BRISTERS Chuck Wagon User manual

Type
User manual

This manual is also suitable for

Brister’s Utility Vehicles
2 Wheel & 4 Wheel Drive Models
Operator’s Manual
Copyright
January 1, 2007
DIN EX
Section 1 Introduction pages 3-4
Serial Number Plate Location page 4
2 10 Section Safety pages 5-
Pre-Delivery Steps page 9
page 66
Warrant ate
Dealer Inspection Checklist page 10
ection 3 Assembly Instructions pages 11-13 S
Seat Back, Brush guard, Bumper page 12
Steering wheel page 12
Cargo Bed page 13
Seat Base page 13
Section 4 Operating Instructions page 14
Section 5 Maintenance pages 15-22
Fuel Valve Lever page 15
Air Cleaner Page 16
Engine Oil page 17
Transaxle Oil page 18
Drive Belt page 19
Section Troubleshooting pages 20-28 6
Troubleshooting Chart page 26
ection 7 Parts Diagrams pages 29-64 S
Wiring Diagram page 30
11hp 2 wheel drive pages 31-42
265cc 2 wheel drive pages 43-53
13hp 4-wheel drive pages 54-64
arranty Policy page 65 W
Contact Information
y Registration Certific page 67
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 yo
will make a sincere effort to put safety above a
u
ll other
riorities. The Brister Utility Vehicle was designed and
pared to instruct you in the
al
end each section in this
anual to develop an understanding of your vehicle and
a
The Operator’s Section is designed to help familiarize
intenance. Read this manual
the recommendations to help ensure safe
and efficient operation.
* The information contained within this manual was
current at the time of printing. Some parts may change
slightly to assure you of the best performance.
* To order a new Operator’s or Parts Manual contact
thorized dealer.
p
built for work, recreation, and enjoyment; however,
improper and irresponsible operation could result in
serious injury or death. Since this is an off-road vehicle,
operators will seldom see the road safety and warning
signs they are accustomed to seeing on highways and
public streets. This places additional responsibility on
the driver to operate this vehicle well within the safe
operational limits and capabilities of the unit.
This manual has been pre
safe and responsible operation of your Brister Utility
Vehicle. Read and abide by all safety alert information
about this vehicle. If you do not understand any part of
this manual, contact your local dealer for additional
information and clarification. As the operator of this
iece of equipment, you are in complete control. Only p
you can prevent an accident from happening.
Using This Manual
* Prior to any vehicle operation it is absolutely essenti
that you read and compreh
m
for your safety. After reviewing this manual, store it in
dry and easily accessible place for future reference.
*
you with safety, assembly, operation, adjustments,
troubleshooting, and ma
and follow
y
our au
Brister’s Design & Manufacturing Co. LLC
Toll Free PH: 1-866-646-5278
d,
y
y
n,
rear differential.
lso unlike an ATV’s one person “straddle saddle” seat,
e Brister Utility Vehicle sports dual headrest
ushioned seats with seat belts mounted in a highly
gers
shing water and mud. The Brush Guard Bar
Fax: 1-866-329-5278
www.bristers.com
Terminology
Right-hand and left-hand as used in this manual are
determined by facing the direction the vehicle will travel
while in use unless otherwise stated.
Getting Acquainted with your Utility Vehicle
This off-road utility vehicle is a very unique vehicle
designed exclusively for off-road use. It is not designe
properly equipped, or licensed to be safely operated on
public streets and highways. This vehicle is designed to
carry two people and a limited amount of gear or cargo
comfortably and safely over rough terrain that was onl
accessible by ATV’s in the past.
Unlike ATV’s that have handlebar steering, Brister Utilit
Vehicle’s have a steering wheel with easy handling
rack-and pinion steering. The steering’s tight turning
radius makes this vehicle more maneuverable than
most ATV’s. Its four wheeled independent suspensio
large diameter hi-flotation tires and high center-frame
ground clearance adds up to excellent stability and a
smooth ride over rough terrain. Outstanding two
wheeled rear traction drive is achieved by using
premium off-road ATV type tires in tandem with the
engine mounted directly in front of the
A
th
c
styled and protective full length body. Two passen
can ride comfortably in this vehicle protected from
spla
mounted to the vehicle’s frame provides protection
against low hanging limbs and briars.
