User manual BRISTERS CHUCK WAGON

[. . . ] Brister's Utility Vehicles 2 Wheel & 4 Wheel Drive Models Operator's Manual Copyright January 1, 2007 INDEX Section 1 Introduction Serial Number Plate Location Safety Pre-Delivery Steps Dealer Inspection Checklist Assembly Instructions Seat Back, Brush guard, Bumper Steering wheel Cargo Bed Seat Base Operating Instructions Maintenance Fuel Valve Lever Air Cleaner Engine Oil Transaxle Oil Drive Belt Troubleshooting Troubleshooting Chart Parts Diagrams Wiring Diagram 11hp 2 wheel drive 265cc 2 wheel drive 13hp 4-wheel drive pages 3-4 page 4 pages 5-10 page 9 page 10 pages 11-13 page 12 page 12 page 13 page 13 page 14 pages 15-22 page 15 Page 16 page 17 page 18 page 19 pages 20-28 page 26 pages 29-64 page 30 pages 31-42 pages 43-53 pages 54-64 page 65 page 66 page 67 Section 2 Section 3 Section 4 Section 5 Section 6 Section 7 Warranty Policy Contact Information Warranty Registration Certificate 2 Section 1 Introduction Brister's welcomes you to its growing family of new product owners. This Brister Utility Vehicle UTV is a light utility vehicle that has been designed with care and built by skilled workers using quality materials. Proper set-up, maintenance and safe operating practices will help you get years of satisfactory use from this vehicle. Safety First Brister's is fully aware of the need for safe operating procedures around all of our equipment. We hope you will make a sincere effort to put safety above all other priorities. [. . . ] __ Check engine oil level at the dipstick. __ Check differential oil level at the differential oil plug. Valve lever should be off except when running the engine. __ Check fuel level to make sure there is at least 1/8 of a tank of gas prior to performing initial starting operations. 6 Driving is as easy as driving a car with an automatic transmission. A simple forward and reverse shifter provides direction control. Just turn the key and the 12 volt electric starter provides safe and easy starting. There is a manual choke control below the seat for quick cold weather starting. A back-up pull-rope starter mechanism is provided on the engine just in case you accidentally leave the key on and run the battery down. The infinitely variable torque converter drive system means there is no clutching. You just shift into either forward or reverse when the vehicle is stopped and press the throttle pedal to go. Never shift while the vehicle is moving. Braking is accomplished by simply depressing the brake pedal that is located on the floorboard left of the accelerator. A lever action parking brake control is mounted on the center console located between the operator and passenger seats. Depress the button on the park brake control lever to release the park brake. 14 Section 5 Fuel Type Maintenance The fuel tank is located under seat. TW11, TW 413, CW11, CW413 Fuel Capacity is 5 Gal. CW-265 & TW265 Fuel capacity is 6. 