Massimo 500LUTV Owner'S Manual Download

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READ THIS MANUAL CAREFULLY!
It contains important safety information.

This UTV should not be ridden by anyone under 16 years of age.

500UTV
500LUTV

OWNER’S MANUAL

4×4

Summary of Contents for 500LUTV

Page 1: ...READ THIS MANUAL CAREFULLY It contains important safety information This UTV should not be ridden by anyone under 16 years of age 500UTV 500LUTV OWNER S MANUAL 4 4...

Page 2: ...also includes basic maintenance and inspection procedures If you have any questions regarding the operation or maintenance of your UTV please consult you dealer AN IMPORTANT SAFETY MESSAGE READ THIS...

Page 3: ...notations NOTE A NOTE provides key information to make procedures easier or clearer The Safety Alert Symbol means ATTENTION BECOME ALERT Failure to follow WARNING instructions could result in severe...

Page 4: ...egal and unsafe to operate this UTV on any public street road or highway This UTV complies with all applicable OFF ROAD noise level and spark arrester laws and regulations in effect at the time of man...

Page 5: ...or and warning lights 23 Main stitch of light 24 Dump Bed and winch 26 4 2 4 4WD and differential locking exchangeable 27 The Other Switch 28 Seats 30 Driver s seat adjustment 30 Seat Belts 30 Seat Be...

Page 6: ...tion 37 Safe operation practices 38 Starting the engine 39 Stopping the engine 40 Braking 40 Parking the vehicle 40 New operator driving procedures 41 Driving with a passenger 43 Driving on slippery s...

Page 7: ...reverse 50 Parking on an incline 51 MAINTENANCE 52 Periodic maintenance chart 52 Engine oil 55 Transmission main gearcase 59 Spark plugs 60 Constant variable transmission CVT system 61 Filter system 6...

Page 8: ...ng wheel inspection 74 Shock spring adjustment 74 Tires 75 Vehicle immersion 76 Battery 77 Clearing and storage 80 Malfuncation analysis and elimination 82 WARRANTY 97 SPECIFICATIONS 100 Circuit Diagr...

Page 9: ...occur quickly even during routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions Read this owner s manual Understand all safety warnings precautio...

Page 10: ...the vehicle identification number and engine number in the spaces provided for assistance when ordering spare parts from your dealer or for reference in case the vehicle is stolen NOTE The vehicle ide...

Page 11: ...a vehicle any equipment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes Any modifications to the original equipment of the vehicl...

Page 12: ...4 SAFETY Safe Riding Gear Always wear appropriate clothing when riding this vehicle Wear protective clothing for comfort and to reduce the chance of injury...

Page 13: ...epartment of Transportation DOT label Eye Protection Do not depend on eyeglasses or sunglasses for eye protection Whenever riding a vehicle always wear shatterproof goggles or use a shatterproof helme...

Page 14: ...for your safety Operating Without Instruction Operating this vehicle without proper instruction increases the risk of an accident The operator must understand how to operate the vehicle properly in d...

Page 15: ...he 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 owner s manual Accessories Installing no...

Page 16: ...ing the seat belt increases the risk of serious injury in the event of an accident or sudden stop Riders must wear seat belts at all times Seat belts reduce the severity of injury in the event of a su...

Page 17: ...ed surfaces including sidewalks paths Parking lots and driveways may seriously affect handling and control of the vehicle and may cause the vehicle to go out of control This vehicle s tires are design...

Page 18: ...abruptly or at sharp angles Never turn at high speeds Practice turning at slow speeds before attempting to turn at faster speeds Physical Control of the Vehicle Removing hands from the steering wheel...

Page 19: ...lways follow proper procedures for driving down a hill as described in the owner s manual Always drive down a hill with the transmission in forward gear Never drive down a hill with the transmission i...

Page 20: ...le climbing a hill could cause an overturn Maintain a steady speed when climbing a hill If you lose all forward speed Apply the brakes gradually until the vehicle is fully stopped Place the transmissi...

Page 21: ...l or overturn Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions Operating on Sand or Slippery Terrain Operating on sand or on exce...

Page 22: ...overturn Before operating in a new area check for obstacles Never attempt to operate over large obstacles such as rocks or fallen trees Always follow the proper procedures outlined in this manual when...

