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  4. Onslaught 550 EFI 4X4 EPS
  5. Owner's Manual

Bad Boy Onslaught 550 EFI 4X4 EPS Owner's Manual

Summary of Onslaught 550 EFI 4X4 EPS

  • Page 1

    Read this manual carefully! It contains important safety information. . Owner’s manual this vehicle should not be operated by those under 16 years of age. 64752 4 550 efi 4x4 / 550 efi 4x4 eps.

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    1 dear customer: our atv is manufactured under a strict quality control system. Separate documents supplied to the dealer provide information on product warranty and emissions warranty. Failure to follow instructions for emission parts replacement may violate u.S. Federal law (40 cfr part 1068.105 (...

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    2 therefore is subject to change without notice. The manufacturer disclaims liability for errors in this manual, and specifically disclaims liability for incidental and consequential damages resulting from the use of the information and material in this manual. Name: address: telephone: purchase dat...

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    3 introduction read this manual carefully before operating this vehicle. This manual should stay with vehicle if it is sold. This manual will provide you with a good basic understanding of the features and operation of this atv. This manual includes important safety information. It provides informat...

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    4 contents specifications………………………………………………………………………… important identification numbers…………………………………………… location of the warning and specification label…………………….. Safety information…………………………………………………………………. Pre- operation checks…………………………………………………………….. Description…………………………………………………………………………….. Ins...

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    5 specifications 550 efi 4x4 overall length 84.8 in. (2155 mm) overall width 48.6 in. (1235 mm) overall height 49.2 in. (1250 mm) wheel base 50.4 in. (1280 mm) wheel tread front 36.6 in. (930 mm) rear 37.0 in. (940 mm) mass of vehicle in running order front 472 lbs. (214 kg) rear 423 lbs. (192 kg) t...

  • Page 7

    6 rear disk (Ø 180 mm) performance max. Speed 78 [km/hr] climb ability ＜25 ﾟ reduction primary reduction belt secondary reduction gear / shaft clutch centrifugal, wet type transmission c.V.T., auto speed change speedometer 0 ~ 300 [km/hr] horn 93 ~ 112 [db/a] fuel capacity 18 +/- 0.3 l lubrication s...

  • Page 8

    7 important identification numbers 1. Frame number: record chassis and engine number for future reference. Number is located front right hand side of chassis as shown in (1). 2. Engine number is located front of the engine as shown in (2). 3. Manufacturer’s data plate the manufacturer’s data plate i...

  • Page 9

    8 location of the warning and specification labels 1 3 4 2 7 4 8 6 9 14 5 18 17.

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    9 read and understand all of the labels on your atv. These labels contain important information for safe and proper operation. Never remove any labels from your atv. If a label becomes difficult to read or comes off, request a replacement label from your dealer. 1. 2. 12 16 11 13 15 10 19.

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    10 3. 4. 5. 6. 7. 8. 9..

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    11 10. 11. 12. 13. 14. 15..

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    12 16. 17. 18. 19..

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    13 safety information an atv is not a toy and can be hazardous to operate an atv handles differently from other vehicles, including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to tak...

  • Page 15

    14  always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly. Never go over the top of a hill a...

  • Page 16

    15 warning! All engine exhaust contains carbon monoxide, a deadly gas. Carbon monoxide is a colorless, odorless, tasteless gas, which may be present even if you do not see or smell any engine exhaust. Avoid carbon monoxide poisoning.  do not run engine indoors. Even if you try to ventilate engine e...

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    16 pre-operation checks inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in owner’s manual. Warning! Failures to inspect or maintain the vehicle properly increase the pos...

  • Page 18

    17 brake pedal  make sure that operation is smooth. Lubricate pedal pivoting point if necessary. Brake levers  make sure that operation is smooth. Lubricate pedal pivoting point if necessary. Axle boots  check for cracks or damage and replace if necessary. Chassis fasteners  make sure that all n...

  • Page 19

    18 description 1. Stop switch 2. High/low beam switch 3. Four wheel brake lever 4. Starter switch 5. Override 6. Ignition switch 7. Speedometer & display 8. Auxiliary dc jack 9. 2wd/4wd/lock switch 10. Throttle 11. Fuel tank cap 12. L/h/n/r lever 13. Parking brake.

