Bush Hog Automobile 4430 User Manual

BUSH HOG

MODEL

4430

OFF ROAD UTILITY VEHICLE

Operator’s Manual

ASSEMBLY • OPERATION • MAINTENANCE

808

$10.00

50066586

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BUSH HOG

4430 Utility Vehicle

TABLE OF CONTENTS

SECTION

Retail Customer’s Responsibility

Warranty

Dealer Preparation Check List

Safety Alert Symbols

Safety Precautions

PAGE SECTION

PAGE

III MAINTENANCE

Periodic Maintenance Schedule

Lubrication Recommendations

Engine Oil

Engine Oil Filter Change

Transaxle

Front Differential

Right Angle Drive

INTRODUCTIONANDDESCRIPTION 20

Introduction

Description

Specifications

Constantly Variable Transmission 55

Vehicle Immersion

Engine Air Filter

CVT Enclosure Air Filter

Fuel filter

Spark Plugs

Spark Arrestor

Throttle System

Brake Inspection

Parking Brake Adjustment

Steering Wheel Inspection

Seat Belts

II OPERATION

General Safety

Pre-Operation Checklist

Vehicle Break-In Period

Starting The Engine

Driving The Vehicle

Braking

Tires

Stopping The Engine

Using The Cargo Box

Load Distribution

Wheel Lug Nuts

Wheel Installation

Lights

Cleaning Your Vehicle

Storage

Removal From Storage

Battery

Replenishing Battery Fluid

Battery Removal

Battery Installation

Battery Storage

Driving Safely

Driving On Slippery Surfaces

Driving Uphill

Sidehilling

Driving Downhill

Driving Through Water

Driving Over Obstacles

Driving In Reverse

Parking On An Incline

Hauling Cargo

IVASSEMBLY

Attaching Occupant Protection

Structure

Optional Equipment

Items To Check

Emptying The Cargo Box

Towing Loads

70, 71

Parking The Vehicle

4-Wheel Drive

Seat Belt Installation

Rubber Bumper Pad Adjustment

Troubleshooting CheckList

Safety Decals

Disengaging 4-Wheel Drive

Noise Emission Control System

Spark Arrestor

Torque Specifications

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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, main-

tain and store the product in accordance with all instruc-

tions and safety procedures. Failure of the operator to read

the Operator’s Manual is a misuse of this equipment.

It is the Retail Customer and/or Operator’s responsibility

to inspect the product and to have any part(s) repaired or

replaced when continued operation would cause damage

or excessive wear to other parts or cause a safety hazard.

It is the Retail Customer’s responsibility to deliver the prod-

uct to the authorized Bush Hog Dealer, from whom he pur-

chased it, for service or replacement of defective parts

which are covered by warranty. Repairs to be submitted

for warranty consideration must be made within thirty (30)

days of failure.

It is the Retail Customer’s responsibility for any cost in-

curred by the Dealer for traveling to or hauling of the prod-

uct for the purpose of performing a warranty obligation or

inspection.

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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.

Model 4430 also carries a three (3) year limited drive train warranty.

This three (3) year limited drive train warranty covers the CVT

clutches, transaxle, driveline, front differential, and all four CV shaft

assemblies.The obligation of Bush Hog to the purchaser under this

warranty is limited to the repair or replacement of defective parts.

Replacement or repair parts installed in the equipment cov-

ered by this limited warranty are warranted for ninety (90) days from

the date of purchase of such part or to the expiration of the applicable

new equipment warranty period, whichever occurs later. Warranted

parts shall be provided at no cost to the user at an authorized Bush

Hog dealer during regular working hours. Bush Hog reserves the right

to inspect any equipment or parts which are claimed to have been de-

fective in material or workmanship.

DISCLAIMER OF IMPLIED WARRANTIES & CON-

SEQUENTIAL DAMAGES

Bush Hog’s obligation under this limited warranty, to the ex-

tent allowed by law, is in lieu of all warranties, implied or expressed,

INCLUDING IMPLIED WARRANTIES OF MERCHANTABILITY AND

FITNESS FOR A PARTICULAR PURPOSE and any liability for inci-

dental and consequential damages with respect to the sale or use of

the items warranted. Such incidental and consequential damages

shall include but not be limited to: transportation charges other than

normal freight charges; cost of installation other than cost approved by

Bush Hog; duty; taxes; charges for normal service or adjustment; loss

of crops or any other loss of income; rental of substitute equipment,

expenses due to loss, damage, detention or delay in the delivery of

equipment or parts resulting from acts beyond the control of Bush

Hog.

CONTINUED

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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, racing, fire or other accident.

3. If parts not made or supplied by Bush Hog have been used in con-

nection with the vehicle, if, in the sole judgement of Bush Hog such

use affects its performance, stability or reliability.

4. If the vehicle has been altered or repaired outside of an authorized

Bush Hog dealership in a manner which, in the sole judgement of

Bush Hog, affects its performance, stability or reliability.

5. To normal maintenance service and normal replacement items to

include, but not limited to gearbox lubricant, engine oil, all filters, and

spark plugs, or to normal deterioration of such things as belts and

exterior finish due to use or exposure.

6. To expendable or wear items to include, but not limited to teeth,

chains, sprockets, belts, brake pads, springs and any other items that

in the company’s sole judgement is a wear item.

7. To CV boots nor damage to the shaft assemblies from running with

damaged or missing boots.

NO EMPLOYEE OR REPRESENTATIVE OF BUSH HOG IS

AUTHORIZED TO CHANGE THIS LIMITED WARRANTY IN ANY

WAY OR GRANT ANY OTHER WARRANTY UNLESS SUCH

CHANGE IS MADE IN WRITING AND SIGNED BY BUSH HOG’S

SERVICE MANAGER, POST OFFICE BOX 1039, SELMA,

ALABAMA 36702-1039.

OOOOOOOOOOOOOOOOOOOO

Record the model number, serial number and date purchased. This in-

formation will be helpful to your dealer if parts or service are required.

MODEL NUMBER

SERIAL NUMBER

DATE OF RETAIL SALE

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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. All decals in place and readable. (See decal page.)

r 9. Overall condition good (i.e. paint, welds)

r 10.Parking brake checked and adjusted, if necessary.

r 11.Steering checked and adjusted, if necessary.

r 12.Check tire pressure.

r 13.Operators manual has been delivered to owner and

he has been instructed on the safe and proper use

of the utility vehicle.

Dealer’s Signature

Purchaser’s Signature

THIS CHECKLIST TO REMAIN IN

OWNER’S MANUAL

It is the responsibility of the dealer to complete the proce-

dures listed above before delivery of this vehicle to the

customer.

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Safety Alert Symbol

This Safety Alert Symbol means:

“ATTENTION! BECOME ALERT! YOUR SAFETY IS

INVOLVED!”

This symbol is used to call attention to safety pre-

cautions that should be followed by the operator to

avoid accidents. When you see this symbol, care-

fully read the message that follows and heed its ad-

vice. Failure to comply with safety precautions

could result in death or serious bodily injury.

Safety Signs Signal Words

The signal words DANGER, WARNING, AND CAUTION are used on

the equipment safety signs. These words are intended to alert the

viewer to the existence and the degree of hazard seriousness.

This signal word indicates a poten-

tially hazardous situation which, if

not avoided, will result in death or

serious injury.

This signal word indicates a poten-

tially hazardous situation which, if

not avoided, could result in death

or serious injury

This signal word indicates a poten-

tially hazardous situation exist

which, if not avoided, may result in

minor or moderate injury. It may

also be used to alert against unsafe

practices.

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IMPORTANT SAFETY PRECAUTIONS

This symbol is used to call attention

to safety precautions that should be

followed by the operator to avoid ac-

cidents. When you see this symbol,

carefully read the message that fol-

lows and heed its advice. Failure to

comply with safety precautions

could result in serious bodily injury.

In addition to the design and configuration of equipment, hazard con-

trol and accident prevention are dependent upon the awareness, con-

cern, prudence and proper training of personnel in the operation,

transport, maintenance and storage of equipment. Lack of attention

to safety can result in accident, personal injury, reduction of efficiency

and worst of all—loss of life. Watch for safety hazards and correct de-

ficiencies promptly. Use the following safety precautions as a general

guide to safe operations when using this machine. Additional safety

precautions are used throughout this manual for specific operating

and maintenance procedures. Read this manual and review the safety

precautions often until you know the limitations.

IMPORTANT OPERATOR SAFETY PRACTICES:

BEFORE OFF-ROAD UTILITY VEHICLE USE:

•

Read, understand and follow all the Operator’s Manual instruc-

tions.

•

Explain all instructions to operators who cannot read or under-

stand the instructions.

