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SPARTAN 500 OWNERS MANUAL
CHIRONEX MOTORSPORTS INC.
© Copyright Chironex Motorsports Inc. All Rights reserved.
-1-
TABLE OF CONTENTS
S#
I
II
III
IV
V
VI
VII
VIII
IX
X
XI
Topic
Introduction
Technical parameters
Parts Breakdown
Safety Instructions
Operating the Spartan UTV
Breaking-in Period
Maintenance and Repair
Troubleshooting
Torque specifications
Fuel/ Oil / Fluid Specifications
Circuit Diagrams
© Copyright Chironex Motorsports Inc. All Rights reserved.
Pages
3
6
9
13
15
21
22
26
39
41
42
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I. Introduction
Chironex welcomes you to its growing family of new Spartan series Utility Vehicle owners. The Spartan has been designed for the Canadian
outdoors with careful attention paid to every detail. Proper set-up, maintenance and safe operating practices will help you get years of satisfactory
use from this vehicle.
Safety First
Chironex 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. The Spartan Utility Vehicle was designed and 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 prepared to instruct you in the safe and responsible operation of your Spartan 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 piece of equipment, you are in complete control. Only you can prevent an accident from happening.
Using This Manual
* Prior to any vehicle operation it is absolutely essential that you read and comprehend each section in this manual to develop an understanding of
your vehicle and for your safety. After reviewing this manual, store it in a dry and easily accessible place for future reference.
* The Operator’s Section is designed to help familiarize you with safety, assembly, operation, adjustments, troubleshooting, and maintenance.
Read this manual and follow 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 your authorized dealer.
www.chironex.ca
© Copyright Chironex Motorsports Inc. All Rights reserved.
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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 designed, 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.
Unlike ATVs that have handlebar steering, the Spartan Utility Vehicles 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 suspension, large diameter
hi-flotation tires and high center-frame ground clearance adds up to excellent stability and a smooth ride over rough terrain. Outstanding traction
is achieved by using premium off-road ATV type tires in tandem with the engine mounted directly in front of the rear differential.
Also unlike an ATV’s one person “straddle saddle” seat, the Spartan UTV sports dual headrest cushioned seats with seat belts mounted in a
highly styled and protective full length body. Two passengers can ride comfortably in this vehicle protected from splashing water and mud. The
Brush Guard Bar mounted to the vehicle’s frame provides protection against low hanging limbs and briars.
The Brush Guard Bar also provides a mounting system for 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 dump box is for transporting materials and accessories such as camping equipment, tree stands, hunting gear, and fishing gear. A standard
hitch mounting plate enables quick installation of a rear hitch for pulling small trailers full of supplies, tools, gear, and game.
The Spartan UTV has some similarities to an ATV. Like an ATV it has a short wheelbase, narrow stance, and high center clearance all which
provide for narrow and difficult trail access. This combination of short wheelbase and narrow stance also enables this vehicle to be loaded in the
back of most full to mid-sized pickups for transport.
The Spartan UTV’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.
© Copyright Chironex Motorsports Inc. All Rights reserved.
-4-
Owner Assistance
The safety information should be viewed by the owner and the Warranty Registration card should be filled out 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
necessary to provide you with quality customer service.
The parts on your Spartan Utility Vehicle have been specially designed and should only be replaced with genuine Chironex parts.
If customer service or repair parts are required contact a Chironex dealer. They have trained personnel, genuine repair parts and equipment
specially designed to repair Chironex products.
Record your Chironex Spartan Utility Vehicle serial number here for quick reference:
Model Number:___________________________
Serial Number:____________________________
Your Chironex dealer wants you to be satisfied with your new vehicle. If you do not understand any part of this manual or you’re not satisfied
with the service received, please take the following 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 Initial breaking-in period for the Spartan 500 4x4 is 1000km, during which extra care must be taken (see Section VI). Upon
expiration of this period, continue to carry out the necessary maintenance procedures.
© Copyright Chironex Motorsports Inc. All Rights reserved.
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II、Technical parameters
(I)
1
2
Common technical data
Weight parameters (kg)
Dry Weight: 500
(III)
Dimensions (mm)
Length/ Width:
2690×1270
Wheelbase: 1820
Tread:
front tire: 1036 rear tire: 1040
Approach angle(°)：47
Departure angle(°)：82
(II) Operating data
1 Top speed(km/h)：H gear : 70
2 Steering radius(m)： 4.65
3 Braking distance (w/ zero load).
When V０=30km/h：4 m
When V０=40km/h：5.5 m
When V０=50km/h：9 m
4 Gas mileage: 10 km/ L
5 Load capacity:
300Kg
Engine
Type:
Single cylinder, 4-stroke, liquid cooled
Valve train: 4 valve, top camshaft, single shaft
Induction: Carburetor
Bore and stroke (mm): 87.5 x 82
Engine displacement: 493 cc
Compression ratio: 10.2：1
Maximum power (kw/r/min): 24/6500
Maximum torque (N·m/r/min): 38.8/5500
Minimum fuel consumption rate (g/Kw·h):
340
Idle speed (r/min):
1300±100
Starting: Electric
Ignition type:
touch-less CDI DC
Spark Plug: DPR7EA-9(NGK)
Lubricating oil: SAE 15W—40/SF
Engine # location: Topside surface at rear end of left
crankcase
Ignition angle(°/r/min)：
10/1500 – 32/1500
Lubricating type: Pressurized wet sump
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Engine oil pump type： TOTOR
Oil filter: Full-flow mechanical w/ paper element
Fuel Capacity: 20 L
Carburetion type: Vacuum slide
Air filter: Sponge element
Fuel type: RQ-93 or better
Transmission: Automatic CVT (toothed V-belt)
P/R/N/H/L, Electrically controlled 2WD/4WD
Gear change: Hand lever
Clutch type: wet, centrifugal hoof
Primary gear ratio: 0.703—2.88
Gear ratio：
Total gear reduction ratio:
H Gear：3.514
2.47—10.12
L Gear： 5.857
4.12—16.87
R Gear： 3.828
2.69—11.02
Coolant: antifreeze with rust prevention
Dimension: 610 x 568 x 519
Net weight: 70 kg
Final Drive: shaft
Shaft rotation: clockwise (from the back of engine)
(IV)、Chassis
1. Differential：
Tapered arc gear transmission
Transmission rate： 33/9
2. Drive type：Shaft, 2WD/4WD/Differential LOCK
Normal drive: Rear wheel drive.
3. Suspension：
Front suspension: Independent double wishbone
with preload adjustment
Rear suspension：Independent double wishbone
with preload adjustment
4. Front Wheel alignment:
Camber angle： 0° ±1°
Main pin inner angle：
11°50’ ±3°
Main pin back angle：
4°±1°
Front toe-in:
-3—3mm
5. Tires：
Front Tire: 25×8.—12
Air pressure：250Kpa
Rear Tire: 25×10 —12
Air pressure：300Kpa
© Copyright Chironex Motorsports Inc. All Rights reserved.
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6. Steering system：Rack-and-pinion steering
Steering wheel turns, lock to lock: 2.5
Total steering angle:
75°.
Maximum steering angle, right: 37.5°.
Maximum steering angle, left: 37.5°.
7. Brakes:
Front brakes: Dual hydraulic disk
Rear brakes: Dual hydraulic disk
Parking brake: Mechanical disk (rear axle)
8. Electric Dump box：
Dumping angle: 49°
9. Winch:
Rated Single Line Pull:
3000 lbs.
(V)、Electrical components
1. Pipeline voltage: 12V。
2. Alternator power rating: 325W。
3. Battery：12V - 36A·h。
4. Starter motor：12V DC motor
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1. Safety belt
2. Frame
3. Steering wheel
4. Rear view mirror
5. Engine hood
6. Indicator
7. Bumper
8. Headlight
9. Winch
10. Wheel
11. Seat
12. Side cover
13. Rear mudguard
14. Cargo bed
15. Headrest bar
16. Head rest
III Parts Breakdown
© Copyright Chironex Motorsports Inc. All Rights reserved.
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1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Carburetor
Starter
Water temperature sensor
Starting handle
Left cover
Rear shaft flange
Front shaft flange
Oil filter
Thermostat
CVT case
CVT inlet
CVT inlet
13. Plug
Engine Parts Breakdown
© Copyright Chironex Motorsports Inc. All Rights reserved.
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VIN number
Rear suspension
（on the frame above right rear wheel）
Oil drain plug（bottom of engine）
WARNING：ENGINE OIL LEVEL SHOULD BE
BETWEEN UPPER AND LOWER MARKINGS. ELSE
YOU RISK ENGINE DAMAGE.
Oil Intake
Oil Dipstick
© Copyright Chironex Motorsports Inc. All Rights reserved.
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WARNING： Do not unscrew radiator cap when engine is hot;
Fuel tank intake（left side）
Coolant, Brake fluid intake
contents are at a high temperature and pressure.
WARNING：Use only TC / DOT approved brake fluid. Do not mix
different types of brake fluids. Always maintain brake fluid level to
ensure proper functioning of the brakes.
WARNING：Use TC / DOT approved gear oil in the front and rear
differentials. Fill up to just below intake. Filling too much will result
in leakage and too little burn damage to the differential
Rear differential
Front differential
© Copyright Chironex Motorsports Inc. All Rights reserved.
- 12 -
IV、Safety Instructions:
10. Check whether the winch and dump box are in good
working order
1. Check for leaks of engine oil, coolant, fuel, lubricant.
11. Check fuel level.
2. Check the levels of engine oil, brake fluid and coolant. If
necessary, add more.
3. Check the air pressure in tires.
4. Check the functioning of the safety belt.
5. Check steering play.
6. Check engine support frame, bolts, transmission system
and running system.
7. After starting engine, listen for any abnormal noises and
confirm whether all meter readings are normal.
8. Check brake pedal movement and functionality of brakes
(including the hand brake).
9. Check whether the lights (steering light, brake light,
warning light, running lights, headlight – low and high
beams) are working.
© Copyright Chironex Motorsports Inc. All Rights reserved.
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Warning：
(1) Driver must be of legal age to operate the UTV.
(2) Fasten the safety belt before riding the UTV.
(3) Driver should be adequately insured.
