®
BUSH HOG
Trail Series
OFF ROAD UTILITY VEHICLES
Operator’s Manual
MODELS
TH420
TH440
TH4200
TH4400
ASSEMBLY • OPERATION • MAINTENANCE
107
$10.00
50044549
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®
BUSH HOG
Trail Series Utility Vehicles
TABLE OF CONTENTS
SECTION
PAGE SECTION
PAGE
Retail Customer’s Responsibility
2
3
5
6
7
III MAINTENANCE
Periodic Maintenance Schedule
Lubrication Recommendations
Engine Oil
Engine Oil Filter Change
Transaxle
46
47
50
51
52
52
53
54
Warranty
Dealer Preparation Check List
Safety Alert Symbols
Safety Precautions
Front Differential
Right Angle Drive
Constantly Variable Transmission 55
Vehicle Immersion
Engine Air Filter
CVT Enclosure Air Filter
Fuel filter
I
INTRODUCTIONANDDESCRIPTION 20
Introduction
Description
Specifications
20
20
27
56
57
57
58
58
59
60
61
62
63
63
64
64
65
65
66
67
67
67
68
68
69
69
II OPERATION
General Safety
29
29
29
29
30
30
31
31
32
33
34
34
35
36
36
36
38
39
40
41
42
43
43
44
44
45
46
Spark Plugs
Spark Arrestor
Pre-Operation Checklist
Vehicle Break-In Period
Starting The Engine
Driving The Vehicle
Braking
Stopping The Engine
Using The Cargo Box
Load Distribution
Driving Safely
Driving On Slippery Surfaces
Driving Uphill
Sidehilling
Driving Downhill
Driving Through Water
Driving Over Obstacles
Driving In Reverse
Parking On An Incline
Hauling Cargo
Emptying The Cargo Box
Towing Loads
Parking The Vehicle
4-Wheel Drive
Throttle System
Brake Inspection
Parking Brake Adjustment
Steering Wheel Inspection
Seat Belts
Tires
Wheel Lug Nuts
Wheel Installation
Lights
Cleaning Your Vehicle
Storage
Removal From Storage
Battery
Replenishing Battery Fluid
Battery Removal
Battery Installation
Battery Storage
IVASSEMBLY
Attaching Occupant Protection
Structure
Optional Equipment
Items To Check
Seat Belt Installation
Rubber Bumper Pad Adjustment
Troubleshooting CheckList
Safety Decals
70
70
70
70
71
72
73
74
76
Disengaging 4-Wheel Drive
Noise Emission Control System
Spark Arrestor
Torque Specifications
1
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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,
maintain and store the product in accordance with all
instructions and safety procedures. Failure of the opera-
tor 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
product to the authorized Bush Hog Dealer, from whom
he purchased it, for service or replacement of defective
parts which are covered by warranty. Repairs to be sub-
mitted for warranty consideration must be made within
thirty (30) days of failure.
It is the Retail Customer’s responsibility for any cost
incurred by the Dealer for traveling to or hauling of the
product for the purpose of performing a warranty obliga-
tion or inspection.
2
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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.
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 applica-
ble new equipment warranty period, whichever occurs later.
Warranted parts shall be provided at no cost to the user at an author-
ized Bush Hog dealer during regular working hours. Bush Hog
reserves the right to inspect any equipment or parts which are
claimed to have been defective in material or workmanship.
DISCLAIMER OF IMPLIED WARRANTIES & CON-
SEQUENTIAL DAMAGES
Bush Hog’s obligation under this limited warranty, to the
extent allowed by law, is in lieu of all warranties, implied or
expressed, INCLUDING IMPLIED WARRANTIES OF MER-
CHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE
and any liability for incidental 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: trans-
portation charges other than normal freight charges; cost of installa-
tion 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, dam-
age, detention or delay in the delivery of equipment or parts resulting
from acts beyond the control of Bush Hog.
CONTINUED
3
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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, mis-
use, negligence, 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 author-
ized 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
such as gearbox lubricant, or to normal deterioration of such things
as belts and exterior finish due to use or exposure.
6. To expendable or wear items such as teeth, chains, sprockets,
belts, springs and any other items that in the company’s sole judge-
ment is a wear item.
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
information will be helpful to your dealer if parts or service are required.
MODEL NUMBER
SERIAL NUMBER
DATE OF RETAIL SALE
4
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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 pro-
cedures listed above before delivery of this vehicle to the
customer.