1 Liters When filling the fuel tank, place the gear shift in forward or reverse, set the park brake, turn off the engine, and remove ignition key. Clean dirt from around the fuel tank cap, remove cap, and begin filling. When finished, screw the cap back on securely and wipe up any spilled gasoline. Use regular unleaded gasoline with an octane rating of 87 or higher. Engine Fuel Valve Lever Refer to Figure 5-1 The engine fuel valve opens and closes the passage between the fuel tank and carburetor. Leave fuel valve lever in the OFF position when the engine is not in use to prevent carburetor flooding and reduce possibility of fuel leakage into the cylinder cavity and engine oil reservoir. Turn fuel valve lever to the ON position when running the engine. IMPORTANT: Never use methanol, gasoline containing methanol, or gasohol containing more than 10% ethanol because the fuel system could be damaged. Using a fuel stabilizer/conditioner in the vehicle can provide benefits such as: * Keeps gasoline fresh during storage of 90 days or less. [. . . ] Fender Washer 7/16" Lock Washer 7/16 x 2 ½ SAE Bolt Belt, Comet 300668 1/2 x 2" SAE 1/2" Lock Washer 1/2" Uss Flat Washer Key stock ­ 3/16" Tension Mount Engine, 265 - Black 5/16x 3/4" Bolt Hex Hd NF 5/16" Lock Washer 5/16" Flatwasher Rubber Feet (Isolators) 3/8 Nylock Nut 3/8 Flatwasher USS Rod End Sphcl-UTV (4681-MPM-12) 3/4 Jam nut SAE Panhard bar, CW - black bolt, 3/8 x 1 3/8" Nylock Nut 3/8" Flatwasher, USS 3/4' Spacer Washer 3/4 x 2. 5 SAE bolt 3/4 SAE nylock Shifter cable mount Quantity Required 1 4 4 1 1 1 1 1 1 2 4 1 1 1 1 1 1 1 1 1 2 2 2 5 10 5 3 3 1 4 4 4 6 3 3 103 104 107 108 109 110 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 52 Reference Number 129 130 131 135 138 139 140 - Part Number 18012 50084 50000 50715 11103 50150 50007 11013 11082 18313 18314 18315 50624 50050 50770 Part Description - 265cc 2WD Models shifter cable lever, 1/4-20 x 3/4" Hex Hd Bolt 1/4" Keps Nut 1/4" Flatwasher, USS Brake Cables 5/16-18 x 1" Hex Hd Bolt 5/16" Nylock Nut Throttle Cable, 265 Cable, shifter Belt Guard Plastic UTV - Front Belt Guard Plastic UTV - Rear Belt Guard Plastic UTV - Bottom #10 x 3/4" Blunt Point Black #10 Speed Nut - for Plastic #10 Flat washer Quantity Required 1 1 1 2 2 2 2 1 2 1 1 1 7 7 7 53 Brister 4-wheel drive Utility Vehicle Parts Breakdown 54 55 56 57 Reference Number 1 2 Part Number 45501 45401 50168 50007 50702 Part Description ­ 4x4models Frame, CW413 - 4x4 Rear frame stub, CW - black 5/16 x 2-1/4" USS Socket Head bolt nut, 5/16 nylock bent washer 5/16 Quantity Required 1 2 2 2 2 3 4 5 6 7 7a 8 9 11 45413 45433 50167 50007 50702 70208 45412 50168 50007 50702 45411 50168 50007 50702 43007 51100 50266 50015 45150 25001 25009 50028 50041 50801 25020 25003 50163 50005 25002 50040 30621 30623 50060 70301 50400 50404 50065 30122 30123 30480 30195 12L 12R Bumper, CW - black Bumper, Trail Wagon ­ with grill guard - Black bolt, 5/16 x 2 nut, 5/16 nylock bent washer 5/16 Vinyl Caps 1 3/4 x 1 1/2 Brush guard roof, CW - black 5/16 x 2-1/4" USS Socket Head bolt nut, 5/16 nylock bent washer 5/16 Brush guard seat back, CW - black 5/16 x 2-1/4" USS Socket Head bolt nut, 5/16 nylock bent washer 5/16 A-arm 4x4, CW ­ black (left or right) suspension bushings bolt, 5/8 x 9 1/2" Nut, 5/8 nylock Spacer/CW A-arm bushing-4x4 Strut assembly, left Strut assembly, right Nut, 7/16 NF jam Nut, 3/8 NF slotted cotter pin 1/8" x 1 Lower ball joint strut bearing bolt, 5/16 x 3/4" NC Nut, 5/16 keps Hub / rotor 4x4 Nut, 5/8 NF slotted cotter pin