(4) Driver should operate UTV at speeds of 35—45km/h. Speeding will cause an
accident.
(5) Driver should limit speed to 20 km/h when turning.
(6) Do not over load the dump box. If cargo height exceeds height of dump box, it
must be fastened down. This will prevent cargo from falling forward and hurting
the driver.
(7) The antifreeze in radiator is only suitable for use in temperatures above -35 C.
Please use antifreeze with the appropriate temperature rating for temperatures
below -35 C.
(8) Do not use the hand brake at speeds over 50km/h (except in case of
emergency); it may damage the vehicle and cause it to slip or over turn.
(9) Use the two wheel drive for on road driving. Unnecessary use of four wheel
drive may increase wear and tear.
(10) Ensure the vehicle is stopped before switching gears.
V、Operating the Spartan UTV
(1)Key
The same key is used for ignition and to open fuel tank
cover. You are given two copies of your Spartan UTV
key; remember to put aside one copy.
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(2)Ignition switch
Ignition switch has four positions：
“OFF”（close）position： All circuits are turned off
except for the emergency light, electric fan and
cigarette lighter.
“ON”（open）position： All circuits except starter
and ignition are connected, keeps an engine running
“START”（start）position： Connects starter and
ignition circuit to start engine; automatically returns to
“ON” position after engine starts
WARNING: Ignition key can not be turned to “LOCK”
position and pull out before vehicle is stopped stably. This
could causes the vehicle lost control when the steering wheel is
locked.
Note: You only can start the engine when gear is in “N”
position. The engine can not be started up when gear is in “H”,
“L” or “R” positions.
“LOCK”（lock）position: The steering wheel is
locked at this position and the key can be pulled out.
(3) Instruments
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1、Temperature Gauge 2.3.、L/R Indicators 4、Fuel Gauge
5、High beam 6、Odometer 7、Speedometer 8、2WD/ 4WD
（ 1 ）Temperature Gauge: Displays the temperature
of engine coolant.
（2, 3）Indicators: Left or Right indicator blinks
corresponding to turning signal switched on.
Both indicators blink if hazard light is switched
on.
（4） Fuel Gauge: Displays quantity of fuel left in the
fuel tank.
（5）High-beam: Lit when high-beam is switched on.
（6）Odometer: Displays the total distance travelled
（7）Speedometer: Display the current speed
（ 8）.2WD/4WD and differential lock
Single axle indicator being lit corresponds to
2WD. In 4WD mode both axles indicator are
lit. When an “X” in displayed, it indicates 4WD
with the front differential locked.
(4) Lights
Press light switch to center position to turn on
the dashboard as well as the running lights of the
UTV. Press switch to “on” position to turn on the
headlight.
（L/H/N/R）Gear Indicator：Displays the currently
operational gear corresponding to Low, High,
Neutral and Rear.
With the light switch in the “on” position, press
the headlight switch to turn on high beam.
Hazard light: switches on the front and rear
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flashers in case of emergency.
Use the turn signal button to switch on left
and right signal lights corresponding to the left and
right arrows marked. To turn off both signal lights keep
button in the center position.
(6) Accelerator and brake pedals
The accelerator pedal (left) and brake pedal (right) are
located at the floor board on the driver side of the
UTV. Step on the brake pedal before switching into
L/H/R gear as required, then step on the accelerator
pedal to move.
(5) Horn
Press button located at the center of the steering wheel to
blow horn.
(7) Hand brake (Parking brake)
Remember to pull up the hand brake when the UTV is
parked to prevent vehicle from rolling.
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(9) Winch
Keep the winch button pressed in the “OUT” position to
extend the winch cable to the required length. To retract
keep the button pressed in the “IN” position.
WARNING：After parking the vehicle, pull up the hand
brake lever. Push down the hand brake lever before stepping
on the accelerator. Do not use the hand brake to stop vehicle
when moving (except in case of emergency).
WARNING: Always switch the “MAIN” button to the OFF
position when done using the winch or dump box to conserve
battery power. Once the dump box has been lifted to the
(8) Dump box
To dump contents of the dump box, open the rear gate.
Switch on (“O” position) the red “MAIN” button on the
dash. Now keep the “TRAILER” button pressed in the
“UP” position to lift the dump box, release the button
once box is at desired angle and contents are emptied. To
lower the dump box, keep the “TRAILER” button pressed
in the “DOWN” till the box is completely lowered.
maximum inclination or lowered completely, do not continue
(10)
2WD/ 4WD/LOCK
to
press
thenormal
“TRAILER”
To select
rear button.
wheel drive switch button to 2WD
position; this mode is for on road driving. Switch to 4WD
position to select all wheel drive; use this mode for offroading. If the UTV gets stuck or you are driving in extreme
terrain and/or weather conditions switch to LOCK position;
this locks the front differential.
© Copyright Chironex Motorsports Inc. All Rights reserved.
- 18 -
(11)Windshield and wiper (optional)
Turn knob in clockwise direction to the preferred “Low” or
“High” setting. To switch off the wiper, turn knob in anticlockwise direction to the “Off” position.
(12)Reverse speed over ride button (installation optional)
Under normal circumstances do not use the reverse over ride.
Use the over ride only when you are stuck or need to reverse in
rough terrain.