Page 23: ...proper procedures for operating in water as described in the owner s manual Wet brakes may have reduced stopping ability After leaving water test the brakes Apply them lightly several times while driv...

Page 24: ...turn or accident have a qualified service dealer inspect the entire vehicle for possible damage including but not limited to brakes throttle and steering systems Operating on Frozen Bodies of Water Op...

Page 25: ...r near the refueling area or where gasoline is stored Never refuel while a person is in the vehicle Do not over fill the tank Do not fill the tank neck If gasoline spills on your skin or clothing imme...

Page 26: ...mptly remove any grass or debris clinging to the vehicle Unauthorized Use of the Vehicle Leaving the keys in the ignition can lead to unauthorized use of the vehicle which could result in an accident...

Page 27: ...handling and control With non approved accessories they may seriously affect stability At speeds that are too fast for the operator s skills the conditions and or the terrain ALWAYS require operator a...

Page 28: ...his vehicle WARNING VEHICLE OVERTURN could cause severe injury or death The cab frame is not designed or intended to provide rollover protection MINMUM TIRE PRESSURE IN PSI KPa Front 21 145 Rear 28 19...

Page 29: ...21 FEATURES AND CONTROLS Component Locations...

Page 30: ...22 FEATURES AND CONTROLS Component Locations...

Page 31: ...cators 4 Fuel indicator 5 High beam 6 odometer 7 Speed indicator 8 2 and 4 wheel drive 9 Brake liquid warming light 10 Reverse over speed alarm light Speedometer 7 Display the speed of vehicle Odomete...

Page 32: ...riving When display X in the middle it means the both front and rear axles are in driving Meanwhile the front differential will be locked up i Alarm light of brake fluid level 9 The alarm light is on...

Page 33: ...ights down headlight low beam meter light and tail light is on c When ignition switch is at ON ACC or ON position press down alarm light blinks d When ignition switch is at ACC or ON position press do...

Page 34: ...stop after when release the press When vehicle stuck in the mud the self rescue could be done by utilizing the front fix stuff or peg Press SWITCH to ON position and then press WINCH to OUT or IN the...

Page 35: ...drive Please use two wheel drive on the normal road In case to prolong the usage of the vehicle four wheel drive could only be used on muddy slippery snow or up slope road Warning 1 Engine is matched...

Page 36: ...ed for phone charging and external power supply Windshield and wiper optional When ignition switch is at ACC or ON position press down at the first step the wiping speed is low Press down at the secon...

Page 37: ...Press the button you can release the limitation MP3 PLAYER When turn the ignition key to ON or ACC switch on the power button on the middle of MP3 you could listen to the radio and music The USB socke...

Page 38: ...at belt properly follow this procedure 1 Pull the seat belt latch downward and across your chest toward the buckle at the inneredge of the seat The belt should fit snugly across your hips and diagonal...

Page 39: ...t does not operate properly have the seat belt system checked and or replaced by an authorized dealer 4 To clean dirt or debris from the seat belts sponge the straps with mild soap and water Do not us...

Page 40: ...rn windshield wiper ON open position All circuits except engine are connected and they could start at any moment or make engine keep running status ST start position Connect engine and ignition circui...

Page 41: ...tant to assure proper transmission function See your dealer if you experience any shifting problems NOTICE Do not attempt to shift the transmission while the vehicle is moving or damage to the transmi...

Page 42: ...the brake pedal to slow or stop the vehicle Apply the brakes while starting the engine Throttle Pedal Push the pedal down to increase engine speed Spring pressure returns the pedal to the rest positio...

Page 43: ...f gasoline No single action on your part is as important as a proper break in period Careful treatment of a new engine and drive components will result in more efficient performance and longer life fo...

Page 44: ...ot operate at sustained idle 6 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page37 7 Change the engine oil at 10 hours or one month...

Page 45: ...ating condition Item Remarks Page Brake Ensure proper operation 72 Steering Ensure free operation 74 Engine oil Ensure proper levels 56 57 58 Air filter Inspect clean 63 64 Seat Belts Check length of...

Page 46: ...manner appropriate for your skills and operating conditions Never operate at excessive speeds DO NOT attempt to do power slides donuts jumps or other driving stunts Keep both hands on the steering whe...