5
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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,
carefully read the message that follows and heed
its advice. Failure to comply with safety precau-
tions 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.
6
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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
accidents. When you see this sym-
bol, carefully read the message that
follows 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,
concern, 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 efficien-
cy and worst of all—loss of life. Watch for safety hazards and correct
deficiencies promptly. Use the following safety precautions as a gen-
eral guide to safe operations when using this machine. Additional
safety precautions are used throughout this manual for specific oper-
ating 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.
7
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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.
•
8
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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.
•
•
•
9
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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.
10
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OPERATOR TRAINING:
The controlling Party should develop, conduct an operator-training
program and permit only properly trained persons to operate the util-
ity vehicle.
OPERATOR-TRAINING PROGRAM:
The program should include, as a minimum, the following:
Review:
• Vehicle operator’s manual instructions.
• Vehicle’s safety decals.
• Safe loading practices.
• Proper use of vehicle’s controls and consequences of
improper use.
• Controlling Party’s safety practices developed from operating
area safety survey.
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
competency 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.
• 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.
11
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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.
12
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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 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.
13
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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.
14
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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.
15
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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
operating conditions, and your experience.
WARNING
POTENTIAL HAZARD
Attempting jumps and other stunts
WHAT CAN HAPPEN
Loss of control, accident and/or vehicle overturn
HOW TO AVOID THE HAZARD
Never attempt jumps and other stunts. Avoid exhibition driving.
WARNING
POTENTIAL HAZARD
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.
16
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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
unfamiliar 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.
17
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WARNING
POTENTIAL HAZARD
Failure to follow the minimum age recommendations for this
vehicle.
WHAT CAN HAPPEN
Serious injury or death (the child or others)
HOW TO AVOID THE HAZARD
Only persons with a valid driver’s license should operate this
vehicle.
Even though a child may be within the age group for which
some vehicles are recommended, he or she may not have the
skills, abilities, or judgement needed to operate the vehicle
safely and may be involved in a serious accident.
WARNING
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.
18
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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
inspect the entire vehicle for possible damage, including (but
not limited to) brakes, throttle and steering systems.
WARNING
Always keep combustible materials away from the exhaust sys-
tem. Exposure to the hot components could result in a fire.
WARNING
Gasoline is highly flammable and is explosive under certain
conditions. 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
refueling 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.
19
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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 keep-
ing your vehicle in top operating condition. Please read this manual
thoroughly. 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 assis-
tance or additional information is needed, contact your authorized
Bush Hog dealer.
DESCRIPTION (Trail Hunter shown on next page)
17.Ignition Key
18.Fuel Gauge
19.Hour Meter
1. Occupant Protection
Structure (O.P.S.)
2. Hand hold
20.Choke Knob
21.Power Bed Lift Switch
(Optional)
3. Gear Selector
4. Steering wheel
5. Seat
22.Neutral Light
6. Seat Belt
23.4-Wheel Drive Switch
and Light
7. Fuel Tank Cap
8. Battery (Under Hood)
9. Headlights
10.Front Bumper/
Brush Guard
11.Power Winch (Optional)
12.Cargo Light (Optional)
13.Cargo Box
14.Hitch Receiver
15.Winch Wiring Pigtail
16.Cup Holder
24.Winch Switch (Optional)
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
32.Throttle Pedal
33.Tailgate Latch
17.Ignition Key
34. Cargo Box Release Handle
20
18.Fuel Gauge
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1
NOTICE!
LOCATIONS OF CON-
TROLS AND FEATURES
MAY VARY SLIGHTLY
ON DIFFERENT MODELS.
2
6
5
8
10
7
9
11
3
27 28 22 23
29
4
18
19
17
16
30
24
31
32
12
13
20
25
26
21
33
34
21
15
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UNDER HOOD AREA (WITH CARGO TRAY REMOVED)
Battery, Brake Fluid Reservoir, Fuses and Relays, Grease Fitting
UNDER SEAT AREA
Engine Air
Intake
Engine Oil
Filler Cap
Engine Oil
Dipstick
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 Trail Series 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
ON
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
IGNITION 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.
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
reverse.
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
PARKING BRAKE APPLIEDAND TURN THE VEHICLE OFF
WHENEVER THE VEHICLE IS LEFT UNATTENDED.
