UTVs Factory UTV500CC User Manual Download

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UTV500CC User’s Manual www.UTVsFactory.com

Checking Kilometers

term

Checking

Item month

First 1000Km

first 3 months

Every
3000Km

Every 3
months

Every 6000Km

Every 3 months

Brake soft pipe

Check Check —

Change once every three years

Brake liquid

Change once every one and half year

Brake

Check

—

Steering organization

Check

—

Accelerator cable

Check

—

Brake pedal free travel

Check

—

Carburetor

Check

—

Tyre

Check

—

Spark plug

—

Check

—

Engine oil

Change

—

Air filter(filter core)

— Clean —

Change if necessary

（

usually change once every

10000Km

）

Valve clearance

—

Check

—

Shift driving belt

—

Check

—

Fuel pipe

Check Check —

Change once every three years

Gear oil in Gear box

change

—

Gear oil in F/R main driver

change

—

Front and rear absorber

—

Check

Summary of Contents for UTV500CC

Page 1: ...UTV500CC User s Manual www UTVsFactory com 500CC Utility Vehicle User Manual Vision 2007 1 0 UTVs Factory...

Page 2: ...ment drawing for whole vehicle IV Inspection before driving V Driving operation VI Running in of new vehicle VII Maintenance and repair VIII Trouble diagnosis and elimination IX Screwing moment of imp...

Page 3: ...storage which do not accord with this operating instruction 2 Damages caused by force majeure chemical substance bad substance or other natural disasters 3 Consumed parts in normal usage such as bulb...

Page 4: ...rt from ground 210 Wheelbase 1730 Tread front wheel 1036 rear wheel 1040 Approach angle 47 Removed angle 82 II Using data 1 High running speed km h H gear 70 2 Small steering semi diameter m 4 65 3 Br...

Page 5: ...lter type whole filtering with paper element Carburetor style vacuum film Air filter Sponge element filtering Fuel type higher class than RQ 93 Transmission V belt with teeth on auto stepless gear cha...

Page 6: ...50Kpa Rear wheel Tyre type 25 10 00 12 Air inflating pressure 300Kpa 7 Steering system Adopt gear rack type redirector total circle number of steering plate 3 75 total swing angle of steering wheel 75...

Page 7: ...UTV500CC User s Manual www UTVsFactory com 7 4 Starting engine type 12V forever magnetic DC electric engine III Placement drawing for whole vehicle...

Page 8: ...UTV500CC User s Manual www UTVsFactory com 8...

Page 9: ...UTVsFactory com 9 1 Top roof 2 Safe belt 3 Frame 4 Steering wheel 5 Rear mirror 6 Engine hood 7 Indicator 8 Bumper 9 Headlight 10 Winch 11 Wheel 12 Seat 13 Side cover 14 Rear mudguard 15 Dump bed 16 R...

Page 10: ...r temperature sensor 4Hand pill staring handle 5 Left cover 6 Rear shaft flange 7 Front shaft flange 8 Oil filter 9 water outlet temperature adjuster 10 CVT case 11 CVT inlet 12 CVT inlet 13 Plug VIN...

Page 11: ...use the correct gear box oil and quantity More or less oil can cause the gear box burned out Warning Brake liquid should be filled by regulated trademark it could not mix different brake liquids from...

Page 12: ...uld have no leakage 2 Check the levels of engine oil brake liquid and cooling liquid if necessary add more 3 Check the air pressure in tyre 4 Check the function of safety belt 5 Check whether steering...

Page 13: ...try his best to keep vehicle run at economical speed 35 45km h Overspeed driving will cause accident 5 Driver should control speed strictly by the size of swerve when turn around the highest speed cou...

Page 14: ...cle and bring bad influence for your running safe so it is necessary to note 2 Operation Key Keys can be used on ignition and fuel box There are two keys one of them should be preserved carefully for...

Page 15: ...imes when warning light is on Fuel meter 4 Display the quantity of fuel Gear display The corresponding indicating L H N R P will be displayed when the gear changed g Thermometer 1 Display the temperat...

Page 16: ...ed to position press down lamplight main switch handle headlight changes to far light from close light raise lamplight main switch handle headlight changes to close light from far light When ignition...

Page 17: ...flash When ignition switch is at ON position step down brake pedal brake light will illumine Horn button Press down horn button on steering wheel anyone of these two loudspeaker will hoot Accelerator...

Page 18: ...will be up backwards And stop after releasing the press while press down DOWN on TRAILER switch the cargo box will be back And stop after when release the press Warning After parking the vehicle pull...

Page 19: ...the bottom is Off Note It will increase the wear and tear when use four wheel drive Please use two wheel drive on the normal road In case to prolong the usage of the vehicle four wheel drive could onl...

Page 20: ...0Km 50Km h Exceed 1600Km 60Km h 2 Accelerate and decelerate It is necessary to avoid sudden and frequent acceleration and deceleration and keep running in even speed in running in period 3 Heating eng...

Page 21: ...intenance and repair 1 1 First maintenance item table Sequence number Category Checking item Adjusting content 1 Engine Change engine oil and oil filter Check coolant Adjust idling speed 1300 100r m l...

Page 22: ...pper and lower limit marked it is necessary to note only distilled water could be filled in storage cell 11 Meter Display is normal and correct 12 Dump bed and self saving winch Work normally 2 Routin...