3
Section 1 Introduction
Always use the serial and model number when ord
arts r your Brister Utility Vehicle. The serial-num
ering
fo ber
The Brush Guard Bar also provides a mounting system
for Brister’s optional windshields, canopy tops and
weather enclosures. It also serves as a mounting base
for many other optional cargo racks, gun and bow racks
The cargo bed is for transporting accessories such as
camping equipment, tree stands, hunting gear, and
fishing gear. A standard hitch moun
.
ting plate enables
uick installation of a rear hitch for pulling small trailers
an
ll
and narrow stance also
nables this vehicle to be loaded in the back of most full
ransport.
is
ards.
ed by the owner
nd the Warranty Registration card should be filled out
sary to provide you with quality
customer service.
T
have been spec
replaced with g
If customer service or repair parts are required contact a
Brister’s dealer. They have trained personnel, genuine
repair parts and equipment specially designed to repair
Brister’s products.
Product Support
Brister’s Design & Manufacturing Co. LLC
P.O. Box 649
Roseland, LA 70456
Toll Free PH: 1-866-646-5278
Fax: 1-866-329-5278
p
plate is located under the cargo bed on the driver’s side
just above the engine, on the frame as shown in figure 1
below.
q
full of supplies, tools, gear, and game.
The Brister Utility Vehicle has some similarities to
ATV. Like an ATV the Brister Utility Vehicle has a short
wheelbase, narrow stance, and high center clearance a
which provide for narrow and difficult trail access. This
combination of short wheelbase
e
to mid-sized pickups for t
The Brister Utility Vehicle’s ground compaction and is
very gentle on the ground and surrounding vegetation.
The highly energized four wheeled independent
suspension system provides an incredibly soft ride and
outstanding stability over difficult terrain. The engine
EPA certified and meets California Air Resources Board
ARB) certification (C stand
Owner Assistance
The safety information should be view
Serial Number Plate Location
_________________
Your Brister’s dealer ur
f this
r you’re not satisfied with the service received,
t e the llowing actions.
Discuss the matter with your dealership service
manager. Make sure they are aware of any problems so
they can assist you.
If you are still unsatisfied, seek out the owner or general
manager of the dealership.
For further assistance write to
Figure 1
Record your Brister Utility Vehicle serial number here for
quick reference:
a
by the dealer at the time of purchase. The owner, upon
purchasing the vehicle, should have participated in a
short drivers training course with the dealer. This
information is neces
Model Number:___________________________
Serial Number:___________
he parts on your B le Utility Vehicle rister Utility Vehic
designed and sho
wants you to be satisfied with yo
ou do not understand any part o
ially uld only be
enuine Brister’s parts.
new vehicle. If y
manual o
please ak fo
4
Read These Important Rules for Safe Operation
Note: The Operator, Passenger, Parent or Guardian must read, study and understand all the items contained
within this owners/operators manual before operating utility vehicle. Failure to follow these instructions
could endanger the personal safety of the Operator, Passenger and any Bystanders.
Close adult supervision is required at all times!
Pay close attention to all Caution and Warning labels
Located on the Utility Vehicle
*IMPORTANT*
When transporting any Brister Utility Vehicle with an installed windshield or
Color matched top DO NOT reach high speeds!
Assumption Of Risk
The owner or operator assumes all the risks incident to or arising out of the operation of
this Utility Vehicle
Failure to follow and comply with all warnings may
cause serious injury or death
5
Section 2 Safety
It is very important to read, understand, and follow all
instructions and warnings located on the decals on your
rister Utility Vehicle. B
6
Section 2 Safety
Safe Operating Procedures
oncern to
ll consumers. Your Brister Utility Vehicle has been
uld operate this vehicle before carefully
ading this Operator’s Manual. Also read all
Keep all bystanders away from this vehicle during
his vehicle who has
ot fully read and comprehended this manual and who
epair all damages and defective parts before
utting vehicle back in to service.
one under 16 years of age to operate
is vehicle.
Operator must always use both hands on the steering
No riders allowed except in factory designed and
Operate this vehicle from the driver’s seat only.
with engine
nning.
vehicle as serious injury or
eath could occur.
and belts exposed.
ey are hot.
* Keep hands, feet, long hair, clothing, and jewelry away
from moving parts and obvious pinch points to avoid
getting caught.
* Wear snug-fitting clothing to avoid entanglement with
moving parts.
The safe operation of any machinery is a big c
a
designed with many built-in safety features. However,
no one sho
re
instructions noted on the safety decals.
* Be familiar with all functions of this vehicle.
*
operation.
* Do not allow anyone to operate t
n
has not been properly trained in the safe operation of
this vehicle.
* Do not operate a vehicle with damaged or defective
parts. R
p
* Do not allow any
th
*
wheel.
*
supplied seating.