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SPECIFICATIONS
TRAIL HUNTER
TRAIL HAND
TH4200 TH4400
ENGINE
TH420
TH440
Type
4-cycle, OHV V-twin, air-cooled gas
Briggs & Stratton Honda Honda
16 hp (480cc) 20 hp (614CC) 24 hp (670cc)
Make
Honda
HP / (cc)
Lubrication
Air Cleaner
Electrical Systems
Full Pressure with automotive style spin-on canister
Remote, 2-stage cyclone type with replacement dual elements
12 volt DC with 20-amp alternator
CHASSIS
Suspension, Front
Suspension, Rear
MacPherson strut, single A-Arm, coil-over-shock
Independent trailing arm, coil-over-shock
Wheel travel, Frt/Rr 5.7 inches / 4.4 inches
5.7 inches / 6.0 inches
Steering
Rack and Pinion
13 ft
Turning Radius
Front Tires
Rear Tire
Brakes
AT 23 x 8.0 - 12 NHS
AT 23 x 10.0 - 12 NHS
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
10-inches
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SPECIFICATIONS
TRAIL HUNTER
TRAIL HAND
TH4200 TH4400
DRIVE TRAIN
TH420
TH440
Transmission
Continuously Variable Transmission (CVT)
CVT Protection
Shielded (TH420 only), Fully enclosed pressurized with
filtered air intake (TH440, TH4200 and TH4400)
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™
Ground Speed
0 - 25 mph
4WD
True On-Demand 4-wheel drive; switch engage
(4wd models only)
DIMENSIONS
Dry Weight
1,270 lbs.
1,320 lbs.
1,450 lbs.
1,500 lbs.
Wheel Base
72 inches
76 inches
Vehicle
1,250 lbs.
750 lbs.
1,500 lbs.
1,000 lbs.
Load Capacity
Cargo Box
Load Capacity
Towing Capacity
Fuel Capacity
Seating Capacity
Lights
1,500 lbs.
7 gallons
2
3
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. See dealer for complete details.
Two-year engine limited warranty administered
through engine manufacturers.
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SECTION II
OPERATION
GENERAL SAFETY
Only qualified people familiar with this operator’s manual should
operate this machine.
WARNING
IF A PROPER INSPECTION IS NOT DONE BEFORE EACH
USE, SEVERE INJURY OR DEATH COULD RESULT.
ALWAYS INSPECT THE VEHICLE BEFORE EACH USE
TO ENSURE IT’S IN PROPER OPERATING CONDITION.
PRE-OPERATION CHECKLIST
1. Fill the fuel tank with unleaded regular gasolIne.
2. Make sure dirt and foreign matter are kept out of fuel tank. Use
a clean funnel and fuel can.
3. Do not mix oil with gasoline.
4. Do not use white, high test or premium gasoline. Do not use
de-icers, carburetor cleaners or othersuch 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: Trail Hunter models require 18 psi in all four
tires. Trail Hand models require 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
efficient performance and longer life for the engine. Carefully perform
the following procedures.
29
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Starting The Engine
WARNING
ENGINE EXHAUST GASES CONTAIN
POISONOUS CARBON MONOXIDE.
l
l
NEVER RUN ENGINE IN A CLOSED BUILDING OR CONFINED AREA.
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 VEHI-
CLE. 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
ENGINE 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, REMEM-
BER THAT LOAD WEIGHT WILL INCREASE BRAKING DIS-
TANCES. FAILURE TO ALLOW FOR INCREASED BRAKING DIS-
TANCES MAY RESULT IN ACCIDENT AND INJURY.
Braking
Practice starting and stopping (using the brakes) until you are famil-
iar 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
1. Release the throttle pedal completely
2. Place the transmission selector lever in neutral.
3. Apply the parking brake to help prevent the vehicle from rolling.
4. 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 RUN-
NING. IF THE VEHICLE MOVES, IT MIGHT BE DAMAGED OR
CAUSE INJURY.
CAUTION
EXHAUST SYSTEM COMPONENTS ARE VERY HOT DURING
AND AFTER USE OF THE VEHICLE AND WILL CAUSE
BURNS IF THEY COME IN CONTACT WITH SKIN.
Using The Cargo Box
CAUTION
NEVER EXCEED THE LOAD CAPACITY LISTED IN THE
SPECIFICATIONS CHART FOR YOUR PARTICULAR VEHI-
CLE. AN OVERLOADED CARGO BOX CAN CAUSE INSTA-
BILITY DURING 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.