Page 47: ...If the engine does not start within five seconds return the ignition switch to the ON position and wait five seconds Repeat steps 5 and 6 until the engine starts Tip If a warm engine has cooled to a...

Page 48: ...e braking 2 Press on the brake pedal evenly and firmly Practice starting and stopping using the brakes until you re familiar with the controls Parking the Vehicle 1 Stop the vehicle on a level surface...

Page 49: ...pre ride inspection page 37 4 Wear appropriate riding gear including an approved helmet and eye protection goggles or face shield 5 Select a level open area to practice driving 6 Sit in the driver s s...

Page 50: ...erse Learn how the vehicle handles when making both left and right turns at a slow speed 16 Increase speed only after mastering all maneuvers at a slow speed 17 After you become skilled at making turn...

Page 51: ...of driving experience with this vehicle 4 Never operate with a passenger age 12 and under Make sure the passenger is tall enough to comfortably and safely sit in the passenger seat with the seat belt...

Page 52: ...ould cause discomfort or injury to a passenger 11 Always follow all operating guidelines as outlined on safety labels and in this manual Driving on Slippery Surfaces When driving on slippery surfaces...

Page 53: ...slippery conditions 1 Slow down before entering slippery areas 2 Be alert watch the path ahead and avoid quick turns which can cause skids 3 Correct a skid by turning the steering wheel in the direct...

Page 54: ...rive at a steady rate of speed Never press the throttle suddenly 6 Avoid unnecessary changes in speed or direction 7 Never go over the crest of a hill at a high speed An obstacle a sharp drop or anoth...

Page 55: ...or cause the vehicle to slide 4 If the vehicle begins to slide downhill immediately turn downhill to stop the slide Driving Downhill Whenever driving down a hill follow these precautions 1 Avoid stee...

Page 56: ...n will help dry out the pads NOTICE Major engine damage can result if the vehicle is not thoroughly inspected after operation in water Perform the services outlined in the maintenance chart See page 5...

Page 57: ...such as logs rocks and low hanging branches 3 Drive slowly and use extra caution when driving on unfamiliar terrain Obstacles are not always clearly visible 4 Do not drive over large obstacles such a...

Page 58: ...these precautions when driving in reverse 1 Always check for obstacles or people behind the vehicle 2 Apply the throttle lightly Never apply the throttle suddenly 3 Back slowly 4 Apply the brakes lig...

Page 59: ...n serious injury Avoid parking on an incline If parking on an incline is unavoidable follow these precautions 1 Place the transmission in neutral 2 Set the parking brake 3 Stop the engine 4 Turn the f...

Page 60: ...ified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately ten 10 miles per hour Vehicles...

Page 61: ...services at whichever maintenance interval is reached first Perform these operations more often for vehicles subjected to severe use I means inspect clear adjust lubricate or change if needed C means...

Page 62: ...a qualified dealer perform these operations For safety we recommend that have a qualified dealer perform these operations Remark 1 If the Odometer indication is large please repeat this maintenance 2...

Page 63: ...ck and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 53 Oil may need to be changed more frequently if the recommended oil is not used Oil Recommen...

Page 64: ...ean cloth 3 Reinstall the dipstick completely 4 Remove the dipstick and check the oil level Tip A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moist...

Page 65: ...around the drain plug CAUTION Hot oil can cause burns to skin Do not allow hot oil to contact skin 4 Place a drain pan under the engine crankcase 5 Remove the drain Screw Allow the oil to drain compl...

Page 66: ...0 Reinstall the sealing washer on the drain plug 11 Reinstall the drain plug Add the recommended engine oil 12 Place the transmission in PARK Apply the brakes 13 Start the engine Allow it to idle for...

Page 67: ...fluid as needed 5 Reinstall the fill plug Fluid Change The drain plug is located on the bottom of the gearcase 1 Remove the fill plug 2 Place a drain pan under the drain plug 3 Remove the drain plug A...

Page 68: ...g 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 A hot exhaust system and engine can cause bur...

Page 69: ...ause the system to be out of balance creating vibration and additional loads on components The CVT syst em rotates at high speeds creating large amounts of force on clutch components Extensive enginee...

