the brakes.
2. With the vehicle fully stopped, pull the parking brake lever upward as far as possible to set the parking brake.
3. Stop the engine.
4. To release the parking brake, apply the brakes and push the lever toward the passenger seat and down.
41

Warning!
Operating the vehicle while the parking brake is engaged could cause an accident resulting in serious injury or death.
It could also result in drive line or engine damage. Always be sure to disengage the parking brake before operating the
vehicle. Always remove the keys and engage the parking brake whenever the vehicle is left unattended.
Brake Pedal
Depress the brake pedal to slow or stop the vehicle.
The brakes must be pressed down while starting the engine.
Throttle Pedal
Push the pedal down to increase engine speed. Spring pressure
returns the pedal to the rest position when released. Always
check that the throttle pedal returns normally before starting
the engine. Make sure there’s adequate free play in the throttle pedal.
Follow the instruction in this manual for throttle pedal adjustment procedures. Brake Accelerator
If the throttle cable should stick in an open position when the operator releases Pedal Pedal
the throttle pedal, the engine will stop and power to the rear wheels will cease.
42

OPERATION
Warning!
Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result in
serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual.
Vehicle Break-in Period

The break-in period for your new vehicle is defined as the first ten hours of operation, or the time it takes to use the first two full
tanks of gasoline.
No single action is as important as a proper break-in period. Careful treatment of a new engine and components will result in more
efficient performance and longer life. Perform the following procedures carefully.
Caution!
Excessive heat build-up during the first three hours of operation will damage close-fitted engine parts and drive components.
DO NOT OPERATE AT FULL THROTTLE OR HIGH SPEEDS DURING THE FIRST THREE HOURS OF USE.
Mixing brands or using a non-recommended oil may cause serious engine damage.
Always use the recommended oil.
Never substitute or mix oil brands.
43

OPERATION
Vehicle Break-in Period
Engine and Drivetrain Break-in
1. Fill the fuel tank with gasoline. Always exercise extreme caution whenever handling gasoline. Never allow a child to handle
gasoline.
2. Check the oil level. Add the recommended oil as needed to maintain the oil level in the safe operating range.
3. Complete the New Operator Driving Procedures outlined in this manual.
4. Avoid aggressive use of the brakes. See Brake System Break-in below.
5. Vary throttle positions. Do not operate at sustained idle.
6. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride inspection checklist.
7. Change the engine oil at 10 hours or one month.
Brake System Break-in
Apply only moderate braking force for the first 50 stops. Aggressive or overly forceful braking when the brake system is new
could damage brake pads and rotors.
CVT Break-in (Clutches/Belt)
A proper break-in of the clutches and drive belt will ensure a longer life and better performance. Break in the clutches and
belt by operating at slower speeds during the break-in period as recommended. Avoid aggressive acceleration and high speed
operation during the break-in period.
44

OPERATION
Pre-Ride Inspection
Failure to inspect and verify that the vehicle 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.
Item Remarks Page
Brake Ensure proper operation 78
Steering Ensure proper operation and free play 80
Engine oil Ensure proper levels 63 - 65
Air filter Inspect, clean 70
Seat Belts Check full length of belt for damage, 38

check latches for proper operation
Brake fluid Ensure proper levels 79
Tires Inspect condition and air pressure 81
Throttle system Ensure proper operation 74, 75
Gear Case fluid Ensure proper levels 66

Spark plug Inspect condition 67
45

OPERATION
Safe Operating Practices
1. Complete the New Operator Driving Procedures outlined in this manual.
2. Do not ride at night or when visibility is poor (rain, fog, dusk). Your vehicle doesn’t have lights that are designed for driving in
these conditions.
3. Engine exhaust fumes are poisonous. Never start the engine or let it run in an enclosed area. Never allow a child to handle
gasoline.
4. Never install accessories not approved by our company for use on this vehicle.
5. Never operate the vehicle on pavement or on any public street, road or highway, including dirt and gravel roads.
6. Drive in a manner appropriate for your skills and operating conditions. Never operate at excessive speeds. DO NOT attempt to
do power slides, “donuts”, jumps or other driving stunts. Keep both hands on the steering wheel at all times.
7. Never consume alcohol or drugs before or while operating this vehicle.
8. Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure.
9. Never operate a damaged vehicle. After any overturn or accident, have a qualified service dealer inspect the entire machine
for possible damage.
10. Never operate the vehicle on a frozen body of water.
11. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.
12. Always remove the ignition key and engage the parking brake when the vehicle is not in use to prevent unauthorized use.
13. Always provide adequate supervision when children are present. Never leave children unattended near your TrailRover™.
14. Always wear appropriate safety gear and a helmet when operating your TrailRover™.
46

OPERATION
Starting the Engine
1. Sit in the driver’s seat and fasten the seat belt.
2. Place the transmission in neutral. Set the parking brake.
3. Apply the brakes.
4. Do not press the throttle pedal while starting the engine.
5. Turn the ignition key to the “ST” position. Engage the starter for a maximum of five seconds. Release the key when the engine
starts.
Caution!
Operating the vehicle immediately after starting could cause engine damage.
Allow the engine to warm up for several minutes before operating the vehicle.
6. If the engine does not start within five seconds, return the ignition switch to the “ON” position and wait five seconds. Repeat
steps 5 and 6 until the engine starts.
Tip:
If a warm engine has cooled to a point where it does not readily start, intermittent use of the choke (pulled half way out)
may be necessary. If the engine is over-choked when warm, depress the throttle lever fully while cranking to aid in
starting. Release the throttle lever immediately after the engine starts. If the engine does not start, change the spark plug and try
again.
7. Vary the engine RPM slightly with the throttle to aid in warm-up until the engine idles smoothly.
8. Release the parking brake before driving. 47

OPERATION
Turning the Engine “OFF”
1. Release the throttle pedal completely and brake to a complete stop.
2. Place the transmission in neutral.
3. Set the parking brake.
4. Turn the ignition switch to “off”.
5. Turn the fuel valve off.
Braking
1. Release the throttle pedal completely. (When the throttle pedal is released completely and engine speed slows to near idle, the
vehicle has no engine braking.)
2. Press on the brake pedal evenly and firmly. Practice starting and stopping (using the brakes) until you’re familiar with the
controls.
Parking
1. Stop the vehicle on a level surface. When parking inside a garage or other structure, be sure that the structure is well
ventilated and that the vehicle is not close to any source of flame or sparks, including any appliance with pilot lights.
4. Stop the engine.
5. Remove the ignition key to prevent unauthorized use.
48

OPERATION
New Operator Driving Practices

Never operate your TrailRover™ without proper training and instruction. Free training is available to anyone who buys a
new UTV by calling 877-251-8975 for more information.
1. Read and understand the owner’s manual and all warning and instruction labels before operating this vehicle.
2. Review the section of this owner’s manual about starting the engine, stopping the engine, braking and parking.
3. Perform the pre-ride inspection.
4. Wear appropriate riding gear, including an approved helmet and eye protection (goggles or face shield).
5. Select a level open area to practice driving.
6. Sit in the driver’s seat and fasten the seat belt.
7. Do not carry a passenger until you have at least four hours of driving experience with this vehicle.
10. Start the engine.
11. Apply the brakes and shift into gear.
12. Release the parking brake.
13. Check your surroundings. Make sure the area is clear of people and obstacles.
14. Keeping both hands on the steering wheel, slowly release the brakes and press the throttle with your right foot to begin
driving.
15. Drive slowly at first. Practice starting, stopping, turning, using the throttle and brakes and driving in reverse. Learn how the
vehicle handles when making both left and right turns at a slow speed.
49
16. Increase speed only after mastering all maneuvers at a slow speed.