ALWAYS SLOW DOWN AND ALLOW ADDITIONAL
BRAKING DISTANCE WHEN TOWING OR HAULING
CARGO.
The tailgate of the cargo box can be opened by pulling up on the han-
dle 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
ATTEMPTING 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
conditions, 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.
34
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Driving Uphill
Whenever traveling uphill, follow these precautions:
1. Always travel straight uphill.
2. Avoid steep hills (15° maximum).
3. Keep both feet on the floor.
4. Proceed at a steady rate of speed and throttle opening.
15° Maximum
WARNING
CLIMBING HILLS IMPROPERLY CAN CAUSE LOSS OF
CONTROL OR VEHICLE OVERTURN. ALWAYS CHECK
THE TERRAIN CAREFULLY BEFORE CLIMBING A HILL.
BRAKING AND HANDLING ARE GREATLY AFFECTED
WHEN OPERATING IN HILLY TERRAIN. IMPROPER
PROCEDURE COULD CAUSE LOSS OF CONTROL OR
OVERTURN 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
RESULT IN LOSS OF CONTROL OR VEHICLE OVERTURN,
RESULTING IN SEVERE INJURY OR DEATH. AVOID
CROSSING THE SIDE OF A HILL WHEN POSSIBLE. WHEN
UNAVOIDABLE, EXERCISE EXTREME CAUTION. AVOID
OPERATING ON STEEP HILLS (15° MAXIMUM)
Driving Downhill
Whenever descending a hill, follow these precautions:
1. Proceed directly downhill.
2. Slow down.
3. Apply the brakes slightly to aid in slowing.
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
procedures when operating through water:
36
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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 per-
form the services outlined in the Maintenance section on page 47.
Give special 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,
PERFORM THE SERVICE OUTLINES IN PAGE 56, AND
TAKE THE VEHICLE TO YOUR DEALER AT THE FIRST
OPPORTUNITY.
37
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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
VEHICLE SUDDENLY COMES IN CONTACT WITH A
HIDDEN OBSTACLE. NOT ALL OBSTACLES ARE
IMMEDIATELY VISIBLE. REDUCE SPEED AND TRAV-
EL WITH CAUTION IN UNFAMILIAR TERRAIN
38
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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
INJURY OR DEATH. BEFORE SHIFTING INTO
REVERSE, ALWAYS CHECK FOR OBSTA-
CLES OR PEOPLE BEHIND THE VEHICLE
AND FOLLOW THE REVERSE OPERATION
PROCEDURES OUTLINED IN THIS MANUAL.
ALWAYS BACK SLOWLY.
39
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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.
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
INJURY OR DEATH. ALWAYS DISENGAGE THE
PARKING BRAKE BEFORE OPERATING THE
VEHICLE.
40
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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
Trail Hunter
Trail Hand
1,250 lbs.
1,500 lbs.
750 lbs.
1,500 lbs.
1,500 lbs.
1,000 lbs.
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.
41
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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
VEHICLE WITH THE CARGO BOX IN THE RAISED POSITION.
1. Select a level site to empty the cargo box. Do not attempt to
unload the vehicle while parked on an incline.
2. Set the parking brake.
3. Dismount the vehicle.
4. Release the tailgate latch.
5. 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 LOCAT-
ED TOWARD THE REAR OF THE BOX WHEN THE
RELEASE LEVER IS PULLED UPWARD, THE BOX MAY
DUMP UNEXPECTEDLY AND CAUSE SERIOUS INJURY
TO THE OPERATOR OR BYSTANDERS.
NEVER OPERATE THE DUMP LEVER WITHOUT ENSUR-
ING THAT THE BOX IS EMPTY.
Cargo Box
Release Lever
42
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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 INCREAS-
ES 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 VENTILAT-
ED AND THAT THE VEHICLE IS NOT CLOSE TO ANY
SOURCE OF FLAME OR SPARKS, INCLUDING ANY
APPLIANCE WITH PILOT LIGHTS.
4-Wheel Drive
Your Bush Hog Utility Vehicle is equipped with an exclusive 4-wheel
drive system that can be activated by a switch on the dash board.
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 automati-
cally engage anytime the rear wheels begin to lose traction. When
the rear wheels regain traction, the front wheels will automatically dis-
engage.
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
remain 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
remain engaged unnecessarily. This condition causes increased
steering 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
DURING AND AFTER USE OF THE VEHICLE. HOT COM-
PONENTS 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
intervals 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
qualified dealer perform these operations.
