Textron ALTERRA 500 2018 Operator's Manual
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Textron ALTERRA 500 2018 Operator's Manual

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  • Page 2 Your ATV can be hazardous to operate. A collision or rollover can occur quickly, even during routine maneuvers such as turning and driving on hills or over obstacles, if you fail to take proper precautions. For your safety, it is important to understand and follow all of the warnings contained in this Operator’s Manual and the labels on your ATV prior to riding.

  • Page 3: Foreword

    Foreword Congratulations and thank you for pur- At the time of publication, all informa- chasing a a Textron Off Road All-Terrain tion and illustrations in this manual were Vehicle (ATV). Built with American technically correct. Some illustrations engineering and manufacturing know-...

  • Page 4: Table Of Contents

    Table of Contents Foreword ..........1 Seat Latch ..........43 Parts and Accessories......1 Safety Flag Bracket ......43 Rack Loading (Front and Rear) .... 44 Division I - Safety Trailering and Towing......44 Transporting ATV........44 ATV Safety Alert ........4 Gasoline-Oil-Lubricant ......

  • Page 5: Division I - Safety

    Division I - Safety An ATV is not a toy and • Always use proper procedures if you stall can be hazardous to or roll backward when climbing a hill. To operate. avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll •...

  • Page 6: Atv Safety Alert

    ATV Safety Alert Never carry a passenger on an ATV. Car- rying a passenger may upset the bal- The Consumer Product Safety Commis- ance of the ATV and may result in sion has concluded that ALL-TERRAIN loss of control. VEHICLES (ATVs) may present a risk of SERIOUS INJURY or DEATH in certain Always avoid paved surfaces.

  • Page 7: Rider Training Course

    Rider Training Course The Textron Specialized Vehicles divi- sion of Textron, Inc. (hereinafter “the manufacturer”) sponsors a free Rider Training Course to teach ATV riding skills or to reinforce current riding skills. First-time purchasers without any previ- ous ATV riding experience will receive a $100.00 coupon from the manufacturer...

  • Page 8: Hangtags

    Hangtags This vehicle comes with hangtags containing important safety information. Anyone who rides the vehicle should read and understand this information before riding. 2258-133 Indicates a hazardous situation which, if not ! WARNING avoided, could result in death or serious injury.

  • Page 9: Warning Labels & Information

    Warning Labels & Information This vehicle comes with several labels containing important safety information. Any- one who rides the vehicle should read and understand this information before riding. The labels should be considered as permanent parts of the vehicle. If a label comes off or becomes hard to read, contact your authorized dealer for a replacement.

  • Page 10: Warning Labels & Information

    Warning Labels & Information XR188B XR184B 1411-865 1411-809 1411-932 5411-998 1411-682 0411-426 Pour commander des Étiquettes de Mise en Garde gratuites, voyez votre concession- 2436-559. naire agréé VTT pour le numéro de pièce Indicates a hazardous situation which, if not ! WARNING avoided, could result in death or serious injury.

  • Page 11: Warnings

    Warnings ! WARNING POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain. HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered.
  • Page 12 ! WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN The ATV’s tires are designed for off-road use only, not for use on pavement. Paved surfaces may seriously affect handling and control of the ATV and may cause the ATV to go out of control.
  • Page 13 ! WARNING POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to over- turn. HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in this Operator’s Manual. Always check the terrain carefully before you start down any hill.
  • Page 14 ! WARNING POTENTIAL HAZARD Attempting wheelies, jumps, and other stunts. WHAT CAN HAPPEN Increases the chance of an accident including a roll- over. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Don’t try to show off. ! WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating.
  • Page 15 ! WARNING POTENTIAL HAZARD Failure to use extra care when operating the ATV on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes without enough time to react. Could result in the ATV overturning or going out of control.
  • Page 16 ! WARNING POTENTIAL HAZARD Operating on steep hills. WHAT CAN HAPPEN The ATV can overturn more easily on steep hills than on level surfaces or small hills. HOW TO AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for your abilities.
  • Page 17 ! WARNING POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN You could hit an obstacle or person behind you, resulting in serious injury. HOW TO AVOID THE HAZARD Before you engage reverse gear, make sure there are no obstacles or people behind you.
  • Page 18 ! WARNING POTENTIAL HAZARD Stalling, rolling backwards, or improperly dismounting while climbing a hill. WHAT CAN HAPPEN Could result in the ATV overturning. HOW TO AVOID THE HAZARD Use proper gear and maintain steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill.
  • Page 19 ! WARNING POTENTIAL HAZARD Operating the ATV through deep or fast flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident. HOW TO AVOID THE HAZARD Never operate the ATV in fast flowing water or in water deeper than the footrests. Remember that wet brakes may have reduced stopping capability.