Operation
17. After you become skilled at making turns and begin to operate at faster speeds, follow these precautions:
Avoid sharp turns. Make turns gradually.
Never turn while applying heavy throttle or at high speeds.
Never turn the steering wheel abruptly.
Operate at speeds appropriate for your skills, the conditions and the terrain.
Do not attempt to do power slides, “donuts”, jumps or other driving stunts.
Driving with a Passenger
1. Complete the New Operator Driving Procedures outlined
in this manual.
2. Perform the pre-ride inspections detailed in this manual.
3. Do not carry a passenger until you have at least four hours
of driving experience with this vehicle.
4. Never operate with a passenger age 12 and under.
Make sure the passenger is tall enough to comfortably and
safely sit in the passenger seat with the seat belt secured,
put both feet on the floor and grasp the hand holds.
5. Never carry more than one passenger in the 800TX
or more than three passengers in the 800TXE.
6. Never allow a passenger to ride in or on the cargo box. Passengers must ride only in the passenger seats only.
50

OPERATION
7. Make sure the passenger is wearing appropriate riding gear, including an approved helmet and eye protection.
8. Make sure the passenger secures the seat belt.
9. Tell your passenger to always keep hands and feet inside the vehicle at all times.
10. Drive slowly. Vehicle handling may change with a passenger on board. Always travel at a speed appropriate for your skills,
your passenger’s skills, and operating conditions. Avoid unexpected or aggressive maneuvers that could cause discomfort or
injury to a passenger.
11. Always follow all operating guidelines as outlined on safety labels and in this manual.
Driving on Slippery Surfaces

When driving on slippery surfaces such as wet trails, loose gravel, sand or ice, be alert for the possibility of skidding and sliding.
Skidding or sliding can cause loss of control or overturn, especially if tires regain traction unexpectedly. When operating on
slippery surfaces such as ice or loose gravel, slow down and use extra caution to help prevent skidding or sliding. Always use
extra caution when operating on sand or on rough, slippery or loose terrain. Do not operate on excessively rough, slippery or
loose terrain.
51

OPERATION
Follow these precautions when driving in slippery conditions:
1. Slow down before entering slippery areas.
2. Be alert, watch the path ahead and avoid quick turns, which can cause skids.
3. Correct a skid by turning the steering wheel in the direction of the skid. Never apply the brakes during a skid.
52

OPERATION
Driving Uphill
Whenever traveling uphill, follow these precautions:
1. Always check the terrain carefully before ascending a hill.
2. Avoid steep hills (15° maximum).
3. Drive straight uphill.
4. Never climb hills with excessively slippery or loose
surfaces.
5. Drive at a steady rate of speed. Never press the
throttle suddenly.
6. Avoid unnecessary changes in speed or direction.
7. Never go over the crest of a hill at a high speed.
An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.
8. If the vehicle stalls while climbing a hill, apply the brakes. Place the transmission in reverse and slowly allow the vehicle to roll
straight downhill while applying the brakes lightly to control speed.
53

OPERATION
Driving on the side of a hill
Driving on the sides of hills is not recommended. Driving on the sides of hills improperly causes loss of control or overturning.
If crossing a hill is unavoidable, follow these precautions:
1. Drive slowly and use extreme caution.
2. If the vehicle begins to overturn, or if it feels as if it may overturn, immediately turn downhill.
3. Avoid obstacles and changes in terrain that may lower or raise one side of the vehicle or cause the vehicle to slide.
4. If the vehicle begins to slide downhill, immediately turn downhill to stop the slide.
Driving Downhill
Whenever driving down a hill, follow these precautions:
1. Avoid steep hills (15° maximum).
2. Slow down. Never travel down a hill at high speed.
3. Always check the terrain carefully before driving down a hill.
4. Always drive down a hill with the transmission in forward gear. Never “coast” or drive down a hill with the transmission in
neutral.
5. Avoid driving down a hill at an angle, which would cause the vehicle to lean sharply to one side. Always drive straight downhill.
6. Apply the brakes lightly to keep speed slow.
54

OPERATION
Driving Through Water
Your vehicle can drive through shallow water.
Make sure the water is no deeper than the floor
of the vehicle. Follow these precautions when driving
through water:
1. Check water depth. Never drive through water that is
deeper than the floor level.
2. After driving through water, test the brakes. Apply
them lightly several times while driving slowly. The
friction will help dry out the pads.
NOTICE:
Major engine damage can result if the vehicle is not thoroughly inspected after operation in water. Perform the services
outlined in the maintenance chart. Give special attention to engine oil, transmission oil and all grease fittings.
If your vehicle is operated in water deeper than the floor level, take it to your dealer for service before starting the engine.
If it’s impossible to bring the vehicle to your dealer before starting the engine, perform the service outlined in this manual and
take the vehicle in for service as soon as possible to prevent engine and component damage.
55

OPERATION
Driving Over Obstacles
Follow these precautions when driving over obstacles:

1. Always check for obstacles before driving in a new area.
2. Look ahead and watch the terrain. Always be alert for hazards such as logs, rocks and low hanging branches.
3. Drive slowly and use extra caution when driving on unfamiliar terrain. Obstacles are not always clearly visible.
4. Do not drive over large obstacles such as rocks and fallen trees. If it’s unavoidable, use extreme caution and drive slowly.
5. Always have a passenger dismount and move away from the vehicle before driving over an obstacle that could cause an
overturn.
56

OPERATION
Driving in Reverse
Follow these precautions when driving in reverse:

1. Always check for obstacles or people behind the vehicle.
2. Apply the throttle lightly. Never apply the throttle suddenly.
3. Back up slowly.
4. Apply the brakes slowly. Avoid heavy braking at high speeds.
5. Avoid making sharp turns.
57

OPERATION
Parking on an Incline
A rolling vehicle can result in serious injury. Avoid parking on an incline. If parking on an incline is unavoidable, follow these
precautions:
3. Stop the engine.
4. Turn the fuel valve off.
5. Always block the rear wheels on the downhill side.
58

MAINTENANCE
Periodic Maintenance
Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and
lubrication of important components is explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace
parts as necessary. When inspection reveals the need for replacement parts, use genuine parts available from your dealer.
Service and adjustments are important for proper vehicle operation. If you’re not familiar with safe service and adjustment
procedures, have a qualified dealer perform these operations. Maintenance intervals in the chart are based upon average riding
conditions and an average vehicle speed of approximately ten (10) miles per hour.
Vehicles subjected to severe use and high speeds must be inspected and serviced more frequently.
Severe Use Definition
Frequent immersion in mud, water or sand
Racing or race-style high RPM use
Prolonged low speed operation
Extended idle
Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil pump
or crankcase.
Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine
the cause or call a factory trained service representative at 877-722-4097.
59

MAINTENANCE
Periodic Maintenance Chart
Perform all services at whichever maintenance interval is reached first.
Maintenance Interval
Item (whichever comes first) Remarks
Hours Calendar Miles(Km)
II Steering － Daily －
Tires － Daily －
Check each day before driving the vehicle. Make
I Brake fluid level － Daily －
adjustments as needed. See the Pre-Ride Checklist.
Brakes － Daily －
I Brake pedal travel － Daily －
I Engine oil level － Daily －
I Engine oil change 30 6M 300 (480) Perform a break-in oil change at one month
CVT housing (if Drain water as needed,check often if driving in wet
－ Weekly －
equipped) conditions
I Air filter, main element － Weekly － Inspect; replace as needed
I, 10 Monthly 100 (160) Inspect periodically
Brake pad wear
II
Idle speed 10 Monthly 100 (160) Check; adjust as needed
I Front Suspension 50H 6M 500 (800) Lubricate
60

MAINTENANCE
Periodic Maintenance Chart
Maintenance Interval
Item (whichever comes first) Remarks
Hours Calendar Miles(Km)
I Rear Suspension 50H 6M 500 (800) Lubricate
I Spark plug 100 12M 600 (1000) Inspect; replace as needed
II Front wheel bearings 100 H 12M - Inspect; replace as needed
Shift Linkage 50H 6M 500 (800) Inspect, lubricate, adjust
Battery 25 Monthly 250 (400) Check terminals; clean; test
II Toe adjustment - Inspect periodically; adjust when parts are replaced
Headlight aim - Adjust as needed
Check for proper operation;see dealer for
II Choke 10 Monthly 100 (160)
adjustments
I Main gearcase oil 25 Monthly 250 (400) Inspect level; change yearly
I Perform these procedures more often for vehicles subjected to severe use.
II Have an authorized dealer perform these services.
61