Page 70: ...l Set the parking brake 3 Start the engine Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds...

Page 71: ...Access the air box through left rear wheel well 1 Remove the air filter fixed card 1 and the cover 2 2 Loose screw 3 1 Fixed card 3 Remove the filter element of the air filter 4 2 Cover from the air b...

Page 72: ...y any oil or sediments in the air box 6 Reinstall the filter element and air box cover Secure the fixed card NOTICE Never operate the vehicle with the filter element removed Dirt will enter the engine...

Page 73: ...over you will see the coolant cap remove the cap add coolant to the maximum level mark install the reservoir cap Don t removing the radiator cap when the engine and radiator are still hot or you could...

Page 74: ...pipe 2 Add more coolant If only a little coolant needed fill up from the intake of radiator till it is full and then cap the radiator 3 Method of release the air If the engine is still overheat when t...

Page 75: ...n and out coolant pipe by hand make sure do not burn your hand if the temperature is close to the engine s and also the temperature of coolant in pipe is higher than coolant out pipe this means the ci...

Page 76: ...roblems 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 or misadjustme...

Page 77: ...pection 1 Place the transmission in neutral Set the parking brake 2 Start the engine Allow it to warm up thoroughly 3 Measure the distance the throttle pedal moves before the engine begins to pick up...

Page 78: ...ary trouble 2 Carburetor idling monsoonal adjustment vehicle engine performance according to differences and seasonal changes can be properly adjusted idle screw air fuel ratio The changes in the 1 2...

Page 79: ...nd all other conditions are favorable the carburetor can be adjusted 1 Place the transmission in neutral 2 Set the parking brake 3 Start the engine and allow it to warm up for approximately five minut...

Page 80: ...m operation including excessive pedal travel contact your dealer for proper diagnosis and repairs Operating the vehicle with a spongy brake pedal can result in loss of braking which could cause an acc...

Page 81: ...scopic meaning 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 sev...

Page 82: ...by an authorized dealer Shock Spring Adjustment The front and rear shock absorber springs are adjustable to increase or decrease spring tension Rotate the adjuster either clockwise or counterclockwis...

Page 83: ...ire pressure When replacing tires always use original equipment size and type Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less Front Wheel Hub Tightening Front wheel...

Page 84: ...ry the air box and replace the filter with a new filter Thor oughly dry the air filter See page 63 3 Remove the spark plugs 4 Loosen the carburetor drain screw 5 Turn the engine over several times 6 D...

Page 85: ...he sulfuric acid in battery electrolyte Batteries produce explosive gases So you should avoid contact with skin eyes or clothing Always shield eyes when working near batteries Keep out of reach of chi...

Page 86: ...own turn off the main switch and the switch of the circuit in question then install a new fuse of the specified amperage Turn on the main switch If the fuse immediately blows again consult your dealer...

Page 87: ...e the connections are correct when putting the battery back in the machine WARNING Do not use an improper fuse because an improper fuse can cause damage to the electrical system which could lead to a...

Page 88: ...come wet and slip in the clutches Always avoid spraying water directly toward the CVT inlet and outlet ducts when washing the vehicle from the rear High water pressure may damage components We recomme...

Page 89: ...Ground the spark plug wire and turn the engine over several times to coat the cylinder wall with oil 3 Block up the frame to raise all wheels off the ground 4 Tie a plastic bag over the exhaust pipe...

Page 90: ...of valve is not suitable plug is loose Starting motor is too slow Air circulation is not right Gap of valve is not suitable change change change Repair or change Tighten Check electric system Adjust...

Page 91: ...l 1 Mechanic problem Valve gap no suitable Valve base is not suitable Problem on air pipe Broken on bush of swing arms Fuel level of bobber cab is not right Jam on muzzle of carburetor Fuel pipe probl...

Page 92: ...Adjust or change Adjust or change Change Adjust the height of floater Clean or change Clean Change Exhaust blue smoke Mechanical fault too many lube Piston ring worn out Valve pipe worn out Cylinder w...

Page 93: ...nder worn out Piston Ring worn out Valve base not correct Swing arm or cam shaft worn out Change operation method Check remove or change Adjust Change Change Change or repair Change 1 Fuel system faul...