dust cap Lug nuts, 1/2" Shock, Heavy duty #1 Bolt, 10 mm x 40mm 10 mm x 70mm bolt Nut, 10mm nylock spacer, shock Rim/Tire Assembly, UTV 22/9-10" Left Rim/Tire Assembly, UTV 22/9-10" Right Wheel rim, 10" x 6" Tire, Pathfinder 22/9-10" 1 4 4 4 2 1 4 4 4 1 2 2 2 2 2 ea 1 ea 1 ea 1 1 2 2 2 2 2 8 8 2 2 2 2 16 4 6 2 8 2 1 1 58 Reference Number 13L 13R 14 15 16 17 18 19 20 21 22 23 24 25 Part Number 30124 30125 30480 30194 20851 20868 20839 20848 50206 50740 50741 25006 50092 50003 25008 50163 50005 25007 50631 10184 20804 10591 10593 50171 50005 10594 10595 10593 10592 50402 50066 50403 50780 45422 45400 51100 50152 50005 10502 10506 50081 50001 45402 50152 50081 50159 50005 50701 Part Description ­ 4x4models Rim/Tire Assembly, UTV 22/11-10" Left Rim/Tire Assembly, UTV 22/11-10" Right Wheel rim, 10" x 6" Tire, Pathfinder 22/11-10" CV half shaft (axle) ­ (Left or Right) Boot CV front differential ­ 4x4 Hilliard Front Differential Replacement Oil Bolt, 3/8 x 1 washer, 3/8 flat washer, 3/8 lock drive shaft, front bolt, ¼ x 2" nut, ¼ keps bearing, shaft support bolt, 5/16 x ¾" NC Nut, 5/16 keps drive shaft, rear telescoping Screw, 3/8" ­ 16 x ½" square head set key, 3/16 x 1 convoluted tubing Rack & pinion with rod ends 4x4 Rack & Pinion Boots Bolt, 5/16 x 3 3/4" USS Nut, 5/16 keps Rod end 4x4 Tie rod 4x4 Rack boot Steering Shaft w/u-joints 4x4 Bolt, 10mm x 30mm Nut, 10mm Tri Lock Jam Bolt, 8mm x 30mm Lock washer, 8mm Steering Stub Shaft Assembly, CW - Black Steering support, CW - black suspension bushings bolt, 5/16 x 1 Nut, 5/16 keps Steering Wheel 13" Center cap screw, black center cap bolt, 1/4 x 1 3/4 nut, 1/4 nylock Pedal assembly, CW - black bolt, 5/16 x 1 bolt, 1/4 x 1 3/4" bolt, 5/16 x 1 1/2 Nut, 5/16 keps Washer, 5/16 flat Quantity Required 1 1 2 1 4 4 4 1 2 2 1 2 2 1 2 3 17 inch 1 2 4 4 2 2 2 1 1 1 1 1 1 1 2 ea 4 4 1 30 3 3 1 6 1 1 8 2 59 Reference Number 31 32 33 34 35 36 37 38 40 41 Part Number 11123 50167 50005 50806 50077 11124 11167 11168 11169 50826 50217 50013 18030 11127 50086 50001 50163 50005 50701 18038 50152 50007 11135 11136 11085 11083 11082 50053 50616 50770 11086 11083 11091 50053 50616 50770 50087 50000 50159 50005 70012 70000 70002 70010 70009 50087 50000 50000 Part Description ­ 4x4models master cylinder bolt, 5/16 x 2 Nut, 5/16 keps Clevis, 5/16 rod end Nut, 5/16" Hex SAE brake caliper brake pads (2 pads required per wheel) brake pins brake clips Spacer Lock collar, 3/8 bolt, 3/8 x 1 1/2 nut, 3/8 keps caliper bracket Parking Brake Bolt, 1/4 x 1 1/4 nut, 1/4" nylock bolt, 5/16 x 3/4" NC Nut, 5/16 keps Washer, 5/16 flat Brake spreader bolt, 5/16 x 1 nut, 5/16 nylock Brake hose, front Brake hose, rear Shifter control assembly, black Knob Cable, shifter nut, #10-24 Keps nut screw, #10-24 X 3/4" Pan Head phillips Washer, #10 flat Differential Control Assy - 4x4 Diff Control w/ cable Knob cable, diff lock nut, #10-24 Keps nut screw, #10-24 X 3/4" Pan Head phillips Washer, #10 flat 1/4-20 x 1" Hex Hd Bolt 1/4" Keps Nut 5/16-18 x 1 1/2" Hex Hd Bolt 5/16" Keps Nut Wire Harness Battery, U1L-8250-UTV ­ 12 Volt ­ 240 CCA Battery Cable, Red - 17" Battery Cable, Black (24") Battery Terminal Cover bolt, 1/4" x 1 nut, 1/4" keps nut, 1/4" keps Quantity Required 1 2 2 1 1 2 4 