MAINTENANCE
Important Service Notes:
1. If the Odometer reading shows high mileage, more frequent service may be required.
2. If you operate your TrailRover™ in very wet or dusty area, you should perform maintenance more frequently.
3. If you operate your TrailRover™ frequently on rough terrain ,you should perform maintenance more frequently.
Engine Oil
Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. Oil
may need to be changed more frequently if the recommended oil is not used.
Oil Recommendations
NOTICE: Mixing brands or using a non-recommended
oil may cause serious engine damage. Always use the
recommended oil. Never substitute or mix oil brands.
Engine oil classification of the UTV
62

MAINTENANCE
Engine Oil
Oil Check
Maintain the oil level within the safe range on the dipstick.
Do not overfill.
1. Position the vehicle on a level surface.
2. Remove the dipstick. Wipe it dry with a clean cloth.
3. Reinstall the dipstick completely.
4. Remove the dipstick and check the oil level.
Tip: If oil level elevates between checks in cool weather driving
may indicate contaminants such as gas or moisture collecting in
the crankcase. If the oil level is over the full/safe mark,
change the oil immediately.
5. Add the recommended oil as needed.
6. Reinstall the dipstick.
63

MAINTENANCE
Engine Oil
Oil and Filter Change
Always change the oil and filter at the intervals outlined in the
Periodic Maintenance Chart outlined in this manual .
Always change the oil filter whenever changing oil.
The engine drain plug is located on the bottom of the crankcase.
1. Position the vehicle on a level surface. Set the parking brake.
2. Start the engine. Allow it to idle for two to three minutes, Stop the engine.
Drain Plug
3. Clean the area around the drain plug.
Caution!
Hot oil can cause burns to skin. Do not allow hot oil to contact skin.
4. Place a drain pan under the engine crankcase.
5. Remove the drain Screw. Allow the oil to drain completely.
NOTE: The sealing surfaces on drain plug and crankcase should be clean and free of burrs or scratches.
6. Using a cap-style oil filter wrench,turn the oil filter cartridge to remove it.
7. Using a clean dry cloth,clean the filter sealing surface on the crankcase.
8. Lubricate the o-ring on the new filter with a film of fresh engine oil. Check to make sure the o-ring is in good condition.
64

MAINTENANCE
Engine Oil
Oil and Filter Change
9. Install the new oil filter cartridge with an oil filter wrench ,and then tighten it to the specific torque with a torque wrench. Oil
filter cartridge tightening torque: 17N·m (17m·kgf,12ft·lbf).
10. Reinstall the sealing washer on the drain plug.
11. Reinstall the drain plug. Add the recommended engine oil.
12. Put the gear in PARK. Apply the brakes.
13. Start the engine. Allow it to idle for one to two minutes.
14. Stop the engine. Inspect for leaks.
15. Re-check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick.
16. Dispose of used filter and oil properly.
65

MAINTENANCE
Main Gear Box
Fluid Check
The fill plug is located on the rear of the gear case. Access the Fill Plug
fill plug through the left rear wheel well. Maintain the fluid
level to the bottom of the fill plug hole.
2. Remove the fill plug.
3. Check the fluid level.
4. Add the recommended fluid as needed.
5. Reinstall the fill plug.
Fluid Change
The drain plug is located on the bottom of the gear case. Drain Plug
1. Place a drain pan under the drain plug.
2. Remove the drain plug.
3. Allow the fluid to drain completely into the drain pan.
4. Clean the drain plug.
5. Reinstall the drain plug with a new o-ring.
6. Add SAE15W/40 SF or SAE 80W/90 GL-4 of the recommended fluid to the fill hole. Maintain the fluid level at the bottom of
the fill plug hole. Do not overfill.
7. Reinstall the fill plug.
8. Check for leaks.
66
9. Discard used fluid properly.

MAINTENANCE
Spark Plugs
Spark Plug Gap/Torque
Electrode Gap Plug Tightening Torque
0.8-0.9 mm 12.5 ft. lbs. (17.5 Nm)
Caution!
Using non-recommended spark plugs can result in serious engine damage. Always use recommended spark plugs.
Spark plug condition is indicative of engine operation. The condition of the spark plug firing end should be checked after the
engine has warmed up and the vehicle is driven at higher speeds. Immediately check the spark plug for correct color.
Warning!
A hot exhaust system and engine can cause burns. Wear protective gloves when removing a spark plug for inspection.
Recommended spark plug: DPR7EA-9.
Spark Plug Removal and Replacement

1. Remove the spark plug cap.
2. Using the spark plug wrench provided in the tool kit, remove the plug by rotating it counterclockwise.
3. Reverse the procedure for spark plug installation.
67

MAINTENANCE
Constant Variable Transmission (CVT) System
Warning!
Failure to comply with the instructions in this warning can result in severe injury or death.
Do not modify any component of the CVT system. Doing so may reduce its strength so that a failure may occur at a high speed.
The CVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration
and additional loads on components. The CVT system rotates at high speeds, creating large amounts of force on clutch
components. Extensive engineering and testing has been conducted to ensure the safety of this product.
However, as the owner, you have the following responsibilities to make sure this system remains safe:
This CVT system is intended for use on TrailRover™ products only. Do not install it in any other product.
Always make sure the CVT housing is securely in place during operation.
68

MAINTENANCE
CVT Drying
There may be some instances when water is accidently ingested into the CVT system. Use the following instructions to dry it out
before operating. The drain plug is located on the bottom of the CVT cover.
1. Remove the drain plug. Allow the water to drain into a drain pan. Reinstall the drain plug.
2. Shift the transmission to neutral. Set the parking brake.
3. Start the engine. Apply varying throttle for 10-15 seconds to expel the moisture and air-dry the belt and clutches. Do not hold
the throttle wide open for more than 10 seconds.
4. Allow the engine RPM to settle to idle speed.
5. Test for belt slippage. If the belt slips, repeat the process.
6. Take the vehicle to your dealer for service as soon as possible.
NOTE: Exposure to salt water will cause corrosion to metal components. If your vehicle is operated in salt water areas,
rinse it off frequently with fresh water.
69

MAINTENANCE
Air Filter
Filter Systems
Air Filter
Always change the air filter at the intervals outlined in the Periodic
Maintenance Chart detailed in this manual. Access the air box
through left rear wheel well.
1. Remove the air filter fixed card (1) and the cover (2) .
2. Loosen screw (3).
3. Remove the filter element of the air filter (4) from the air box
4. Wash the filter element in warm soapy water, then rinse and let dry.
If the filter element is damaged, install a new filter.
5. Clean away any oil or sediments in the air box.
6. Reinstall the filter element and air box cover. Secure the fixed card.
1. Fixed card
NOTE: Never operate the vehicle with the filter element removed. 2. Cover
Dirt will enter the engine, causing rapid wear and severe damage to the engine. 3. Screw
4. Filter Element
70

MAINTENANCE
Cooling system
1. Place the vehicle on a level surface.
2. Check the coolant level in the coolant reservoir when the engine is cold as the coolant level will vary with engine temperature.
3. If the coolant is at or below the minimum level mark, open the cover 1 which locates on the engine cover ,you will see the
coolant cap , remove the cap, add coolant to the maximum level mark, install the reservoir cap.
Coolant Brake Fluid

Intake Intake
NOTE: The coolant should be between the minimum and maximum level marks.
Don’t removing the radiator cap when the engine and radiator are still hot, or you could be burned by hot fluid steam blown out
under pressure. Wait for the engine to cool before removing the radiator cap. Always use a thick rag over the cap. Allow any
remaining pressure to escape before completely removing the cap.
71