Page 94: ...m Block in water channel or radiator Air in Cooling system or coolant is not enough Water pump problem Unsuitable coolant Constant temperature unit problem Fault on motor of fan or switch of heat sens...

Page 95: ...crankshaft Change clutch Noise from Crankshaft Bearing noise Needle bearing damaged Gap too big Change Change Change Noise from CVT Belt loose or worn out Roller or main wheel damage Change Change No...

Page 96: ...ange Change Adjust Starting problem Blocked in muzzle Blocked in muzzle channel Leakage on connecting part of carburetor and starting part Starting pin not work properly Clean Clean Tighten Adjust or...

Page 97: ...alve worn out or damaged Spring on valve broken Floater not work well Dirt or scale in valve Change Change Adjust or change Clean Engine coolant temperature is lower Cooling System Fault on heat senso...

Page 98: ...f 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 changing rods bended High and L...

Page 99: ...ust load Adjust or Change Check or adjust Repair arrester Screw or Change suspension parts Tyre is abraded abnormally or greatly Steering organiza tion running system suspension Left and right absorbe...

Page 100: ...of redirector is too big Fixed bolts on each part of steering organization has been loosened Balance wheel or Change tyre Change or adjust Change Change Check adjust Change tyre or wheel hub Change t...

Page 101: ...e is leaning Brake system suspen sion Some brake drums and hoof pads have oil stain Individual brake branch pump leaks oil or is blocked The air pressure in right and left tyre is not even Front wheel...

Page 102: ...in pump Change Adjust Lubricate or Change Repair or Change Change Change V Malfunction in lamplight circuit and meter system Front headlight does not illuminate Lighting system Bulb has been damaged A...

Page 103: ...rter is bad Ignition switch has been damaged Repair or Change Change Repair Change All electric apparatuses do not work Circuit system Total fuse has been burned Ignition switch has been damaged Gener...

Page 104: ...96 Meter works badly Meter and wire Fuse has been burned Route has been cut off tie in contacts badly Instrument has been damaged Sensor has been damaged Change Repair route Change Change...

Page 105: ...ree operation WARRANTY COVERAGE LIMITATIONS OF WARRANTIES AND REMEDIES The limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cove...

Page 106: ...take it to a company Servicing Dealer When requesting warranty service you must present your related proof form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY C...

Page 107: ...ere your vehicle was purchased you should take your vehicle to an authorized Company dealer You must show the related proof Upon verification the servicing dealer will be authorized to perform the war...

Page 108: ...4 3in 830mm 32 7in Wheelbase 1760mm 69 3in 2450mm 96 5in Minimum ground clearance 210mm 8 3in Minimum turning radius 4200mm 165 4in 4900mm 192 9in Maximum speed 80 km h Basic weight Mass of whole equi...

Page 109: ...system Pressure spray Engine oil Type Recommended engine oil classification Quantity Without oil filter cartridge replacement 1 8L 1 90 US qt With oil filter cartridge replacement 1 9L 2 01 US qt Fina...

Page 110: ...change 0 28L 0 30 US qt Air filter dry element Fuel Type UNLEADED GASOLINE ONLY Fuel tank capacity 22 0 L 5 8Gal Fuel reserve amount about 4 L 1Gal Carburetor Type quantity vacuum film Manufacturer M...

Page 111: ...ansmission type V belt automatic Operation Right hand operation High gear 3 514 Low gear 5 857 Reverse gear 3 828 Chassis Frame type Steel tube frame Caster angle 4 Trail Tire Type Tubeless front 25 8...

Page 112: ...ear suspension Double wishbone Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber Coil spring oil damper Wheel travel Front wheel travel Rear wheel travel Electrical Igniti...

Page 113: ...1 High gear indicator light LED 1 Low gear indicator light LED 1 Reverse gear indicator light LED 1 Coolant temperature warning light LED 1 4WD Lock drive indicator light LED 1 Fuses Power fuse 30A B...

Page 114: ...106 MODEL 500UTV 500LUTV Low beam fuse 10A High beam fuse 10A Wiper fuse 15A Turning light fuse 5A Cigarett light fuse 15A MP3 fuse 5A Horn fuse 5A...

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Massimo 500LUTV, Owner'S Manual

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