  • Page 20: Prevention

    Prevention Overview When using an ATV, prevention is the name of the game. “Had you only known” something could go wrong, you would have prevented it. If you don’t notice your conditions and surroundings before riding your ATV, you give up con- trol over the situation.

  • Page 21: Condition Of The Atv

    Gloves 5. Chassis Your hands are targets for flying objects 6. Miscellaneous Items and branches. Along with providing skin 1. Tires and Wheels protection, gloves will shield your hands from harsh weather. Wear gloves that are Correct tire pressure is crucial. Consult weather resistant and have a gripping sur- the Specifications section of this Opera- face to keep them from sliding off the...

  • Page 22: First Aid And Survival

    B. Throttle 5. Chassis Before starting the ATV, push the throttle Grass and leaves can gum-up your sus- lever several times. The throttle should pension and shocks. Clear and clean the have a free, smooth range of motion. If it suspension arms, shock springs, and seems to “stick”...
  • Page 23 Tools Cellular Phone Routine maintenance will generally elim- It may be necessary to make an urgent inate the need for emergency repairs. phone call. Riding on rough terrain could cause loos- Maps/GPS (Global ening of nuts, bolts, and fasteners. Espe- Positioning System) cially on long rides, carrying the right tools can prevent an inconvenience from...

  • Page 24: Active Riding

    Active Riding Overview “Active Riding” is the second part of “P.A.S.S.” It involves an understanding of how your body weight, balance, gravity, and physical forces affect the handling of the ATV. Knowing how to shift your weight is necessary to avoid rolling or flipping the ATV.

  • Page 25: Sound Judgment

    Sound Judgment Overview Trail Riding You are not invincible. Knowing that the Use sound judgment when trail riding; first “S” in “P.A.S.S.” stands for “Sound that means riding on a trail that fits your Judgment” means you need to use yours. ability level.

  • Page 26: Those Around You

    ATV Maintenance Those Around You You have to maintain your ATV. The People do all kinds of things that you General Maintenance section of this can’t predict or control. Operator’s Manual tells you about taking care of your ATV. If, at any time, abnor- Riding Companions mal noises, vibrations, or improper func- Leave a lot of space between you and...

  • Page 27: Load Capacity Ratings Chart

    Load Capacity Ratings ! WARNING Chart POTENTIAL HAZARD Item Specifications Overloading the ATV or carrying or tow- (lb) (kg) ing cargo improperly. WHAT CAN HAPPEN Vehicle Load Capacity Could cause changes in ATV handling, Front Rack (max) which could lead to an accident. Rear Rack (max) HOW TO AVOID THE Tongue Weight...
  • Page 28 Reckless Riding THE EFFECTS OF Where excessive or high speed is a fac- ALCOHOL* tor, the potential for personal injury is greatly increased. Ride within reason and The Number of Drinks that Impair your skill level. Avoid maneuvers that are Mental and Physical Abilities reckless.

  • Page 29: Supervision

    Supervision Overview ATVs are all a little different from the handling to the stability to the controls. You’re responsible for supervising those So regardless of how much experience who ride your ATV. Your wisdom is valu- your family members have with ATVs, able...

  • Page 30: Division Ii - Operation/Maintenance

    Division II - Operation/Maintenance ATV Specifications ENGINE Type Four-Cycle/Liquid Cooled Bore x Stroke 89 mm x 71.12 mm (3.5 x 2.8 in.) Displacement 442 cc (27 cu in.) Spark Plug Type NGK CR7E Spark Plug Gap 0.7-0.8 mm (0.028-0.031 in.) Brake Type Hydraulic w/Brake Lever Lock and Rear Foot Brake CHASSIS...