*
* Do not leave this vehicle unattended
ru
* Do not dismount a moving
d
* Always operate vehicle with belt guard installed. Do
not leave pulleys
* Do not touch engine, engine exhaust pipe and/or
muffler while th
* Some conditions may warrant extra safety gear to be
orn such as safety helmets and/or goggles. w
Keep hands, arms, feet and all bodily a* ppendages
d tree limbs and brush
ill
f
.
of control may result.
evice to
e.
bject causing serious injury
ull gently. Always stay clear of the
go
nd.
ever make turns at full speed. Reduce
peed when turning empty and reduce speed even
safely inside the confines of the vehicle.
Always be aware of and avoi*
that have a potential of hitting and/or poking individuals
riding the vehicle. Serious body harm could result.
* Avoid sudden stops, starts, and turns.
* Always operate your vehicle at a safe speed that w
allow you to maintain control.
* Operator and passenger are responsible for deciding i
their situation warrants using seat belts.
* Do not exceed total payload capacity of this vehicle
* Do not pull a trailer or implement exceeding 1100
ound towing capacity or lossp
Do not attach an implement, trailer or other d*
the hitch that will produce negative tongue weight.
* Follow all towing instructions in this manual when
towing the UTV behind another vehicle. Do not tow
vehicle faster than 25 MPH.
Do not use the vehicle as an anchor devic*
* Beware, tow ropes, cables and chains can break when
ulling another vehicle or op
or death to anyone in line with the whipping action
created when they break. Never jerk when pulling,
lways ease into a pa
tow line. Never be in line with the tow line.
* Reduce speed when loaded with cargo. Heavy car
load takes longer to stop.
* Reduce speed and payload on hilly, rough, wet, slick
r unstable grouo
* Always make turns at a speed that will maintain control
f vehicle. No
s
7
more when turning loaded with cargo or when pulling a
cargo load. The heaver the cargo load, the slower the
rn should be.
all gear or cargo is properly secured and
ed down.
s.
tal on this vehicle.
latform to
e vehicle.
quipment. Rollover could result from such loading.
rtified ROPS (Roll Over
rotection System). Always avoid rollovers.
traffic.
the
. Never
afe
Never use vehicle for racing and never modify the
rectly and indirectly affected by
e modification.
f all
personnel
round vehicle and especially location of small children.
Always park on level ground, stop engine, set parking
k tires if condition warrants.
u are sure trail
resting hills or going
ver bumps.
top, start suddenly or over accelerate on hills.
oss of control and rollover could result.
ing
nd tractive
apabilities are greatly diminished.
teeper.
ay occur.
control.
When crossing a slope on soft terrain, turn the front
avel.
free wheel in neutral or
ss of control may result.
engage the foot brake and back slowly
own the hill maintaining a straight downhill line of
ts
in
Avoid water crossings when possible and never cross
r
d waterways
rodes shore line and damages water-born habitat. If
designed as
usher bars. Do not attempt to push other vehicles or
When refueling use an (UL) approved non-metallic
t the container
n the ground before fueling to eliminate static
lectrical devices including cell
hones while refueling.
tu
* Make sure
ti
* Do not exceed 400 lbs. in cargo bed area, or 900 lb
to
* Do not mount a receiver hitch type carrier p
th
* Do not load the Brush Guard Bar with heavy
e
* The Brush Guard Bar is not ce
P
* Do not operate this vehicle on highways, public roads,
or where it may be a hazard to faster moving
* Do not operate this vehicle while drinking or under
influence of alcohol and drugs.
* Never attempt wheelies, jumps, or other stunts
drive recklessly. Always operate your vehicle at a s
speed that will allow you to maintain control.
*
engine to exceed 25 MPH vehicle speed.
* Never modify any parts on the vehicle without
authorization. Unauthorized modifications will void
warranty to all parts di
th
* Always make sure the vehicle pathway is clear o
objects when backing up. Know location of
a
Take extra precautions when rear view is hindered by
cargo.
*
brake and remove ignition key before leaving the
vehicle. Choc
* Use extreme caution when cresting hills or when
visibility is limited. Proceed slowly until yo
conditions immediately ahead are safe.
* Keep front wheels straight when c
o
* Do not s
L
* Use extreme caution when descending hills or runn
on loose slippery surfaces. Towing, braking, a
c
* Do not operate vehicle on 15 degree slopes or
s
* Avoid changing direction or making sharp steering
corrections on slopes or rollover m
* If this vehicle begins to tip when crossing a slope, turn
the front wheels downhill to regain stability and
*
wheels slightly uphill and maintain a constant speed to
maintain a straight line of tr
* When descending hills or slopes apply steady
pressure to the foot brake to avoid potential of
freewheeling or runaway.