MAINTENANCE
Cooling system
Correctly fill up the coolant and release the air inside.
To fill when completely empty:

As shown in the picture, pull out the small circulating pipe on the temperature
adjusting set (TAS). Fill the coolant from the intake of radiator. Reconnect the
pipe when coolant overflows Continue filling up until the coolant is full.
Cap the radiator, Tighten the hoop of the pipe.
To add additional coolant:
Brake
If only a little coolant needed, fill up from the intake of radiator till it is full, Coolant Fluid
Intake Intake
and then cap the radiator.
Releasing the air.
If the engine is still overheating when the radiator and water pump is full,
and the Temperature Adjusting Set (TAS), fan is working properly, there may be
some air in pipe. To release the air, pull out the small circulating pipe, keep
adding coolant from intake of radiator. Reconnect the pipe when the
coolant flows from the pipe. Then fill the radiator to correct level.
Cap the radiator and tighten the hoop on the pipe.
72

MAINTENANCE
Cooling system
Troubleshooting Coolant Circulation:
Touch the in and out coolant pipe by hand (making sure you do not burn your hand), if the temperature is close to the engine’s,
and also the temperature of coolant-in pipe is higher than coolant-out pipe, this means the circulation is ok.
If the temperature is colder at the in and out coolant pipe than the engine temperature, the circulation is not working.
Warning!
Avoid the risk of serious burns and injury!
Never remove the radiator cap or attempt to remove the intake line when your TrailRover™ is hot. Pressurized steam and boiling
fluid are immediately released from the radiator if the cap is removed while the engine is hot! Fluid added to a hot radiator will
bubble over quickly and may cause severe burns.
Warning!
Improper disposal of coolant is hazardous to the environment and is dangerous to pets and children.
Never release used coolant into ground water supplies. Proper disposal of used coolant is required. Contact your local
authorities for information about proper disposal requirements in your area.
73

MAINTENANCE
Throttle System
Warning!
Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious
injury or death if the throttle pedal sticks during operation.
Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal.
Immediately contact your dealer for service if throttle problems arise.
Always check the pedal for free movement and return before starting the engine and occasionally during operation.
Throttle Free Play

If the throttle pedal has excessive play or is not properly adjusted, it will cause a
delay in throttle response, especially at low engine speed. The throttle may also
not open fully. If the throttle pedal has no free play, the throttle may be hard to
control, and the idle speed may be erratic. Check the throttle pedal free play at
the intervals outlined in the Periodic Maintenance Chart in this manual.
Adjust the free play if necessary.
Brake Accelerator
Pedal Pedal
74

MAINTENANCE
Throttle System
Throttle Free Play Inspection
1. Place the transmission in neutral. Set the parking brake.
2. Start the engine. Allow it to warm up thoroughly.
3. Measure the distance the throttle pedal moves before the engine begins to pick up speed. Free play should
be 1/16 to 1/8 inches (1.5-3 mm).
75

MAINTENANCE
Carburetor
Carburetor/Engine Idle RPM Adjustment
If the engine is functioning properly but the idle speed needs to be adjusted:

3. Start the engine and allow it to warm up for approximately five minutes.
4. Turn the carburetor idle screw in (clockwise) to raise RPM. Turn the screw out (counterclockwise) to lower RPM.
76

MAINTENANCE
Throttle body
Connect air filer to engine, control the throttle switch angle of valve
through throttle cable, corner from the throttle position sensor signals to ECU.
77

MAINTENANCE
Brakes
Always check brake pedal travel and the brake fluid reservoir level before each use of the vehicle. When applied, the brake pedal
should feel firm. Any sponginess would indicate a possible fluid leak or low brake fluid level, which must be corrected before
riding. Follow the information provided in this manual for brake fluid information. If you discover any irregularities in brake
system operation, including excessive pedal travel, contact your dealer for proper diagnosis and repairs.
Warning!
Operating the vehicle with a spongy brake pedal can result in loss of braking, which could cause an accident resulting
in severe injury or death. Never operate the vehicle with a spongy-feeling brake pedal.
Brake Inspection
1. Check the brake system for fluid leaks.
2. Check the brake pedal for excessive travel or a spongy feel.
3. Check the friction pads for wear, damage and looseness.
4. Inspect the brake pad wear surface for excessive wear.
5. Change pads when worn to 3/64” (1 mm).
78

MAINTENANCE
Brakes
Brake Fluid
Warning!
To prevent the risk of serious injury or death, check and maintain brake fluid at proper levels before each use.
Never mix brake fluid from different manufacturers. Follow the manufacturer’s instructions on the label.
If the Brake Fluid Warning Indicator Light is on add DOT 3 or DOT 4 brake fluid.
After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is
hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid
to drop, which can lead to early brake fade and the possibility of accident or severe injury.
Change the brake fluid every two years and any time the fluid becomes contaminated. Alarm light of brake fluid level 9 on the
meter will be on if the brake fluid is too low (add brake fluid). Open the cover 1 which is located on the engine cover, to access
the brake fluid intake.
Brake Fluid
Brake Fluid
Warning
Intake
Indicator Light
High Beam
Indicator 79

MAINTENANCE
Steering Wheel Inspection
1. Position the vehicle on level ground.
2. Lightly turn the steering wheel left and right.
3. There should be 0.8”-1.0” (20-25 mm) of freeplay.
4. If there is excessive freeplay or strange noises, or the steering feels rough or catchy, have the steering system inspected by an
authorized dealer.
Shock Spring Adjustment

The front and rear shock absorber springs can be adjusted to increase or decrease spring tension. Rotate the adjuster either
clockwise or counterclockwise to make adjustments. Always apply the same adjustment setting to all four wheels.
Warning!
Uneven adjustment may cause poor handling of the
vehicle, which could result in an accident. Always
adjust both the left and right spring preloads
equally or have your dealer perform the adjustments.
80

MAINTENANCE
Tires
Operating your vehicle with worn tires will increase the possibility of skidding, loss of control and an accident, which could result
in serious injury or death. Always replace tires when the tread depth measures 1/8” (3 mm) or less. Improper tire inflation or the
use of non-standard size or type of tires may adversely affect vehicle handling, which could result in vehicle damage or personal
injury. Always maintain proper tire pressure. When replacing tires, always use original equipment size and type.
Tire Tread Depth

Always replace tires when tread depth is worn to
1/8” (3 mm)or less.
Front Wheel Hub Tightening
Front wheel bearing tightness and spindle nut retention are
critical component operations. All service must be performed
by your authorized dealer.
Wheel Removal
2. Place the transmission in neutral. Set the parking brake. Stop the engine.
3. Loosen the wheel nuts slightly.
4. Elevate the side of the vehicle by placing a suitable stand under the frame.
5. Remove the wheel nuts. Remove the wheel.
81

MAINTENANCE
Vehicle Immersion
NOTICE: If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the
vehicle to your dealer before starting the engine.
If it’s impossible to take your vehicle to a dealer before starting it, follow the steps outlined below.
1. Move the vehicle to dry land.
2. Check the air box. If water is present, dry the air box and replace the filter with a new filter.
Thoroughly dry the air filter following the instructions in this manual.
3. Remove the spark plugs.
4. Loosen the carburetor drain screw.
5. Turn the engine over several times.
6. Dry the spark plugs and reinstall them, or install new plugs.
7. Tighten the carburetor drain screw.
8. Attempt to start the engine. If necessary, repeat the drying procedure.
9. Take the vehicle to your dealer for service as soon as possible, whether you succeed
in starting it or not.
10. If water has been ingested into the transmission follow the procedure in this manual
for drying.
82

MAINTENANCE
Battery
The battery is located under the passenger seat. Your TrailRover™ is equipped with a sealed battery. It is not necessary to check
the electrolyte or add distilled water in the battery. If the battery seems to have discharged, consult your dealer.
Caution!
Do not try to remove the sealing caps of the battery cells. You may damage the battery.
Failure to handle batteries or battery electrolyte carefully may cause poisoning and severe burns from the sulfuric acid in
battery electrolyte.
Batteries produce explosive gases.
Avoid contact with skin, eyes and clothing.
Always shield eyes when working near batteries.
Keep out of reach of children.
If external contact occurs, flush with water.