4 4 4 4 4 2 1 1 1 4 4 4 2 4 1 1 1 1 1 2 2 2 2 1 1 1 2 2 2 1 2 1 2 1 1 1 1 2 2 2 2 60 Reference Number 42 43 44 45 46 47 48 50 51 52 53 54 55 56 57 58 Part Number 45414 50083 50002 70055 70052 70060 70080 70081 18500 50625 50053 70129 70019 18380 18384 18381 50620 50621 50717 50001 50846 18309 50624 18308 50624 18383 50624 18316 50624 18382 50624 18304 18303 70150 50091 50717 55060 55063 55062 55061 50163 50706 50703 Part Description ­ 4x4models Battery strap, CW (8 3/4") - black bolt, 1/4 x 7 1/2 nut, 1/4" wing Light Switch / 4x4 switch Key Switch Key, 1 pair Accessory Plug Accessory Plug cap Terminal Block Cover - plastic screw, #10-24 X 1" Pan Head phillips nut, #10-24 Keps nut Headlights Relay w/harness, 4x4 Hood, plastic - 4x4 (green) Hood, plastic - 4x4 (camo) Hood, plastic - 4x4 (red) 1/4" X 1 1/4" Pan phillips Machine screw 1/4" X 2" Pan phillips Machine screw 1/4" SAE Flat washer nut, 1/4" nylock Clamp-Tube-vinyl coated 1-1/4" Glove Box Screw, #10 x 3/4 hex - black Steering Cover Screw, #10 x 3/4 hex - black Center Console 4x4 Screw, #10 x 3/4 hex - black Access Cover, Center Console Screw, #10 x 3/4 hex - black Plastic, Seat Bottom wrap 4x4 Screw, #10 x 3/4 hex - black Underseat storage box Rear Fender Reflectors 1/4"-20 X 3/4" Carriage bolt 1/4" SAE Flat washer Fuel Tank Elbow Fuel Inlet w/ #200 Mesh Screen Fuel Fitting Grommet Cap Fuel Tank bolt, 5/16 x 3/4" NC Washer, 5/16 fender Washer, 5/16 lock Quantity Required 1 2 2 2 1 1 1 1 2 2 2 1 1 1 1 2 2 8 4 2 1 5 1 1 1 14 1 4 1 5 1 1 2 4 4 1 1 1 1 3 3 3 59 18033 50163 50005 50171 10001 Shaft guard bolt, 5/16 x 3/4" NC Nut, 5/16 keps Bolt, 5/16 x 3 3/4" USS tube, 1" 14ga 1 3 4 1 1 61 Reference Number 60 61 62 63 65 70 73 75 78 80 85 88 101 102 Part Number 10754 50619 10803 50085 10755 45416 50609 10705 50025 45426 45420 45424 18352 18353 18354 50255 50015 18402 50208 50013 50740 45427 45421 45425 50152 50701 50007 70230 50815 18312 18301 18351 18391 18390 50847 50087 50717 50001 50718 18400 18401 18403 40729 50162 50704 50007 20012 50202 50740 20838 Part Description ­ 4x4models Seatback 43 1/2 x 17 1/2 #14 X 1-3/4" Pan head-Tapping screw Headrest - UTV 9 x 6 1/2 bolt, 1/4 x 1 1/2" Seat bottom 43 1/2 x 17 1/2 seat bar, CW (17 1/2") - black #14 x 3/4 pan head tapping Seat Belt, 2pt 7/16 Nylock Cargo Bed, Green Cargo Bed, Red Cargo Bed, Black Camo Bed Panel Left Camo Bed Panel Right Camo Bed Panel Tail Gate 5/8 x 4" bolt Zinc plate 5/8 nylock Bed Rubber Plug Bed latch bolt, 3/8 x 2 1/2" nut, 3/8 keps washer, 3/8 flat Tail gate, green Tail gate, Red Tail gate, Black bolt, 5/16 x 1 washer, 5/16 sae nut, 5/16 nylock rubber bump stops 1/4" Lynch Pin - tailgate latch Roof, green Roof, Red Roof, Camo Roof, Top Vinyl Trim Roof, Hardware bolt kit Clamp-Tube-vinyl coated 1-3/4" bolt, 1/4" x 1 1/4" SAE Flat washer nut, 1/4" nylock Washer, ¼" Rubber Domed Windshield - clear Windshield - tinted Fastener kit, windshield Front receiver hitch 4x4 kit Bolt, 5/16 x 1-3/8 - U Washer, 5/16 Flat Nut, 5/16 Nylock Engine, Honda 13hp 3/8-16 x 1 3/4" Hex Hd Bolt 3/8" Flatwasher, USS Dana Transaxle 4x4 Quantity Required 1 6 2 4 1 2 6 2 4 1 1 1 1 1 1 2 2 2 1 2 2 1 1 1 2 4 2 4 2 1 1 1 1 4 4 4 4 4 1 4 8 8 1 4 4 1 62 Reference Number 103 104 105 