WARNING:
Do not change from 2WD to 4WD when the UTV is
in motion. Selected gear is displayed on the dash. At times the
gear is selected only after stepping on the accelerator. In order
to prevent damage to the transmission, step lightly on the
accelerator pedal momentarily, to ensure that the gear is in the
right position.
NOTE：Using the
4WD mode increases wear and tear on the
UTV. In order to prolong the life of UTV components use 4WD
only when the terrain is muddy, slippery, covered with snow
and/or steep terrain.
© Copyright Chironex Motorsports Inc. All Rights reserved.
- 19 -
VI、Breaking-in period
The operating quality and longevity of the UTV depends on
taking proper care during the breaking-in period. During the
initial 1600 km of driving the various components of the UTV
should be allowed to wear into each other. Adhere to the
speed limit, keep total UTV payload to a minimum and carry
out periodic maintenance as per the guidelines in this manual.
(13) Choke
When operating the UTV in cold weather, if you
experience difficulty in starting the engine, pull out the choke.
After the UTV starts push down the choke to restore the
carburetor to normal operation.
1. Maximum permissible speed:
Mileage
Maximum permissible speed
< 800Km
40Km/h
800 - 1600Km
50Km/h
> 1600Km
60Km/h
Avoid full throttle starts, sudden acceleration or
deceleration during the breaking-in period.
2. Warming up engine
During the breaking-in period, it is necessary idle the
engine for 3-5 minutes after starting and warm it up.
This gives time for the engine oil and lubricants to
flow over surfaces in contact.
3. Coolant Temperature Monitoring
© Copyright Chironex Motorsports Inc. All Rights reserved.
- 20 -
During the breaking -in period, it is necessary to
monitor engine coolant temperature to avoid running
engine at low temperatures for long periods or at high
temperatures without coolant. This will accelerate
abrasion and cause damage to the engine cylinder.
4. Check if all nuts and bolts are properly tightened,
including those of transmission components.
5. First maintenance of vehicle
After the first 1000km, it is necessary to carry out a
complete maintenance. For maintenance instructions
refer to the “Maintenance and repair” section in this
manual.
VII、Maintenance and repair
WARNING：It is important to carry out a complete
maintenance after driving the UTV for 1000 km. The
operating quality and longevity of the UTV depends on
taking proper care during the breaking-in period.
© Copyright Chironex Motorsports Inc. All Rights reserved.
- 21 -
S#
Part/ Component
1 Engine
2 Brakes
3 Steering assembly
4 Transmission box
5 Gear box
6 Front & rear differential
7 Tires
8 Transmission assembly
9 Lights
Maintenance Item
Change engine oil and oil filter
Check coolant level
Front and rear brakes
Hand brake
Steering play
Gear shifting
Belt abrasion
Change gear oil
Change gear oil
Tire pressure and tread depth
Bolts on front and rear differentials
Bolts, flange nuts on transmission
shaft
Headlight, brake light, Signal light,
Dashboard lights, Running lights
19 Battery
Battery electrolyte level
11 Instruments
12 Dump box and winch
Normal reading
Normal working order
Troubleshooting
Adjust idling speed: 1300 + 100 r/m, listen for any abnormal
noises coming from the engine, clean air filter core
Brake fluid level; Brake pedal travel 15 - 20 mm;
Hand brake travel 2 to 3 clicks
Tighten bolts and nuts of steering assembly
Front tie-in: -3 - 3 mm
Tighten bolts and nuts
Bulbs; Switches; Buttons
Electrolyte level should be in between the upper and lower
markings. Use only distilled water to top off electrolyte level,
Routine maintenance item table (checked by UTV owner)
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S#
Part/ Component
Engine
1
2 Steering assembly
3 Brakes
4 Gear box
5 Front & rear differential
6
7
Tires
Lights
Battery
8
9 Instruments
10 Dump box and winch
11 Transmission assy
Maintenance Item
Change engine oil and oil filter
Check coolant level
Steering play
Troubleshooting
Adjust idling speed: 1300 + 100 r/m, listen for any abnormal
noises coming from the enginem clean air filter core
Tighten all bolts and nuts of steering assembly
Brake fluid level; Brake pedal travel 15 - 20 mm;
Brake performance
Hand brake travel 2 to 3 clicks
Brake Pad thickness minimum 4 - 5 mm
Gear Oil; Noise
Gear oil level should be within specified limit
Gear Oil; Noise
Gear oil level should be upto the intake
Front tire pressure: 250 kPa; Rear tire pressure: 300 kPa
Tire pressure, tread depth, abrasion
Tread depth: greater than 1.6 mm
Headlight, brake light, Signal light,
Bulbs; Switches; Buttons
Dashboard lights, Running lights
Electrolyte level should be in between the upper and lower
Battery electrolyte level
markings. Use only distilled water to top off electrolyte level,
Normal reading
Normal working order
Nuts and Bolts
Tighten
Periodic maintenance item table for UTV
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- 23 -
First 1000 km
MAINTENANCE ITEM
First 3 months
Check
Brake Hose
Brake Fluid
Brake
Steering assembly
Accelerator Cable
Brake Pedal Movement
Carburetor
Tire(s)
Spark plug
Engine oil
Check
Check
Check
Check
Check
Check
Change
-
Air filter/ core
Valve clearance
V-belt
Check
Fuel pipe
Gear oil (Gear box)
Gear oil (F/R Differential)
Front and rear shock absorber
Change
Change
-
MILEAGE
Every 3000 km
PERIOD of OPERATION
Every 3 months
Check
Change once every 3 years
Change once every 18 months
Check
Check
Check
Check
Check
Check
Check
Change
Clean
Change once every 10000 km
Check
Check
Check
Change once every 3 years
Change
Change
-
© Copyright Chironex Motorsports Inc. All Rights reserved.
