BUSH HOG Trail Series OFF ROAD UTILITY VEHICLES ® Operator’s Manual TH420 TH440 TH4200 TH4400 MODELS ASSEMBLY • OPERATION • MAINTENANCE 107 $10.
CONGRATULATIONS! You have invested in the best vehicle of its type on the market today. The care you give your Bush Hog vehicle will greatly determine your satisfaction with its performance and its service life. We urge a careful study of this manual to provide you with a thorough understanding of your new vehicle before operating, as well as suggestions for operation and maintenance. If your manual should become lost or destroyed, Bush Hog will be glad to provide you with a new copy.
® BUSH HOG Trail Series Utility Vehicles TABLE OF CONTENTS SECTION PAGE SECTION Retail Customer’s Responsibility Warranty Dealer Preparation Check List Safety Alert Symbols Safety Precautions 2 3 5 6 7 I INTRODUCTION AND DESCRIPTION 20 Introduction 20 Description 20 Specifications 27 II OPERATION General Safety Pre-Operation Checklist Vehicle Break-In Period Starting The Engine Driving The Vehicle Braking Stopping The Engine Using The Cargo Box Load Distribution Driving Safely Driving On Slippery Surf
RETAIL CUSTOMER’S RESPONSIBILITY UNDER THE BUSH HOG WARRANTY It is the Retail Customer and/or Operator’s responsibility to read the Operator’s Manual, to operate, lubricate, maintain and store the product in accordance with all instructions and safety procedures. Failure of the operator to read the Operator’s Manual is a misuse of this equipment.
LIMITED WARRANTY OOOOOOOOOOOOOOOOOOOO OOOOOOOOOOO Bush Hog warrants to the original purchaser of any new Bush Hog equipment, purchased from an authorized Bush Hog dealer, that the equipment be free from defects in material and workmanship for a period of one (1) year for non-commercial, state, and municipalities’ use and ninety (90) days for commercial use from date of retail sale. The obligation of Bush Hog to the purchaser under this warranty is limited to the repair or replacement of defective parts.
CONTINUED THIS LIMITED WARRANTY SHALL NOT APPLY: 1. To vendor items which carry their own warranties, such as engines, tires, and tubes. 2. If the vehicle has been subjected to misapplication, abuse, misuse, negligence, fire or other accident. 3. If parts not made or supplied by Bush Hog have been used in connection with the vehicle, if, in the sole judgement of Bush Hog such use affects its performance, stability or reliability. 4.
DEALER PREPARATION CHECK LIST UTILITY VEHICLE BEFORE DELIVERING MACHINE — The following check list should be completed. Use the Operator’s Manual as a guide. r 1. Engine has been serviced. r 2. Battery fluid level is checked. r 3. All warning lights checked for operation.(Engine oil, park brake, & neutral light) r 4. Assembly completed r 5. All fittings lubricated. r 6. All shields in place and in good condition. r 7. All fasteners torqued to specifications given in Torque Chart. r 8.
Safety Alert Symbol This Safety Alert Symbol means: “ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!” This symbol is used to call attention to safety precautions that should be followed by the operator to avoid accidents. When you see this symbol, carefully read the message that follows and heed its advice. Failure to comply with safety precautions could result in death or serious bodily injury.
IMPORTANT SAFETY PRECAUTIONS This symbol is used to call attention to safety precautions that should be followed by the operator to avoid accidents. When you see this symbol, carefully read the message that follows and heed its advice. Failure to comply with safety precautions could result in serious bodily injury.
• • • Do not tow heavy loads on hills steeper than 5 degree slope. Avoid driving through water exceeding floorboard height. Before leaving, servicing, or adjusting the vehicle, stop engine, set parking brake, remove key, wait for engine and all moving parts to stop. AVOID VEHICLE RUNOVER AND RIDER OR OPERATOR FALL OFF: • • • • • • Only allow persons to ride in seats equipped with seat belts. All persons fasten seat belts when riding. Allow no riders in cargo box or on vehicle.
• • • Reduce loads and speed when operating over rough or hilly terrain. Use low vehicle speeds when operating with cargo box loads. Heavy loads will affect steering, braking, stability, and overall handling of the vehicle. Limit loads to those that can be safely controlled. Allow for increased braking distance. UNLOADING: • Stop vehicle on level ground, set parking brake before raising cargo box. • Avoid unloading or dumping on slopes, hills or inclines.