Inspect, clean, lubricate, adjust or replace parts as necessary. When
inspection reveals the need for replacement parts, always use gen-
uine 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
n
MARKED WITH A
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
Pre-operation Inspect
Pre-operation Inspect
Tires
Wheels
Frame nuts, bolts, Pre-operation Inspect
fasteners
Parking Brake
Pre-operation Check lever adjustment
daily; adjust
Pre-operation Inspect
Pre-operation Inspect
Throttle Cable
Steering
Coolant/Level
Headlamp
Daily
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
Inspect; replace if necessary
s Transmission Oil 25 hrs.
Check level; change oil
annually
Battery
25 hrs.
Check terminals; clean;
check fluid level
n
Brake pad wear
25 hrs.
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/Cylinderr
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.
100 hrs.
50 hrs.
50 hrs.
Replace with oil change
H
H Engine breather
hose
Inspect
Carburetor Float
Bowl
Drain bowl periodically and
prior to storage
n
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.
50 hrs.
Inspect; adjust
n
n
Inspect; adjust, replace if
necessary
Steering
50 hrs.
Inspect; lubricate
Inspect; lubricate, tighten
Fasteners
s Front Suspension 50 hrs.
s Rear Suspension 50 hrs.
Inspect; tighten fsteners
Inspect
Engine Mounts
Valve Clearance
300 hrs.
300 hrs.
n
H
Inspect; adjust
H Spark Plug
100 hrs.
100 hrs.
Inspect; replace if necessary
Inspect and adjust as needed
n
H
n
Ignition Timing
Front Hub Bearings 100 hrs
Check at 100 hrs. and
replace as needed
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Item
Frequency Remarks
n
H
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.
100 hrs.
Spark Arrestor
s Front Gearcase Oil 100 hrs.
Check monthly; change
annually
n
Clutches (drive
and driven)
Brake Fluid
Front Wheel
Bearings
100 hrs.
Inspect; clean
n
n
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.
n
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
Refill to middle of Check monthly;
change every 100 hrs.
w/LSD additive sight window
Front Differential Mobil 424
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 Grease
Struts, Swing
gun
Arm Pivots,
Pillow Block
on Driveshaft
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. Severe use includes continuous duty in dusty or wet condi-
tions, and cold weather operation. NOTE: Severe use/cold weather
operation is when all operating is at below 10°F and/or when operat-
ing 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 over-
fill.
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
vehicle 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 compo-
nents.
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
reduce its strength so that a failure may occur at a high speed. The
CVT system has been precision balanced. Any modification will
cause the system to be out of balance, creating vibration and addi-
tional 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 sys-
tem 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
ENGINE DAMAGE CAN RESULT IF THE VEHICLE IS NOT
THOROUGHLY INSPECTED. TAKE THE VEHICLE TO
YOUR DEALER BEFORE STARTING THE ENGINE.
If it is impossible to take your vehicle to a dealer before starting it, 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.
Briggs & Stratton Engines
The procedure for the Briggs & Stratton engine would be the same as
for the Honda except that there is no drain feature on the carburetor
fuel bowl. The carburetor should be removed and thoroughly cleaned
inside and out.
NOTE: Water damage to electrical components may necessitate
replacement of that component.
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Engine Air Filter
We recommend that the air filter be cleaned every 25 hours and
replaced once a year.
1. The air filter is accessible from the right side of the vehicle, below
the passenger seat. Loosen both fastening clips and remove the
housing cover. There is an outer and inner filter that may then be
pulled out for service or replacement.
2. Inspect the filter housing and clean out any debris or moisture.
3. Replace the filter elements or install new ones.
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
replaced once a year
The CVT filter is accessible by folding the seat forward. The filter
housing 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
SERIOUS BURNS. WEAR PROTECTIVE GLOVES WHEN
REMOVING A SPARK PLUG FOR INSPECTION.
Spark plug condition is indicative of engine operation. The spark plug
firing 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
adjustments.
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
incorrect 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).
58
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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 COMPO-
NENTS 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.
EXHAUST 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
muffler. 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
several 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
PARTIAL BOTTLE. BRAKE FLUID IS HYGROSCOPIC, MEAN-
ING IT RAPIDLY ABSORBS MOISTURE FROM THE AIR. THE
MOISTURE 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 stepping on the foot lever (Trail
Hand) or pulling up the hand lever (Trail Hunter). the vehicle
should not roll while parked. If the vehicle moves, adjustment is
needed.