Every 6000 km
-
Check
- 24 -
First 3 months
MILEAGE
Every 3000 km
PERIOD of OPERATION
Every 3 months
Check
Check
Check
Check
Check
Check
Check
-
Check
Check
Check
Check
Check
Check
Check
Check
First 1000 km
MAINTENANCE ITEM
F/R Differentials, reverse gear
(including gear oil)
Battery
Steering assembly
Transmission assembly
Lights/ Instruments
Brake line and master cylinder
Engine suspension
Front and rear axle suspension
Every 6000 km
-
NOTE：Periodic maintenance is
to be conducted at the specified mileage or time
period of operation, whichever comes first.
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- 25 -
VIII、Troubleshooting
（I）Engine Trouble
Problem
Starting trouble
Indication
Cause(s)
1. Lack of compression in
cylinder
Cylinder is worn out
Piston is worn out
Leaks
Air intake valve worn out/ Cylinder head
damage
Plug is loose
Solution
Change
Change
Change gasket
Starter motor cranks too slow
Air intake improper
Incorrect valve setting
Repair/ Change
Tighten
Change battery or starter
motor
Adjust
Adjust
2. No spark
Dirt
Water
Ignition coil
Connector short/open circuit
Magneto
CDI
Clean/ Change
Clean/ Dry/ Change
Change
Change
Change
Change
3. No fuel in carburetor
Fuel tank vent pipe tank block
Fuel pipe block
Damage to carburetor needle valve
Block in fuel tank
Block at fuel filter
Clean or change
Clean or change
Change
Change
Clean or change
4. Miscellaneous
Gear selected is not neutral
Switch to neutral gear
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- 26 -
（I）Engine failure
Problem
Uneven or no idle speed
Indication
1. Mechanical fault
Cause(s)
Incorrect valve clearance
Valve housing
Intake manifold
Improper fuel level in float bowl
Carburetor jet block
Fuel pipe
Idle Adjustment screw setting is wrong
Solution
Adjust
Repair/ Change
Change
Adjust
Clean
Change
Adjust
2. Electrical fault
Dirt
Water
Ignition coil
Connectors open/ short circuit
Magneto
CDI
Clean/ Change
Clean/ Dry/ Change
Change
Change
Change
Change
Poor onroad performance Mechanical fault
Valve spring
Cam shaft worn out
Spark plug is not clean
Insufficient spark plug gap
Improper air circulation
Ignition coil
Fuel level too low in float bowl
Air filter is not clean
Fuel pipe block
Fuel pipe damage
Change
Change
Clean/ change
Adjust/ Change
Adjust
Change
Adjust
Clean/ change
Clean
Change
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- 27 -
（I）Engine failure
Problem
Blue exhaust smoke
Indication
Mechanical fault
Cause(s)
Excess engine oil
Piston ring worn out
Valve pipe worn out
Cylinder wall damage
Valve rod worn out
Valve gasket damage
Solution
Drain the excess engine oil
Change
Change
Change
Change
Change
Lack of power
1. Fuel supply fault
Carburetor jet blocked
Improper fuel level in float bowl
Air filter is not clean
Intake manifold leak
Excess engine oil
Clean/ Change
Adjust the height
Clean/ Change
Tighten/ Change
Drain the excess engine oil
2. Electrical fault
Spark plug is not clean
Insufficient spark plug gap
Ignition coil defect
CDI defect
Magneto defect
Clean/ Change
Clean/ Adjust
Change
Change
Change
3.Mechanical fault
Incorrect valve clearance
Valve spring weak
Improper air circulation
Cylinder worn out
Piston Ring worn out
Cylinder head damage
Cranskshaft or cam shaft worn out
Adjust
Check, remove or change
Adjust
Change
Change
Change/ Repair
Change
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- 28 -
（I）Engine failure
Problem
Engine overheating
Noise from engine
Indication
1. Fuel system fault
Cause(s)
Octane number is lower than specified
Fuel passage blocked
Fuel pump fault
Fuel level in floater bowl is low
Solution
Use the right fuel
Clean the fuel pipe
Change
Adjust the height of floater
2. Electrical fault
Ignition time is late or early
Spark is weak or no spark
Adjust ignition timing
Check spark plug & magneto
3. Air Intake
Air mixture is too lean or rich
Engine leak
Air filter is not clean
Cylinder, piston, piston rings worn out
Leak at air intake connecting face
Block in exhaust pipe
Intake manifold leak
Adjust carburetor
Repair
Clean or change filter
Repair/ change
Repair/ change
Dredge
Repair/ change
4. Engine cooling system
Block in coolant channel or radiator
Air in Cooling system or insufficient coolant
Water pump fault
Unsuitable coolant
Thermostat fault
Fan motor or temperature sensor fault
Clear
Release air, refill coolant
Change
Change
Change
Change
5. Miscellaneous
Carbon accumulation on top of piston
Improper amount of engine oil
Engine oil corrupt
Clear
Drain/ Refill
Change
Noise from valve
Valve clearance too large
Valve spring damage
Crankshaft or cam shaft worn out
Adjust
Change
Change
© Copyright Chironex Motorsports Inc. All Rights reserved.