If internal contact occurs, drink large quantities of water or milk, followed by milk of magnesia, beaten egg or vegetable oil. Get
prompt medical attention.
If contact is made with the eyes, flush with water for 15 minutes and get prompt medical attention.
Keep batteries away from sparks, flames, cigarettes or other sources of ignition.
Ventilate when charging.
83

MAINTENANCE
Battery
Caution!
A special battery charger (constant voltage/ampere or constant voltage) is required for recharging a sealed type battery. Using a
conventional battery charger may shorten the battery life.
Fuse replacement
1. The fuses are under the meter cover.
2. If a fuse is blown, turn off the main switch and the switch to the circuit in question. Then, install a new fuse of the
specified amperage. Turn on the main switch. If the fuse immediately blows again, consult your dealer.
Specified fuses:
Battery fuse: 30A Cigarette lighter fuse: 15A Fuel pump fuse: 10A
Fan fuse: 10A Winch/dump pump fuse: 10A High beam fuse: 10A
Brake light Fuse: 10A Turning light fuse: 5A Low beam fuse: 10A
Light power fuse: 15A Horn fuse: 5A Wiper fuse: 15A
Ignition fuse:10A 2/4 WD fuse: 5A MP3 fuse: 5A
84

MAINTENANCE
Battery
1. When the machine is not used for a month or longer, removes the battery and stores it in a cool, dark place. Completely recharge
the battery before reinstallation.
2. Always make sure the connections are correct when putting the battery back in the machine.
Warning!
Do not use an improper fuse, because an improper fuse can cause damage to the electrical system which
could lead to a fire. Always use a fuse of the specified rating. Never use a material in place of the proper fuse.
Caution!
To prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse.
85

MAINTENANCE
Cleaning and Storage
Washing the Vehicle
Keeping your vehicle clean will not only improve its appearance but it can also extend
the life of various components. Before washing the vehicle, locate the CVT
inlet and outlet duct. The inlet duct is located under the passenger seat and the
outlet duct is located at the right side of the vehicle. Avoid spraying water
directly toward the ducts when washing the vehicle from the rear.
NOTE: Water in the CVT system could cause the drive belt to become wet and slip in
the clutches. Always avoid spraying water directly toward the CVT inlet and
outlet ducts when washing the vehicle from the rear. High water pressure may
damage components. We recommend washing the vehicle by hand or with a
garden hose, using mild soap. Certain products, including insect repellents a
nd chemicals, will damage plastic surfaces.
Do not allow these types of products to contact the vehicle.
The best and safest way to clean your vehicle is with a garden hose and mild soap
and water.
1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts last.
2. Rinse with clean water frequently.
3. Dry surfaces with a chamois to prevent water spots.
86

MAINTENANCE
Cleaning and Storage
Storage
Long term storage (60 days or more) of your machine will require some preventive procedures to guard against deterioration.
After thoroughly cleaning the machine, prepare for storage as follows:

1. Drain the fuel system.
2. Remove the spark plug, pour about one tablespoon of SAE 10W30 or 20W40 motor oil in the spark plug hole and reinstall the
spark plug. Ground the spark plug wire and turn the engine over several times to coat the cylinder wall with oil.
3. Block up the frame to raise all wheels off the ground.
4. Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering.
5. If storing in a humid or salt-air atmosphere, coat all exposed metal surfaces with a light film of oil. Do not apply oil to any rubber
parts or the seat cover.
6. Remove the battery and charge it. Store it in a dry place and recharge it once a month. Do not store the battery in an excessively
warm or cold place (less than 0 °C (30 °F) or more than 30 °C (90 °F)).
87

Troubleshooting
Problem Potential Problem Potential Cause Potential Solution

Cylinders are worn Change
Pistons are worn. Change
Leak on Washer of cylinder. Change
Pressure in Wearing on Pipe of air valve or seat Repair or Change
cylinder is too of valve is not suitable.
low. Plug is loose. Tighten
Starting motor is too slow. Check electric system.
Difficulty Air circulation is not right. Adjust
starting or Gap of valve is incorrect. Adjust
will not start
Clean or change
Drain on Spark Plug
Clean, dry or Change
No ignition Dampness or smudge on plug
Change
generated from Ignition coil problem
Change
plug Open or short circuit on touch loop
Change
CDI problem
88

Clean or change
Vent hole on tank jammed
Clean or change
Problem or block in fuel pipe.
No fuel in Problem on needle valve of
Change
carburetor carburetor
Change
Block in fuel tank
Clean or Change
Block in fuel filter
Difficulty Vent hole on tank jammed Clean or change
starting or Problem or block in Injector Clean or change
will not start High-pressure fuel pump does not
No fuel in work. Clean or change
Throttle body Low-pressure in high-pressure fuel
pump Clean or change
Block in high-pressure fuel pump
strainer Clean or change
Miscellaneous Gear is not in neutral Put gear on neutral
89

Valve gap not correct Adjust
Valve base is not correct Repair or Replace
Problem on air pipe Change
Swing arm bushing broken Replace
Mechanical
IAC valve blocked in inlet exhaust Adjust or Replace
problem
pipe.
Engine has Fuel level in carburetor is not right Adjust the height of float
no or uneven Jam on muzzle of carburetor Clean
Adjust screw of idle sets wrong. Adjust
idle speed
Dirt on plug Clean or Replace

Gap of plug not correct Adjust or Replace
Electrical parts
Ignition loop problem Repair or Replace
problem
CDI problem Replace
90

The force of Valve spring is weak.
Adjust
Cam axle worn
Replace
Plug is dirty
Clean or Replace
Gap of plug is too small.
Middle and Adjust or Replace
Air circulation is not right.
high engine Adjust or Replace
Ignition loop problem
rotation Mechanical Replace
Float of carburetor is too low.
speed is problem Adjust the height of float
Air filter is dirty.
uneven Clean or Replace
Block in fuel pipe causing fuel
Clean
supply problem
Fuel pipe problem
Replace
Low pressure in high-pressure fuel
Adjust or Replace
pump
Excessive lubrication Drain the excess lube
Piston ring worn Replace
Blue exhaust Mechanical Valve pipe worn Replace
smoke problem Cylinder wall scratched Replace
Valve rod worn Replace
Seal of valve rod broken Replace
91

Block in muzzle of carburetor Clean or Replace
Level not correct Adjust
Air filter is dirty Clean or Replace
Blue exhaust Leakage on air intake pipe Tighten or Replace
Fuel system
smoke Excessive lubrication Drain the excess lube
Problem or block in Injector
Low-pressure in high-pressure fuel Clean or Replace
pump Adjust or Replace
Dirt on plug Clean or Replace

Gap of plug not correct Adjust or Replace
Electrical parts
Ignition loop problem Replace
problem
CDI problem Replace
Engine power Gap of Valve is not correct Adjust

is low The force of valve spring is weak. Check, Adjust or Replace
Air circulation is not right. Adjust
Mechanical
Cylinder worn Replace
problem
Piston Ring worn Replace
Valve base not correct Repair or Replace
Swing arm or cam shaft worn Replace
92

Octane rating in gas too low Use correct fuel
Fuel line blocked Clean
Fuel system
Fuel pump problem Repair or Replace
Low or No Fuel Add Fuel
Ignition timing incorrect Adjust ignition timing
Electric System
Weak or no spark from plug Clean or Replace Spark Plug
Air mixture is incorrect Adjust carburetor

Leak in engine Repair
Air filter is dirty Clean or Replace Filter
Air pass problem Cylinder, piston, ring worn out Repair or Replace
Engine
Leak on connecting face Repair or Replace
overheats
Block in exhaust pipe Remove
Leak in Air inlet pipe Repair or Replace
Block in water or radiator Remove Blockage
Air in Cooling system or low coolant Release air, refill coolant
Engine cooling Water pump problem Replace
system Low coolant level Replace
Constant temperature unit problem Replace
Problem with fan or heat sensor switch Replace
Carbon accumulation on top of piston Remove
Miscellaneous Too much or not enough lubrication Drain or Refill
Unsuitable lube used Change 93

