gio Vyper 4WD 1100cc 2 seater Owner's Manual
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gio Vyper 4WD 1100cc 2 seater Owner's Manual

2 seater & 4 seater
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Vyper 4WD 1100cc
Owner's Manual
4 seater
2 seater
GIO MOTORS

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  • Page 1 Vyper 4WD 1100cc Owner’s Manual 4 seater 2 seater GIO MOTORS...
  • Page 2 INTRODUCTION Congratulations on your purchase of the GIO 1100cc Vyper UTV. With the purchase of this UTV, you can now appreciate the high degree of craftsmanship. This manual will provide you with a good basic understanding of the features and operation of this UTV. This manual includes important safety information.
  • Page 3 INFORMATION 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: The Safety Alert Symbol means ATTENTION! BECOME ALERT! Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander or a person inspecting or repairing the machine.

  • Page 4: Important Notice

    IMPORTANT NOTICE This UTV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this UTV on any public street, road or highway. This UTV complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Introduction……………………………………………………………………………………1 SAFETY………………………………………………………………………………………3 Features and Controls…………………………………………………………………………21 Component Locations…………………………………………………………………………21 Indicator and warning lights…………………………………………………………………23 Switch…………………………………………………………………………………………24 Seats……………………………………………………………………………………………25 Seat Belts………………………………………………………………………………………25 Seat Belt Inspection……………………………………………………………………………26 Fuel cap …………………………………………………………………………………27 Ignition Switch ………………………………………………………………………………28 Gear Selector…………………………………………………………………………………29 Brake Pedal……………………………………………………………………………………30 Throttle Pedal…………………………………………………………………………………30 OPERATION…………………………………………………………………………………31 Vehicle break-in period………………………………………………………………………31 Pre-ride inspection……………………………………………………………………………33...
  • Page 6 Safe operation practices………………………………………………………………………34 Starting the engine……………………………………………………………………………35 Stopping the engine……………………………………………………………………………36 Braking…………………………………………………………………………………………36 Parking the vehicle……………………………………………………………………………36 New operator driving procedures……………………………………………………………37 Driving with a passenger………………………………………………………………………39 Driving on slippery surface……………………………………………………………………40 Driving uphill…………………………………………………………………………………42 Driving on a sidehill…………………………………………………………………………43 Driving downhill………………………………………………………………………………43 Driving through water…………………………………………………………………………44 Driving over obstacles…………………………………………………………………………45 Driving in reverse………………………………………………………………………………46 Parking on an incline…………………………………………………………………………47...
  • Page 7 MAINTENANCE………………………………………………………………………………48 Periodic maintenance chart …………………………………………………………………48 Engine oil ……………………………………………………………………………………51 Transmission (main gearcase)………………………………………………………………55 Spark plugs……………………………………………………………………………………56 CVT system ……………………………………………………………………………57 Filter system …………………………………………………………………………………66 Cooling system …………………………………………………………………………………68 Throttle system ………………………………………………………………………………69 EFI system ……………………………………………………………………………………71 Brakes…………………………………………………………………………………………73 Steering wheel inspection ……………………………………………………………………75 Shock spring adjustment ……………………………………………………………………75 Tires……………………………………………………………………………………………76 Vehicle immersion……………………………………………………………………………77...
  • Page 8 Battery…………………………………………………………………………………………78 Clearing and storage…………………………………………………………………………81 Malfunction analysis and elimination ………………………………………………………83 W A R R A N T Y … … … … … … … … … … … … … … … … … … … … … … … … … … … 9 7 SPECIFICATIONS…………………………………………………………………………100 Circuit Diagram…………………………………………………………………………105...

  • Page 9: Introduction

    INTRODUCTION Failure to follow the warnings and safety precautions contained in this manual can result in severe injury or death. Your vehicle is not a toy and can be hazardous to operate. This vehicle handles 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.

  • Page 10: Identification Number Records

    INTRODUCTION Identification number records Record the vehicle identification number and engine number in the spaces provided for assistance when ordering spare parts from your dealer or for reference in case the vehicle is stolen. 800cc/1100cc: 1100cc: 800cc: NOTE:The vehicle identification number is used to identify your machine.