- 29 -
（I）Engine failure
Problem
Noise from engine
Indication
Noise from piston
Cause(s)
Piston worn out
Cylinder worn out
Carbon deposit on spark plug
Piston pin or pin hole worn out
Piston ring or ring notch worn out
Solution
Change
Change
Clean
Change
Change
Noise from chain circulation
Chain elongated
Chain worn out
Chain adjustor defect
Change chain & sprocket
Repair & Change
Change
Noise from clutch
Crankshaft spline damage
Clutch spline damage
Change crankshaft
Change clutch
Noise from Crankshaft
Bearing
Needle bearing damage
Gap too big
Change
Change
Change
Noise from CVT
Belt loose or worn out
Roller or main wheel damage
Change
Change
Gear damaged
Input/ output shaft damaged
Bearing worn out
Bushing worn out
Change
Change
Change
Change
Noise from transmission
system
© Copyright Chironex Motorsports Inc. All Rights reserved.
- 30 -
（I）Engine failure
Problem
Engine lacks power
Clutch skiding
Indication
Cause(s)
Solution
Fuel system fault
Octane number is too low
Fuel passage blocked
Use the right fuel
Clean fuel pipe
Transmission system
Clutch shoe worn out
Clutch spring is weak
Fly wheel worn out
Belt worn out or loose
Change
Change
Change
Change
Operating gear damage
Shift rod bent
Shift drum worn out
Shifter fault
Change
Change
Change
Adjust
Gear change not smooth
or stuck
Gear box or Gear change
system
Carburetor malfunction
Starting trouble
Carburetor jet block
Venturi block
Leak at valves
Starting pin adjustment incorrect
Clean
Clean
Tighten/ Adjust/ change
Adjust
Idle and low speed uneven
Slow jet valve block
Valve channel Blocked
Air inlet channel block
Air inlet bypass Block
Starting pin not closed completely
Idle screw setting improper
Height of floater not correct
Clean/ Tighten
Clean
Clean
Clean
Adjust
Adjust
Adjust
© Copyright Chironex Motorsports Inc. All Rights reserved.
- 31 -
（I）Engine failure
Problem
Carburetor malfunction
Indication
Not stable in high and middle
speed
Spill over or fuel level
fluctuation
Cause(s)
Solution
Carburetor jet block
Main air channel block
Needle valve block
Throttle defect
Fuel filter block
Height of floater incorrect
Starting pin not closed
Clean
Clean
Clean
Adjust
Clean/ Change
Adjust
Adjust
Needle valve worn out or damaged
Valve Spring broken
Floater defect
Valve not clean
Change
Change
Adjust/ Change
Clean
Engine coolant
temperature is low
Cooling System
Fan temperature sensor defect
Cold weather
Thermostat defect
Change
Cover the radiator
Change
Spark weak
Ignition System
Faulty starter
Faulty spark plug
Faulty magneto
Voltage weak
Faulty ignition coil
Faulty starting loop
Change
Change
Change
Change
Change
Change
© Copyright Chironex Motorsports Inc. All Rights reserved.
- 32 -
（II）Transmission failure
Problem
Indication
Vehicle not moving
Transmission
Transmission not staying
in gear/ difficult to shift
gears
Gear box or shifter
（III）Running, suspension and/or steering trouble
Vehicle leaning
Running system
Cause(s)
Shift belt slips
Speed adjusting plate abrasion
Speed adjusting plate jam
Spring
Solution
Change
Change
Repair/ Change
Repair/ Change
Speed changing drum groove worn out
Right and left gear changing rods bent
High/Low driven gear groove worn to taper
Speed changing principal and countershaft
worn out
Sector gear tooth worn out
Sector gear spring defect
Change
Change
Repair/ Change
Air pressure difference in left and right tires
Different loads on left and right side
Shock absorber setting
Misalignment of front wheel
Wheel locked or brake jammed
Front or rear suspension parts loose, bent or
damaged
Adjust air pressue in tire
Adjust load
Adjust/ Change
Check/ Adjust
Repair brakes
Screw or change suspension
parts
© Copyright Chironex Motorsports Inc. All Rights reserved.