CONTROLLING PARTY INFORMATION (Reference: SAE J2258-DEC 2003-Light-Utility Vehicle, APPENDIX B, PART II - For the Controlling Party.) The Controlling Party is the person(s) or organization(s) responsible for the operation and maintenance of a vehicle. MAINTENANCE AND OPERATIONS: The Controlling Party should perform the following: • Properly use and maintain utility vehicle to avoid serious injury or death. • Follow additional specific safety practices as may reasonably be required for safe operations.
OPERATOR TRAINING: The controlling Party should develop, conduct an operator-training program and permit only properly trained persons to operate the utility vehicle. OPERATOR-TRAINING PROGRAM: The program should include, as a minimum, the following: Review: • Vehicle operator’s manual instructions. • Vehicle’s safety decals. • Safe loading practices. • Proper use of vehicle’s controls and consequences of improper use. • Controlling Party’s safety practices developed from operating area safety survey.
FUEL SYSTEM: • Check for leaks and condition of parts. • Before disconnection fuel system parts and making repairs: • Allow engine to run until fuel system is depleted. • Allow engine to stop. • Allow engine to cool. • Disconnect battery. CONDUCT PERIODIC INSPECTION ON THE FOLLOWING SYSTEMS: • Brake system. • Steering system. • Electrical system. • Transmission system. • Exhaust system. • Warning system. • Switches and devices. • Follow vehicle manufacturer’s recommended inspection maintenance procedures.
WARNING POTENTIAL HAZARD Stalling, rolling backwards while climbing a hill WHAT CAN HAPPEN Vehicle overturn HOW TO AVOID THE HAZARD Maintain a steady speed when climbing a hill If you lose forward speed: Apply the brakes. Lock the parking brake after fully stopped. If you begin rolling backwards: Never apply engine power. Apply the brake gradually. When fully stopped, lock parking brake.
WARNING POTENTIAL HAZARD Operating this vehicle on paved surfaces WHAT CAN HAPPEN Loss of control HOW TO AVOID THE HAZARD This vehicle’s tires are designed for off-road use only, not for use on pavement. Paved surfaces may seriously affect handling and control of the vehicle, and may cause the vehicle to go out of control. Avoid operating the vehicle on pavement. If you must operate on a paved surface, travel slowly and do not make sudden turns or stops.
WARNING POTENTIAL HAZARD Operating this vehicle on public streets, roads or highways WHAT CAN HAPPEN Collision with another vehicle HOW TO AVOID THE HAZARD Never operate this vehicle on any public street, road or highway, including dirt or gravel. In many states it’s illegal to operate vehicles of this type on public streets, roads and highways. WARNING POTENTIAL HAZARD Operating this vehicle after consuming alcohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment.
WARNING POTENTIAL HAZARD Operating this vehicle at excessive speeds WHAT CAN HAPPEN Loss of control, accident HOW TO AVOID THE HAZARD Always travel at a speed proper for the terrain, visibility and operating conditions, and your experience. WARNING POTENTIAL HAZARD Attempting jumps and other stunts WHAT CAN HAPPEN Loss of control, accident and/or vehicle overturn HOW TO AVOID THE HAZARD Never attempt jumps and other stunts. Avoid exhibition driving.
WARNING POTENTIAL HAZARD Failure to inspect the vehicle before operating Failure to properly maintain the vehicle WHAT CAN HAPPEN Accident, equipment damage HOW TO AVOID THE HAZARD Always inspect your vehicle before each use to make sure it’s in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Operator’s Manual.
WARNING POTENTIAL HAZARD Failure to follow the minimum age recommendations for this vehicle. WHAT CAN HAPPEN Serious injury or death (the child or others) HOW TO AVOID THE HAZARD Only persons with a valid driver’s license should operate this vehicle. Even though a child may be within the age group for which some vehicles are recommended, he or she may not have the skills, abilities, or judgement needed to operate the vehicle safely and may be involved in a serious accident.
WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use. WARNING 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. WARNING Always keep combustible materials away from the exhaust system. Exposure to the hot components could result in a fire.
SECTION I INTRODUCTION AND DESCRIPTION INTRODUCTION We are pleased to have you as a Bush Hog customer. Your Bush Hog Trail Series utility vehicle has been carefully designed to give maximum service with minimum down time. This manual is provided to give you the necessary operating and maintenance instructions for keeping your vehicle in top operating condition. Please read this manual thoroughly. Understand what each control is for and how to use it.