•

Only allow vehicles to be operated by trained persons.

Allow no persons younger than 16 years old to operate.

Do not operate under the influence of alcohol or drugs.

Inspect vehicle for safe operating condition.

DURING OFF-ROAD UTILITY USE:

•

Fasten seat belt.

Use vehicle only for off-road operations.

Avoid sudden starts, stops, turns, or direction reversals to prevent

load shifts, endanger passengers, or losing vehicle control.

Use speeds to allow vehicle to stop safely and be under control

in all travel conditions.

Reduce speeds for wet, slippery, loose surfaces, steep grades

and unfamiliar terrain.

•

Never operate vehicle on hills steeper than 15 degree slope.

Use proper loading and securing material for loads in cargo box

and trailers.

•

Use proper towing practices.

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•

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.

Keep all persons clear of operating vehicle.

Keep alert for stumps, holes, ruts, wet, slippery and uneven terrain.

Before backing up or turning, look behind and around vehicle for

persons.

AVOID VEHICLE UPSETS AND ROLLOVER:

•

Avoid sudden starts, stops, or turns.

Use very slow speed when turning.

Always use brakes when going down slope.

Reduce speed and load on rough or hilly terrain.

Avoid overloading vehicle and shifting loads.

Keep alert for stumps, holes, ruts, wet, slippery and uneven terrain.

AVOID FUEL FIRE AND EXPLOSIONS:

•

Stop engine and allow to cool before refueling.

Do not smoke while refueling.

Never fill fuel tank indoors.

Clean up spilled fuel before starting engine.

Only use approved Underwriter’s Laboratory (U.L.) or American

Society for Testing & Material (ASTM) non-metal portable fuel

containers.

•

Remove fuel containers from vehicle beds or trunks and placing

on the ground before filling.

•

Keep nozzle in contact with fuel container opening while filling.

Remove utility vehicle and equipment from truck beds or trailers

and re-fuel on the ground.

CARGO BOX LOAD OPERATIONS:

LOADING:

•

Do not exceed vehicle’s Gross Vehicle Weight (GVW) rating. This

includes vehicle operating weight, material load (cargo box load),

personnel weight, options weight, accessories weight, and

attachments weight (towing loads).

•

Do not exceed cargo box load rating.

Confine loads to cargo box physical dimensions.

Spread load evenly and securely anchor all loads in cargo box.

Shifting and uneven loads will effect vehicle control and stability.

Avoid sudden starts, stops, and turns which could cause load

shifts.

•

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•

Reduce loads and speed when operating over rough or hilly ter-

rain.

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.

MANUALLY RAISED CARGO BOX UNITS:

•

Unload manual lift cargo box before raising cargo box by

hand.

Securely lock manual support lift rod before working beneath

raised cargo box.

Fully lower cargo box and securely re-latch lift rod before operat-

ing vehicle.

OPTIONAL ELECTRIC POWER LIFT CARGO BOX UNITS:

•

Operate switch while seated in operator seat.

Keep body parts away from cargo box and all bystanders away

from vehicle.

•

Do not dump or unload vehicle parked on an incline, slopes, hills,

or with rear wheels at an edge of a drop-off. The cargo box

weight may shift and cause the vehicle to tip or rollover.

Fully lower cargo box before operating vehicle.

TOWING OPERATIONS:

•

Do not exceed vehicle’s Gross Vehicle Weight (GVW) rating. This

includes vehicle operating weight, material load (cargo box load),

personnel weight, options weight, accessories weight, and attach-

ment weight (towing loads).

•

Always use approved rear hitch point.

Do not tow a load weight (trailer weight and cargo weight) that

exceeds towing weight rating.

•

Do not exceed the tongue weight rating.

Never exceed 16 km/h (10 mph)when towing loads. Use slow

speeds to maintain control of vehicle and towing load.

Allow for increased braking distance from towed load weight.

Do not tow heavy loads on slopes greater than 5 degree incline.

Heavy towed equipment may jackknife and cause utility vehicle

to overturn when going downhill or turning.

•

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CONTROLLING PARTY INFORMATION

(Reference: SAE J2258-DEC 2003-Light-Utility Vehicle, APPENDIX B,

PART II - For the Controlling Party.) The Controlling Party is the per-

son(s) or organization(s) responsible for the operation and mainte-

nance 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.

•

Perform periodic safety survey of vehicle operating areas.

Identify operating area hazards.

Identify areas where vehicle should not be operated.

SAFETY SURVEY:

The Controlling Party should conduct an operating area safety survey

to identify possible hazards:

•

Steep Grade Hazards:

• Restrict vehicle operations to designated pathways in steep

grade areas.

• Erect steep grade warning signs.

• State: “Warning, steep grade, descend slowly” on signs.

Loose Terrain Hazards:

• Keep vehicle traction, steering, stability and braking under

control by avoiding loose terrain areas.

Wet area Hazards:

• Keep vehicle traction, steering, stability and braking under

control by avoiding wet areas.

Sharp Turns, Blind Corners, Bridge Approaches Hazards:

• Erect warning signs,

•

• State precautions to avoid the hazards on signs.

Pedestrian and Utility Vehicle Traffic Hazards:

• Erect warning signs.

• State warnings of traffic conditions and use caution on signs.

• Reroute vehicle or pedestrian traffic to avoid interference.

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OPERATOR TRAINING:

The controlling Party should develop, conduct an operator-training pro-

gram and permit only properly trained persons to operate the utility ve-

hicle.

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.

Review conditions that affect vehicle’s stability and may cause

its instability:

• Operator’s failure to follow safety practices.

• Operator’s exercise of judgement.

• Operating area slopes, grades, and terrain conditions.

• Vehicle’s speed, turning, braking, loadings, towing and

dynamic forces.

• Attachments and improper loading.

The Controlling Party should train and evaluate vehicle operator’s com-

petency to comply with these practices.

MAINTENANCE AND INSPECTION PROCEDURES:

• Review and perform vehicle manufacturer’s recommended

procedures.

• Use a scheduled preventive maintenance, lubrication, and

inspection program.

• Use trained and authorized personnel to maintain, repair,

adjust, and inspect vehicles

• Conduct recommended procedures in a properly ventilated

work area.

• Use original vehicle manufacturer’s replacement parts.

• Use recommended procedures for returning vehicle to service.

• Conduct vehicle performance checks in an area free of vehic-

ular and pedestrian traffic.

• Use vehicle manufacturer’s engine shut down and vehicle

immobilization recommended procedures before undertaking

maintenance or repairs.

• Chock wheels and block chassis before working underneath

vehicle.

• Do not use open flames to check level or leakage of fuel,

battery electrolyte, or coolant.

• Equip work area with fire extinguisher equipment.

• Follow vehicle manufacturer’s recommended inspection and

maintenance procedures.

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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 main-

tenance procedures.

• Keep vehicle clean to reduce fire hazards and allow ease of

vehicle inspection.

VEHICLE INSTRUCTION AND SAFETY DECALS:

• Keep clean and legible.

• Replace illegible decals.

VEHICLE MODIFICATION AND ADDITIONS:

• Contact vehicle manufacturer before making modifications

that affect vehicle capacity and safe vehicle operations.

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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 service brake gradually.

When fully stopped, lock parking brake.

In the event of an accident, have a qualified service dealer

check the complete vehicle for possible damage, including (but

not limited to) brakes, throttle and steering.

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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 han-

dling 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 without proper instruction

WHAT CAN HAPPEN

Loss of control, accident

HOW TO AVOID THE HAZARD

The risk of an accident is greatly increased if the operator does

not know how to operate the vehicle properly in different situa-

tions and on different types of terrain.

All opertors must read and understand the Operator’s manual and

all warning and instruction labels before operating the vehicle.

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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 high-

way, 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.

Could cause you to react more slowly.

Could affect your balance and perception.

Could result in an accident.

HOW TO AVOID THE HAZARD

Driving this vehicle requires your full attention. DO NOT drink

alcohol or use drugs or medications before or while driving. They

will reduce your alertness and slow your reaction time. In most

states and provinces, it’s prohibited by law to drive while intoxi-

cated or under the influence of drugs.

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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 op-

erating 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

Operating on frozen bodies of water.

WHAT CAN HAPPEN

Severe injury or death can result if the vehicle and/or the oper-

ator fall through the ice.

HOW TO AVOID THE HAZARD

Never operate the vehicle on a frozen body of water.

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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 use extra caution when operating this vehicle on un-

familiar terrain

WHAT CAN HAPPEN

Loss of control, vehicle overturn

HOW TO AVOID THE HAZARD

Travel slowly and use extra caution when operating on unfa-

miliar terrain.

always be alert to changing terrain conditions when operating

the vehicle. May come upon hidden conditions when operating

the vehicle. You may come upon hidden rocks, bumps, or

holes suddenly, without enough time to react.