  • Page 20

    19 intrument and control function 1. Ignition switch function / position position function key out position lamp no on all electrical systems operational no off while parking yes 2. Signs and functions position name function starter switch start engine dimmer switch hi-beam/lo-beam switch stop switc...

  • Page 21

    20 4. Rear brake pedal the rear brake (pedal) is located on the right side of the atv. To apply the rear brake, push down on the brake pedal. Warning! Before each trip check whether the accustomed resistance is present when pressure is applied to the brake lever. Check the brake fluid level, the lev...

  • Page 22

    21 5. Shift lever l: high torque use (advance gear) h: normal use (driving gear) n: neutral r: reverse use shift lever instructions: 1. Engine starts only in neutral (n) position. 2. Lift up and hold the pull rod of shift lever to disengage and move the shift lever from n to h, l or r. (l shift is u...

  • Page 23

    22 6. 2wd/4wd/lock switch the 2wd/4wd/lock select button is used to change the engine drive power to two wheels or all four wheels. Select 2wd, 4wd or lock based on different terrain conditions. 2wd: engage the engine power on rear wheels only. This is mainly used for normal riding. 4wd: engage the ...

  • Page 24

    23 4wd/lock warning! Always ride at a slow speed when the atv is in differential gear lock and allow extra time and distance for maneuvers. All wheels turn at the same speed when the differential gear is locked, so it takes more effort to turn the atv. The effort needed to turn increases with the ri...

  • Page 25

    24 stop the atv, make sure the 4wd button is pushed in, then turn the differential gear lock lever to the lock position. When the differential gear is locked, the differential gear lock indicator “lock” will come on along with the indicator “ “ in the multi-function display. To release the different...

  • Page 26

    25 set the tire pressure to the following specifications: model 550 efi 4x4 550 efi 4x4 eps recommend front 7 psi (0.492kgf/㎝ 2) 6 psi (0.422kgf/㎝ 2) rear 7 psi (0.492kgf/㎝ 2) 6 psi (0.422kgf/㎝ 2) the low-pressure tire gauge is included as standard equipment. Make two measurements of the tire pressu...

  • Page 27

    26 aftermarket tires and rims the tires and rims that came with your atv were designed to match the performance capabilities and to provide the best combination of handling, braking and comfort. Other tires, rims, sizes and combinations may not be appropriate. 8. Coolant the coolant level should be ...

  • Page 28

    27 1. Place the atv on a level surface. Turn the key to the off position and remove it from the vehicle. 2. Remove front cover. 3. Place a container under the engine and then remove the coolant drain bolt and its gasket. 4. Remove the radiator cap. 5. Remove reservoir cap. 6. Disconnect the coolant ...

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    28 9. Steering lock the steering lock in principle should be used for theft protection. The handlebar is to be turned to the left and the key in the steering lock pressed and turned simultaneously as shown. Remove key. 10. Speedometer panel descriptions 1. 2wd/ 4wd indicator 5. Set button 2. Eps mod...

  • Page 30

    29 indicator will run a self-diagnostic. If the system does not run the self-diagnostic program there is a malfunction in the system. Please contact your local dealer for inspection. 4. Turn signal light (green): on use of turn signal, lights will flash with an audible warning. Hazard warning: both ...

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    30 1. Calculates total operation time from the beginning of vehicle use. 2. Count automatically begins with vehicle movement. 3. Tt data is stored in memory even when power is off. Fuel meter (only for models with the function) 1. 7 bar graphic indicator of fuel status. 2. Last bar flashes to indica...

  • Page 32

    31 11. Spark plug checking the spark plug. The spark plug is an important engine component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accordance with the periodic maintenance and lubrication chart. In ad...

  • Page 33

    32 12. Air cleaner 1. Remove the seat. 2. Release the four latches that secure the air cleaner cover, remove the cover. 3. Loosen the clamp strip screw and remove the air cleaner element. 4. Clean the element with non-flammable solvent. Warning! Always use parts cleaning solvent to clean the sponge ...

  • Page 34

    33 note: the engine oil should be between the minimum and the maximum level mark. 5. If the engine oil is not between the minimum and the maximum level mark, add sufficient oil of the recommended type to raise it to the correct level. Note: be sure the engine oil is at the correct level, otherwise e...