  • Page 31: Location Of Parts And Controls

    Location of Parts and Controls 1. Battery 2. Headlights 3. Hand Brake Lever 4. Power Distribution Module 5. Electrical Access Panel 6. Seat Latch 7. Storage Compartment 8. Reverse Override Switch XR184C 9. Rear Foot Brake 10. Brake Lever Lock 11.

  • Page 32: Atv Operation

    ATV Operation Basic Operating CAUTION Maneuvers Do not run the starter motor for more Active riding and basic maneuvers are than eight seconds per starting the foundation of your ATV ride. Without attempt. The starter motor may over- heat causing severe starter motor basic skills, it’s impossible to execute damage.

  • Page 33: Shifting

    3. Never “ride” the brake. Even main- CAUTION taining minimal pressure on the brake lever will cause the brake pads Always shift into low range when to drag on the disc and may overheat operating on wet or uneven terrain, the brake fluid.

  • Page 34: How To Handle The Atv (Active Riding Techniques)

    Leaning, Weight Shift, and How to Handle the ATV Balance (Active Riding When you turn, the trick is to move for- Techniques) ward and slide over to the side of the seat Active riding involves moving your that’s on the inside of the turn. Support body.

  • Page 35: Sharp Turns

    ATV-0046 ATV-0045 ATV-202 1. Ease off the throttle as you approach the turn to slow down. 2. Use the principles of leaning, weight shifting, and balancing—shift your body weight to the inside of the turn. ATV-0044 3. You might have to lean into the turn 1.

  • Page 36: Riding Uphill

    6. Partially release the brake, but lightly hold the brake lever. 7. Let the ATV roll to your right side until it faces slightly downhill. 8. Reapply the brakes. 9. Get back on the ATV from the uphill side, and keep your weight shifted uphill when you sit down.

  • Page 37: Riding Downhill

    Sidehilling/Traversing 4. If that doesn’t work and you still have forward motion and the terrain Sidehilling is considered an advanced permits, do a U-turn, go back down, skill; it’s really tricky and unpredictable. and try climbing again, OR So, whether your skills are advanced or 5.

  • Page 38: Crossing Obstacles

    ATV-0016 ATV-0026 ATV-206 1. Ease off the throttle as you approach the obstacle. 2. Turn the handlebar. At the same time, shift your weight and balance ATV-0027 as you swerve. Use the principles of 1. Keep your speed way down; less leaning, weight shifting, and balanc- than 5 mph.

  • Page 39: Tips

    1. Keep it in gear. Tips 2. Engage the brake lever lock. Driving an ATV and a car have some 3. Find something to block the rear similarities; however, there are a few sit- tires. uations that require special attention: Stalling on a Hill •...

  • Page 40: Stopping The Atv

    5. Once you’ve cleared the water, 5. Take into account that your ATV briefly apply the brakes to make sure could stall while crossing; give they work. yourself enough time to get off the road. ! WARNING 6. You have to assume that oncoming cars don’t see you, and if they do, Do not operate this vehicle on a frozen they won’t be able to predict your...

  • Page 41: General Information

    General Information Control Locations and Shift Lever Functions Ignition Switch Key Two keys come with the ATV. Keep the spare key in a safe place. An identifying number is stamped on each key. Use this number when ordering a replacement key.

  • Page 42: Drive Select Switch

     Use the headlight HI/LO switch to select NOTE: The brake lever lock must the high or low headlight beam when the lock the wheels. If it doesn’t, take the ignition switch is in the LIGHTS posi- ATV to an authorized dealer for ser- tion.

  • Page 43: Speedometer/Lcd Gauge (Digital)

    To either engage or disengage the front 2. Turn the throttle limiter screw clock- wheels, move the switch to the 4WD wise to decrease engine RPM maxi- position or to the 2WD position. counterclockwise increase engine RPM maximum. Reverse Override Switch 3.
  • Page 44  10. 4WD Lock Indicator - Displays NOTE: The engine hour meter will LOCK when the front differential not activate until engine speed lock has been engaged. Not utilized exceeds 500 RPM. on this model. 2. Temperature Indicator - If the engine 11.