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WARNING

POTENTIAL HAZARD

Failure to follow the minimum age recommendations for this ve-

hicle.

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

POTENTIAL HAZARD

Operating this vehicle with improper tires or with improper or

uneven tire pressure

WHAT CAN HAPPEN

Loss of control, accident and/or overturn

HOW TO AVOID THE HAZARD

Always use the size and type of tires specified in the Operator’s

Manual for this vehicle.

always maintain proper tire pressure as described on the decal

and in the Operator’s Manual.

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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 in-

spect 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 sys-

tem. Exposure to the hot components could result in a fire.

WARNING

Gasoline is highly flammable and is explosive under certain con-

ditions. Always exercise extreme caution whenever handling

gasoline.

Always stop the engine when refueling.

Always refuel outdoors or in a well ventilated area.

Do not smoke or allow open flames or sparks in or near the refu-

eling area or where gasoline is stored.

Do not over fill the tank. Do not fill the tank neck.

If gasoline spills on your skin or clothing, immediately wash it off

with soap and water and change clothing.

Never start the engine or let it run in an enclosed area. Gasoline

powered engine exhaust fumes are poisonous and can cause

loss of consciousness and death in a short time.

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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 maxi-

mum 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 thor-

oughly. Understand what each control is for and how to use it. Observe

all safety precautions decaled on the machine and noted throughout

the manual for safe operation of the vehicle. If any assistance or addi-

tional information is needed, contact your authorized Bush Hog dealer.

DESCRIPTION (Model 4430 shown on next page)

1. Occupant Protection

Structure (O.P.S.)

2. Hand hold

18.Fuel Gauge

19.Hour Meter

20.Choke Knob

3. Gear Selector

4. Steering wheel

5. Seat

21.Power Bed Lift Switch

(Optional)

22.Neutral Light

6. Seat Belt

23.4-Wheel Drive Switch

and Light

24.Winch Switch

7. Fuel Tank Cap

8. Battery (Under Hood)

9. Headlights

10.Front Bumper/

Brush Guard

11.Power Winch

(Optional - Not Shown)

12.Cargo Light

(Optional - Not Shown)

13.Cargo Box

(Optional - Not Shown)

25.Driving Light Switch

26.Cargo Bed Light Switch

27.Parking Brake Light

28.Oil Pressure Light

29.DC Power Outlet

30.Parking Brake

31.Brake Pedal

14.Hitch Receiver

15.Winch Wiring Pigtail

16.Cup Holder

32.Throttle Pedal

33.Tailgate Latch

34. Cargo Box Release Handle

17.Ignition Key

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NOTICE!

LOCATIONS OF CON-

TROLS AND FEATURES

MAY VARY SLIGHTLY ON

DIFFERENT MODELS.

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UNDER HOOD AREA

Battery

Brake Fluid Reservoir

Fuses and Relays

UNDER SEAT AREA

Engine Air

Intake

Engine Oil

Filler Cap

Engine Oil

Dipstick

CVT Enclosure

Air Cleaner

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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

Engine Air

Cleaner Housing

with

Grease Fitting

Evacuator Valve

For Pillow Block

Hidden From View

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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.

Trailer Hitch Receiver

This vehicle is equipped with receiver hitch brackets at the front and

rear for use with trailer hitches or the optional winch kit. Trailer tow-

ing equipment if not supplied with this vehicle.

To avoid injury and property damage, observe the precautions on

page 43.

Seat Belts

The Bush Hog 4300 UTV is equipped with lap-style seat belts for the

operator and passengers.

WARNING

Falling from a moving vehicle could result in serious injury or

death. Always fasten your seatbelt securely before operating or

riding in the vehicle.

Passengers under five years of age require special restraints,

which are not available on this vehicle. No person under the age

of five years may ride in the Bush Hog utility vehicle.

To wear the seat belt properly, follow this procedure:

1. Place the belt across your lap as low on your hips as possible,

taking care that the belt is not twisted.

2. Push the latch plate into the buckle until it clicks.

3. Release the strap, it will self tighten.

To unfasten, press the red button on the side of the buckle.

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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.

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.

WARNING

LEAVING THE KEYS IN THE IGNITION CAN LEAD TO

UNAUTHORIZED USE OF THE VEHICLE RESULTING IN

SERIOUS INJURY OR DEATH. ALWAYS REMOVE THE IG-

NITION KEY WHEN THE VEHICLE IS NOT IN USE.

Light Switch

Turn the headlights and tailights on by flipping the rocker switch up

(the ignition switch must be in the ON position). Flip the switch down

to turn the lights off.

Cargo Bed Light Switch (Optional)

Flip the rocker switch up to turn on and down to turn off.

Power Bed Lift Switch (Optional)

Push and hold the spring loaded rocker switch up to raise the bed or

down to lower the bed.

4-Wheel Drive Switch (On 4-wheel drive models only)

Flip the rocker switch up to engage 4-wheel drive at any time and

down to disengage 4-wheel drive.

Winch Switch (Optional)

Push and hold the spring loaded rocker switch to the left to unwind

the cable or push and hold to the right to wind in the cable.

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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.

Parking Brake Lever

The parking brake lever is located under the dash and is rotated back

and upward to engage and pushed down and forward to release. .

Make sure the parking brake is working properly before each opera-

tion. Always depress service brake pedal before engaging park brake.

Gear Selector

The transmission gear selector is located on the console to the right

of the steering wheel. It has four positions: high, low, neutral, and re-

verse.

NOTE: Low gear is the primary driving range on this vehicle. High is

intended for use in hard packed surfaces with light loads

To change gears, stop the vehicle and with the engine idling, move the

gear lever to the desired gear. Do not attempt to shift gears with the

engine speed above idle or while the vehicle is moving.

Always place the transmission in gear with the parking brake locked

whenever the vehicle is left unattended.

Maintaining shift linkage adjustment is important to assure proper

transmission function. See your dealer if you experience any shifting

problems.

CAUTION

DO NOT ATTEMPT TO SHIFT THE TRANSMISSION

WHILE THE VEHICLE IS MOVING OR DAMAGE TO THE

TRANSMISSION COULD RESULT.

ALWAYSPLACETHETRANSMISSIONINGEARWITHTHE

PARKINGBRAKEAPPLIEDANDTURNTHEVEHICLEOFF

WHENEVER THE VEHICLE IS LEFT UNATTENDED.

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SPECIFICATIONS

Bush Hog 4430 UTV

ENGINE

Type

4-cycle, OHV V-twin, air-cooled gas

Honda

Make

HP / (cc)

Lubrication

Air Cleaner

24 hp (670cc)

Full Pressure with automotive style spin-on canister

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

Suspension, Rear Independent trailing arm, coil-over-shock

Wheel travel, Frt/Rr 5.7 inches / 6.0 inches

Steering

Rack and Pinion

13 ft

Turning Radius

Front Tires

Rear Tire

Brakes

AT 25 x 10.0 - 12 NHS

AT 25 x 11.0 - 12 NHS

4-wheel hydraulic disc brakes; self-adjusting with

tandem master cylinder

Park Brake

Rear mechanical disc

Ground Clearance 9-inches

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SPECIFICATIONS

Bush Hog 4430 UTV

DRIVE TRAIN

Transmission

Continuously Variable Transmission (CVT)

Fully enclosed pressurized with filtered air intake.

CVT Protection

Final Drive

Bush Hog Dual-Range transaxle with High, Low, Neutral and Reverse

Differential Lock

Truck-Style, automatic positive locking differential;

featuring Detroit Gearless Locker^TM

Ground Speed

0 - 25 mph

4WD

True On-Demand 4-wheel drive; switch engage

(4wd models only)

DIMENSIONS

Dry Weight

1,500 lbs.

76 inches

1,500 lbs.

Wheel Base

Vehicle

Load Capacity

Cargo Box

1,000 lbs.

Load Capacity

Towing Capacity 1,500 lbs.

Fuel Capacity

Seating Capacity

Lights

7 gallons

Dual 37-watt halogen headlights, tail lights and brake lights

Colors

Classic Bush Hog Red. Deep Forest Green and

Mossy Oak’s Obsession™ camouflage

WARRANTY

•One-year limited.

•Two-year engine limited warranty administered

through engine manufacturers.

•Three-year limited drivetrain warranty.

•See dealer for complete details.

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SECTION II

OPERATION

GENERAL SAFETY

Only qualified people familiar with this operator’s manual should op-

erate this machine.

WARNING

IF A PROPER INSPECTION IS NOT DONE BEFORE EACH

USE, SEVERE INJURY OR DEATH COULD RESULT. AL-

WAYS 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. Do not mix oil with gasoline.

