SANMEN COUNTY YONGFU MACHINE UTV650 Maintenance Manual Download

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UTV650

Maintenance Manual

SANMEN COUNTY YONGFU MACHINE CO.,LTD

Any copy or without written permission

or authorization of Yongfu is prohibited to use

the manual (version 1, Oct 2017).

Summary of Contents for UTV650

Page 1: ...UTV650 Maintenance Manual SANMEN COUNTY YONGFU MACHINE CO LTD Any copy or without written permission or authorization of Yongfu is prohibited to use the manual version 1 Oct 2017 All rights reserved...

Page 2: ...show the basic principles of operation and work procedures They may not represent the actual vehicle exactly in detail Manufacturer reserves the right of no prior notice on product improvement or mod...

Page 3: ...ation shall be carried out at places with good ventilation 7 Battery may produce explosive hydrogen in charging Please ensure charging at places with good ventilation 8 Use legal parts lubricating oil...

Page 4: ...ening and flexible movement 23 Brake fluid and coolant may damage shell and plastic and rubber parts In case of being splashed by them please use water for washing 24 In installing pipeline please ins...

Page 5: ...40 SJ Oil quantity 3700ml Fuel Type Unleaded gasoline only 93 or higher Fuel pressure 350 kpa Fuel tank capacity 7 66 Gallons Valve clearance Intake 0 05 to 0 09mm Exhaust 0 10 to 0 15mm Diameter of...

Page 6: ...ing journal New 34 95 to 34 975mm Timing chain side 21 959 to 21 980mm Spark plug side Service limit 34 94mm Timing chain side 21 95mm Spark plug side Camshaft main bearing journal bore New 35 000 to...

Page 7: ...n opening Magneto generator output Crankshaft position sensor value of resistance Type Pressure Size Front Size Rear System Type Front Type Rear New disk thickness Minimum disk thickness Maximum disk...

Page 8: ...Battery Type Maintenance Free Voltage 12V capacity 30AH Fuses Lock fist shift 10A Fan 20A Light relay 30A Main relay 20A Lock second shift 10A Reserve power 15A Driving lamp 10A Head lamp Fog light T...

Page 9: ...0 7 1 Fastening nut of suspension arm M10 70 7 1 Bolt of rear shock absorber M12 80 8 2 Bolt of front shock absorber M10 80 8 2 Fastening nut of wheel rim M10 80 8 2 Nut of wheel hub M22 300 30 6 Bolt...

Page 10: ...in plug M12 20 2 0 Gearbox oil drain plug M12 20 2 0 Decompression valve plug M22 20 2 0 Cylinder head bolt M10 60 6 1 Cylinder head bolt M6 12 5 1 3 Connecting rod bolt M8 50 5 1 Timing chain wheel b...

Page 11: ...lls In case of complicated road conditions regular maintenance shall be carried for vehicles ITEM ROUTINE Whichever Comes first INTIAL EVERY month 1 3 6 6 12 Km mi 320 200 1 200 750 2 400 1 500 2 400...

Page 12: ...ce if damaged O O O O Front and rear Suspension Check operation and for leakage Correct if necessary O O Steering system Check operation and for looseness Replace if damage Check toe in Adjust if nece...

Page 13: ...EDULE If the air cleaner is clogged with dust intake resistance will be increased with a resultant decrease in power output and an increase in fuel consumption never remove or modify any component in...

Page 14: ...f necessary Valve clearance is to be checked when the engine is cold The intake and exhaust valves must be checked an adjusted when the piston is at TOP DEAD CENTER TDC on the compression stroke Remov...

Page 15: ...se Allen key to turn crankshaft 360 1 Printed marks on camshaft timing gear 2 Cylinder head base Insert the feeler gauge between the valve stem end and adjusting screw on the rocker arm to check the c...

Page 16: ...check the clearance If the valve clearance is out of specification adjust valves as follows Valve clearance Intake 0 05 to 0 09mm Exhaust 0 10 to 0 15mm Use mean valve of exhaust intake to ensure a pr...

Page 17: ...NGK Colder type DCPR9E NGK Hotter type DCPR7E NGK CAUTION THROTTLE CABLE PLAY Before starting the engine check the gas pedal to be sure it is operating correctly Make sure the gas pedal fully returns...

Page 18: ...el may be indicated 1 Ensure vehicle is on a level surface 2 Start engine and let idle for a few minutes 3 Stop engine Wait a few minutes to allow oil to flow down to crankcase then check oil level 4...

Page 19: ...ine drain plug area 8 Clean the drain plug area 9 Unscrew drain plug then remove dipstick 1 Drain plug 2 Gasket ring 10 Allow oil to drain completely from crankcase 11 Clean the magnetic drain plug fr...