  • Page 45: Oil Level Stick

    Oil Level Stick 4. Remove the oil level stick; the engine oil level should be above the “L” mark but not higher than the “F” mark. CAUTION Do not overfill the engine with oil. Always make sure the oil level is above the “L”...

  • Page 46: Rack Loading (Front And Rear)

    Rack Loading (Front Trailer Tongue Weight is the downward and Rear) force exerted on the hitch by the trailer coupler when the trailer is fully loaded The front rack and rear rack are designed and the coupler is at its normal towing to carry specified load capacities.

  • Page 47: Gasoline-Oil-Lubricant

     When using ethanol blended gasoline, it NOTE: Suitable hold-down straps is not necessary to add a gasoline anti- are available from your authorized freeze since ethanol will prevent the dealer. Ordinary rope is not recom- accumulation of moisture in the fuel sys- mended because it can stretch under tem.

  • Page 48: Engine Break-In

    The recommended lubricant (front differ- When the engine starts, allow it to warm ential and rear drive) is SAE approved up properly. Idle the engine several min- 80W-90 hypoid. This lubricant meets all utes until the engine has reached normal of the lubrication requirements for this operating temperature.

  • Page 49: General Maintenance

    General Maintenance  NOTE: Proper maintenance of the ATV is important for optimum perfor- mance. Follow the Maintenance Schedule and all ensuing maintenance and care instructions/information.  NOTE: Proper maintenance procedures for each item can be found on the corresponding page indicated. If, at any time, abnormal noises, vibrations, or improper functioning of any compo- nent of this ATV is detected, DO NOT OPERATE THE ATV.

  • Page 50: Liquid Cooling System

    Liquid Cooling System Checking/Filling  NOTE: Debris in front of the ! WARNING engine or packed between the cool- ing fins of the radiator can reduce Only check/fill the cooling system cooling capability. Using a garden when the engine is cold. hose, wash the radiator to remove 1.

  • Page 51: General Lubrication

    Engine/Transmission Oil  NOTE: When the ATV is operated and Filter in extremely cold weather (-23°C/- 10°F or colder), a small amount of Change the engine oil and oil filter at the leakage may be present. Unless the scheduled intervals. The engine should leakage is excessive, replacement is always be warm when the oil is changed not necessary.
  • Page 52 7. Apply oil to the new filter O-ring and check to make sure it is posi- tioned correctly; then install the new oil filter. Tighten securely. 8. Install the oil filter drain plug and tighten securely. 9. Install the engine drain plug and tighten it securely.

  • Page 53: Hydraulic Hand Brake

    Hydraulic Hand Brake Brake Pads The clearance between the brake pads and brake discs is adjusted automatically as the brake pads wear. The only mainte- nance that is required is replacement of the brake pads when they show excessive wear. Check the thickness of each of the brake pads as follows: 1.

  • Page 54: Protective Rubber Boots

    Tie Rod Boots (Inner and Outer/Right and Left) CD474A  NOTE: The brake fluid reservoir is located under the seat. CC792 1. Secure the ATV on a support stand 2. Press the rear foot brake pedal sev- to elevate the front wheels. eral times to check for firmness.

  • Page 55: Battery

    Battery  NOTE: Optional battery charging adapters are available from your The battery is located under the seat. authorized dealer to connect directly After being in service, batteries require to your vehicle from the recom- regular cleaning and recharging in order mended chargers to simplify the to deliver peak performance and maxi- maintenance...
  • Page 56 Jump-Starting CAUTION  NOTE: Jump-starting a vehicle Always make sure the electrical sys- with a dead battery is not recom- tems are of the same voltage and mended but rather removing the bat- ground polarity prior to connecting tery, servicing and correctly jumper cables.

  • Page 57: Spark Plug

    7. Attach one clamp of the negative Adjust to the recommended gap for (black) jumper cable to the negative proper ignition. Use a wire-type feeler (-) terminal (3) of the good battery gauge to check the gap. (B); then attach the other clamp of the negative (black) jumper cable (4) to an unpainted metal surface (A) on the engine or frame well away from...