4. Do not use white, high test or premium gasoline. Do not use

de-icers, carburetor cleaners or other such additives.

5. Check the crankcase oil level. Make sure the engine is off. The

vehicle should be parked on a level area. Do not overfill. (See

your engine manual for more detailed instructions.)

6. Check battery fluid level.

7. Check tire pressure: 12 psi in all four tires.

8. Clean the air intake screen on the engine if necessary.

9. Perform any other maintenance as it becomes necessary. (See

“Maintenance” section)

VEHICLE BREAK-IN PERIOD

The break-in period for your new Bush Hog Utility Vehicle is defined

as the first 24 hours of operation, or the time it takes to use the first two

tanks full of fuel. A proper break-in procedure will result in more effi-

cient performance and longer life for the engine. Carefully perform the

following procedures.

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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. If engine does not start, release ignition switch and wait five sec-

onds; then turn the ignition switch for another five seconds.

Repeat this procedure until engine starts. NOTE: do not

press the accelerator pedal while starting the engine.

7. If the engine slows or stops, push the choke knob in half way.

8. Vary the engine RPM slightly with the throttle to aid in warm up

until engine idles smoothly. Then push the choke all the way in.

Starting A Warm Engine

Warm engines do not normally require the use of the choke. Overuse

of the choke can cause the spark plugs to become fouled.

1. Place the transmission in neutral and lock the parking brake.

2. Sit in the driver’s seat with the seat belt fastened.

3. Turn the ignition key to START.

4. If the engine has cooled and does not readily start, intermittent

use of the choke knob (pulled half way out) may be necessary.

5. If the engine is over-choked when warm, depress the throttle

pedal fully while cranking to aid in starting.

6. Release the throttle pedal immediately after the engine starts.

NOTE: If the engine does not start and all conditions are favorable,

change the spark plugs.

Driving The Vehicle

1. Check the surrounding area and determine your path of travel.

Select an area which is open and will give you room to famil-

iarize yourself with the operation and handling of the vehicle.

2. With foot on brake pedal, release parking brake and shift trans-

mission into low gear.

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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. It will only engage when

the rear wheels begin to lose traction.

7. Do not exceed recommended towing capacity.

8. Perform regular checks on fluid levels, and all important areas on

the vehicle as outlined on the pre-operation check list.

IMPORTANT

LOW GEAR IS THE PRIMARY GEAR FOR OPERATING THIS VE-

HICLE. HIGH IS INTENDED FOR USE ON HARD PACKED SUR-

FACES WITH LIGHT LOADS. PREMATURE BELT WEAR IS THE

RESULT OF OPERATING IN A GEAR THAT IS UNSUITABLE FOR

THE TERRAIN.

TO CHANGE GEARS, STOP THE VEHICLE AND WITH THE EN-

GINE IDLING, MOVE THE LEVER TO THE DESIRED GEAR. DO

NOT ATTEMPT TO SHIFT GEARS WITH THE ENGINE ABOVE IDLE

OR WHILE MOVING.

WARNING

WHEN CARRYING CARGO OR TOWING A TRAILER, REMEMBER

THAT LOAD WEIGHT WILL INCREASE BRAKING DISTANCES.

FAILURE TO ALLOW FOR INCREASED BRAKING DISTANCES

MAY RESULT IN ACCIDENT AND INJURY.

WARNING

WHEN VEHICLE IS IN MOTION, DRIVER AND PASSANGERS

SHOULD ALWAYS KEEP ALL BODY PARTS INSIDE THE VEHI-

CLE. FAILURE TO DO SO CAN RESULT IN INJURY OR DEATH.

Braking

Practice starting and stopping (using the brakes) until you are familiar with

the controls. NOTE: When the accelerator is released completely and the

engine speed drops to near idle, the vehicle has no engine braking.

1. Release the throttle pedal completely.

2. Press on the brake pedal evenly and firmly.

Stopping The Engine

Release the throttle pedal completely

Place the transmission selector lever in neutral.

Apply the parking brake to help prevent the vehicle from rolling.

Turn the ignition key to the off position and remove the key.

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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 SPEC-

IFICATIONS CHART FOR YOUR PARTICULAR VEHICLE. AN

OVERLOADED CARGO BOX CAN CAUSE INSTABILITY DUR-

ING OPERATION OF THE VEHICLE.

WARNING

FAILURE TO ALLOW FOR INCREASED BRAKING DIS-

TANCE WHEN HAULING CARGO OR TOWING A

TRAILER MAY RESULT IN ACCIDENT AND INJURY. AL-

WAYS SLOW DOWN AND ALLOW ADDITIONAL BRAK-

ING DISTANCE WHEN TOWING OR HAULING CARGO.

The tailgate of the cargo box can be opened by pulling up on the handle

at the rear center of the tailgate.

The cargo box can be raised for dumping material or gaining access to

the engine area. Models with the electric power lift feature only require

pushing the rocker switch on the dash. Manual models require pulling

the release handle (located under the front left corner of the cargo box)

upward. (Refer to photograph on next page)

CAUTION

ON MODELS WITHOUT THE ELECTRIC POWER LIFT FEA-

TURE, THE CARGO BOX SHOULD BE EMPTIED BEFORE AT-

TEMPTING TO LIFT THE BOX.

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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 secure-

ly 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.

WARNING

NEVER OPERATE THIS VEHICLE WITH THE CARGO BOX IN

THE RAISED POSITION. THE CARGO BOX COULD CLOSE

UNEXPECTEDLY WHILE DRIVING, SEVERELY INJURING

THE DRIVER.

Manual Cargo Box

Release Handle

Electric Cargo Box

Power Lift Actuator

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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 trans-

mission shifting is automatic.

6. Drive slowly. Practice maneuvering and using the throttle and

brakes on level surfaces.

NOTE: Low is the primary gear for operating this vehicle. High gear is

intended for use on hard-packed surfaces with light loads.

Driving on Slippery Surfaces

When driving on slippery surfaces such as wet trails, loose gravel, or

ice, be alert for the possibility of skidding and sliding. Under these con-

ditions, follow these precautions:

1. Slow down when entering slippery areas.

2. Maintain a high level of alertness, reading the trail and avoiding

quick, sharp turns, which can cause skids.

3. Correct a skid by turning the steering wheel in the direction of the skid.

4. Drive with 4-wheel drive engaged to assist in controlling the vehicle.

WARNING

FAILURE TO EXERCISE CARE WHEN OPERATING ON

SLIPPERY SURFACES CAN RESULT IN LOSS OF TIRE

TRACTION AND CAUSE LOSS OF CONTROL, ACCIDENT,

AND SERIOUS INJURY OR DEATH.

NEVER APPLY THE BRAKES DURING A SKID.

DO NOT OPERATE ON EXCESSIVELY SLIPPERY SUR-

FACES.

ALWAYS REDUCE SPEED AND USE ADDITIONAL CAU-

TION WHEN OPERATING ON SLIPPERY SURFACES.

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Driving Uphill

Whenever traveling uphill, follow these precautions:

1. Always travel straight uphill.

2. Avoid steep hills (15° maximum).

3. 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. IMPROPER PRO-

CEDURE COULD CAUSE LOSS OF CONTROL OR OVER-

TURN AND RESULT IN SERIOUS INJURY OR DEATH.

AVOID CLIMBING STEEP HILLS (15° MAXIMUM)

USE EXTREME CAUTION WHEN OPERATING ON HILLS,

AND FOLLOW PROPER OPERATING PROCEDURES

OUTLINED IN THE OPERATOR’S MANUAL

NEVER CLIMB HILLS WITH EXCESSIVELY SLIPPERY OR

LOOSE SURFACES.

NEVER ACCELERATE SUDDENLY.

NEVER GO OVER THE CREST OF A HILL AT HIGH

SPEED. AN OBSTACLE, A SHARP DROP, OR ANOTHER

VEHICLE OR PERSON COULD BE ON THE OTHER SIDE

OF THE HILL.

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Sidehilling

WARNING

CROSSING DOWNHILL OR TURNING ON HILLS CAN RE-

SULT 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.

WARNING

TRAVELING DOWNHILL IMPROPERLY COULD CAUSE

LOSS OF CONTROL OR VEHICLE OVERTURN. ALWAYS

CHECK TERRAIN CAREFULLY BEFORE DESCENDING A

HILL

NEVER DESCEND A HILL AT HIGH SPEED. EXCESSIVE

SPEED MAY RESULT IN LOSS OF VEHICLE CONTROL

AND LEAD TO SERIOUS INJURY OR DEATH. ALWAYS

OPERATE SLOWLY WHEN TRAVELING DOWNHILL

AVOID DESCENDING A HILL AT AN ANGLE, WHICH

WOULD CAUSE THE VEHICLE TO LEAN SHARPLY TO

ONE SIDE. TRAVEL STRAIGHT DOWNHILL WHEN POS-

SIBLE.