Page 23: ...0 20Mpa rear wheel 0 25Mpa Thread depth no less than 1 6mm 7 Lamplight Illumination signal and loudspeaker Every kind of lamplights signal switches and buttons etc 8 Battery Liquid height in storage c...

Page 24: ...ke Check Check Steering organization Check Check Accelerator cable Check Check Brake pedal free travel Check Check Carburetor Check Check Tyre Check Check Spark plug Check Engine oil Change Change Air...

Page 25: ...eck Check Transmission organization Check Check Lamplight and meter Check Check Brake pipeline and branch pump Check Check Engine suspension Check Check Front and rear axle suspension Check Note Perio...

Page 26: ...art difficultly or could not start 1 pressure in cylinder is too low Cylinder wear out Piston wear out Leakage on Washer of cylinder Wearing on Pipe of air valve or seat of valve is not suitable plug...

Page 27: ...roblem Clean or change Clean dry or Change Change Change Change Change 3 No fuel in carburetor Vent hole on tank jammed Problem or blocked in fuel pipe Problem on needle valve of carburetor Blocked in...

Page 28: ...cab is not right Jam on muzzle of carburetor Fuel pipe problem Adjust screw of idle sets wrong Adjust Repair or Change Change Change Adjust the height of bobber Clean Change Adjust Engine has no idle...

Page 29: ...ter of carburetor is too lower Air filter is dirty Block in fuel pipe cause fuel supply problem Fuel pipe problem Change Change Clean or Change Adjust or change Adjust or change Change Adjust the heig...

Page 30: ...trical parts problem Dirt on plug Gap of plug not correct Ignition loop problem CDI problem Magneto problem Clean or Change Change or Adjust Change Change Change Engine power is not enough 3 Mechanica...

Page 31: ...r mixture is too thick or thin Leakage on engine Air filter is dirty Cylinder piston ring worn out Leakages on connecting face Block in exhaust pipe Leakage on Air inlet pipe Adjust carburetor Repair...

Page 32: ...arbon gathered in firebox Piston pin or pin hole worn out Piston ring or ring notch worn out Change Change Clean Change Change Noise from chain of circulation Chain elongated Chain worn out Adjustor o...

Page 33: ...acks power and accelerating Clutch skiding Transmission system Hoof of clutch worn out Spring on clutch is weak Out wheel worn out Belt worn out loose Change Change Change Change Gear change not smoot...

Page 34: ...ed Muzzle blocked Main air channel blocked Needle valve blocked Throttle not work well Fuel filter blocked Height of floater not right Starting pin not closed Clean Clean Clean Adjust Clean or change...

Page 35: ...g is blocked Spring force of adjuster is short Change Change Repair or Change Repair or Change Out of gear Gear Box or Gear shifting system Speed changing drum groove worn out Right and Left gear chan...

Page 36: ...running system suspension Left and right absorber has been damaged spring force is short Tyre is not balance and wheel hub is distorted Front wheel location is wrong Vehicle is over load Tyre has not...

Page 37: ...ck adjust Change tyre or wheel hub Change tyre Change or adjust Fasten Steering is heavy Steering organization running system Air pressure in tyre is short Ball head of left and right swing arm and dr...

Page 38: ...not even Front wheel adjustment is wrong Vehicle frame is distorted and left and right wheelbase is different Some brake pipelines is not smooth Individual brake drum and brake hoop contacts badly Su...

Page 39: ...ulb has been damaged Adjuster has been damaged adjusting voltage is too high to burn bulb Fuse has been burned Headlight relay has been damaged Lead or grounding happens malfunction Combination switch...

Page 40: ...grounding wire has been cut off Electric bottle contacts badly or happens oxygenation Check and Change Change Repair circuit Repair Some kind of lamplight is bad or complete lamplights are damaged no...

Page 41: ...M14X1 5 97 9 Nut of driving prick gear 1 M22X1 145 10 Nut of driven prick gear 1 M16X1 5 150 11 Fixed nut of clutch 1 M18X1 5 70 12 Nut of position limitation of driven gear 1 M60 110 13 Nut of posit...

Page 42: ...on chain adjuster 2 M6 10 36 Nuts on chain adjuster 1 M8 8 37 Bolts on fan motor 3 M6 10 38 Bolts on constant temperature unit 2 M6 10 39 Bolts on pump cover 3 M6 6 40 Bolts on pump 2 M6 10 41 Bolts...

Page 43: ...22 Bolts on bumper 2 M10x20 50 23 Bolts on driving axle 2 M8x25 30 24 Bolts on flange and rear wheel upper swing arm 1 M12x90 70 25 Bolts on flange and rear wheel lower swing arm 2 M12x175 70 26 Bolt...

Page 44: ...Specification Capacity Remark Fuel RQ 90 or upper grade lead free gasoline 27L Content of fuel box Lubricating oil engine Gear box SAE15W 40 SF or SC 1900ml change oil 2000ml change filter 2200ml repa...

Page 45: ...0 75 0 75 0 75 0 75 Z 0 75 4 0 75 0 75 0 75 0 75 12 24WD 1 5 0 75 2 3 4 5 10 10 10 10 5 30 10 10 10 0 75 2 4WD 0 75 1 5 1 5 1 5 0 75 0 75 0 75 0 75 0 75 0 75 0 75 0 75 5 10 0 75 0 75 1 5 1 5 1 5 0 75...

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