Gap on valve is too big Adjust
Noise on air valve Spring on valve is broken Replace
Swing arm or cam shaft worn out Replace
Piston worn out Replace
Cylinder worn out Replace
Noise from piston Carbon gathered in firebox Clean
Piston pin or pin hole worn out Replace
Piston ring or ring notch worn out Replace
Chain elongated Change chain & sprocket
Noise from chain of
Chain worn out Change chain & sprocket
circulation
Noise from Chain adjustment problem Repair & Change
engine Spline of crankshaft damaged Replace crankshaft
Noise from clutch
Spline of clutch damaged Replace clutch
Bearing noise Replace
Noise from
Needle bearing damaged Replace
Crankshaft
Gap too big Replace
Belt loose or worn out Replace

Noise from CVT
Roller or main wheel damage Replace
Gear damaged Replace
Noise from Input and output shaft damaged Replace
transmission system Bearing worn out Replace
94 Bush worn out Replace

Low Power Fuel system Fuel with low octane rating Use premium unleaded fuel
accelerating malfunction with no less than 91 octane.
Clutch skidding Oil line blocked preventing oil flow Clean
Hoof of clutch worn Replace

Clutch Transmission Spring on clutch is weak Replace
skidding system Out wheel worn Replace
Belt worn out & loose Replace
Gear changes Operating gear damaged Replace
are not Gear box or Gear Shift rod twisted Replace
smooth or changing system Shift drum worn Replace
sticking Shift pulling stick unsuitable Adjust
95

Blocked in Muffler Clean
Leak on connecting part of carburetor and Tighten, Adjust or Replace
Starting problem starting part Adjust
Starting pin not work properly
Reducer valve blocked or loose Clean or tighten

Valve channel blocked Clean
Air inlet channel blocked Clean
Idle and low speed
Air inlet bypass Blocked Clean
not stable
Starting pin not closed completely Adjust
Idle screw not properly adjusted Adjust
Carburetor Float not properly adjusted Adjust
not working Muffler blocked Clean
properly Main air channel blocked Clean
Needle valve blocked Clean
Not stable in high &
Throttle not adjusted properly Adjust
middle speed
Fuel filter blocked Clean or Replace
Float not properly adjusted Adjust
Starting pin not closed Adjust
Needle valve worn out or damaged Replace
Spill over or fuel level Spring on valve broken Replace
fluctuation Floater not adjusted or damaged Adjust or Replace
96 Dirt or scale in valve Clean

Engine coolant Heat sensor switch on fan Replace
temperature is Cooling System Cold weather Cover the radiator
lower Problem on constant temperature meter Replace
Starter Replace
Spark plug Replace
Spark weak Ignition System Battery weak Replace
Ignition loop problem Replace
Starting loop problem Replace
Transmission
Vehicle speed Transmission system Shift belt slips Replace
does not Speed adjusting plate abrasion is too much Replace
increase with Speeding adjusting plate slipping is blocked Repair or Replace
engine speed Spring force of adjuster is short Repair or Replace
97

High and Low driven gear groove Replace
wear to taper
Speed changing drum groove worn Replace
Right & Left gear changing rods bent Replace
Gear Box or Gear
Out of gear Speed changing principal and counter Repair or Replace
shifting system
shaft worn
Sector gear tooth worn Repair or Replace
The force of spring of sector gear is
weak or broken. Replace
98

Suspension and steering
Air pressure in left and right wheel is different Adjust air pressure in tire
Load on left and right wheel is different Adjust load
Spring force of left and right absorbing spring Adjust or Replace
Leans to one Running
Front wheel location is wrong Check or adjust
side system
One side wheel is locked or brake could not Repair arrester
release
Front and rear suspension parts have been Screw or Replace
loosened, bent or damaged suspension parts
Left and right absorber has been damaged, Adjust or Replace
spring force is short
Tire is not balance, and wheel hub is distorted Replace
Front wheel location is wrong Check or adjust
Tire is worn Steering Vehicle is over-loaded Check load
abnormally or system, Tire has not change its position Replace
greatly Suspension Wheel hub bearing has been damaged or Adjust or Replace
adjusted improperly
Wheel assembly jump (axial, radial) is too great Replace
Air pressure in tire is too high or too low Adjust air pressure in tire
99

Front wheel Steering or Tire and wheel is not balance Balance wheel or Replace
shakes Suspension tire
System Wheel hub bearing has been damaged or adjusted Replace or adjust
improperly
Left and right swing arm ball head has been abraded Replace
or loosened
Drag pole tie-in has been abraded or loosened Replace
Front wheel location is wrong Check and adjust
Wheel (axial, radial)jump is too big Replace tire or wheel hub
Tire has tympanic bag Replace tire
Excess free play in steering Replace or adjust
Fixed bolts on each part of steering column loose Tighten
Steering is Steering Air pressure in tire is low Correct air pressure

difficult Ball head of left and right swing arm and drag pole Replace
is blocked
Front wheel location is wrong Check and adjust
Steering is blocked Repair or Replace
Not enough play in steering Adjust
100

Brake System
Brake is not Brake Brake pipeline leaks oil Repair
hard enough system Brake disk and pad need adjusting or dirty Repair or clean the dust
Brake drum and brake pad worn Replace
Brake main pump is damaged or leaks oil Repair or Replace
Brake branch pump is damaged or leaks oil Repair or Replace
Brake fluid level low Add
Brake pipeline has air Eliminate air
Arrester is too hot Repair or Replace
Pulls when Brakes, Brake drums and pads have oil stain Clean or Replace
Brakes are Suspension Individual brake branch pump leaks oil or is blocked Repair or Replace
applied The air pressure in right and left tires is not even Equalize the air pressure
Front wheel alignment is wrong Adjust
Vehicle frame is distorted, left and right wheelbase is Repair or Adjust
different
Brake lines not smooth Repair or adjust
Individual brake drum and brake drum contact bad Repair
Suspension parts loose Check, repair and fasten
Vehicle is leaning Check, balance load
Left and right wheel wear not even Replace
101

Brake main pump could not return Repair main pump
Brake hoop return spring is too soft Replace
Parking brake adjustment is wrong Adjust
Brake system Parking brake drag line could not return Lubricate or Replace
Brake clip block
Brake branch clip block Repair or Replace
Abrasion of brake drum and brake hoop is too big, Replace
and clearance is too great
Brake pipeline is concave Replace
Light, circuit and meter system

Front headlight Lighting Bulb has been damaged Replace bulb
does not system Adjuster has been damaged (voltage is too high to Change adjuster
illuminate burn bulb)
Fuse has been burned Check, Replace
Headlight relay has been damaged Replace
Lead or grounding wire connection Repair circuit
Combination switch has been damaged Repair, Replace
Storage cell has been damaged (bulb is burned) Replace
102

Only one front
Bulb damaged Replace
headlight Lighting system
Lead or grounding malfunction Repair circuit
works
Steering relay has been damaged Replace
Steering light Individual steering bulb has burned Replace
does not Grounding is bad Repair
illuminate Fuse burned out Replace
Switch damaged Replace
Starter damaged Repair or Replace

Starter does
Starting relay damaged Replace
not rotate
Grounding of starter is bad Repair
when starting
Ignition switch damaged Replace
Fuse burned Check and Replace

All electric
Ignition switch damaged Replace
apparatuses do Circuit system
General wire or grounding wire has been cut off Repair circuit
not work
Electric bottle contacts bad Repair
103

Lamps not Switch damaged Replace
working (not Lamp circuit Bulb burned Replace
including Circuit cut off, contacts bad Repair circuit
headlight) Fuse burned Replace
Grounding wire contacts bad Repair
Fuse burned. Replace