Repair/ Change
Change
Change
- 33 -
（III）Running system, suspension and steering failure
Problem
Indication
Steering assembly, running
Tire worn out abnormally system, suspension
Front wheel unstable
Steering assembly, running
system
Cause(s)
Left and right absorber has been
damaged, weak
Tyre not balanced or wheel hub is
distorted
Front wheel alignment wrong
Vehicle overload
Wheel hub bearing has been damaged or
adjustment is wrong
Wheel assembly spacing (axial, radial) is
too big
Air pressure in tire is too high or too low
Tire or wheel imbalance
Wheel hub bearing has been damaged or
adjustment is wrong
Left and right swing arm ball head worn or
loose
Drag pole tie-in has been worn or loose
Front wheel alignment is wrong
Wheel (axial, radial) spacing
Tire damage
Excessive steering free play
Fixed bolts on steering assembly loose
© Copyright Chironex Motorsports Inc. All Rights reserved.
Solution
Adjust/ Change
Change
Check/ Adjust
Check load
Adjust/ Change
Change
Adjust air pressure in tire
Balance wheel/ Change tire
Change/ Adjust
Change
Change
Check/ Adjust
Change tire/ wheel hub
Change tire
Change/ Adjust
Fasten
- 34 -
（III）Running system, suspension and steering failure
Problem
Indication
Steering assembly, running
Steering is heavy
system
（IV）Brake system failure
Braking is weak
Brake system
Brake is leaning
Brake system suspension
Cause(s)
Solution
Low air pressure in tire
Ball head of left and right swing arm and
drag pole is blocked
Steering block
Mesh clearance is too small
Change air pressure
Change
Repair/ Change
Adjust
Brake line leaks oil
Brake disk or pads not clean
Brake disk or pads worn
Repair
Repair/ Clean dust
Change
Brake main pump is damaged or leaks oil
Brake branch pump is damaged or leaks
oil
Insufficient brake fluid
Air in brake fluid
Brake disk overheated
Repair/ Change
Repair/ Change
Add
Remove air
Repair/ Change
Oil stain on brake disks or pads
Hydraulic pump leaking oil or block
Clean/ Change
Repair/ Change
Uneven air pressure in right and left tires
Front wheel alignment is wrong
Equalize air pressure
Adjust
© Copyright Chironex Motorsports Inc. All Rights reserved.
- 35 -
（IV）Brake system failure
Problem
Indication
Braking leads to leaning
Brake system suspension
Brake clip block
Brake system
Cause(s)
Vehicle frame damage, left and right
wheelbase is different
Brake line
Brake disks not in contact
Suspension parts loose
Repair/ Adjust
Repair/ Adjust
Repair
Check, repair and fasten
Brake pump
Brake return spring
Hand brake adjustment
Hand brake line
Brake branch clip block
Brake disk worn
Brake line
Repair main pump
Change
Adjust
Lubricate or Change
Repair or Change
Change
Change
© Copyright Chironex Motorsports Inc. All Rights reserved.
Solution
- 36 -
（V）Lights, Instruments, Circuit Failure
Problem
Indication
Front headlight does not
Lighting system
illuminate
Only one front headlight
does not illuminate
Lighting system
Steering light does not
illuminate
Starter does not rotate
when starting
All instruments not working Circuit
Cause(s)
Solution
Switch damage
Battery damage
Bulb defective
Repair/ Change
Change
Change
Bulb defective
Lead or grounding defect
Change
Repair circuit
Steering relay has been damaged
Individual steering bulb has burned
Grounding defect
Fuse blown
Switch damage
Change
Change
Repair
Change
Change
Starter has been damaged
Starter relay has been damaged
Grounding defect
Ignition switch has been damaged
Repair/ Change
Change
Repair
Change
Main fuse blown
Ignition switch has been damaged
Wiring
Loose contact/ oxidation
Check and Change
Change
Repair circuit
Repair
© Copyright Chironex Motorsports Inc. All Rights reserved.
- 37 -
（V）Lights, Instruments, Circuit Failure
Problem
Indication
Lights not working (not
Light circuit
including headlight)
Instruments not working
Instrument or wiring
Cause(s)
Solution
Switch damage
Bulb defective
Wiring damage, loose contact
Fuse blown
Ground wire loose contact
Change
Change
Repair
Change
Repair
Fuse blown
Wiring damage, loose contact
Instrument damage
Sensor damaged
Change
Repair
Change
Change
© Copyright Chironex Motorsports Inc. All Rights reserved.
- 38 -
IX、Torque specifications
Engine
S#
Item
1 Reverse gear sensor
2 Spark plug
3 Water temperature sensor
4 Air valve adjustment screw
5 Driver gear nut
6 Driven gear nut
7 Driven gear round nut
8 Front shaft nut
9 Driver prick gear nut
10 Driven prick gear nut
11 Clutch fixed nut
12 Driven gear nut
13 Front output bearing nut
14 Swing arm axle nut
15 Drain bolt
16 Clutch bolt
17 Stator bolts
18 CVT cover screws
19 Fuel pipe bolts
20 Fuel pump bolts
21 Needle valve screw
22 Bolts on driver gear cover
23 Bolts on driven gear cover
24 Gear positioning bolt
Thread
diameter
Qty
(mm)
1 M10x1.25
1 M12x1.25
1 R/c1/8
4 M5
1 M20x1.5
1 M20x1.5
1 M30x1
1 M14x1.5
1 M22x1
1 M16x1.5
1 M18x1.5
1 M60
1 M55
2 M14x1.25
1 M12x1.5
6 M8
3 M6
3 M6
2 M14x1.5
3 M6
2 M6
4 M8
4 M8
1 M14x1.5
Torque
(Nm)
20
18
8
10
115
115
100
97
145
150
70
110
80
28
30
26
10
10
18
10
10
32
25
18
S#
Item
25 Bolt on ignition switch
26 Bolts on crankcase
27 Bolt on sector gear
28 Oil filter bolt
29 Oil filter bolt
30 Bolt on starter motor
31 Bolts on cylinder cover
32 Nuts on cylinder cover
33 Bolts on cylinder
34 Bolts on cylinder cover
35 Bolts on chain adjuster
36 Nuts on chain adjuster
37 Bolts on fan motor
38 Bolts on Thermostat
39 Bolts on pump cover
40 Bolts on pump
41 Bolts on circulation unit
42 Other bolts
© Copyright Chironex Motorsports Inc. All Rights reserved.