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 Part Number 45502 45430 18023 50086 50082 50000 50715 20648 20665 20649 20666 11166 50745 50742 50741 50219 20693 20694 50239 50722 50721 45431 50157 50703 50704 70250 50010 50740 10581 50021 42093 50206 50010 50740 50730 50280 50020 18012 50084 50000 18011 11104 50150 50007 11010 50087 50000 11804 Part Description ­ 4x4models Swing arm, CW - Black 4x4 Motor Plate, CW - Black Throttle Guard Laser 1/4-20 x 1 1/4" Hex Hd Bolt 1/4-20 x 2 1/4" Hex Hd Bolt 1/4" Keps Nut 1/4" Flatwasher, USS TC, Driver Comet 500 ­ used before Serial Number #25663 TC, Driver CVTECH ­ used after Serial Number #25663 TC, Driven Comet 500 ­ used before Serial Number #25663 TC, Driven CVTECH ­ used after Serial Number #25663 Brake Shoes - Rear UTV ­ Dana ( 1 set per wheel) 1" I. D. Spacer Washer­ Comet only (not used with CVTech pulley) 1/4 x 3/16" Keystock 3/8" I. D. Fender Washer­ Comet only (not used with CVTech pulley) 3/8" Lock Washer­ Comet only (not used with CVTech pulley) 3/8x 3" Bolt Hex Hd NF­ Comet only (not used with CVTech pulley) Belt, Comet 300668 used before Serial Number # 25663 Belt, CV TECH ­ used after Serial Number # 25663 1/2 x 2" SAE 1/2" Lock Washer 1/2" Uss Flat Washer 3/16" Key stock Tension Mount Engine, CW - Black 5/16x 3/4" Bolt Hex Hd NF 5/16" Lock Washer 5/16" Flatwasher Rubber Feet (Isolators) 3/8 Nylock Nut 3/8 Flatwasher USS Rod End Sphcl-UTV (4681-MPM-12) 3/4 Jam nut SAE Panhard bar, CW - black 4x4 bolt, 3/8 x 1 3/8" Nylock Nut 3/8" Flatwasher, USS 3/4' Spacer Washer 3/4 x 2. 5 SAE bolt 3/4 SAE nylock shifter lever, CW - black 1/4-20 x 3/4" Hex Hd Bolt 1/4" Keps Nut shifter cable mount, CW - black Parking Brake Cables 4x4 5/16-18 x 1" Hex Hd Bolt 5/16" Nylock Nut Throttle Cable, UTV 1/4-20 x 1" Hex Hd Bolt 1/4" Keps Nut Spring #80704 Black painted Quantity Required 1 1 1 3 1 5 8 1 1 1 1 2 4 1 1 1 1 1 1 1 1 1 1 1 2 2 2 5 10 5 3 3 1 4 4 4 6 3 3 1 2 4 1 2 2 2 1 1 2 1 63 Reference Number 133 136 137 138 139 140 141 150 151 152 153 Part Number 11804 65500 50849 18313 18314 18315 50624 50050 50770 20011 25004 10184 20852 18042 18083 70232 50163 50701 50703 50005 50303 50794 50028 18032 50163 50701 50703 Part Description ­ 4x4models Spring #80704 Black painted fuel hose 3/16" dia - 24" hose clamps - small Belt Guard Plastic UTV - Front Belt Guard Plastic UTV - Rear Belt Guard Plastic UTV - Bottom #10 x 3/4" Blunt Point Black #10 Speed Nut - for Plastic #10 Flatwasher Choke Bracket Honda Engine right angle gearbox Key, 3/16 x 1 gearbox coupling Gear box bracket "torque arm" (long) built before 10-06 Gear box bracket (short) built after 10-06 rubber washer - built before 10-06 bolt, 5/16 x 3/4" NC Washer, 5/16 flat Washer, 5/16 lock Nut, 5/16 keps Bolt 7/16 x 1 3/4" - built before 10-06 Washer, 7/16 flat - built before 10-06 Nut, 7/16 nylock - built before 10-06 diff lock mount bolt, 5/16 x 3/4" NC Washer, 5/16 flat Washer, 5/16 lock Quantity Required 1 1 3 1 1 1 7 7 7 1 1 3 1 1 1 2 4 6 2 2 1 2 1 1 2 2 2 Accessories Available call 1-866-646-5278 BRISTER'S DESIGN & MANUFACTURING CO. , LLC. 64 LIMITED PRODUCT WARRANTY This warranty applies to defects in workmanship or materials only. No other warranty expressed or implied exists. [. . . ]