Page 20: ...right seats gear shift handle 5 Remove engine shield FRONT DIFFERENTIAL OIL To change the front differential oil locate the vehicle on a level posion and carry out the following steps Clean the oil le...

Page 21: ...EM Check to see if any brake fluid is leaking out of the pipe joints or the brake fluid reservoir Apply the brakes firmly for one minute If there is any leakage have the vehicle inspected by an author...

Page 22: ...ll the parking brake lever up to engage the parking brake To release the unit press button on front end of parking lever then push the parking lever to the bottom The free play is 15 20mm the travel i...

Page 23: ...er Do not use tap water straight antifreeze or straight water in the system Tap water contains minerals and impurities which build up in the system During cold weather straight water causes the system...

Page 24: ...ARNING Coolant replacement Park vehicle at flat ground and check horizontal line of cooling liquid Remove the upper cover of engine hood Remove radiator cap and the radiator cap To avoid potential bur...

Page 25: ...e When engine has completely cooled down recheck coolant level in radiator and coolant tank Top up if necessary WHEELS Lift wheels up at horizontal position and ensure no load to each wheel Shake whee...

Page 26: ...designated torque and reasonable clearance of valve Standard cylinder pressure 0 9 1 2Mpa Too low cylinder pressure may cause the following Excessive wear to cylinder Wear to piston or piston ring Blo...

Page 27: ...should be within the following values Oil pressure 1250 RPM 6000 RPM Minimal 70 KPa 350 KPa Nominal 180 KPa 420 KPa Maximal 300 KPa 550 KPa Remove oil pressure gauge and adapter hose Installation oil...

Page 28: ...f fins is blocked or damaged Correct curved fins Use water and compressed air to clean soil If damaged area reaches 20 please replace radiator 3 Pump overhauling can be carried out before dismantling...

Page 29: ...ant leaks or air bubbles Inspection Check general condition of hoses and clamps tightness Check the leak indicator hole if there is oil or coolant NOTE Flowing coolant indicates a defective rotary sea...

Page 30: ...val procedure pay attention to the following details Install the thermostat cover then torque screws to 6N m Check coolant level in radiator and coolant tank and top up if necessary Do not forget to b...

Page 31: ...d Coolant tank support bolt and Overflow hose and clamp Tank Installation The installation is the reverse of the removal procedure RADIATOR FAN Radiator Fan Removal Remove radiator shroud Remove bolts...

Page 32: ...3 Cooling system 3 5 Radiator Fan Installation For the installation reverse the removal procedure...

Page 33: ...event leaking take care that the gasket is exactly in groove when you reinstall the water pump housing Tighten screws of water pump housing in a criss cross sequence WATER PUMP IMPELLER Impeller Remov...

Page 34: ...spilling Wipe off any fuel spillage in the engine compartment Do not allow fuel to spill on hot engine parts and or electrical connectors Never use a hose pincher on injection system high pressure hos...

Page 35: ...uel pump A slow pressure drop indicates leakage either from the fuel injector or from the fuel pressure regulator Check fuel injector and the fuel pressure regulator for leaks If it is not leaking the...

Page 36: ...following Install a new gasket Pay attention to pump orientation Tighten retaining screws as per illustrated sequence Install hose properly on OUT nipples and harness FUEL TANK Fuel tank draining Neve...

Page 37: ...FRONT PROPELLER SHAFT Removal Place vehicle on PARK position and select 4WD Remove left and right seats gear shift handle and engine shield Unscrew propeller shaft bolt on engine side Inspection Insp...

Page 38: ...f its grooves is aligned with a cotter pin hole Install a new cotter pin and the wheel cap Fold one pin of cotter pin over drive shaft end FRONT DRIVE SHAFT Removal Remove the appropriate wheel hub Re...

Page 39: ...t the end of drive shaft in differential and pull joint a little to make sure that the stop ring is locked in differential side gear groove Insert the other end of drive shaft in the knuckle and insta...

Page 40: ...emove the caliper from knuckle Pull the wheel hub to remove it Inspection Check wheel hub for cracks or other damages Check inner splines and wheel rim bolts for wear or other damages If any damage is...

Page 41: ...spect the gear case case cover bearing oil seals and dust seal for wear or damage If any damage or wear is found replace the oil seal or dust seal with a new one Check back lash and drag torque Check...

Page 42: ...the distance between the rim line and the wheel rim varies this indicates that the bead is not properly seated If this is so deflate the tire completely and unseat the tire bead on bosh sides Then co...

Page 43: ...movement If there are any abnormalities replace the tie rod end with a new one Inspect the tie rod end boot for wear or damage If any damage are found replace the tie rod end with a new one Tie rod in...

Page 44: ...nge of toe in Adjust nut of tie rod CAUTION A Af ft te er r a ad dj ju us st ti in ng g t to oe e i in n f fi is st t r ro ot ta at te e s st te ee er ri in ng g w wh he ee el l f fr ro om m c ce en n...