* Never allow vehicle to coast or
lo
* If your vehicle loses power and stops on a hill,
immediately
d
travel. Do not attempt to turn the vehicle sideways on
the hill or a rollover could result.
* When traveling at night always use your headligh
and reduce speed according to visibility, trail, and terra
conditions.
*
a body of water where depth is unknown. Loss of powe
will occur if the drive belt becomes submerged or wet.
Unnecessary crossing of streams an
e
you must cross, do it at a point where banks are not
steep and proceed at a slow and steady speed.
* Front bumper and brush guards are not
p
implements or damage may result.
*
container that has no screen or filter. Se
o
discharge and do not use Methanol fuel.
* Do not smoke or use e
p
* Always maintain proper tire inflation.
8
* Always disconnect the negative battery terminal befo
making a
re
djustments to the vehicle electrical system or
elding on this vehicle.
ing a
d in this
anual.
at least 15
inutes if battery acid has gotten on them.
fter initial operation and two hours after each tire repair
e
ng.
cle must undergo a Pre-Delivery Inspection
y the Dealer. Listed below is an example of the
ith the Warranty Registration
st
e “Pre-Delivery” steps
efore customer may take possession of the vehicle.
d
erforming the checks.
ealership’s name, signatures of individuals filling in the
r’s signature, and
is re uired to be
ehicle Information
__
w
* Battery fumes are explosive. A spark will ignite battery
fumes. Wear a face shield when charging or jump
battery. Follow all battery safety rules outline
m
* Avoid battery acid spills. Do not get battery acid on
eyes, face, or other body parts. Flush eyes and other
body parts immediately with water for
m
* Always check wheel lug nut torque values two hours
a
and/or replacement. Routinely check lug nut torqu
valves every 100 hours of operation.
* Support this vehicle securely before working beneath.
Chock the wheels to prevent the vehicle from rolli
* Do not shift transaxle unless this vehicle is fully
stopped and the engine is at idle or damage may occur.
Each vehi
b
checklist that is included w
that is to be submitted to Brister’s upon Retail Sale. The
Pre-Delivery Certificate and Warranty Registration mu
be submitted to Brister’s in order to activate the vehicle
warranty.
Pre-Delivery Steps
The dealer is required to complet
b
This information must be filled in and check list checke
off or initialed by individuals p
D
form, seller’s signature, custome
signing dates are also required.
Below is a list of the information that q
ompleted and checked off. c
V
Model No. _______ __
Date ___________
al No. ___________ Seri
Engine Serial No.
ealer Service and Inspection List
charged.
ts/nuts are tightened to 90
l at the dipstick. Add SAE
ark on the dipstick.
nd under seat storage
ck engine for correct RPM. Set to factory
tness.
l is firm and
seat belts are properly fastened
ce.
and
cuting a full lock to lock turn in
ke sure it will engage,
old and release.
D
__
Fully charge battery. Check battery voltage to verify
hat it is fullyt
__ Check fuel valve lever to make sure it is in the
correct position.
__ Check tire pressure to make sure front and rear tires
have 6 psi.
_ Make sure wheel lug bol_
Newton meters (65ft.lbs).
__ Check engine oil leve
10W30 oil if oil is below the full m
*this should be done with seat (a
Tray if equipped) removed
_ Che_
specification if needed.
__ Check tie rods for tigh
__ Check Choke Control. It should move and return
reely. f
_
d
_ Step on foot brake to make sure the peda
oes not go to the floor.
__ Make sure seats and
to the frame.
_ Make sure all safety decals are in pla_
__ Check headlights to make sure they are working
are properly mounted.
__ Inspect air cleaner element. Make certain it is clean
and in place.
__ Inspect the fuel tank to make sure it is properly
installed and that there are no leaks.
__ Check fuel level to make sure there is at least 1/8 of
a tank of gas prior to performing initial starting
operations.
__ Inspect fuel lines to make sure they are properly
installed and that there are no leaks.
_ Check steering by exe_
each direction.
__ Check parking brake to ma
h
9
__ Check throttle control to make sure it moves and
returns freely.
__ Fluid fill and lubrication points have been located and
explained to the customer.
__ Check differential oil level at the differential oil plug.
cleanliness and for
ealer Test Ride List
ng
sponse. Also check neutral start response.
k parking brake to make sure it engages, holds,
nd disengages.
_ Make sure throttle is responsive and returns freely.
sion ride is satisfactorily and
table.
re there are no fuel or petroleum leaks.
gement and
tration form is complete.
d
mer.
ustomer.