Thread
diameter Torque
Qty
(Nm)
(mm)
1 M10x1.25
55
14 M6
10
3 M8
25
1 M6
12
1 M20x1.5
63
1 M20x1.5
63
2 M6
10
4 M10
38
2 M6
10
1 M8
25
4 M6
10
12 M6
10
2 M6
10
1 M8
8
3 M6
10
2 M6
10
3 M6
6
2 M6
10
2 M6
15
M5
4.5 - 6
M6
8 -- 12
M8
18 - 25
- 39 -
FRONT, REAR SUSPENSION：
S#
Item
Bolts on front steering joint and
1 shock absorbers
2 Bolts on F/R brake disks
3 Bolts on F/R brake disks
Bolts on support brackets of F/R
4 brake pumps
Bolts on front steering joint and
5 shaft
6 Nuts on front and rear axle
7 Nuts on rod connector
8 Locknuts of rod
9 Steering screw
10 Bolts on steering transfer block
11 Screws on steering column
12 Nuts on front shock absorber
13 Screw of winch
14 Screw of brake master cylinder
15 Bolt on push rod of main brake
16 Bolt on pin of push rod
17 Drive shaft flange nuts
18 Tire nuts
19 Rollcage screws
20 Steering wheel nut
Qty
Thread
diameter
(mm)
Torque
(Nm)
4 M12x50
18 M10x50
4 M12x50
110
60
110
4 M12x20
110
2 M10x30
4 M18
2 M12
4 M12
4 M10x30
2 M8x25
2 M10x20
2 M8
4 M8x16
2 M10x55
1 M10
1 M8x20
4 M14
16 M12
6 M12x95
2 M12x70
1 M12
60
200
100
60
50
25
50
25
25
55
50
23
100
55
S#
Item
21 Hand brake bolt
22 Bumper bolt
23 Axle bolt
24 Flange bolt, upper
25 Flange bolt, lower
26 Front axle gear box bolt
27 Screw on front axle motor
28 Front axle pin shaft screw
29 Front axle nut
30 Differential bolt
31 Oil intake bolt
32 Drain bolt front axle
33 Bolt on rear axle
34 Bolt on rear axle
35 Rear axle input shaft nut
36 Bolt on rear axle input shaft
37 Bolt on rear axle positioning
38 Nut
39 Drain bolt rear axle
40 Oil intake rear axle bolt
Thread
Torque
Qty diameter (mm) (Nm)
2 M8x20
28
2 M10x20
50
2 M8x25
30
1 M12x90
70
2 M12x175
70
6 M8x28
25
4 M8x20
13
1 M14x1.5
10
1 M10x1.25x18
62
6 M10x1.25x18
40
1 M14x1.25x12
25
1 M10x1.25
25
2 M10x1.25x25
40
4 M8x25
25
1 M12x1.25
62
4 M8x30
25
1 M65x1.5x10
90
1 M8
16
1 M14x1.25x12
25
1 M20x1.5x12
25
60
70
© Copyright Chironex Motorsports Inc. All Rights reserved.
- 40 -
Other screws (8.8 grade)
Specification
M6
M8
M10
M12
Torque
(Nm)
10
25
50
80
X、Fuel and Lubricating oil specification
Category
Specification
Fuel
RQ-90 or higher grade lead-free 27 L
1900 ml (change oil)
2000 ml (change filter)
2200 ml (repair engine)
SAE15W - 40/SF or SC
First 0.33 L/ change 0.28
SAE15W - 40/SF or
SAE80W - 90GL-4
First 0.33 L/ change 0.28
GB1083JG3
1.1 L
Distilled water : Glycol :: 1 : 1
Engine Oil, Gear Oil (Gear box)
Front Differential Oil
Rear Differential Oil
Brake fluid
Coolant
Capacity
© Copyright Chironex Motorsports Inc. All Rights reserved.
Remark
Fuel tank capacity
- 41 -
2WD AND 4WD TRANSFER CIRCUIT
© Copyright Chironex Motorsports Inc. All Rights reserved.
- 42 -
SPARTAN 500 CIRCUIT DIAGRAM
© Copyright Chironex Motorsports Inc. All Rights reserved.
- 43 -
© Copyright Chironex Motorsports Inc. All Rights reserved.
- 44 -
_________________________________________________________________________
© Copyright 2007-2008 Chironex Motorsports Inc. All Rights reserved