  • Page 58: Air Filter

    Air Filter 6. Remove any excess water from the element by pressing with a towel. The air filter inside the air filter housing must be kept clean to provide good 7. Allow the element to dry com- engine power and gas mileage. If the pletely.

  • Page 59: Draining V-Belt Cover

    Draining V-Belt Cover 0732-649 ! WARNING KC0049A  NOTE: If the ATV has been driven The use of worn-out tires is danger- through water, the V-belt cover must ous and can increase the risk of an be drained of any water. accident.

  • Page 60: Muffler/Spark Arrester

    7. Using a crisscross pattern, tighten  NOTE: The bulb portion of the the wheel nuts in 20 ft-lb increments headlight is fragile. HANDLE WITH to a final torque of 40 ft-lb (steel CARE. When replacing the headlight wheel), 60 ft-lb (aluminum wheel w/ bulb, do not touch the glass portion black nuts), or 80 ft-lb (aluminum of the bulb.

  • Page 61: Checking/Adjusting Headlight Aim

    1. Rotate the socket counterclockwise 7. Adjust each headlight until correct and remove it from the housing. aim is obtained by turning the adjuster clockwise to lower or coun- 2. To remove the bulb from the socket, terclockwise to raise the beam. push in and rotate counterclockwise.

  • Page 62: Preparation For Storage

    Preparation for Storage 6. Apply light oil to the upper steering CAUTION post bushing and plungers of the shock absorbers. Prior to storing the ATV, it must be properly serviced to prevent rusting 7. Tighten all nuts, bolts, cap screws, and component deterioration.

  • Page 63: Preparation After Storage

    Preparation after Storage Taking the ATV out of storage and cor- 7. Check the entire brake systems rectly preparing it will assure many miles (fluid level, pads, etc.), all controls, and hours of trouble-free riding. We rec- headlights, taillight, brakelight, and ommend the following procedure to pre- headlight aim;...

  • Page 64: Limited Warranty

    Limited Warranty Textron Specialized Vehicles, a division of Textron, Inc. (the Company) extends a limited warranty as described below on each new vehicle it assembles and on each genuine part and accessory assembled and sold by an authorized dealer. The limited warranty on the vehicle is extended to the original retail purchaser for the time periods described below;...

  • Page 65: Warranty Procedure/Owner Responsibility

    Warranty Procedure/Owner Responsibility At the time of sale, an ATV Rider Training Certificate and Owner Registration form is to be completed by the selling dealer and consumer. The receipt of the form by the Company is a condition precedent to warranty coverage.

  • Page 66: Epa Emission Control Statement/Warranty Coverage (U.s. Only)

    Textron Specialized Vehicles warrants to the original retail purchaser, and each subsequent purchaser, that all U.S. EPA-certified Textron Off Road vehicles are designed, built, and equipped to conform to all U.S. EPA Emission Control Regulations. Please read the following information completely.

  • Page 67: Change Of Address, Ownership, Or Warranty Transfer

    Change of Address, Ownership, or Warranty Transfer Textron Specialized Vehicles, a division of Textron, Inc. keeps on file the current name and address of the owner of this vehicle. This allows us to reach the current owner with any important safety information which may be necessary to protect customers from personal injury or property damage.
  • Page 68 Fold Back Place Stamp Here CHANGE OF ADDRESS/OWNERSHIP TEXTRON OFF ROAD PRODUCT SERVICE AND WARRANTY DEPT. P.O. BOX 810 THIEF RIVER FALLS, MN 56701...

  • Page 69: Maintenance Record

    Maintenance Record DATE MILEAGE SERVICE PERFORMED/NOTES...
  • Page 70 Maintenance Record DATE MILEAGE SERVICE PERFORMED/NOTES...

  • Page 71: Identification Numbers Record

    Identification Numbers Record Identification Numbers This ATV has two identification numbers: Vehicle Identification Number (VIN) and Engine Serial Number (ESN). These numbers are required by the dealer to complete warranty claims properly. No warranty will be allowed if the VIN or ESN is removed or mutilated in any way.
  • Page 72 ©2017 Textron Specialized Vehicles, a division of Textron, Inc. ™ ®Trademarks of Textron Specialized Vehicles p/n 2261-433...

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