Driving Through Water

WARNING

THE LARGE TIRES ON YOUR UTILITY VEHICLE MAY

CAUSE THE VEHICLE TO FLOAT IN DEEP OR FAST-

FLOWING WATER, WHICH COULD RESULT IN LOSS OF

CONTROL AND LEAD TO SERIOUS INJURY OR DEATH.

NEVER CROSS DEEP OR FAST FLOWING WATER WITH

YOUR BUSH HOG UTILITY VEHICLE.

Your Bush Hog utility vehicle can operate through water up to a max-

imum recommended depth equal to the floorboards. Follow these pro-

cedures when operating through water:

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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 pres-

sure 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. Give spe-

cial attention to engine oil, transmission oil, front and rear gearcases,

and all grease fittings.

CAUTION

IMMERSION CAN RESULT IN MAJOR DAMAGE IF THE

VEHICLE ISN’T SERVICED CORRECTLY AND

PROMPTLY. AFTER IMMERSION, ALWAYS TAKE THE

VEHICLE FOR YOUR DEALER TO SERVICE. DO NOT

START THE ENGINE!

IF IT IS NOT POSSIBLE TO TAKE THE VEHICLE TO

YOUR DEALER BEFORE STARTING THE ENGINE, PER-

FORM THE SERVICE OUTLINES IN PAGE 56, AND

TAKE THE VEHICLE TO YOUR DEALER AT THE FIRST

OPPORTUNITY.

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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 VE-

HICLE SUDDENLY COMES IN CONTACT WITH A HID-

DEN OBSTACLE. NOT ALL OBSTACLES ARE

IMMEDIATELY VISIBLE. REDUCE SPEED AND TRAVEL

WITH CAUTION IN UNFAMILIAR TERRAIN

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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 OPERAT-

ING IN REVERSE CAN RESULT IN SERIOUS IN-

JURY OR DEATH. BEFORE SHIFTING INTO

REVERSE, ALWAYS CHECK FOR OBSTACLES

OR PEOPLE BEHIND THE VEHICLE AND FOL-

LOW THE REVERSE OPERATION PROCE-

DURES OUTLINED IN THIS MANUAL. ALWAYS

BACK SLOWLY.

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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 after depressing service 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 STOP-

PING THE ENGINE. ALWAYS BLOCK THE

DOWNHILL SIDE OF THE WHEELS IF LEAVING

THE VEHICLE ON A HILL, OR PARK THE VEHI-

CLE IN A SIDEHILL POSITION INSTEAD.

OPERATING THE VEHICLE WHILE THE PARK-

ING BRAKE IS ENGAGED COULD CAUSE LOSS

OF CONTROL AND RESULT IN SERIOUS IN-

JURY OR DEATH. ALWAYS DISENGAGE THE

PARKING BRAKE BEFORE OPERATING THE

VEHICLE.

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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 PRE-

CAUTIONS 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. Always read and understand the load distribution warnings

listed on the warning decals.Never exceed the following capacities.

Model

Max. Capacity Cargo Box Towing Capacity

1,500 lbs. 1,000 lbs. 1,500 lbs.

4430

WARNING

DRIVING WITH PASSENGERS IN THE CARGO BOX CAN

RESULT IN SEVERE INJURY OR DEATH.

NEVER ALLOW PASSENGERS TO RIDE IN THE CARGO

BOX. PASSENGERS MUST ALWAYS RIDE IN THE CAB

WITH SEAT BELTS FASTENED SECURELY.

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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 VE-

HICLE 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. Operate the bed lift switch to raise the box.

6. Using the switch, lower the cargo box completely before moving

the vehicle.

WARNING

ON MANUAL LIFT MODELS:

IF THE WEIGHT DISTRIBUTION ON THE BOX IS LOCATED

TOWARD THE REAR OF THE BOX WHEN THE RELEASE

LEVER IS PULLED UPWARD, THE BOX MAY DUMP UN-

EXPECTEDLY AND CAUSE SERIOUS INJURY TO THE OP-

ERATOR OR BYSTANDERS.

NEVER OPERATE THE DUMP LEVER WITHOUT ENSUR-

ING THAT THE BOX IS EMPTY.

Cargo Box

Release Lever

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Towing Loads

WARNING

TOWING IMPROPERLY CAN ALTER VEHICLE HANDLING

AND MAY CAUSE LOSS OF CONTROL OR BRAKE INSTA-

BILITY, 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 IN-

CREASES BRAKING DISTANCE.

DO NOT TOW MORE THAN THE RECOMMENDED 1,500

LB. WEIGHT FOR THE VEHICLE.

ATTACH A TRAILER TO THE HITCH BRACKET ONLY. DO

NOT ATTACH A TRAILER TO ANY OTHER LOCATION OR

YOU MAY LOSE CONTROL OF THE VEHICLE.

NEVER TOW A TRAILER ON A GRADE STEEPER THAN 15°.

Belt Life

Use low forward gear when hauling or towing heavy cargo to extend

belt life.

Parking The Bush Hog Utility Vehicle

WARNING

A ROLLING VEHICLE CAN CAUSE PROPERTY DAMAGE

AND SERIOUS INJURY. ALWAYS APPLY THE PARKING

BRAKE AFTER STOPPING THE ENGINE.

1. Stop the vehicle on a level surface.

2. When the engine has stopped, apply the parking brake.

3. Remove the ignition switch key to prevent unauthorized use.

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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 AP-

PLIANCE 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.

When the switch is off, the vehicle is in two-wheel drive at all times.

When the switch is in 4-wheel drive, the front wheels will automatically

engage anytime the rear wheels begin to lose traction. When the rear

wheels regain traction, the front wheels will automatically disengage.

The 4-wheel drive switch light indicates whether the vehicle is in 4-

wheel drive. There is no limit to the length of time the vehicle may re-

main in 4-wheel drive.

The 4-wheel drive switch may be turned on or off while the vehicle is

moving. If the switch is turned off while the front hubs are driving, they

will not release until the rear wheels regain traction.

CAUTION

SWITCHING TO 4-WHEEL DRIVE WHILE THE REAR

WHEELS ARE SPINNING MAY CAUSE SEVERE DRIVE

SHAFT AND CLUTCH DAMAGE. ALWAYS SWITCH TO 4-

WHEEL DRIVE WHILE THE REAR WHEELS HAVE TRAC-

TION OR ARE AT REST.

Disengaging 4-Wheel Drive

Under certain conditions, it may be possible for one or both hubs to re-

main engaged unnecessarily. This condition causes increased steer-

ing effort and some vehicle speed restriction.

Take the following steps to disengage the 4-wheel drive system:

1. Stop the vehicle.

2. Shift to reverse and back up a minimum of 10 feet.

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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 PRO-

CEEDING.

NOISE EMISSION CONTROL SYSTEM

TAMPERING WITH NOISE CONTROL SYSTEEM IS PROHIBITED!

U.S. Federal law prohibits the following acts or the causing thereof:

1. The removal or rendering inoperative by any person other than

for purposes of maintenance, repair, or replacement of any

device or element of design incorporated into any new vehicle for

the purpose of noise control prior to its sale or delivery to the ulti-

mate purchaser or while it is in use or

2. The use of the vehicle after such device or element of design has

been removed or rendered inoperative by any person.

“AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPER-

ING ARE THE ACTS LISTED BELOW,”

1. Removal or alteration or the puncturing of the muffler or any

engine component which conducts removal of engine exhaust gases.

2. Removal or alteration or the puncturing of any part of the engine air

induction system.

3. Replacement of any vehicle parts with parts not in compliance with

federal regulations.

4. Lack of proper maintenance.

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CAUTON

EXHAUST SYSTEM COMPONENTS ARE VERY HOT DUR-

ING AND AFTER USE OF THE VEHICLE. HOT COMPO-

NENTS 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.

SECTION III

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Careful periodic maintenance will help keep your vehicle in the safest,

most reliable condition. Inspection, adjustment and lubrication inter-

vals of important components are explained in the following schedule.

Maintenance intervals are based upon average operating conditions.

Vehicles subjected to severe use, such as operation in wet or dusty

areas, should be inspected and serviced more frequently. If you’re not

familiar with safe service and adjustment procedures, have a quali-

fied dealer perform these operations.

Inspect, clean, lubricate, adjust or replace parts as necessary. When

inspection reveals the need for replacement parts, always use genuine

Bush Hog parts available from you Bush Hog dealer.