  • Page 11: Safety

    SAFETY Equipment Modifications Your vehicle is designed to provide safe operation when used as directed. Modifications to your vehicle may negatively impact vehicle stability. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power. This vehicle may become less stable at speeds higher than those for which it is designed.
  • Page 12 SAFETY Safe Riding Gear Always wear appropriate clothing when riding this vehicle. Wear protective clothing for comfort and to reduce the chance of injury.
  • Page 13 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.
  • Page 14 SAFETY 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.
  • Page 15 SAFETY Safety Warnings Rider Height Some riders may be too tall to ride safely in this vehicle. Do not operate or ride in this vehicle if the clearance between the top of your helmet and the overhead cab frame is less than 2 inches (5 cm). Failure to Inspect Before Operating Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk...
  • Page 16 SAFETY Safety Warnings Protective Apparel 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).
  • Page 17 SAFETY Safety Warnings Carrying a Passenger Never carry a passenger until you have operated this vehicle for at least four hours. Carrying Multiple Passengers Carry more than limitative passengers of the labels of the 800/1100UE or 800/1100UEL can affect the operator’s ability to steer and operate the controls, which increases the risk of loss of control and accident or overturn.
  • Page 18 SAFETY 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.
  • Page 19 SAFETY 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.
  • Page 20 SAFETY 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.
  • Page 21 SAFETY 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.
  • Page 22 SAFETY 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.
  • Page 23 SAFETY 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.
  • Page 24 SAFETY Safety Warnings Operating a Damaged Vehicle Operating a damaged vehicle 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.
  • Page 25 SAFETY 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. ●...
  • Page 26 SAFETY 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 touches hot exhaust system components. Always keep combustible materials away from the exhaust system. Use caution when traveling through tall grass, especially dry grass.
  • Page 27 SAFETY Safety Labels and Locations Warning Label 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 one passenger. ●...
  • Page 28 ● Watch for branches or other hazards that could enter vehicle. SAFETY Safety Labels and Locations Warning Label 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.

  • Page 29: Features And Controls

    FEATURES AND CONTROLS Component Locations...
  • Page 30 FEATURES AND CONTROLS Component Locations...

  • Page 31: Indicator And Warning Lights

    FEATURES AND CONTROLS Indicator and warning lights 1. AWD indicator 2. Tachometer 3. Temperature warming light 4.Low battery and Over Voltage 5. Fuel indicator 6. turning indicator 7.Engine malfunction warming light 8. Fuel warming light 9.Water temperature warming light 10. High beams indicator 11.Gear indicator 12.Oil pressure low warming light 13.

  • Page 32: Switch

    FEATURES AND CONTROLS Switch 1. Meter adjust button 2. Driver model turn switch 3. Turning switch 4. Light switch 5. Low beams/High beams turn 6. Horn switch 7. Warning indicator light switch Wiper switch (optional) 9. Spot light (optional) 10. Cigarette lighter Winch switch (optional) 12.

  • Page 33: Seats

    FEATURES AND CONTROLS Seat Seat Removal Pull up on the front of the seat and slide it toward the front of the vehicle. Install the seat by sliding the tabs into the rear of the seat base. Push down firmly on the front of the seat until the pins are fully seated into the grommets.

  • Page 34: Seat Belt Inspection

    FEATURES AND CONTROLS 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. 2.

  • Page 35: Fuel Tank Cap

    FEATURES AND CONTROLS Fuel Tank Cap Never allow a child to refuel or handle gasoline. The fuel tank filler cap is located on the right-hand side of the vehicle behind the passenger seat. When refueling, always use unleaded gasoline.

  • Page 36: Ignition Switch

    FEATURES AND CONTROLS Ignition Switch (1) Turn the key switch to “ST” position. The engine can be started only at this position and the key can not be removed. (2) Turn the key switch to “ON” position, the engine will turn off. When turn the key switch to “OFF”...

  • Page 37: Gear Selector

    FEATURES AND CONTROLS Gear Selector 1100cc: R: Reverse 800cc: R: Reverse N: Neutral N: Neutral L: Low gear H: High gear H: High gear L: Low gear The gear selector is located on the right of the steering wheel. To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear.