1 NOTICE! LOCATIONS OF CONTROLS AND FEATURES MAY VARY SLIGHTLY ON DIFFERENT MODELS.
UNDER HOOD AREA (WITH CARGO TRAY REMOVED) Battery, Brake Fluid Reservoir, Fuses and Relays, Grease Fitting UNDER SEAT AREA Engine Air Intake Engine Oil Filler Cap Engine Oil Dipstick 22 CVT Enclosure Air Cleaner
RIGHT FRONT WHEEL REMOVED Disc Brake Assembly Front Strut Assembly Winch (Optional) CARGO BED RAISED (SHOWING ENGINE COMPARTMENT) Transfer Gearbox Trailing Arm Pivot Grease Fitting Grease Fitting For Pillow Block Hidden From View 23 Engine Air Cleaner Housing with Evacuator Valve
FEATURES DC Power Outlet The 12 volt accessory port is provided to power auxiliary lights or other accessories. Indicator Lights Lights on the dash indicate when the transmission is in neutral. Four wheel drive models have a light that indicates when 4- wheel drive is engaged. An oil pressure light indicates when oil pressure is lower than normal and oil level needs to be checked.
CONTROLS Switches Ignition Switch The ignition switch is a three position, key-operated switch. The key can be removed from the switch when it is in the OFF position. OFF Engine off. All electrical circuits are off except ACC. 12V. ON Electrical circuits are on. Electrical equipment can be used START Electric starter is engaged by holding ignition switch key in this position. Upon release, the key will return to the ON position.
Brake Pedal The brake pedal is the left pedal on the floor board. Depress the brake pedal to slow or stop the vehicle. Throttle Pedal The throttle pedal is the right pedal on the floor board. Push the pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check to make sure that the pedal returns normally before starting the engine.
SPECIFICATIONS TRAIL HUNTER ENGINE Type TH420 TRAIL HAND TH440 TH4200 TH4400 4-cycle, OHV V-twin, air-cooled gas Make Briggs & Stratton Honda Honda HP / (cc) 16 hp (480cc) 20 hp (614CC) Honda 24 hp (670cc) Lubrication Full Pressure with automotive style spin-on canister Air Cleaner Remote, 2-stage cyclone type with replacement dual elements Electrical Systems 12 volt DC with 20-amp alternator CHASSIS Suspension, Front MacPherson strut, single A-Arm, coil-over-shock Suspension, Rear I
SPECIFICATIONS TRAIL HUNTER DRIVE TRAIN Transmission CVT Protection Final Drive Differential Lock TH420 TH440 TH4200 TH4400 Continuously Variable Transmission (CVT) Shielded (TH420 only), Fully enclosed pressurized with filtered air intake (TH440, TH4200 and TH4400) Bush Hog Dual-Range transaxle with High, Low, Neutral and Reverse Truck-Style automatic positive locking differential; featuring Detroit Gearless Locker™ Ground Speed 4WD (4wd models only) TRAIL HAND 0 - 25 mph True On-Demand 4-wheel dri
SECTION II OPERATION GENERAL SAFETY Only qualified people familiar with this operator’s manual should operate this machine. WARNING IF A PROPER INSPECTION IS NOT DONE BEFORE EACH USE, SEVERE INJURY OR DEATH COULD RESULT. ALWAYS INSPECT THE VEHICLE BEFORE EACH USE TO ENSURE IT’S IN PROPER OPERATING CONDITION. PRE-OPERATION CHECKLIST 1. Fill the fuel tank with unleaded regular gasolIne. 2. Make sure dirt and foreign matter are kept out of fuel tank. Use a clean funnel and fuel can. 3.
Starting The Engine WARNING ENGINE EXHAUST GASES CONTAIN POISONOUS CARBON MONOXIDE. l NEVER RUN ENGINE IN A CLOSED BUILDING OR CONFINED AREA. l AVOID INHALING EXHAUST GASES. 1. Sit in the driver’s seat and fasten the seat belt. 2. Lock the parking brake 3. Place the transmission in neutral. 4. Pull the choke control all the way out. 5. Turn the ignition key to START and crank for 10 seconds maximum. 6.
3. With both hands on the steering wheel, release pressure on brake pedal and carefully apply pressure to throttle pedal. Vehicle speed is controlled by the amount of pressure on the throttle pedal. The CVT shifting is done automatically. 4. Drive slowly at first, practicing maneuvering and using the throttle and brakes on level surfaces. 5. Vary the throttle pedal position. Do not operate at sustained idle. 6. You may switch to 4-wheel drive at any time.