Maintenance Chart Key

s Perform these operations more often under severe use, such as in

dirty or wet conditions, to purge water or dirt contamination from

grease fillings and othe critical components.

H Emission Control System Service - NOTE: Some models may have

an additional California-only emissions warranty.

n Dealer service item.

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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

Brake System

Frequency Remarks

Pre-operation Inspect

Tires

Wheels

Frame nuts, bolts, Pre-operation Inspect

fasteners

Parking Brake

Pre-operation Check lever adjustment

daily; adjust

Pre-operation Inspect

Throttle Cable

Steering

Coolant/Level

Headlamp

Daily

Replace every two years

Inspect daily; apply dielec-

tric grease to donnector

when replaced

Taillamp

Daily

Inpect daily; apply dielectric

grease to socket when

replaced

s Air Filter- Main

H Element

Weekly

25 hrs.

Inspect; replace if necessary

s Transmission Oil

Check level; change oil

annually

Battery

Check terminals; clean;

check fluid level

Brake pad wear

25 hrs.

Inspect periodically

Inspect; replace annually

and as needed

s Engine breather

H filter

s General

Lubrication

25 hrs.

Lubricate all fittings, pivots,

cables

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Item

Frequency Remarks

Engine Cylinder

Head/Cylinder

Base Fasteners

s Engine Oil-Level

25 hrs.

Re-torque required at first

service only

25 hrs.

Check level daily; break-in

service at 25 hrs.

s Engine Oil -

H Change

100 hrs.

Change oil at 100 hours;

more often in cold weather

use

s Oil Filter

100 hrs.

50 hrs.

Replace with oil change

H Engine breather

hose

Inspect

Carburetor Float

Bowl

Drain bowl periodically and

prior to storage

Throttle Cable

Inspect; adjust, lubricate,

replace if necessary

Inspect;adjust, replace if

necessary

H Choke (Enricher) 50 hrs.

Cable

Shift Linkage

Drive Belt

50 hrs.

Inspect; adjust

Inspect; adjust, replace if

necessary

Steering

50 hrs.

Inspect; lubricate

s Front Suspension 50 hrs.

Inspect; lubricate, tighten

Fasteners

s Rear Suspension 50 hrs.

Inspect; tighten fsteners

Inspect

Engine Mounts

Valve Clearance

300 hrs.

100 hrs.

Inspect; adjust

H Spark Plug

Inspect; replace if necessary

Inspect and adjust as needed

Ignition Timing

Front Hub Bearings 100 hrs

Check at 100 hrs. and

replace as needed

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Item

Frequency Remarks

Fuel System

100 hrs.

Check for leaks at fuel cap

lines, fuel valve, filter, pump

and carburetor.Replace

lines every two years.

Replace annually

Clean out

Fuel Filter

100 hrs.

Spark Arrestor

s Front Gearcase Oil 100 hrs.

Check monthly; change

annually

Clutches (drive

and driven)

Brake Fluid

Front Wheel

Bearings

100 hrs.

Inspect; clean

200 hrs.

300 hrs.

Change every two years

Inspect; replace if necessary

H Idle Speed

As required

Adjust

Engine Side Cover As required

Drain moisture after driving

in water.

Toe Adjustment

As required

Periodic inspection, adjust

when parts are replaced

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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.

Lubrication Chart

Item

Lube

Method

Frequency

Engine Oil

SAE 10W-30, Add to proper level Check level daily

API SJ for

on dipstick

gereral use

Brake Fluid

DOT 3 or 4

Maintain level be- As required; change

tween fill lines

every 200 hrs.

Transaxle Oil SAE 80W-90

Front Differential Mobil 424

Refill to middle of

w/LSD additive sight window

Check monthly;

change every 100 hrs.

Refill to check plug Every 100 hrs.

Right Angle

Drive

SAE 80W-90

w/LSD additive sight window

Refill to middle of

Every 100 hrs.

Lube Fittings: Lithium Based Grease with grease Every 25 hrs.

Top of Front

Struts, Swing

Arm Pivots,

Pillow Block

on Driveshaft

Grease

gun

CAUTON

MIXING BRANDS OR USING A NON-RECOMMENDED OIL

MAY CAUSE SERIOUS ENGINE DAMAGE

WARNING

VEHICLE OPERATION WITH INSUFFICIENT, DETERIO-

RATED, OR CONTAMINATED ENGINE OIL WILL CAUSE

ACCELERATED WEAR AND MAY RESULT IN ENGINE

SEIZURE, ACCIDENT, AND INJURY. ALWAYS PERFORM

THE MAINTENANCE PROCEDURES AS OUTLINED IN THE

PERIODIC MAINTENANCE SCHEDULE.

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Engine Oil

Maintain the engine oil at the proper level to ensure a properly func-

tioning engine, and change the oil and oil filter every 100 hours or

every six months, whichever comes first. Dirt and metal particles col-

lect 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. Se-

vere use includes continuous duty in dusty or wet conditions, and cold

weather operation. NOTE: Severe use/cold weather operation is when

all operating is at below 10°F and/or when operating between 10°F

and 30°F if most trips are slow speed and less than five miles. Always

change the oil filter when changing oil.

Oil Check

The engine oil can be checked and/or refilled by folding the bottom

seat cushion up and forward exposing the engine.

1. Position the vehicle on a level surface.

2. Start the engine and let it idle for 20 - 30 seconds.

3. Stop the engine and fold the seat forward.

4. Remove the dipstick and wipe it clean with a clean cloth.

5. Replace the dipstick completely into the engine.

6. Remove the dipstick and check to see that the oil level is

between the full and add marks. Add oil if necessary. Do not overfill.

NOTE: A rising oil level between checks in cool weather driving can indi-

cate moisture collecting in the crankcase. If the oil level is above the full

mark, change the oil.

Oil Filler Cap

Oil Dipstick

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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. Lubricate the new filter 0-ring with clean engine oil.

7. Install the new filter and turn by hand until filter gasket contacts

the sealing surface, then turn an additional 1/2 turn.

8. Remove the dipstick and fill the engine with approximately 1-1/2

quarts of SAE 10W-30, API SJ motor oil. Replace the dipstick.

9. Start the engine and check for leaks at the drain plug and oil filter.

10. Stop the engine and check the oil level on the dipstick.

11. Dispose of used oil and filter properly.

Transaxle

The transaxle oil should be changed every 100 hours.

1. Park the vehicle on a level surface.

2. Remove the drain plug from the transaxle and let oil drain into a

drain pan. Dispose of used oil properly.

3. Clean drain hole and replace the drain plug.

4. Refill transaxle with Mobilube HD LS 80W-90 (or equivalent) to

the middle of sight window. If the transaxle does not have a sight

window, refill to top of check plug.

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Front Differential

The front differential oil should be changed every 100 hours If the ve-

hicle is used in wet conditions, the oil should be checked more fre-

quently. 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. Oil should be filled until it overflows from the

fill plug.

2. Replace the fill plug and tighten.

Oil Change

1. Support the vehicle securely with a jack stand.

2. Remove the front tire on the driver’s side.

3. Remove the fill plug.

4. Remove the drain plug located on the bottom right-hand side and

drain the oil into a drain pan. Discard the used oil properly.

5. Clean and reinstall the drain plug.

6. Add Mobil 424 oil to 3/4” below the threads of the fill plug hole.

7. Reinstall the fill plug and tighten. Check for leaks.

Front Differential

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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 mid-

dle 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. Clean and replace the drain plug and fill the right angle

drive with Mobilube HD LS 80W-90 (or equivalent) - Refill

to the center of the sight window.

4. Replace the breather/fill plug and tighten. Check for leaks.

Right Angle Drive

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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 re-

duce 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.

The CVT system rotates at high speeds, creating large amounts of

force on clutch components. Extensive engineering and testing has

been conducted to ensure the safety of this product. However, as the

owner, you have the following responsibilities to make sure this system

remains safe:

Always follow all recommended maintenance procedures. See your

dealer if required.

This CVT system is intended for use on the Bush Hog utility vehicle.

Do not install it on any other product.

Always make sure the CVT housing is securely in place during operation.

CVT Drying

There may be some instances when water is accidently ingested into the

CVT system Use the following instructions to dry it out before operating.

1. Shift the transmission into neutral and apply full throttle for no longer

than 10 seconds and repeat as necessary. This will expel the mois-

ture and air dry the belt and clutches.

2. Allow the engine RPM to settle to idle speed, then shift the trans-

mission to the lowest available range.