2. (Trail Hand) On the underside of the vehicle the threaded end of
the parking brake cable passes through an equalizer bracket.
Hex nuts on each side of the equalizer position the brake cable.
Loosen the nut on the front side of the equalizer and then tighten
the rear side nut to increase pressure on the brake system. Test
the brake system and adjust again, if needed. When adjustment
is satisfactory, tighten both nuts securely against the equalizer
bracket.
(Trail Hunter) 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.
Trail Hand Parking Brake
Trail Hunter 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
particular seat before driving. Make sure the seat belt angle is adjust-
ed 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.
NOTE: On the Trail Hand model, the center belt does not self adjust.
Before riding, pull on the strap to secure the belt on the lap of the cen-
ter passenger.
WARNING
FAILURE TO FOLLOW THE AGE RECOMMENDATIONS FOR THIS
VEHICLE 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
INCREASE 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
VEHICLE HANDLING, WHICH COULD RESULT IN VEHICLE
DAMAGE OR PERSONAL INJURY. ALWAYS MAINTAIN
PROPER TIRE PRESSURE. WHEN REPLACING TIRES,
ALWAYS 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
INSTALLED WHEELS WILL AFFECT VEHICLE HAN-
DLING AND COULD CAUSE AN ACCIDENT RESULTING
IN SERIOUS 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
SEVERE INJURY OR DEATH. HEADLIGHT AND TAIL-
LIGHT 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 deal-
er 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
expensive repair bills can result from using high pressure detergent
systems.
NOTE: If a high pressure car wash is used, grease all zerk fittings
immediately 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
terminals 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
magnesia, 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. The fluid level should be kept between the upper and lower level marks.
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. Remove the nuts from the battery tie-down bracket and lift off the bracket.
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 illustrations on following pages)
Remove occupant protection structure from shipping bundle and
arrange weldments around the vehicle. Loosen all fasteners before
beginning assembly.
Disconnect the front cross member from one front side frame mem-
ber so the front frame weldments can be positioned independently
from each other.
With the hood fully opened, position one of the front frame weld-
ments into position and loosely bolt into place using 1/2 x 3” bolts and
locknuts. Place opposite side frame weldment into position and fas-
ten loosely into place.
Reposition the cross member and replace the bolts that were previ-
ously removed.
With rear components assembled as shown below, place bottom
mounting plates into position on frame and join with front frame mem-
bers. Fasten mounting plates to frame with 5/8 x 3” bolts and lock-
nuts.
Fasten bottom panel to frame with 3/8 x 1” bolts and locknuts. Once
the complete cab frame is in place securely tighten all fasteners.
Install seat belts to mounting locations on frame as shown in illustra-
tions on next page.
Place seat back against rear of cab frame with the five studs extending
through the matching mounting holes. Fasten to frame 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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Seat Belt Installation
Install all seat belts so that the release button will be to the outside
of the occupant when fastened.
TH4200/TH4400 Models
1/2” x 2-1/2”
Bolt & Locknut
Release
Button
Inner
Seat Belt
1/2” x 1-1/2”
Bolt & Locknut
Outside
Seat Belt
TH420/TH440 Models
1/2” x 1”
Bolt & Locknut
Release
Button
Inner
Seat Belt
Outside
Seat Belt
1/2” x 1”
Bolt 7 Locknut
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Cross Member
Front Left
OCCUPANT PROTECTION
STRUCTURE
Frame Member
5/16 x 3/4”
Hex Socket
Button Head Bolts
Seat Back
Mounting Holes
(Use 5/16” Flatwashers &
Locknuts)
(Use 1/ 2 x 3” Bolts & Locknuts)
Bottom Panel
(Use 3/8 x 1” Bolts & Locknuts)
Bottom
Mounting Plates
(Use 5/8 x3” Bolts
& Locknuts)
Rubber Bumper Pad Adjustment
The plastic bed of the Utility Vehicle is equipped with two rubber
bumper pads located at the bottom front of the bed. 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 information.
No. 1 or 2
No. 5
No. 7
No. 6
No. 3
No. 4
No. 1
No. 2
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No. 4
No. 3
No. 5
No. 6
No. 7
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“ B ”
B o l t
D i a m e t e r
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NOTES:
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NOTES:
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P.O. Box 1039 • Selma, AL 36702-1039
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