_ Fuel transportation and storage procedures have
__ Information on the safety decals have been reviewed
with the customer.
Add 30 weight oil if oil is low.
_ Check overall appearance for
Customer Acceptance List
_
body and molding damage.
Customer initials required where accepted as
successfully completed.
D
__ Check engine for starting, accelerating, runni
smooth, and idling smoothly.
__ Customer has reviewed and understood warranty
policy (ies).
__ Check steering response. There should be no free
play.
__ Customer has inspected the vehicle and it meets
customer satisfaction.
__ Check forward, neutral, and reverse shifting
__ Customer understands the importance of following
the owner’s manual instructions.
re
__ Chec
a
_
__ Make sure the suspen
s
* IMPORTANT NOTICE *
__ Make su
WHEN TRANSPORTING ANY
BRISTER UTILITY VEHICLE
WITH A WINDSHEILD OR COLOR MATCHED
TOP DO NOT EXCEED 55MPH
__Make sure the foot brake has a firm enga
that stopping is straight.
__ Make sure there are no abnormal rattles or
vibrations.
Dealer Delivery to Customer List
__ Warranty regis
__ Owner’s Manual has been delivered to and reviewe
by the customer.
Brister’s Design & Manufacturing Co. LLC
Toll Free PH: 1-866-646-5278
Fax: 1-866-329-5278
__ Engine Manual has been delivered to and reviewed
by the custo
www.bristers.com
__Warranty Policy limits and requirements have been
explained to the c
__ Location and functions of vehicle controls have been
explained.
_
been explained.
__ Transportation of utility vehicle is limited to 55mph,
hen equipped with top and windshield w
10
Section 3 Assembly Instructions
Brister Utility Vehicle Utility Vehicle
Assembly Instructions
ollowing items to be assembled:
Your new Brister Utility Vehicle Utility vehicle should include the f
Qty Item
1 #8 black screw (steering cap)
3 ¼” x 1 ¾” Hex head bolts
7 ¼” nylock nuts
4 ¼” x ¾” carriage bolts
4 ¼” flat washers
8 5/16” x 2” socket head bolts
12 5/16” curved washers
10 5/16” nylock nuts
4 5/16” x 2” hex head bolts
2 5/16” center lock nuts
Qty Item
2 5/8” x 4” Hex bolt
2 5/8” nylock nuts
1 set of keys
1 Steering wheel (with cap)
1 Bumper
2 Rear fenders
2 Rear frame stubs
1 Seat back
1 Cage
1 Cargo Bed with tailgate
11
Section 3 Assembly Instructions
Pre-Assembly Instructions
1) wner’s Manual.
nd assembly parts. Make sure you
ed on the previous page.
o have any questions or problems with your
Brister's Design & Manufacturing Co. LLC product
please call us, 66-646-5278.
Read O
2) Unpack all vehicle a
have everything list
3) If y u
toll free 1-8
Seat / Brushguard Assembly
1) Place seat back frame on vehicle frame tubes.
Insert a 5/16” x 2” socket head bolt through
both bottom joints. The head of the bolt should
be on the outside of the vehicle. Put a curved
washer on the threaded end of the bolt. Place
a 5/16” nylock nut on the bolts but do not
tighten.
2) Place the cage on front vehicle frame tubes
and seat back. Insert a 5/16” x 2” socket head
bolt through all four joints. The head of the
bolt should be on the outside of the vehicle.
Put a curved washer on the threaded end of
the bolt. Place a 5/16” nylock nut on the bolts.
Tighten all 6 nuts (including step 3).
Bumper Installation
1) Align the holes in the front bumper with the
mounting holes in the front frame tubes. Insert
the four 5/16” x 2” bolts through the bumper
bracket and then into the frame tubes. Put a
curved washer on the threaded end of the bolt.
Place a 5/16” nylock nut on the bolts and
tighten.
Steering Wheel Installation
1) Remove the plastic steering column cover by
removing the 3 screws on the bottom with a
5/16” socket. If equipped with top and bottom
steering column covers
2) Turn vehicle steering so that it is pointed
straight forward. Line up holes in steering
wheel with mounting holes so that the center
spoke is pointing down. Install ¼” x 1 ¾” hex
head bolts from the back. Tighten with ¼”
nylock nuts.
3) Install steering cap with #8 black screw.
4) Re-install steering column cover.
12
Cargo Bed Installation
1) Locate rear frame stubs at the rear of frame.
The bed pivot tube on the stub should be at
the top. Insert 5/16” x 2” socket head bolt.