3. Test for belt slippage. If the belt slips, repeat the process.

4. Take the vehicle to your dealer for service as soon as possible.

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Vehicle Immersion

CAUTION

IF YOUR VEHICLE BECOMES IMMERSED, MAJOR EN-

GINE 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, fol-

low 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. Loosen the carburetor drain screw by turning the screw counter-

clockwise to allow fuel to drain from the fuel bowl . This screw is

accessible with a long handled screwdriver from above, and

behind the engine.

5. Turn the engine over several times with the electric starter.

6. Dry the spark plugs and reinstall, or install new spark plugs.

7. Tighten the carburetor drain screw.

8. Connect the fuel pump wires.

9. Attempt to start the engine. If necessary, repeat the drying pro-

cedure.

NOTE: Water damage to electrical components may necessitate re-

placement of that component.

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Engine Air Filter

We recommend that the air filter be cleaned every 25 hours and re-

placed 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.

NOTE: Service the air filter more frequently if the vehicle is operated

in wet conditions or at high throttle openings for extended periods.

CVT Enclosure Air Filter

We recommend that the air filter be cleaned every 25 hours and re-

placed once a year

The CVT filter is accessible by folding the seat forward. The filter hous-

ing is located on the driver’s side above the gas tank.

1. Remover the two wing nuts and remove the housing cover.

2. Remover the filter element, clean the inside of the housing and

reinstall the filter or install a new one.

CVT Air Filter Housing

Engine Air Filter Housing

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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 opera-

tion.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 SE-

RIOUS BURNS. WEAR PROTECTIVE GLOVES WHEN RE-

MOVING A SPARK PLUG FOR INSPECTION.

Spark plug condition is indicative of engine operation. The spark plug fir-

ing end condition should be read after the engine is warmed up and the

vehicle is driven at higher speeds. Immediately check the spark plug for

correct color.

1. Normal

The normal insulator tip is gray, tan, or light brown. There will be few

combustion deposits. The electrodes are not burned or eroded. This

indicates the proper type and heat range for the engine and service.

NOTE: The tip should not be white. A white tip indicates overheating,

caused by use of an improper spark plug or incorrect carburetion ad-

justments.

2. Wet Fouled

The wet fouled insulator tip is black. A damp oil film covers the firing

end. There may be a carbon layer over the entire nose. Generally, the

electrodes are not worn. General causes of fouling are excessive oil,

use of non-recommended injection oil, improper use of the choke. or in-

correct carburetion adjustments.

Spark Plug Removal and Replacement

1. Open the seat and/or the cargo box to access the engine compart-

ment.

2. Remove the spark plug boot and using a socket wrench, remove

the plug.

3. Reverse the procedure for spark plug installation. Torque to 14 ft.

lbs. (19 Nm).

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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 TEM-

PERATURES 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. EX-

HAUST CONTAINS POISONOUS CARBON MONOXIDE

GAS THAT CAN CAUSE LOSS OF CONSCIOUSNESS OR

DEATH IN A VERY SHORT TIME.

NEVER GO UNDER THE VEHICLE WHILE IT IS INCLINED.

Use the following procedure to periodically purge accumulated car-

bon from the exhaust system.

1. Loosen the set screw and remove the spark arrestor from the muf-

fler. Tap the arrestor on a hard surface to loosen carbon deposits and

clean the inside of the tubing.

2. Place the engine in neutral and start the engine. Purge the accu-

mulated carbon from the system by momentarily revving the engine

several times. Rap the exhaust system and repeat the procedure sev-

eral times to expel additional carbon.

3. Stop the engine and allow the exhaust system to cool.

4. Reinstall the spark arrestor.

Spark Arrestor

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Throttle System

WARNING

FAILURE TO CHECK OR MAINTAIN PROPER OPERA-

TION 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.

Throttle Freeplay

If the throttle pedal has excessive play due to cable stretch or cable

misadjustment, it will cause a delay in throttle response, especially at

low engine speed. The throttle may also not open fully. If the throttle

pedal has no freeplay, the throttle may be hard to control, and idle may

be erratic.

Throttle Freeplay Inspection

1. Apply parking brake.

2. Shift the gear lever into neutral.

3. Start the engine and warm it up thoroughly.

4. Measure the distance the throttle pedal moves before the engine

begins to pick up speed. Freeplay should be from 1/16” to 1/8”.

Note: The throttle system is not intended to be adjusted by the owner.

If problems occur, take the vehicle to your dealer for adjustments.

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Brake Inspection

The front and rear brakes are hydraulic disc type brakes and are acti-

vated 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. The brake fluid should also be

changed if it becomes contaminated, if the fluid level is below the min-

imum, or if the type and brand of the fluid in the reservoir are unknown.

Inspection Procedure

1. Position the vehicle on level ground.

2. Inspect the brake fluid by looking at the reservoir under the hood.

The level should be between the upper (MAX) and lower (MIN)

level lines.

3. If the fluid level is lower than the lower level line, add brake fluid

to the upper (MAX) line.

4. Apply the brake forcefully for a few seconds and check for fluid

leakage around the fittings.

WARNING

AFTER OPENING A BOTTLE OF BRAKE FLUID, ALWAYS DIS-

CARD ANY UNUSED PORTION. NEVER STORE OR USE A PAR-

TIAL BOTTLE. BRAKE FLUID IS HYGROSCOPIC, MEANING IT

RAPIDLY ABSORBS MOISTURE FROM THE AIR. THE MOIS-

TURE CAUSES THE BOILING TEMPERATURE OF THE BRAKE

FLUID TO DROP, WHICH CAN LEAD TO EARLY BRAKE FADE

AND THE POSSIBILITY OF ACCIDENT OR SEVERE INJURY.

Brake Fluid

Reservoir

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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 pulling up the hand lever, the vehicle

should not roll while parked. If the vehicle moves, adjustment is

needed.

2. The hand lever is equipped with a rotating knob to

adjust the engagement of the parking brake. Loosen the set

screw on the side of the knob and turn the knob clockwise to

increase pressure on the brake system. Test the brake system

and adjust again, if needed. When adjustment is satisfactory,

tighten the set screw securely in the adjustment knob.

Parking Brake

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Steering Wheel Inspection

Check the steering wheel for freeplay and smooth operation as out-

lined 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.

Seat Belts

Inspect all seat belts for proper operation before each use of the vehicle.

1. Push the latch plate into the buckle until it clicks. The latch plate

must slide smoothly into the buckle. A click indicates that it is

securely latched.

2. Push the red button to make sure it releases freely.

3. Check the belt for wear, cuts or damage. If any irregularities are

found, have the seat belt system checked and/or replaced by an

authorized dealer.

The seat belt angles should be adjusted to suit the individual in that par-

ticular seat before driving. Make sure the seat belt angle is adjusted to

the lowest possible lap position before riding.

1. To adjust, loosen the bolts on each end of the belts.

2. Reposition both the buckle and retractor. Tighten the bolts.

WARNING

FAILURE TO FOLLOW THE AGE RECOMMENDATIONS FOR THIS VE-

HICLE COULD RESULT IN SERIOUS INJURY OR DEATH. NO ONE

UNDER THE AGE OF 16 MAY OPERATE THIS VEHICLE. NO ONE

UNDER THE AGE OF 5 MAY RIDE AS A PASSENGER IN THIS VEHICLE.

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Tires

WARNING

OPERATING YOUR VEHICLE WITH WORN TIRES WILL IN-

CREASE THE POSSIBILITY OF SKIDDING, LOSS OF CON-

TROL 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-STAN-

DARD SIZE OR TYPE TIRES MAY ADVERSELY AFFECT VE-

HICLE HANDLING, WHICH COULD RESULT IN VEHICLE

DAMAGE OR PERSONAL INJURY. ALWAYS MAINTAIN

PROPER TIRE PRESSURE. WHEN REPLACING TIRES, AL-

WAYS USE THE ORIGINAL EQUIPMENT SIZE AND TYPE.

Tire Tread Depth

Always replace tires when tread depth is worn to 1/8” (.3 cm) or less.

Wheel Lug Nuts

Inspect the lug nuts occasionally for tightness or missing nuts. Tighten

to 35 ft. lbs.

WARNING

OPERATING YOUR VEHICLE WITH IMPROPERLY IN-

STALLED WHEELS WILL AFFECT VEHICLE HANDLING

AND COULD CAUSE AN ACCIDENT RESULTING IN SE-

RIOUS INJURY OR DEATH. MAKE CERTAIN WHEELS

ARE INSTALLED PROPERLY.

Wheel Removal

1. Stop the engine, place the transmission in gear and engage the

parking brake.

2. Loosen the lug nuts slightly.

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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.

Lights

When servicing a halogen lamp, don’t touch the lamp with bare fin-

gers. Oil from your skin leaves a residue, causing a hot spot that will

shorten the life of the lamp.