  • Page 38: Brake Pedal

    FEATURES AND CONTROLS Tip: Always set the parking brake whenever the vehicle is left unattended. Operating the vehicle while the parking brake is engaged could cause an accident resulting in serious injury or death. It could also result in driveline or engine damage. Always be sure to disengage the parking brake before operating the vehicle.

  • Page 39: Operation

    OPERATION 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.
  • Page 40 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. See page 52. Add the recommended oil as needed to maintain the oil level in the safe operating range.

  • Page 41: Pre-Ride Inspection

    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...

  • Page 42: Safe Operation Practices

    OPERATION Safe Operation Practices 1. Complete the New Operator Driving Procedures outlined on pages 37-38. 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.

  • Page 43: Starting The Engine

    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.

  • Page 44: Stopping The Engine

    OPERATION Stopping the Engine 1. Release the throttle pedal completely and brake to a complete stop. 2. Place the transmission in neutral. 3. Set the parking brake. 4. Stop the engine. 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.

  • Page 45: New Operator Driving Procedures

    OPERATION New Operator Driving Procedures 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 (pages 35-36). 3.
  • Page 46 OPERATION 9. Set the parking brake. 10. Place the transmission in neutral. 11. Start the engine. 12. Apply the brakes and shift into gear. 13. Release the parking brake. 14. Check your surroundings. Make sure the area is clear of people and obstacles. 15.

  • Page 47: Driving With A Passenger

    OPERATION Driving with a Passenger 1. Complete the New Operator Driving Procedures outlined on Pages 37-38. 2. Perform the pre-ride inspection. See page 3. Do not carry a passenger until you have at least four hours of driving experience with this vehicle. 4.

  • Page 48: Driving On Slippery Surface

    OPERATION 7. Never allow a passenger to ride on the back of the vehicle. Allow a passenger to ride only in the passenger seat. 8. Make sure the passenger is wearing appropriate riding gear, including an approved helmet and eye protection.
  • Page 49 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.

  • Page 50: Driving Uphill

    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.

  • Page 51: Driving On A Sidehill

    OPERATION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Driving on a sidehill improperly cause loss of control or overturn. If crossing a hill is unavoidable, follow these precautions: 1. Drive slowly and use extreme caution. 2.

  • Page 52: Driving Through Water

    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.

  • Page 53: Driving Over Obstacles

    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.

  • Page 54: Driving In Reverse

    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 slowly. 4. Apply the brakes lightly for stopping. 5.

  • Page 55: Parking On An Incline

    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: 1. Place the transmission in neutral. 2. Set the parking brake. 3. Stop the engine. 4.

  • Page 56: Maintenance

    MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are 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.
  • Page 57 MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first. Maintenance Interval (whichever comes first) Item Remarks Hours Calendar Miles(Km) Steering － Ⅱ Daily － Tires Daily － － Ⅰ Brake fluid level Daily － － Check each day before driving the vehicle.
  • Page 58 MAINTENANCE Periodic Maintenance Chart Maintenance Interval (whichever comes first) Item Remarks Hours Calendar Miles(Km) Front Suspension 500 (800) Lubricate Ⅰ Ⅰ Rear Suspension 500 (800) Lubricate 600 (1000) Ⅰ Spark plug Inspect; replace as needed 100 H Inspect; replace as needed Ⅱ...

  • Page 59: Engine Oil

    MAINTENANCE 3.If you vehicle often operate on rough terrain ,you must maintenance to maintain your vehicle’s performance. 4.Change every two years , have a qualified dealer perform these operations. Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 49.
  • Page 60 MAINTENANCE Engine Oil 1100cc: 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. 800cc: 4.
  • Page 61 MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page49.Always 1100cc: change the oil filter whenever changing oil. The engine drain plug is located on the bottom of the crankcase. 1.
  • Page 62 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:20N·m (20m·kgf, 14ft·lbf). 10. Reinstall the sealing washer on the drain plug. 11.

  • Page 63: Transmission (Main Gearcase)

    MAINTENANCE Transmission (Gearcase) Oil Check Rear Gearcase The fill plug is located on the rear of the gearcase. Access the fill plug through the right rear wheel well. Maintain the oil level at the bottom of the fill plug hole. 1.