  • Page 35

    34 with oil filter replacement: 4 quarts (3.86 l) ※ be sure to wipe off spilled oil on any parts after the engine and exhaust system have cooled down. Caution!  in order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives.  make sure that...

  • Page 36

    35 3. Remove the differential gear oil filler bolt, the differential gear oil drain bolt and their gaskets to drain the oil from the differential gear case. Note: dispose of lubricant in accordance with local regulations. 4. Install the drain bolt and its new gasket and then tighten the bolt to the ...

  • Page 37

    36 to change the final gear oil 1. Place the atv on a level surface and raise up with a lift or jack. 2. Place an oil pan under the final gear case to collect the used oil. 3. Remove the final gear oil filler bolt; the final gear oil drain bolt and their gaskets to drain the oil form the final gear ...

  • Page 38

    37 when storing any documents in the storage compartments, be sure to wrap them in a plastic bag so that they will not get wet. When washing the atv, be careful not to let any water enter the storage compartments. If any water has collected in a storage compartment, remove the drain plug to allow th...

  • Page 39

    38 to charge the battery if the battery is discharged and will not allow the vehicle to start. Use a constant voltage battery charger to charge the battery. Keep in mind that the battery tends to discharge more quickly if the atv is equipped with optional electrical accessories. Caution! To charge f...

  • Page 40

    39 for non eps model, the maxi fuse is located beside the starter relay. Replacing a fuse the main fuse box and the eps fuse box are located under the seat. If a fuse is blown, replace it as follows. 1. Turn the key to “off” and turn off all electrical circuits. Caution! To prevent accident short-ci...

  • Page 41

    40 19. Replacing a headlight bulb if a headlight bulb burns out, replace it as follows. 1. Disconnect the wiring connector. 2. Turn the headlight bulb counterclockwise then remove it. 3. Insert a new headlight bulb, and turn clockwise to lock in place. 4. Connect the wiring connector. Caution! Do no...

  • Page 42

    41 2. Remove the tail / brake light bulb holder (together with bulb) by turning it counterclockwise. 3. Remove the burnt out bulb by pushing it in and turning it counterclockwise. 4. Insert a new bulb into the bulb holder, push it in and then turn it clockwise until it stops. 5. Install the bulb hol...

  • Page 43

    42 precaution of atv riding this atv is for recreation and utility use. This section, riding your atv, provides general atv riding instructions for recreational riding. The skills and techniques described in this section however are appropriate for all types of riding. Riding your atv requires speci...

  • Page 44

    43 this atv is designed to carry the operator and cargo only, passengers are prohibited. The long seat is to allow the operator to shift position as needed during operation. It is not for carrying passengers. Warning! Never carry a passenger. Carrying a passenger on this atv greatly reduces your abi...

  • Page 45

    44 warning! Never consume alcohol or drugs before or while driving this atv. You increase your chance of an accident. Pre-operation checks always inspect your atv each time you use it to make sure the atv is in safe operating condition. Perform the pre-operation checks listed on this manual. Always ...

  • Page 46

    45 during operation always keep your feet on the footboards during operations. Warning! Removing even one hand or foot can reduce your ability to control the atv or could cause you to lose your balance and fall off of the atv. Avoid wheelies and jumping. Warning! Attempting wheelies, jumps and other...

  • Page 47

    46 cleaning the spark arrester be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Remove the bolts. 2. Remove the tailpipe by pulling it out of the muffler. 3. Tap the tailpipe lightly, and then use a wire brush to remove any carbon deposits from the spark arrester ...

  • Page 48

    47 warning! Failure to use extra care when operating on excessively rough, slippery or loose terrain could cause loss of traction or atv control which could result in an accident, including an overturn. When riding in an area where you might not easily be seen such as desert terrain, mount a caution...

  • Page 49

    48 to achieve maximum traction while riding off-road, the two rear wheels turn together at the same speed. Therefore, unless the wheel on the inside of the turn is allowed to slip or lose some traction, the atv will resist turning. A special turning technique must be used to allow the atv to make tu...

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    49  shift your weight forward.  never open the throttle suddenly. The atv could flip over backwards.  never go over the top of any hill at high speed. An obstacle, a sharp drop or another vehicle or person could be on the other side of the hill.  never attempt to turn the atv around on any hill ...

