XY Powersports XY500UTV, Service Manual

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2. VEHICLE BODY
，
MUFFLER
2-1
Overhaul info……………………………2-1 Side door(R&L)... ... ... ... ... ... ... ... ... ...2-11
Troubleshooting…………………………2-1 Bumper&
Fuel tank
………………………2-12
Center cover, steering wheel ……………2-2 Headrest, driver & Backrest, passenger …2-13
Holder, meter& Engine cover……………2-3 Safety belt…………………………………2-14
Front side support (L&R) ………………2-5 Roll-over bar……………………………2-15
Seat, driver& passenger …………………2-6 Bumper Protector………………………2-17
Gearshift unit……………………………2-7 Cargo box………………………………2-18
Handle, parking brake& skid plate………2-8 Muffler…………………………………2-19
Rear fender& fender, cargo box………….2-9 Description of visible parts………………2-20
Cargo box………………………………2-10
Overhaul Information
Operation Cautions
Warning
Gasoline is highly flammable, therefore smoke and fire are strictly forbidden in the work
place. Special attention should also be paid to sparks. Gasoline may also be explosive
when it is vaporized, so operation should be done in a well-ventilated place.
Remove and Install muffler after it is fully cold.
●
This chapter is on the disassembly and installation of rack, visible parts, exhaust pipe,
Muffler and fuel tank.
● Hoses, cables and wiring should be routed properly
● Replace the gasket with a new one after muffler is removed
● After muffler is installed, check if there is any exhaust leakage.
Tightening torque
Muffler Rear Fixing Bolt: 20-25N.m
Muffler Exhaust Pipe Nut: 20-25N.m
Troubleshooting
Loud exhaust noise
● Broken muffler
● Exhaust leakage
Insufficient power
● Distorted muffler
● Exhaust leakage
● Muffler clogged
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