WARNING ALWAYS APPLY THE PARKING BRAKE BEFORE LEAVING THE VEHICLE. THE ENGINE/TRANSMISSION PROVIDES NO BRAKING EFFORT WHEN THE ENGINE IS NOT RUNNING. IF THE VEHICLE MOVES, IT MIGHT BE DAMAGED OR CAUSE INJURY. CAUTION EXHAUST SYSTEM COMPONENTS ARE VERY HOT DURING AND AFTER USE OF THE VEHICLE AND WILL CAUSE BURNS IF THEY COME IN CONTACT WITH SKIN. Using The Cargo Box CAUTION NEVER EXCEED THE LOAD CAPACITY LISTED IN THE SPECIFICATIONS CHART FOR YOUR PARTICULAR VEHICLE.
Load Distribution 1. Always load the cargo box placing the load as far forward as possible. 2. Always operate the vehicle with extreme care whenever hauling or towing loads. 3. Drive slowly with the transmission in low range. 4. Insure that the cargo box latch (on manual lift models) is securely latched before loading and operating. Unintentional box tilting may result if weight is place in the rear of the box and the latch is not secured.
Driving Safely Driving Procedures 1. Sit in the driver’s seat with the seat belt fastened. 2. After starting the engine and allowing it to warm up, shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4. Release the parking brake. 5. Keeping both hands on the steering wheel, slowly depress the throttle with your right foot and begin driving. Vehicle speed is controlled by the amount of throttle opening and the CVT transmission shifting is automatic. 6.
Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid steep hills (15° maximum). 3. Keep both feet on the floor. 4. Proceed at a steady rate of speed and throttle opening. 15° Maximum WARNING CLIMBING HILLS IMPROPERLY CAN CAUSE LOSS OF CONTROL OR VEHICLE OVERTURN. ALWAYS CHECK THE TERRAIN CAREFULLY BEFORE CLIMBING A HILL. BRAKING AND HANDLING ARE GREATLY AFFECTED WHEN OPERATING IN HILLY TERRAIN.
Sidehilling WARNING CROSSING DOWNHILL OR TURNING ON HILLS CAN RESULT IN LOSS OF CONTROL OR VEHICLE OVERTURN, RESULTING IN SEVERE INJURY OR DEATH. AVOID CROSSING THE SIDE OF A HILL WHEN POSSIBLE. WHEN UNAVOIDABLE, EXERCISE EXTREME CAUTION. AVOID OPERATING ON STEEP HILLS (15° MAXIMUM) Driving Downhill Whenever descending a hill, follow these precautions: 1. Proceed directly downhill. 2. Slow down. 3. Apply the brakes slightly to aid in slowing.
1. Always determine water depths and current before entering. 2. Choose a crossing where both banks have gradual inclines. 3. Proceed slowly, avoiding rocks and obstacles. 4. After leaving water, always dry the brakes by applying light pressure to the lever repeatedly until braking action is normal. NOTE: After running your vehicle in water, it’s critical that you perform the services outlined in the Maintenance section on page 47.
Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you’re traveling on. Watch for hazards such as logs, rocks and low hanging branches. WARNING SEVERE INJURY OR DEATH CAN RESULT IF YOUR VEHICLE SUDDENLY COMES IN CONTACT WITH A HIDDEN OBSTACLE. NOT ALL OBSTACLES ARE IMMEDIATELY VISIBLE.
Driving In Reverse Follow these guidelines when operating in reverse: 1. Back slowly. 2. Apply the brakes lightly for stopping. 3. Avoid turning at sharp angles. 4. Always avoid backing downhill. 5. Never open the throttle suddenly while backing. 6. Always inspect left and right fields of vision before backing. WARNING FAILURE TO USE CAUTION WHEN OPERATING IN REVERSE CAN RESULT IN SERIOUS INJURY OR DEATH.
Parking On An Incline Avoid parking on an incline if possible. If it is unavoidable, follow these precautions: 1. Place the transmission in low gear to help prevent rolling. 2. Set the parking brake. 3. Block the rear wheels on the downhill side. WARNING A ROLLING VEHICLE CAN CAUSE PROPERTY DAMAGE AND SERIOUS INJURY. ALWAYS APPLY THE PARKING BRAKE AFTER STOPPING THE ENGINE. ALWAYS BLOCK THE DOWNHILL SIDE OF THE WHEELS IF LEAVING THE VEHICLE ON A HILL, OR PARK THE VEHICLE IN A SIDEHILL POSITION INSTEAD.