WARNING

POOR LIGHTING WHILE DRIVING CAN RESULT IN SE-

VERE INJURY OR DEATH. HEADLIGHT AND TAILLIGHT

LENSES BECOME DIRTY DURING NORMAL OPERATION.

WASH THE HEADLIGHTS FREQUENTLY TO MAINTAIN

LIGHTING QUALITY.

HOT COMPONENTS CAN CAUSE SERIOUS BURNS TO

SKIN. DO NOT SERVICE THE HEADLAMPS UNTIL

THEY’VE COOLED SUFFICIENTLY.

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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 precau-

tions, 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.

NOTE: If warning decals are damaged, contact your Bush Hog dealer

for free replacement.

If a high pressure type car wash system is used, extreme care must

be taken to avoid water damage to the wheel bearings, transmission

seals, body panels, brakes, headlights and warning decals. Many ex-

pensive repair bills can result from using high pressure detergent sys-

tems.

NOTE: If a high pressure car wash is used, grease all zerk fittings im-

mediately after washing. Also run the vehicle to evaporate any water

that may have entered the engine or exhaust system.

Storage

If your vehicle is to be placed in extended or off season storage, the

following steps should be taken to preserve its condition.

1. Perform all necessary repairs and thoroughly clean the vehicle.

2. Remove the spark plug and pour approximately one ounce of

motor oil into the cylinder. Operate the starter for a few seconds

and reinstall the spark plugs.

3. Remove the battery. Store it in a cool, dry place out of the sun.

4. Lubricate all suspension pivot points.

5. Block the vehicle so all tires are suspended off the ground.

6. Spray oil on all unpainted metal surfaces to prevent rusting.

Avoid getting oil on rubber parts or in the brakes.

7. Lubricate all cables.

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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 nec-

essary. Install it in the vehicle.

2. Make sure the spark plug is tight.

3. Fill the tank with fuel.

4. Check all the points listed in the Pre-Ride Inspection section on

page 29.

NOTE: Tightness of the bolts, nuts, and other fasteners should be

checked by an authorized Bush Hog dealer.

5. Lubricate as outlined in the Periodic Maintenance Schedule.

Battery

Keep the battery terminals and connections free of corrosion. If clean-

ing is necessary, remove the corrosion with a stiff wire brush. Wash with

a solution of one tablespoon of baking soda and one cup of water. Rinse

well with tap water and dry off with clean shop towels. Coat the termi-

nals with dielectric grease or petroleum jelly.

Be careful not to allow cleaning solution or tap water into the battery.

WARNING

BATTERY ELECTROLYTE IS POISONOUS. IT CONTAINS

SULFURIC ACID. SERIOUS BURNS CAN RESULT FROM

CONTACT WITH SKIN, EYES OR CLOTHING.

Antidote

External: Flush with water

Internal: Drink large quantities of water or milk. Follow with milk of mag-

nesia, beaten egg, or vegetable oil. Call physician immediately.

Eyes: Flush with water for 15 minutes and get prompt medical attention.

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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)

Apoorlymaintainedbatterywilldeterioraterapidly.Checkthebatteryfluidlevel

often.Thefluidlevelshouldbekeptbetweentheupperandlowerlevelmarks.

To refill use only distilled water. Tap water contains minerals that are harmful

to a battery.

WARNING

IMPROPERLY CONNECTING OR DISCONNECTING BAT-

TERY CABLES CAN RESULT IN AN EXPLOSION AND

CAUSE SERIOUS INJURY OR DEATH. WHEN REMOVING

THE BATTERY, ALWAYS DISCONNECT THE NEGATIVE

(BLACK) CABLE FIRST. WHEN REINSTALLING THE BAT-

TERY, ALWAYS CONNECT THE NEGATIVE (BLACK)

CABLE LAST.

Battery Removal (Refer to photograph on next page)

1. Open the hood to access the battery.

2. Disconnect the negative (black) cable first.

3. Disconnect the positive (red) cable next.

4. Removethenutsfromthebatterytie-downbracketandliftoffthebracket.

5. Lift the battery out of the vehicle, being careful not to tip the battery side-

ways and spill electrolyte

CAUTION

IF ELECTROLYTE SPILLS, IMMEDIATELY WASH IT OFF

WITH A SOLUTION OF ONE TABLESPOON OF BAKING

SODA AND ONE CUP OF WATER TO PREVENT DAMAGE

TO THE VEHICLE.

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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.

Battery Storage

When the vehicle is placed in storage for three months or more, the

battery should be removed, stored out of the sun in a cool, dry place

and tested monthly. Before reusing, take the battery to your dealer for

testing and recharging.

Tie-Down Bracket

Negative (Black) Cable

Positive (Red) Cable

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SECTION IV

ASSEMBLY

Attaching Occupant Protection Structure to Vehicle

(Refer to illustration on following page)

Remove occupant protection structure from shipping bundle and

arrange weldments around the vehicle.

With hood fully opened, position one side weldment into position and

loosely bolt into place using ½” x 3” bolts and locknuts in front and 5/8”

x 3” bolts and locknuts in rear. Nuts should be oriented towards the

outside of the vehicle in rear. Place opposite side weldment into po-

sition and fasten loosely into place.

Loosely fasten front weldment into place using ½” x 2-½” button head

cap screws on the top and ½” x 2” button head cap screws in front.

Loosely fasten rear weldment into place using ½” x 2-½” button head

cap screws on top and 3/8” x 1” bolts and locknuts on bottom (where

indicated).

Install seatbelts to holes in rear weldment using ½” x 1” bolts and lock-

nuts. Tightening bottom of rear weldment will help to align seat belt

holes.

Tighten all fasteners. Do not exceed torque specification on rear frame

mounts.

Place seat back against rear of cab frame with the five studs extend-

ing through the matching mounting holes. Fasten using 5/16” flat

washers and locknuts.

OPTIONAL EQUIPMENT

Consult with your Bush Hog dealer for availability of optional equip-

ment. These items will have installation instructions supplied with the

kits.

ITEMS TO CHECK:

Check oil level in the engine (see engine manual)

Check tightness of all fasteners, including bolts, lug nuts, and

setscrews.

Check tire pressure.

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1/2” x 2”

Hex Socket

Button Head Bolts

OCCUPANT PROTECTION

STRUCTURE

1/2” x 2-1/2”

Hex Socket

Button Head Bolts

Cross Tube,

Front

1/2” x 2”

Hex Socket

Button Head Bolts

Light Bar,

Right

Light Bar,

Left

Center Tube,

Rear

Seat Back

Mounting Holes

(5/16” Flatwashers

& Locknuts)

1/2” x 2-1/2”

Hex Socket

Button Head Bolts

1/2” x 3”

Bolts & Locknuts

3/8” x 1” Bolts

& Locknuts

Seat Belt

Mounting Holes

1/2” x 1”

5/8” x 3” Bolts

& Locknuts

Bolts & Locknuts

Seat Belt Installation

Install all seat belts so that the release button will be to the out-

side of the occupant when fastened.

1/2” x 2-1/2”

Bolt & Locknut

1/2” x 1-1/2”

Bolt & Locknut

Outside

Seat Belt

Inner

Seat Belt

1/2” x 1-1/2”

Release

Bolt & Locknut

Button

Outside

Seat Belt

Release Release

Inner

Button Button Seat Belt

Outside

Seat Belt

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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. These rubber

bumpers are factory adjusted to prevent rattling when the bed is in the

down position. If adjustment should be needed at a later time proceed

as follows:

Manual Lift - Screw pads down enough so that slight down pressure

on the front of the bed is needed to unlatch the lift handle.

Electric Lift - Lower bed, then screw pads down for a snug fit to pre-

vent rattling.

Bumper Pad

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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 spark plug

Spark plug fouled

ENGINE STOPS:

•

No fuel in tank

Water in fuel

Fuel filter clogged

Choke left on too long

Air filter clogged or inlet blocked

Fuel tank cap vent clogged

Engine overheated

Too much idling or low speed running (not enough air flow)

Overloaded

Fouled spark plug

Engine oil low

NO POWER:

•

Engine overheated

Too much idling or low speed running (not enough air flow)

Overloaded

Wrong spark plug

Engine oil low

Compression leakage

Valve clearance insufficient

Fuel filter clogged

Air filter clogged or inlet blocked

Spark plug dirty or worn

Choke left on

Engine oil incorrect

Water in fuel

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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 informa-

tion.

No. 1

No. 4

No. 6

No. 5

No. 2 No. 3

No. 1

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No. 3

No. 2

No. 4

No. 5

No. 6

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B o l t

D i a m e t e r “ B ”

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NOTES:

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NOTES:

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P.O. Box 1039 • Selma, AL 36702-1039

Telephone (334) 874-2700 • www.bushhog.com

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