Loosely install 5/16” center lock nut (do not
tighten until after cargo bed is installed)
2) Place the cargo bed on the vehicle and insert a
5/8” x 4” hex head bolt through each pivot
bracket and frame stub tube.
3) Tighten both 5/16” frame stub bolts and nuts.
4) Install the 5/8” nylock nuts on the pivot bolts.
Tighten the pivots and then loosen ¼ turn.
5) Loosen the bed latch pin bolt on the frame just
enough for it to slide in the adjustment slot.
(shown in upper right photo)
6) Close the bed and position the latch pin bolt so
to
prevent rattles. Tighten the latch pin.
that it is at the bottom of the latch slot
7) Fenders installation (if Equipped, no fenders
on TW265) Tilt the cargo bed up. Line up the
holes in the rear fenders with the square holes
in the bed. The raised rectangular surface on
the fender should be completely hidden under
the bed. If not, turn the fender around. Insert
a ¼” x ¾” carriage bolt through the bed and
into the fender. Fasten with a ¼” flat washer
and a ¼” nylock.
Sea a
1) Pl ed to seat base under front seat
t B se Installation
ace tabs attach
frame bar (if equipped into slots in plastic tray), fold
seat base into position. (if equipped The rear tabs
sh
tray)
ould fall into the slots in the rear of the plastic
13
Sec oti n 4 Operating Instructions
General Operation
Start your Brister Utility Vehicle by following the starting
procedures as noted below.
1. Depress brake pedal with your foot and hold.
Pull firmly up on the park brake lever with your
hand until the lever is tight.
2. Place gearshift in neutral
3. Apply choke fully when engine is cold.
4.
engine.
5. Release ignition key to run position and chok
to normal operating position immediately after
engine starts.
Turn ignition key fully clockwise and hold to stop
e
6 Turn ignition key counterclockwise to stop
engine.
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
tarter mechanism is provided on the engine
ou accidentally leave the key on and run
infinitely variable torque converter
s no clutching. You just shift
vehicle is
go. Never shift
ing is accomplished by simply depressing the brake
n the center console located between the
Driving is as
pull-rope s
st in case y ju
the battery down. The
drive system means there i
into either forward or reverse when the
stopped and press the throttle pedal to
while the vehicle is moving.
rakB
pedal that is located on the floorboard left of the
accelerator. A lever action parking brake control is
mounted o
operator and passenger seats. Depress the button on
the park brake control lever to release the park brake.
Pre-Start Check List
__ Check tire pressure as indicated.
s.
_ All nuts, bolts, screws, and fasteners should be
cked.
_ Turn on headlights to make sure battery has a charge
nd electrical lighting circuit is working.
_ Check tail lights and brake lights. (if applicable)
_ Check park brake to make sure it will engage, hold
nd release.
_ Check steering by executing a full lock to lock turn in
__ Check engine oil level at the dipstick. Add oil as
should be
__ Make sure wheel lug bolts/nuts are tightened to 65ft.
lb
_
che
_
a
_
_
a
_
each direction.
indicated.
_ Check differential oil level at the differential oil plug._
Add gear lube as indicated.
__ Check fuel valve lever position. Valve lever
ff except when running the engine. o
__ Check fuel level to make sure there is at least 1/8 of a
tank of gas prior to performing initial starting operations.
14
Section 5 Maintenance
Fuel Type
The fuel tank is located under seat.
is 5 Gal.
W-265 & TW265 Fuel capacity is 6.1 Liters
hen filling the fuel tank, place the gear shift in forward
rake, turn off the engine, and
move ignition key. Clean dirt from around the fuel tank
inished, screw
e cap back on securely and wipe up any spilled
aded gasoline with an octane
ting of 87 or higher.
nol, gasoline
fuel system could be
varnish build-up in the fuel system.
dd the correct amount of gas stabilizer/conditioner to
the gas. Follow the gas stabilizer/conditioner
manufacturer’ st results.
See engine o ual for the following:
* Draining the
g fuel line for cracks and leaks.
Engine fuel valve lever.
attention should be paid to
pplicable data that is not duplicated here.
TW11, TW 413, CW11, CW413 Fuel Capacity
C
W
or reverse, set the park b
re
cap, remove cap, and begin filling. When f
th
gasoline. Use regular unle
ra
IMPORTANT: Never use metha
containing methanol, or gasohol containing more than
10% ethanol because the
damaged. Do NOT mix oil with gasoline.
Using a fuel stabilizer/conditioner in the vehicle can
provide benefits such as:
* Keeps gasoline fresh during storage of 90 days or less.
For longer storage, drain the fuel tank.
* Cleans the engine during operation.