Hauling Cargo WARNING HAULING CARGO IMPROPERLY CAN ALTER VEHICLE HANDLING AND MAY CAUSE LOSS OF CONTROL OR BRAKE INSTABILITY, WHICH CAN RESULT IN SERIOUS INJURY OR DEATH. ALWAYS FOLLOW THESE PRECAUTIONS WHEN HAULING CARGO: ALWAYS LOAD THE CARGO BOX WITH THE LOAD AS FAR FORWARD AS POSSIBLE. ALWAYS OPERATE THE VEHICLE WITH EXTREME CARE WHEN HAULING OR TOWING LOADS. SLOW DOWN AND DRIVE IN LOW GEAR. Bush Hog utility vehicles have been designed to carry or tow specific capacities.
Emptying The Cargo Box (Electric Lift Models) WARNING OPERTATING THE VEHICLE WHILE THE CARGO BOX IS RAISED COULD RESULT IN SEVERE INJURY. THE BOX COULD CLOSE UNEXPECTEDLY AND CAUSE INJURY TO THE DRIVER OR PASSENGER. NEVER OPERATE THIS VEHICLE WITH THE CARGO BOX IN THE RAISED POSITION. 1. Select a level site to empty the cargo box. Do not attempt to unload the vehicle while parked on an incline. 2. Set the parking brake. 3. Dismount the vehicle. 4. Release the tailgate latch. 5.
Towing Loads WARNING TOWING IMPROPERLY CAN ALTER VEHICLE HANDLING AND MAY CAUSE LOSS OF CONTROL OR BRAKE INSTABILITY, WHICH CAN RESULT IN SERIOUS INJURY OR DEATH. ALWAYS FOLLOW THESE PRECAUTIONS WHEN TOWING: NEVER LOAD MORE THAN 150 LBS. (68.1 kg) TONGUE WEIGHT ON THE TOWING BRACKET. DO NOT OPERATE VEHICLE FASTER THAN 10 MPH (16 km/h) WHEN TOWING. TOWING A TRAILER INCREASES BRAKING DISTANCE. DO NOT TOW MORE THAN THE RECOMMENDED 1,500 LB. WEIGHT FOR THE VEHICLE. ATTACH A TRAILER TO THE HITCH BRACKET ONLY.
WARNING GASOLINE IS EXTREMELY FLAMMABLE AND CAN BE EXPLOSIVE UNDER CERTAIN CONDITIONS. WHEN PARKING INSIDE A GARAGE OR OTHER STRUCTURE, BE SURE THAT THE STRUCTURE IS WELL VENTILATED AND THAT THE VEHICLE IS NOT CLOSE TO ANY SOURCE OF FLAME OR SPARKS, INCLUDING ANY APPLIANCE WITH PILOT LIGHTS. 4-Wheel Drive Your Bush Hog Utility Vehicle is equipped with an exclusive 4-wheel drive system that can be activated by a switch on the dash board.
3. Stop completely. 4. Shift into forward and drive. If the hubs remain engaged after following these instructions, return the vehicle to your dealer for service. WARNING OPERATING WITH ONLY ONE FRONT HUB ENGAGED COULD RESULT IN LOSS OF CONTROL, ACCIDENT, AND SEVERE INJURY OR DEATH. WHEN HUB ENGAGEMENT SYMPTOMS ARE PRESENT, USE THE DISENGAGING PROCEDURE BEFORE PROCEEDING. NOISE EMISSION CONTROL SYSTEM TAMPERING WITH NOISE CONTROL SYSTEEM IS PROHIBITED! U.S.
CAUTON EXHAUST SYSTEM COMPONENTS ARE VERY HOT DURING AND AFTER USE OF THE VEHICLE. HOT COMPONENTS CAN CAUSE SERIOUS BURNS AND CAN CAUSE A FIRE. DO NOT TOUCH HOT EXHAUST SYSTEM COMPONENTS. USE CAUTION WHEN TRAVELING THROUGH TALL GRASS, ESPECIALLY DRY GRASS. USFS Approved Spark Arrestor The muffler on this vehicle was tested and approved in accordance with the USFS Forest Service Stanedard 5100-1A.
Periodic Maintenance Schedule WARNING IMPROPERLY PERFORMIMNG THE PROCEDURES MARKED WITH A n COULD RESULT IN A COMPONENT FAILURE AND LEAD TO SERIOUS INJURY OR DEATH. HAVE AN AUTHORIZED BUSH HOG DEALER PERFORM THESE SERVICES.