Meter works Route cut off, tie-in contacts bad Repair route
Meter and wire
badly Instrument damaged Replace
Sensor damaged Replace
104

SPECIFICATIONS
MODEL 800TX 800TXE
Dimensions:
Overall length 2600 mm (102.4in) 3200 mm(126in)
Overall width 1280mm (50.4in) 1300mm(51.2in)
Overall height 1960mm (77.2in) 1880mm(74.0in)
Seat height 870mm (34.3in) 830mm(32.7in)
Wheelbase 1760mm (69.3in) 2440mm(96.0in)
Minimum ground clearance 210mm (8.3in)
Minimum turning radius 4200mm (165.4in) 4900mm(192.9in)
Maximum speed 80 km/h
Basic weight:
Weight (not including driver) 590kg 635kg
Engine:
Engine type Water-cooled 4-stroke, CF188/ CF 188-B/CF196
Cylinder arrangement single cylinder
Displacement 500/493 ml 600/594 ml
Bore × stroke 87.5×82.0 mm (3.4×3.2 in)
105

MODEL 800TX 800TXE
Compression ratio 10.2:1
Starting system Electric
Lubrication system Pressure spray
Engine oil:
Type
Recommended engine oil classification
Quantity:
Without oil filter cartridge replacement 1.8 L (1.90 US qt)
With oil filter cartridge replacement 1.9 L (2.01 US qt)
Final gear case oil:
Type SAE15W-40/SF or SAE 80W-90/GL-4
106

MODEL 800TX 800TXE
Quantity:
Periodic oil change 0.25L(0.26 US qt)
Front gear case oil:
Type SAE15W-40/SF or SAE 80W-90/GL-4
Quantity:
Periodic oil change 0.28L(0.30 US qt)
Air filter: Dry element
Fuel:
Type PREMIUM UNLEADED FUEL ONLY (no less than 91Octane)
Fuel tank capacity 22.0 L (5.8Gal)
Fuel reserve amount about 4 L (1Gal)
Carburetor:
Type/quantity Vacuum Film
Manufacturer MIKUNI
EFI System :
Type/quantity MSE 3.0
Manufacturer BOSCH
Spark plug:
Type/manufacturer DPR7EA-9(NGK)
107

MODEL 800TX 800TXE
Spark plug gap 0.8-0.9 mm (0.032–0.035 in)
Clutch type: wet, hoof centrifugal type
Transmission:
Primary reduction system V-belt
Secondary reduction system Shaft drive
Transmission type V-belt automatic
Operation Right hand operation
High gear 3.514
Low gear 5.857
Reverse gear 3.828
Chassis:
Frame type Steel tube frame
Caster angle 4°
Trail
Tire:
Type Tubeless
Size front 25×8.00-12
rear 25×10.00-12
Brake:
108

MODEL 800TX 800TXE
Front brake type Dual disc brake
operation Left foot operation
Rear brake type Dual disc brake
operation Left foot operation
Suspension:
Front suspension McPherson independent suspension
Rear suspension Double swing arm independent suspension, two shock
absorbers on each side
Shock absorber:
Front shock absorber Coil spring / oil damper
Rear shock absorber Coil spring / oil damper
Electrical:
Ignition system DC. C.D.I./ECU
Generator system A.C. magneto
Battery type
Battery capacity 12V 36Ah
Headlight type:
Bulb voltage, wattage × quantity:
Headlight 12 V 35 W/35.0 W × 2
109

MODEL 800TX 800TXE
Tail/brake light 12 V 5 W/21.0 W × 2
Indicator light
Neutral indicator light LED × 1
High gear indicator light LED × 1
Low gear indicator light LED × 1
Reverse gear indicator light LED × 1
Coolant temperature warning light LED × 1
4WD-Lock drive indicator light LED × 1
Fuses:
Power fuse 30A
Brake light fuse 10A
Light power fuse 15A
Winch/dump pump fuse 10A
E-fan fuse 10A
Ignition fuse 10A
2/4WD fuse 5A
Fuel pump fuse 10A
Low beam fuse 10A
High beam fuse 10A
110

MODEL 800TX 800TXE
Wiper fuse 15A
Turning light fuse 5A
Cigarette lighter fuse 15A
MP3 fuse 5A
Horn fuse 5A
111

24 Month Limited Manufacturer’s Warranty
UTV WARRANTY POLICY AND PROCEDURES

Important Notice: The following are not actual warranties, but detailed descriptions of our warranty policies and procedures.
Certain exclusions and disclaimers may apply to these descriptions. Always read the warranty that comes with each UTV. These
policies and procedures are subject to change at any time and without notice. Throughout this document, TrailRover™ will be
referred to as the “MANUFACTURER and shall include its parent company, its officers, directors, employees and agents.
Each UTV warranty is given to the original consumer only and terminates upon any transfer of ownership. Commercial
applications are excluded from all warranties. Use of your TrailRover™ in any racing, competitive or related event completely
voids this warranty in its entirety. Modifications or alterations to the odometer void the MANUFACTURER’S warranty.
In the event of a warranty claim exists, the warranty covers replacement of parts, not the entire TrailRover™. Whether parts
are repaired or replaced is at the sole discretion of the MANUFACTURER. Normally, problems associated with material and
workmanship can and will be repaired. In the unlikely event your TrailRover™ is replaced, all warranties date back to the
original date of sale. Coverage or repair under this warranty applies only when repairs are pre-approved and completed by an
authorized dealer or repair facility in accordance with the terms of this warranty. The distributor will not cover repairs performed
outside the pre-approved warranty process outlined in this warranty agreement, except in the event of an emergency. The
use of replacement parts not equivalent to the original parts may impair the effectiveness of your TrailRover™ emission control
system. If such a replacement part is used and an authorized service provider determines it is defective or causes failure of the
warranted part, your claim to bring your TrailRover™ into compliance with applicable standards may be denied.
If an emergency situation exists when a warranted part of dealer is not reasonably available to the owner of the TrailRover™,
the repairs may be performed by an available service establishment using available parts. The MANUFACTURER will reimburse
the owner for the expenses not to exceed the MANUFACTURER’S suggested retail for the parts and labor charges deemed
appropriate for the repair. The owner is responsible for providing the receipt for the parts and services provided in order to
receive reimbursement.
112

LABOR WARRANTY
Labor is described as the work completed by an authorized technician on components covered under the labor warranty.
MANUFACTURER will be responsible for Pre-Approved labor charges at a rate not to exceed $65/hour for Pre-Approved
warranty repairs at the authorized service provider for 90 days from the original date of purchase on the following components
ONLY:
* Engine * Transmission
* Injector * Harness
*CDI * Instrument Cluster
*CVT * Manual Clutch
THIS WARRANTY IS GIVEN TO THE ORIGINAL CONSUMER AND TERMINATES UPON TRANSFER OF OWNERSHIP. COMMERCIAL
APPLICATIONS ARE EXCLUDED FROM THIS WARRANTY. It is the responsibility of the owner to deliver the UTV to the pre-
approved service location for repairs. MANUFACTURER is not responsible for any cost associated with making UTV accessible
for repairs. If parts are required for repair, MANUFACTURER is not responsible for the cost of shipping of parts under the terms
of this warranty agreement.
EMISSION CONTROL SYSTEM WARRANTY
The emission control system warranty period for your TrailRover™ begins on the date of delivery to the original purchaser for
24 months provided there has been no abuse, neglect or improper maintenance of your TrailRover™. When a warrantable
condition exists, your TrailRover™ will be repaired at no cost to you. If an emission related part needs on your TrailRover™ is
defective, the part will be repaired or replaced, not the entire vehicle.
Your TrailRover™ is designed, built and equipped to conform, at the time of the initial retail purchase, with all applicable
regulations of the United States Environmental Protection Agency and the California Air Resources Board. and is free from
defects in materials and workmanship which cause your TrailRover™ to fail to conform with applicable regulations of the
United States Environmental Protection Agency or the California Air Resources Board for the model year of your TrailRover™.
Your emission control system warranty covers components whose failure would increase an engine’s emission, including
electronic controls, fuel injection system catalytic converter, or any other system utilized in this vehicle to control emissions
as it is originally equipped. Also included, may be hoses, connectors and other emission related assemblies. Replacing or
repairing other components (including parts, labor and other costs) not covered by this emission control system warranty or
the standard warranty is the sole responsibility of the owner. 113