* Eliminates gum-like
A
s directions for be
perator’s man
fuel tank.
Checkin*
*
Engine Maintenance
General Information
Detailed instructions and recommendations for break-in
and regular maintenance are specified in the engine
operator’s manual. Engine warranty is backed by the
engine manufacturer. Please refer to engine
manufacturer’s manual for engine servicing, lubricating
oil levels, oil quality and viscosity recommendations, bolt
orques, etc. Specialt
a
Engine Fuel Valve Lever
fer to Figure 5-1
closes the passage
tween the fuel tank and carburetor. Leave fuel valve
n use
Re
The engine fuel valve opens and
be
lever in the OFF position when the engine is not i
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.
FUEL VALVE
Figure 5-1
15
Section 5 Maintenance
* Foam element – Clean foam element with
detergent in warm water or in a nonflammable solvent.
Do not wring element. Squeeze excess cleaning fluids
out. Allow time for the element to dry and then soak it
ith clean engine oil. Squeeze excess oil out. Excess oil
ft in the filter will cause engine to smoke briefly when
rst started.
efore installing the filter elements to make sure they
en damaged during cleaning. Never run an
w
le
fi
B
have not be
engine without the filters installed.
Figure 5-2
Spark Plugs
HONDA
NGK BPR6ES
CHAMPION RN9YC
UTOLITE 4263 / 63
UBARU
A
DENSO W20EPR-U
S
RLH6C
NGK BR6HS
HAMPION C
Air Filter Elements Replacement Parts
Description Part No.
Honda
Paper Filter Element 17210-ZE3-000
-010
e monthly for cracks,
ge. Replace immediately if any
amage is suspected.
Honda
Foam Filter Element 17210-ZE3
Refer to Figure 5-2
Subaru
Paper & Foam Element (265cc) 279-32607-07
Fuel Hose – Inspect fuel hos
leaks or other dama
d
16
Section 5 Maintenance
Engine Oil
A general description for engine oil maintenance,
recommendations, and capacities is provided below
See Eng
.
ine Operator’s Manual for a detailed description.
Note:
eng
Note:
illing of oil level can cause loss of
power, engine damage and void engine warranty.
Engin
Ref
REMOV
EAS
ap/dipstick location: At front end of engine
of
J, SL or Equivalent
Honda Engine Oil Capacity: 1.16 US qts. /1.1 liters
Engine Oil Maintenance Schedule
* Check oil level after each use.
* Make first oil change after the first month of operation
or at 20 hours of operation (whichever comes first).
* Make all subsequent oil changes every 6 months or
every 100 hours of operation (whichever comes first).
Engine Oil Level Check
Refer to Figure 5-4
Check engine oil daily with filler cap/dipstick located at
1. Park Vehicle on a level surface, set park brake,
turn off ignition switch, and remove switch key.
2. Remove filler cap/dipstick and wipe it clean.
3. Insert and remove dipstick without screwing it
into the fill neck. Check oil level shown on
ly.
herefore,
rain used engine oil while engine is still warm as
llows:
on a level surface, set park brake,
turn off ignition switch, and remove switch key.
tch
and then
reinstall and tighten drain plug securely.
at is
Running engine low on oil can cause
ine damage and void engine warranty.
Overf
e Oil Fill and Drain Locations
er to Figure 5-4
E SEAT (and plastic tray if equipped) FOR
Y ACCESS
* Filler c
* Drain plug location: At rear end of engine
Type of Lubrication: SAE 30, with API classification*
S
*
* Subaru Engine Oil Capacity: 1.1 US qts. / 1.0 liters
* Quantity: Fill oil to outer edge of oil fill hole.
the engine rear end as follows:
dipstick.
4. Fill to edge of oil fill hole with recommended oil
when oil levels are low.
5. Replace filler cap/dipstick and tighten secure
Engine Oil Change
Warms oil drains quickly and completely. T
d
fo
1. Park vehicle
2. Place a suitable container below engine to ca
used oil. Remove filler cap/dipstick and drain
plug.
3. Allow used oil to drain completely
4. Dispose of used motor oil in a manner th
compatible with the environment. Do not throw
used oil in the trash. Do not pour it on the
ground, or down a drain.
5. Fill oil to the outer edge of the oil fill hole with
recommended oil. Engine must be level when
filling.