Item Frequency Remarks Engine Cylinder 25 hrs. Re-torque required at first Head/Cylinderr service only Base Fasteners s Engine Oil-Level 25 hrs. Check level daily; break-in service at 25 hrs. s Engine Oil - 100 hrs. Change oil at 100 hours; H Change more often in cold weather use s Oil Filter 100 hrs. Replace with oil change 100 hrs. Inspect 50 hrs. Drain bowl periodically and H H Engine breather hose Carburetor Float Bowl n Throttle Cable prior to storage 50 hrs.
Item n Fuel System Frequency Remarks 100 hrs. Check for leaks at fuel cap lines, fuel valve, filter, pump H and carburetor.Replace lines every two years. Fuel Filter 100 hrs. Replace annually Spark Arrestor 100 hrs. Clean out s Front Gearcase Oil 100 hrs. Check monthly; change annually n Clutches (drive 100 hrs. Inspect; clean n Brake Fluid 200 hrs. Change every two years n Front Wheel 300 hrs.
MAINTENANCE AND LUBRICATION Lubrication Recommendations NOTE: Hours are based on 10 mph average. If service is due at 20 hours, the equivalent odometer reading would be 200 miles. Perform all services at whichever reading is reached first.
Engine Oil Maintain the engine oil at the proper level to ensure a properly functioning engine, and change the oil and oil filter every 100 hours or every six months, whichever comes first. Dirt and metal particles collect in the oil, and oil loses its lubricative quality if used too long. Suggested break-in oil change is at 25 hours, or one month, whichever comes first. Severe use operation requires more frequent service.
Engine Oil and Filter Change CAUTION HOT OIL CAN CAUSE SERIOUS BURNS. DO NOT ALLOW OIL TO COME INTO CONTACT WITH SKIN. 1. Run the engine two or three minutes until warm. Stop the engine. 2. Clean the area around the drain plug at the bottom of the crankcase. 3. Place a drain pan beneath the engine and remove the drain plug. Allow the oil to drain completely. 4. Clean drain hole and replace the drain plug. Torque to 14 ft. lbs. 5. Remove the oil filter and clean the sealing surface area. 6.
Front Differential The front differential oil should be changed every 100 hours If the vehicle is used in wet conditions, the oil should be checked more frequently. If the oil has a milky appearance, it should be changed as soon as possible. Failure to properly maintain this area can result in premature wear or possible failure of the front differential components. Oil Check 1. With the vehicle on a level surface, remove the fill plug and check the lubricant level.
Right Angle Drive The right angle drive oil should be changed every 100 hours. 1. With the vehicle on a level surface remove the fill plug and drain plug and drain oil into a drain pan. Discard the used oil properly. 2. Refill the drive box with SAE 80W-90 w/LSD additive, to the middle of the sight window. Oil Change 1. Remove the combination breather/fill plug from the top of the case. 2. Remove the drain plug from the bottom of the case and drain the oil into a pan. Discard the used oil properly. 3.
Constantly Variable Transmission (CVT) 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.
Vehicle Immersion CAUTION IF YOUR VEHICLE BECOMES IMMERSED, MAJOR ENGINE DAMAGE CAN RESULT IF THE VEHICLE IS NOT THOROUGHLY INSPECTED. TAKE THE VEHICLE TO YOUR DEALER BEFORE STARTING THE ENGINE. If it is impossible to take your vehicle to a dealer before starting it, follow the steps outlined below. Honda Engines 1. Move the vehicle to dry ground, or at least to a water level below the floor. 2. Disconnect the fuel pump wires. 3. Remove the spark plugs. 4.
Engine Air Filter We recommend that the air filter be cleaned every 25 hours and replaced once a year. 1. The air filter is accessible from the right side of the vehicle, below the passenger seat. Loosen both fastening clips and remove the housing cover. There is an outer and inner filter that may then be pulled out for service or replacement. 2. Inspect the filter housing and clean out any debris or moisture. 3. Replace the filter elements or install new ones.
Fuel Filter Your Bush Hog utility vehicle is equipped with an in-line fuel filter that should be replaced by your dealer after every 100 hours of operation.Do not attempt to clean the fuel filter. Spark Plugs The spark plugs should be changed every 100 hours. The spark plugs are accessible from under the seat or under the cargo box. Always use the spark plugs recommended by the engine manufacturer and set the gap as specified. WARNING A HOT EXHAUST SYSTEM AND ENGINE CAN CAUSE SERIOUS BURNS.