OWNER’S RESPONSIBILITIES
As the TrailRover™ owner, you are responsible for the performance of required maintenance by an individual who is qualified
to perform the service. You must maintain accurate records of maintenance performed on your TrailRover™ including all
receipts for maintenance on your TrailRover™. You may not be denied a warranty claim solely because of your failure to provide
documentation of the performance of all scheduled maintenance or lack of maintenance records or receipts. You are responsible
for presenting your TrailRover™ to an authorized dealer or an approved technician as soon as a problem exists. The warranty
repairs will be completed within a reasonable time, not to exceed 45 days from the date the TrailRover™ is delivered to the
service provider for warranty repair.
As the owner of the TrailRover™, you should be aware that you may be denied warranty coverage if your vehicle or a part has
failed due to abuse, neglect, improper maintenance, or unapproved modifications.
WARRANTY PROCEDURES
THE CUSTOMER CARE DEPT. WILL WORK WITH YOU TO MAKE THE PROCESS AS
SIMPLE AND EASY AS POSSIBLE. TO ENSURE THE EFFICIENT PROCESSING OF STRUCTURE/SURFACE CLAIMS, PLEASE FOLLOW
THESE STEPS:
1. The MANUFACTURER relies upon the consumer and service technician to assist in warranty claims and how best to work
toward the consumer’s satisfaction. If you have any questions concerning a claim, you should call the TrailRover™ Customer Care
Department for assistance.
2. If the claim is determined to be valid you will need to submit to the TrailRover™ Customer Care Department the proof to
purchase . TrailRover™ Customer Care will determine the proper solution for repairing the UTV. The warranty claim for the
TrailRover™™ should have the following information attached:
* UTV Model * Address of Customer
* UTV Serial Number * Phone number of Customer
* UTV Color * Date of Delivery
* Date of Purchase * Thorough Description of
* Name of Customer Problem
NOTE: MOST OF THE ABOVE INFORMATION IS PROVIDED ON THE ORIGINAL INVOICE.
3. In all situations, a repair is considered the appropriate course of action unless it is deemed irreparable. If the UTV cannot be
114 repaired in the field and must be returned to the factory, approval must be obtained from Customer Care Manager. Cost for

returning the defective UTV and delivery of the replacement UTV are the responsibility of the consumer and will not under any
circumstances be covered by the MANUFACTURER.
If parts are required for repair, MANUFACTURER is not responsible for the cost of shipping of parts under the terms of this
warranty agreement.
ITEMS NOT COVERED UNDER WARRANTY
The following is a general overview of non-warranty, expendable items and labor items that are not covered by this warranty. This
is NOT an all-inclusive list.
* 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 * Body Parts of Any Kind
* Tires * Seals, Gaskets, Belts , Cables and Hoses of any kind
* Gas and Engine Oil Caps * Brake Pads, Brake Shoes, Brake Rotors and Brake Discs
* Bushings * Filters of Any Kind
* Required Routine Maintenance * Coolant or Fluids of Any Kind
* Lubricants * Acts of Nature
* Light Bulbs * Steering Wheel
* Travel Charges * Any part not purchased with TrailRover™
* Failures not caused by a defect in material or workmanship
* Physical damage caused by corrosion, fire or explosion not caused by defective materials 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.
The MANUFACTURER understands that some problems take longer than the allowed time to correct the problem. An
authorization number will be required for warranty coverage of extra time. If you are unable to get an authorization from the
MANUFACTURER, a detailed description must be included with the warranty claim to get approval for the overtime.
115

LIMITATIONS
The TrailRover™ warranty is terminated if the UTV has been subject to alteration, misuse, or abuse.
Misuse or abuse is defined as but not limited to: theft, use of UTV in commercial applications, failure to follow maintenance
schedule, damage caused by clogged or dirty filters, damage of UTV caused by collision, damage to engine caused by use of
engine oil and gasoline that is not recommended by the MANUFACTURER, failure to protect the UTV from excessive heat or cold
and inclement weather, failure to properly store the UTV when not in use. This warranty is terminated if any repairs have been
attempted or made by anyone that is not qualified to make repairs and causes further damage to the TrailRover™ . This warranty
is terminated if any extra components area installed after the manufacturer date.
DISCLAIMER
TrailRover™ specifications are subject to change without notice. No one has the authorization to add, take away, or make any
promise of performance or representation not included in TrailRover™ warranties that accompany each TrailRover™ UTV.
TrailRover™ would not be taken upon to go by any other warranty. There are no additional warranties, express or implied, which
extend beyond the terms of the warranty.
The liability of the Manufacturer under this limited warranty, if any, is solely limited to remedying of defects in material and
workmanship by an authorized dealer at its place of business during normal business hours and shall not exceed the original
amount paid for the original product. TrailRover™ will not be responsible for inconvenience, transportation, loss of use of
the UTV or other incidental or consequential costs, expenses or damages. Under no circumstance shall the MANUFACTURER
or its approved service providers be held responsible to any person for incidental, consequential or special damages of any
description, whether arising out of express or implied warranty of any other contract, negligence or other tort. We ,nor any of our
representatives, are liable for injury to any person or damage to any property, however arising. This warranty gives you specific
legal rights and you may have no other rights. No agent, dealer, Service Company, or other parts representative is authorized to
change, modify, or extend the terms of this warranty in any manner what so ever. Any disputes arising from the purchase of a
TrailRover™ UTV or this warranty are governed by the laws of the State of Tennessee.
116

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2014

Mountaineer 800TX (2 Door)

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TrailRover™ 800 TX/TXE UTV Warranty Summary

Summary of Items Covered Under the Labor Warranty

Summary of Items Not Covered Under the Warranty

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Note: A Note provides key information to make procedures easier or clearer.

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It is illegal and unsafe to operate your TrailRover™

ENGAGE PARKING BRAKE AND REMOVE KEYS WHEN YOUR

Provide adequate supervision when children are present.

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Dashboard Display ..................................................................................................................................................................................................... 31,32

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Break-In Period & Instructions ..................................................................................................................................................................................43,44

Pre-ride inspection ..........................................................................................................................................................................................................45

Safe Operating Instructions............................................................................................................................................................................................46

Starting the Engine ..........................................................................................................................................................................................................47

Turning the Engine Off .....................................................................................................................................................................................................48

Braking Instructions .........................................................................................................................................................................................................48

New Operator Driving Practices ...................................................................................................................................................................................49

Driving with a passenger ...............................................................................................................................................................................................50

Driving on slippery surface .....................................................................................................................................................................................51, 52

6 Driving on the sides of hills ...........................................................................................................................................................................................54

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Driving through water ..................................................................................................................................................................................................55

Driving over obstacles ...................................................................................................................................................................................................56

Driving in reverse ..............................................................................................................................................................................................................57

Parking on an incline .......................................................................................................................................................................................................58

Periodic Maintenance ......................................................................................................................................................................................................59

Severe Use Definition .......................................................................................................................................................................................................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 body ....................................................................................................................................................................................................................77

Steering wheel inspection ............................................................................................................................................................................................80

Shock spring adjustment ...............................................................................................................................................................................................80

Caring for an Immersed Vehicle ....................................................................................................................................................................................82

Clearing and storage................................................................................................................................................................................................. 86, 87

Troubleshooting .....................................................................................................................................................................................................88 - 105

Specifications ............................................................................................................................................................................................................106 - 111

Warranty ...................................................................................................................................................................................................................112 - 117

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NOTE: The vehicle identification number is used to identify your machine.

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Operating at Excessive Speeds