6. Replace filler cap/dipstick and tighten securely.
NOTE:
TO DRAIN OIL REMOVE REAR OIL DRAIN PLUG
Engine Oil Drain, Fill & Check Locations
Figure 5-4
17
Section 5 Maintenance
Transaxle Oil
A general description for transaxle oil maintenance,
endations, and capacities is provided below.
xle oil can
Oil Type, Fill, and Drain
Ref
* Fil p
* Dr
* Ty o
* Transa
Transa
* Ch
leakage
* Check l every 6 months or every 200
hou w
This ccomplished by Parking vehicle on a level
surf ce, set park brake, turn off ignition switch, and
remove switch key, using a clean long bladed screw
driv r hole until it
touch e the screw
There should be approximately 2.1/4” to 2.1/2” of
le on screw driver. Refer to Figure 5-5A
Change transaxle oil once a year or every 600 hours
hichever comes first).
recomm
NOTE:
Running vehicle low on transa
nd void warranty.
damage transaxle a
Transaxle
er to Figure 5-5
l ca location: At rear left hand side (See arrow)
ain plug location: At bottom center of transaxle.
pe f Lubrication: SAE 30W oil.
xle Lubrication Capacity: 20 oz.
xle Oil Maintenance Schedule
eck transaxle housing for damage and possible oil
after each use.
transaxle oil leve
rs ( hichever comes first).
can be a
a
er (or similar object) insert into fille
es the bottom of gear case. Remov
driver.
il visibo
*
(w
Transaxle Oil Change
Refer to Figure 5-5B
Warm oil drains quickly and completely. Therefore, drain
used transaxle oil while transaxle housing is still warm
as follows:
. Park vehicle on a level surface, set park brake,
turn off ignition switch, and remove switch key.
. Place a suitable container below the transfer
case to catch used oil. Remove fill cap and drain
plug.
. Allow used oil to drain completely and then
reinstall drain plug and tighten it securely.
transaxle case oil in a manner
ment. Do not
throw used oil in the trash, pour it on the ground,
or down a drain.
5. Fill transaxle housing with 20 oz. SAE 30W oil.
6. Replace fill cap and tighten securely.
1
2
3
4. Dispose of used
that is compatible with the environ
Figure 5-5B
Figure 5-5A
18
Section 5 Maintenance
Drive Belt
The dive belt is considered a wearable item.
Replacement intervals depend on vehicle use and
environment. If your belt is slipping you may need to
replace it.
1. P brake,
place shifter in Neutral, turn off ignition switch,
and remove switch key.
2. Remove the upper belt covers. (It is not
tom cover.
own in
ark vehicle on a level surface, set park
necessary to remove the bot
3. “Walk” the belt off of the rear pulley as sh
Figure 5-6.
Figure 5-6
4. Install the new belt on the front pulley first and
“walk” it onto the rear pulley.
5. Reinstall the belt guards. Figure 5-7.
rds may
void your warranty.
Attention: Failure to reinstall the belt gua
Figure 5-7
19
Section 6 Troubleshooting
Fuel in the Cylinder Cavity
In the event that the fuel valve is left open while
tran o ter Utility Vehicle it is
pos e cylinder
cav l not start. With
the in will feel like it
has “l per steps to follow if
your Brister ine seems to have fuel in
the cylinde
sp rting or towing this Bris
sible that fuel has leaked down into th
I lity. f this has occurred the engine wi
gine cyl der cavity full of fuel the en
ocked pro up”. Below are the
Utility Vehicle eng
r cavity.
Use EXTREME CAUTION when
y
rk Vehicle on a level surface, set park brake,
k
ch
ray
5.
aution: This gasoline spraying out of the
ylinder cavity is very flammable, use extreme
aution and make sure there are no sparks or
ames nearby.
6. epeat step 3 until only air escapes out of the
park plug hole.
7. roperly replace the spark plug back into the
r head, move the vehicle away from any
pilled fuel. If there is fuel on the vehicle itself,
performing the activity below.
Gasoline is EXTREMELY FLAMABLE!
1. Move the vehicle to a well ventilated area, awa
from sparks or flame.
2. Pa
turn off ignition switch, and remove switch key.
3. Next, remove the wire connected to the spar
plug. And remove the spark plug from the
engine. (See Figure 6-1) (Spark Plug Wren
supplied with Operator’s Manual)
4. WARNING: Stand away from the spark plug
hole when performing step 5. Fuel can sp
several feet.
Wearing eye protection, slowly pull the recoil
start grip handle (See Figure 6-2) in an upward
motion. This should force the fuel out of the
cylinder cavity through the spark plug hole.
C
c
c
fl
R
s
P
cylinde
s
allow for it to evaporate before continuing.
8. Connect the plug wire. Your Brister Utility
Vehicle is now ready to start.
www.bristers.com
Figure 6-1
Figure 6-2
20
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BRISTERS Chuck Wagon User manual

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