Spark Arrestor WARNING FAILURE TO HEED THE FOLLOWING WARNINGS WHILE SERVICING THE SPARK ARRESTOR COULD RESULT IN SERIOUS INJURY OR DEATH. DO NOT PERFORM SERVICE ON THE SPARK ARRESTOR WHILE THE SYSTEM IS HOT. EXHAUST SYSTEM TEMPERATURES CAN REACH 1000° F. ALLOW COMPONENTS TO COOL SUFFICIENTLY BEFORE PROCEEDING. REMOVE COMBUSTIBLE MATERIALS FROM THE AREA. WEAR EYE PROTECTION. DO NOT STAND BEHIND OR IN FRONT OF THE VEHICLE WHILE PURGING. NEVER RUN THE ENGINE IN AN ENCLOSED AREA.
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 STICKS DURING OPERATION. NEVER START OR OPERATE THIS VEHICLE IF IT HAS A STICKING OR IMPROPERLY OPERATING THROTTLE PEDAL. IMMEDIATELY CONTACT YOUR DEALER FOR SERVICE IF THROTTLE PROBLEMS ARISE. ALWAYS CHECK THE PEDAL FOR FREE MOVEMENT AND RETURN BEFORE STARTING THE ENGINE AND OCCASIONALLY DURING OPERATION.
Brake Inspection The front and rear brakes are hydraulic disc type brakes and are activated by the brake pedal. Routine inspections are recommended to keep the brake system in good operating condition. Inspect the level of the brake fluid before each operation. Change the brake fluid at the intervals outlined in the Maintenance Schedule beginning on page 49.
Brake Inspection 5. Check the brake system for fluid leaks. 6. Check the brake pedal for excessive travel or a spongy feel. 7. Check the friction pads for wear, damage and looseness. 8. Inspect the brake disc spline and pad wear surface for excessive wear. 9. Change pads when worn to 3/64” (.1 cm), about the thickness of a dime. Parking Brake Adjustment 1. Engage the parking brake by stepping on the foot lever (Trail Hand) or pulling up the hand lever (Trail Hunter).
Steering Wheel Inspection Check the steering wheel for freeplay and smooth operation as outlined in the Maintenance Schedule. 1. Park the vehicle on level ground. 2. Lightly turn the steering wheel left and right. 3. There should be 0.8 - 1.0 in. (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 Bush Hog dealer.
Tires WARNING OPERATING YOUR VEHICLE WITH WORN TIRES WILL INCREASE THE POSSIBILITY OF SKIDDING, LOSS OF CONTROL AND AN ACCIDENT, WHICH COULD RESULT IN SERIOUS INJURY OR DEATH. ALWAYS REPLACE TIRES WHEN THE TREAD DEPTH MEASURES 1/8” (.3 CM) OR LESS. IMPROPER TIRE INFLATION OR THE USE OF NON-STANDARD SIZE OR TYPE TIRES MAY ADVERSELY AFFECT VEHICLE HANDLING, WHICH COULD RESULT IN VEHICLE DAMAGE OR PERSONAL INJURY. ALWAYS MAINTAIN PROPER TIRE PRESSURE.
3. Elevate the side of the vehicle by placing a suitable stand under the frame. 4. Remove the wheel lug nuts. Remove the wheel. Wheel Installation 1. With the transmission in gear and the parking brake engaged, place the wheel in the correct position on the wheel hub. Be sure the valve stem is toward the outside and the rotation arrows on the tire point toward forward rotation. 2. Attach the lug nuts and finger tighten. 3. Carefully lower the vehicle to the ground. 4. Torque the lug nuts to 35 ft. lbs.
Cleaning Your Vehicle Keeping your vehicle clean will not only improve its appearance, but it can also extend the life of various components. With a few precautions, your vehicle can be cleaned much like an automobile. The best and safest way to clean your vehicle is with a garden hose and a pail of mild soap and water. Use a professional type washing mitten, cleaning the upper body first and the lower parts last. Rinse with water frequently and dry with a chamois to prevent water spots.
8. Tie a plastic bag over the exhaust pipe and air cleaner inlet to prevent moisture or small animals or insects from entering. 9. Cover the vehicle with a canvas cover. Do not use plastic or coated materials since they do not allow ventilation for the vehicle. Removal From Storage 1. Check the battery electrolyte level and charge the battery if necessary. Install it in the vehicle. 2. Make sure the spark plug is tight. 3. Fill the tank with fuel. 4.
Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away. Ventilate when charging or using in an enclosed space. Always shield eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN. Replenishing Battery Fluid (Conventional Battery) A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. The fluid level should be kept between the upper and lower level marks. To refill use only distilled water.
Battery Installation 1. Set the battery in its holder. 2. Install the battery tie-down bracket and tighten the nuts. 3. First connect the positive (red) cable. 4. Second connect the negative (black) cable. 5. Verify that cables are properly routed. NOTE: When installing a new battery, make sure it is fully charged prior to its use. Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance.
SECTION IV ASSEMBLY Attaching Occupant Protection Structure To Vehicle (Refer to illustrations on following pages) Remove occupant protection structure from shipping bundle and arrange weldments around the vehicle. Loosen all fasteners before beginning assembly. Disconnect the front cross member from one front side frame member so the front frame weldments can be positioned independently from each other.
Seat Belt Installation Install all seat belts so that the release button will be to the outside of the occupant when fastened.
Cross Member OCCUPANT PROTECTION STRUCTURE Front Left Frame Member 5/16 x 3/4” Hex Socket Button Head Bolts Seat Back Mounting Holes (Use 5/16” Flatwashers & Locknuts) (Use 1/ 2 x 3” Bolts & Locknuts) Bottom Panel (Use 3/8 x 1” Bolts & Locknuts) Bottom Mounting Plates (Use 5/8 x3” Bolts & Locknuts) Rubber Bumper Pad Adjustment The plastic bed of the Utility Vehicle is equipped with two rubber bumper pads located at the bottom front of the bed.
TROUBLESHOOTING CHECK LIST STARTER MOTOR WON’T TURN ENGINE: • • • • Gear shift lever not in neutral Battery discharged Battery leads do not make good contact with the battery terminals or ground on frame Fuse failure (check to find and correct the cause of the failure) ENGINE CRANKS, BUT WON’T START: • • • • • • • • • No fuel in tank Fuel filter clogged Water in fuel Choke is not used when engine is cold Air filter clogged or inlet blocked Engine flooded Fuel tank vent clogged Spark plug wire not on spar
SAFETY DECALS To promote safe operation, Bush Hog supplies safety decals on all products manufactured. Because damage can occur to safety decals either through shipment, use or reconditioning, Bush Hog will, upon request, provide safety decals for any of our products in the field at no charge. Contact your authorized Bush Hog dealer for more information. No. 1 or 2 No. 5 No. 7 No. 6 No. 3 No. 4 No. 1 No.
No. 4 No. 3 No. 5 No. 6 No.
76 Wrench Size “A” SAE Grade 8 (6 Dashes) D lt ” Bo r “B te e iam SAE Grade 5 (3 Dashes) SAE Grade 2 (No Dashes) Bolt Head Markings AMERICAN TORQUE SPECIFICATIONS 3/4 - 10 UNC 3/4 - 16 UNF 1-1/8 1-1/8 5/8 - 18 UNF 5/8 - 11 UNC 15/16 15/16 9/16 - 18 UNF 9/16 - 12 UNC 7/8 7/8 1/2 - 20 UNF 1/2 - 13 UNC 3/4 3/4 7/16 - 20 UNF 5/8 3/8 - 16 UNC 3/8 - 24 UNF 5/16 - 24 UNF 1/2 9/16 7/16 - 14 UNC 5/16 - 18 UNC 1/2 5/8 13 (17) 1/4 - 28 UNF 7/16 9/16 11 (15) 1/4 - 2O UNC 7/16 192 (26
77 Numbers appearing on bolt heads indicate ASTM class. D lt ” Bo r “B te e iam *U se 7 5 % o f th e sp e cifie d to rq u e va lu e fo r p la te d fa ste n e rs. U se 8 5 % o f th e sp e cifie d to rq u e Wrench Size “A” METRIC 14 16 20 21 24 30 12 18 8 13 10 6 16 5 8 BOLT DIA. (mm) “B” 10 WRENCH SIZE (mm) “A” 122 (165) 62 (84) 40 (54) 25 (34) 14.5 (20) 7.3 (10) 3 (4) 1.8 (2.4) ASTM 4.6 325 (440) 167 (226) 118 (160) 74 (100) ASTM 8.
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P.O. Box 1039 • Selma, AL 36702-1039 Telephone (334) 874-2700 • www.bushhog.