  • Page 64: Spark Plugs

    MAINTENANCE Spark Plugs Spark Plug Gap/Torque Plug Tightening Torque Type Electrode Gap 1100cc 0.9~1.1mm 14.3 ft. lbs. (20±1.5 Nm) 800cc 0.7~0.8mm 14.3 ft. lbs. (20±1.5 Nm) Using non-recommended spark plugs can result in serious engine damage. Always use our NOTICE company recommended spark plugs.

  • Page 65: Cvt System

    MAINTENANCE CVT System(1100cc) CVT---main technical parameter and specification main technical parameters CVT type Rubber PulleyCVT Sheave angle of driving plate(°) Sheave angle of driven plate(°) Grooved surface angle ° Adjustment scope on speed 3.28～0.84 Dimension(a×b×h) 473×245×221 Net weight kg 约 11 Tightening torque Torque Thread...
  • Page 66 MAINTENANCE CVT System(1100cc) Usage and maintenance When assemble CVT and gearbox, if the CVT driving plate is not accord with the center of driven plate will serious effect the operating life of belt and performance of vehicle. So after pulley assembly, you should use exclusive check tool to check whether the CVT driving plate is accord with the center of driven plate.
  • Page 67 MAINTENANCE CVT System(1100cc) Usage and maintenance If there is space between CVT and check tool, use the gasket to adjust between input shaft of gearbox and CVT. The thickness of every gasket is 0.5mm. refer to picture 3-1-1-2...
  • Page 68 MAINTENANCE CVT System(1100cc) Usage and maintenance Belt Assembly： After the belt assembly is finished, the belt tension should be appropriate. Too loose or too tight will obvious effect the operating life of belt. So the verticality of loose edge should be checked after the belt assembly is finished, the drooping height is 10~~15mm, refer to picture 3-1-2...
  • Page 69 MAINTENANCE CVT System(1100cc) Usage and maintenance Running-in: Running-in or not of CVT is very important, will affect the operating life of belt a lot. t. 1000 km is stipulated as running-in mileages, during in the running-in mileages, the rpm of engine should not more than 2/3 of max rpm, and throttle should not more than 60% of full opening.
  • Page 70 MAINTENANCE CVT System(1100cc) CVT Maintenance and Check List Please maintenance and check the CVT as below chart. maintenance Period（As anyone is firstly expired ） Item Month Distance Time（h） 1500 Check, clean, change the abrasion Driving、driven part parts Belt 1500 Check, change if needs Countermark position...
  • Page 71 MAINTENANCE CVT System(1100cc) Appearance、installation dimension map...

  • Page 72: Cvt System

    MAINTENANCE 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.
  • Page 73 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. . Remove the CVT cover. Allow the water to drain. Reinstall the CVT cover. 2.

  • Page 74: Filter System

    MAINTENANCE Filter Systems 1100cc: Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 49. 1. Loose the air filter fixed card and remove the tail cover 5 . 2.Remove the filter element of the air filter 4 from the primary cover.

  • Page 75: Air Filter

    MAINTENANCE Filter Systems 800cc: Air Filter 5. Clean away any oil or sediments in the air box. 6. Reinstall the filter element and tail cover. Secure the fixed card. NOTICE Never operate the vehicle with the filter element removed. Dirt will enter the engine, causing rapid wear and severe damage to the engine.

  • Page 76: Cooling System

    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, remove the reservoir cap, add coolant to the maximum level mark, install the reservoir cap.

  • Page 77: Throttle System

    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.
  • Page 78 MAINTENANCE Throttle System Throttle Freeplay 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. Freeplay should be 1/16 to 1/8 inches (1.5-3 mm).

  • Page 79: Efi System

    MAINTENANCE EFI system (1100cc) The throttle body control inhalation engine cylinder's air Volume, thus achieves controls engine's rotational speed and the load. the throttle body have two channel constit- -utions, namely main channel and by-pass channel. The accelerator pedal controls main channel's damper opening through the accelerator back guy, reduces expenses to enter engine cylinder's gas flow amount;...
  • Page 80 MAINTENANCE EFI system (800cc) The throttle body control inhalation engine cylinder's air Volume, thus achieves controls engine's rotational speed and the load. the throttle body have two channel constit- -utions, namely main channel and by-pass channel. The accelerator pedal controls main channel's damper opening through the accelerator back guy, reduces expenses to enter engine cylinder's gas flow amount;...