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    50 warning! Stalling, rolling backwards or improperly dismounting while climbing a hill could result in atv overturning. If you cannot control the atv, dismount immediately on the uphill side. Riding down hill warning! Going down a hill improperly could cause overturns or loss of control. Always fol...

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    51 crossing a slope warning! Improperly crossing hills or turning on hills could cause loss of control or cause the atv to overturn.  always follow proper procedures as described in the owner’s manual.  avoid hills with excessively slippery or loose surfaces.  avoid crossing the side of a steep h...

  • Page 53

    52 warning! Wet brakes may have reduced stopping ability, which could cause loss of control. After riding your atv in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case, remove the v-belt case drain bolt and front storage compartment drain plug ...

  • Page 54

    53 what to do  if your atv doesn’t turn when you want it to: bring atv to a stop and practice the turning maneuvers again. Be sure you are putting your weight on the footboard to the outside of the turn. Position your weight over the front wheels for better control  if your atv begins to tip while...

  • Page 55

    54 periodic maintenance periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible. Safety is an obligation of the vehicle owner/operator. Warning! Failure to properly maintain the vehicle or performing maintenance activities incorrectl...

  • Page 56

    55 6 engine oil filter  replace r r r 7 engine oil strainer  clean i i i 8 differential gear oil  change  check atv for oil leakage and correct if necessary r r r replace every 4 years 9 final gear oil  change r r r  check atv for oil leakage and correct if necessary replace every 4 years 10 f...

  • Page 57

    56 21 shock absorber assemblies  check operation and correct if necessary  check for oil leakage and replace if necessary i i 22 rear knuckle pivots  lubricate with grease l l 23 steering shaft  lubricate with grease l l 24 steering system  check operation and repair or replace if damaged  che...

  • Page 58

    57 cleaning and storage cleaning frequent, thorough cleaning of your atv will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the atv: a. Block off the end of the exhaust pipe to prevent water entry. A plastic...

  • Page 59

    58 1. Follow all the instructions in the “cleaning” section of this chapter. 2. Turn the fuel cock lever to “off”. 1. Drain the carburetor float chamber by loosening the drain bolt; this will prevent fuel deposits from building up. Pour the drained fuel into the fuel tank. 2. Fill up the fuel tank a...

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    59 trouble shooting contact your dealer for service if you're unable to identify solutions using the following charts. Engine doesn’t turn over possible cause solution tripped circuit breaker reset the breaker low battery voltage recharge battery to 12.5 vdc loose battery connections check all conne...

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    60 loose ignition connections check all connections and tighten water present in fuel replace with new fuel low battery voltage recharge battery to 12.5 vdc kinked or plugged fuel vent line inspect and replace incorrect fuel replace with recommended fuel clogged air filter inspect and clean or repla...

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    61 maintenance record p.D.I. Date: odometer reading: dealer stamp: 1st service date: odometer reading: dealer stamp: 2nd service date: odometer reading: dealer stamp: 3rd service date: odometer reading: dealer stamp: 4th service date: odometer reading: dealer stamp: 5th service date: odometer readin...

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    62 8 th service date: odometer reading: dealer stamp: 9th service date: odometer reading: dealer stamp: 10th service date: odometer reading: dealer stamp: 11th service date: odometer reading: dealer stamp: 12th service date: odometer reading: dealer stamp: 13th service date: odometer reading: dealer...

  • Page 64

    63 consumer information identification number record the key identification number, vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from your dealer or for reference in case the atv is stolen. Key identification number: ...

  • Page 65

    64 2016 my emissions control system warranty: bad boy onslaught 550 emission system warranty statement: distributors' limited warranties emission control systems your textron specialized vehicles' atv complies with us epa and california arb emissions regulations. Textron specialized vehicles provide...

  • Page 66

    65 honor your claim within a reasonable period of time, contact textron specialized vehicles for assistance at 1-800-448-7476. If you are not satisfied with the way in which a warranty claim is resolved by textron specialized vehicles, you may write directly to: director of field operations support ...

  • Page 67

    66 abuse or lack of required maintenance will not be covered by this warranty. Textron specialized vehicles recommends that only parts supplied by textron specialized vehicles or equivalent parts be used to repair your atv. Maintenance, replacement, or repair of emission control devices and systems ...