  • Page 81: Brakes

    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. See page74 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.

  • Page 82: Brake Fluid

    MAINTENANCE Brakes Brake Fluid Inspect the level of the brake fluid before each operation. If the fluid level is low 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.

  • Page 83: Steering Wheel Inspection

    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.

  • Page 84: Tires

    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 mea- sures 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.

  • Page 85: Vehicle Immersion

    MAINTENANCE Vehicle Immersion If your vehicle becomes immersed, major engine damage can result if the machine is not NOTICE: 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.
  • Page 86 MAINTENANCE Battery This machine is equipped with a sealed-type battery. Therefore 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.

  • Page 87: Fuse Replacement

    MAINTENANCE Battery :A special battery charger (constant voltage/ampere or constant voltage) is required for CAUTION recharging a sealed type battery. using a conventional battery charger may shorten the battery life. Fuse replacement 1.The fuses are under the garnish cover of the engine cover. 2.
  • Page 88 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. : Do not use an improper fuse, because an improper fuse can cause damage to the WARNING...
  • Page 89 MAINTENANCE Cleaning and Storage 1100cc: 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, must pay attention prevents the water to enter inside CTV system from the CVT side cover.

  • Page 90: Cleaning And Storage

    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.

  • Page 91: Malfunction Analysis And Elimination

    Malfunction analysis and elimination （I）Engine malfunction Malfunction Malfunction Reason Solving method phenomenon system ① Cylinder wear out change Start 1. pressure in ② Piston wear out. change difficultly or cylinder is too ③ Leakage on Washer of cylinder. change could not start low.
  • Page 92 ① Vent hole on tank jammed Clean or change Start 3. No fuel in ②Problem or blocked in Injector Clean or change difficultly or Throttle body ③Hight-pressure fuel pump do not could not start work. Clean or change ④Low-pressure in hight-pressure fuel pump Clean or change ⑤blocked in hight-pressure fuel...
  • Page 93 ⑤ Magneto problem Change Engine middle Mechanical Change ① The force of Valve spring is high problem weak. rotate speed is Change ② Cam axle worn out uneven Clean or Change ③ Plug is dirty. Adjust or change ④ Gap of plug is too small. Adjust or change ⑤...
  • Page 94 ④ Too many lube Clean or Change ⑤ Problem or blocked in Injector ⑥Low-pressure in hight-pressure Adjust or Change fuel pump Engine power 2. Electrical parts ① Dirt on plug Clean or Change is not enough problem ② Gap of plug not correct Change or Adjust ③...
  • Page 95 2. Electric System ① Ignition time is late or early Adjust ignition time problem ②Spark is weak or no spark Check from plug to magneto 3. Air pass problem ①Leakage on engine Repair ②Air filter is dirty Clean or change filter ③Cylinder, piston, ring worn out Repair or change ④Leakages on connecting face...
  • Page 96 ② Spring on valve is broken Change ③ Swing arm or cam shaft worn out Change Noise from piston ① Piston worn out Change ② Cylinder worn out Change ③ Carbon gathered in firebox Clean ④ Piston pin or pin hole worn out Change ⑤...
  • Page 97 Clutch skiding is not smooth Clean oil routine Clutch skiding Transmission ① Hoof of clutch worn out Change system ② Spring on clutch is weak Change ③ Out wheel worn out Change ④ Belt worn out & loose Change Gear change Gear box or Gear ①...
  • Page 98 Engine Cooling System ① Fault on heat sensor switch on fan Change coolant ② Cold weather Cover the radiator temperature is ③ problem on constant temperature Change lower meter Spark weak Ignition System ① Fault on starter Change ② problem on spark plug Change ③...
  • Page 99 ② Right and Left gear changing rods Change bended ③High and Low driven gear groove Change wear to taper changing principal Repair or Change ④Speed countershaft worn out ⑤Sector gear tooth worn out Repair or Change ⑥The force of spring of sector gear is weak or broken.
  • Page 100 Tyre is Steering ①Left and right absorber has been damaged, Adjust or Change abraded organiza- spring force is short abnormally or tion, ②Tyre is not balance, and wheel hub is distorted Change greatly running ③Front wheel location is wrong Check or adjust system, ④Vehicle is over-load Check load...
  • Page 101 ⑥Wheel (axial, radial)jump is too big Change tyre or wheel ⑦Tyre has tympanic bag Change tyre ⑧Free travel of redirector is too big Change or adjust ⑨Fixed bolts on each part of steering Fasten organization has been loosened Steering is Steering ①Air pressure in tyre is short Charge...
  • Page 102 ⑦Brake pipeline has air Eliminate air ⑧Arrester is too hot Repair or Change ①Some brake drums and hoof pads have oil stain Clean or Change Brake is Brake ②Individual brake branch pump leaks oil or is Repair or Change leaning system blocked suspen...
  • Page 103 （V）Malfunction in lamplight, circuit and meter system Front Lighting ①Bulb has been damaged Change bulb headlight does system been damaged(adjusting Change adjuster ②Adjuster not illuminate voltage is too high to burn bulb） ③Fuse has been burned Check、Change ④Headlight relay has been damaged Change ⑤Lead or grounding happens malfunction Repair circuit...
  • Page 104 All electric Circuit ①Total fuse has been burned Check and Change apparatuses do system ②Ignition switch has been damaged Change not work ③General wire or grounding wire has been cut off Repair circuit ④Electric bottle contacts badly or happens Repair oxygenation Some kind of Lamplight...

  • Page 105: W A R R A N T

    WARRANTY LIMITED WARRANTY Company gives a SIX MONTH LIMITED WARRANTY on all components of your vehicle against defects in material or workmanship. This warranty is transferable to another consumer during the warranty period through a company dealer. REGISTRATION At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to company within ten days.
  • Page 106 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. COMPANY FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY.
  • Page 107 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES In the Country where your vehicle was purchased: Warranty or Service Bulletin repairs must be done by an authorized Company dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Company dealer who sells the same line as your vehicle.

  • Page 108: Specifications

    SPECIFICATIONS MODEL 800/1100UE 800/1100UEL Dimensions: Overall length 2830 mm (111.4 in) 3630 mm (142.9 in) Overall width 1640 mm (64.6 in) Overall height 2130 mm (83.9 in) Seat height 930mm (36.6 in) Wheelbase 1830mm (72.0in） 2630mm (103.5in） Minimum ground clearance 340mm (13.4in）...
  • Page 109 MODEL 800/1100UE 800/1100UEL 1100cc: 72×66.5 mm (2.83×2.62 in) Compression ratio 800cc: 10.3:1 1100cc: 9.5:1 No-load steady speed (idle) 800cc: 1250±50rpm 1100cc: 850±50rpm Starting system Electric Lubrication system Pressure spray Engine oil: Type Recommended engine oil classification Quantity: Without oil filter cartridge replacement 800cc: 2.2L (2.3 US qt) 1100cc: 3.6L (3.8 US qt) With oil filter cartridge replacement...
  • Page 110 MODEL 800/1100UE 800/1100UEL Final gear case oil: Type SAE 85W/90 GL-5 Quantity: Periodic oil change 0.45L(0.5US qt) Front gear case oil: Type SAE 85W/90 GL-5 Quantity: Periodic oil change 0.25L(0.27US qt) Air filter: dry element Fuel: Type UNLEADED GASOLINE 93 OCTANE OR ABOVE Fuel tank capacity 35L (9.3Gal) EFI System :...
  • Page 111 MODEL 800/1100UE 800/1100UEL Transmission: Primary reduction system V-belt Secondary reduction system Shaft drive Transmission type V-belt automatic Operation Right hand operation High gear 1100cc: 2.66 800cc: 2.886 Low gear 1100cc: 5.527 800cc: 5.29 Reverse gear 1100cc: 6.80 800cc: 5.087 Chassis: Frame type Steel tube frame Caster angle...
  • Page 112 MODEL 800/1100UE 800/1100UEL Rear brake type Dual disc brake operation Left foot operation Suspension: Front suspension Double swing arm independent suspension Rear suspension Double swing arm independent suspension Shock absorber: Front shock absorber Coil spring / Air damper Rear shock absorber Coil spring / Air damper Electrical: Ignition system...

This manual is also suitable for:

Vyper 4wd 1100cc 4 seaterVyper 4wd 1100cc

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