Page 45: ...s the same for the RH and LH sides unless otherwise noted During assembly or installation use the torque values and service products as in the torque table In order to prevent collapse of vehicle plea...

Page 46: ...hen reversing stroke at mid travel Seizing or binding conditions except at extreme end of either stroke A gurgling noise after completing one full compression and extension stroke Replace shock if any...

Page 47: ...s or distortion are found replace the suspension arm with a new one Move suspension arm from side to side There should be no noticeable loose Replace bushing if necessary Move suspension arm up and do...

Page 48: ...uckle from ball cage tie rod INSPECTION Shock absorber Inspect the shock absorber for oil leakage or damage inspect the bushing for wear or damage If any damage are found replace the rear shock absorb...

Page 49: ...here should be no noticeable loose Replace bushing if necessary Move suspension arm up and down There should be no noticeable loose Replace bushing if necessary Upper Suspension Arm Inspect the suspen...

Page 50: ...ntainers Never reuse brake fluid left over from the last servicing or which has been stored for a long periods of time When storing brake fluid seal the container completely and keep it away from chil...

Page 51: ...succession and hold the pedal fully squeezed Loosen the air bleeder valve for about quarter of a turn so that the brake fluid runs into the receptacle this will remove the tension of the brake pedal T...

Page 52: ...he brake disc for cracks or damage and measure the thickness using the micrometer If any damage are found or the thickness is less than the service limit replace the brake disc with a new one Minimum...

Page 53: ...r support and pad spring Place rag over piston Place caliper body with piston down and apply small squirts of air pressure to the fluid inlet to remove piston Remove piston seal Clean piston grooves c...

Page 54: ...on can restrict the proper flow of fluid and cause braking problems Check hoses for cracking scrapes This damage can cause hose failure under pressure When hoses are removed or disconnected cleanlines...

Page 55: ...king brake cable from pulley as follows Ensure parking brake is released Unscrew nut securing parking brake cable on parking brake support Remove cable from parking brake support Unhook cable from pul...

Page 56: ...age the parking brake To release the unit press button on front end of parking lever then push the parking lever to the bottom The free play is 15 20mm the travel is 7 teeth If necessary slacken the c...

Page 57: ...very high in turning of headlamp For replacement grease dirt will be splashed to glass in case of operation with bare hands or wearing dirty gloves As a result hot spots and glass deformation may be...

Page 58: ...tall multimeter 1 10 Resistance of generator coil 0 9 1 5 color yellow Insulation resistance yellow grounding wire No load performance of the generator Z Start the engine with the speed at 5000r min Z...

Page 59: ...not within the range of specified values replace the regulator rectifier NOTE If the probe is not connected and the multi meter reading is lower than 1 4V replace the multi meter battery Red Black Yel...

Page 60: ...LECTRICAL SYSTEM 9 4 Starting system Starter motor 1 Bracket 2 Brush holder 3 Brush spring 4 O Ring 5 Washer 6 Motor housing 7 Washer 8 Armature coil 9 Washer supporting tools 10 Inner bracket 11 O Ri...

Page 61: ...r or damage Replace Z If the rectifier is discolored grind it with sanding paper then wipe it with a clean fabric Z If there is concave scrape off insulator B so that the distance with A is d d 1 5mm...

Page 62: ...or damaging the relay coil Z Measure the coil resistance with the multimeter If the resistance exceeds the specified value replace the starter relay The multimeter is set to 1x10 Starter relay coil r...

Page 63: ...Probe Black yellow wire NOTE Z Make sure the battery voltage 12V The ignition coil wires are connected Z When using multi meter and the peak voltage adapter please refer to the user manual Z Move the...

Page 64: ...l spark plug cap Peak voltage of coupling coil Z Check the peak voltage of the coupling coil with following steps Z As shown in right figure connect the multi meter with the peak voltage adapter Probe...

Page 65: ...bubbles in cooling system Air in cooling system Refill and bleed cooling system refer to cooling system 3 Check temperature sensor for electrical mechanical failure Temperature sensor defective Repla...

Page 66: ...to technical specifications Crankcase is leaking due to loose screws Retighten screws with recommended torque Sealing rings O rings and or gaskets are brittle hard or damaged Replace damaged parts Pos...

Page 67: ...INDER AND HEAD Symptom UNUSUAL ENGINE NOISE AND OR VIBRATION 1 Check noise coming from cylinder head area Improper valve clearance adjustment Readjust valve clearance and or replace defective part s F...

Page 68: ...t one way clutch is worn Replace friction washer refer to CONTINUOUSLY VARBRIABLE TRANSMISSION CVT 4 Check transmission lever and connecting rod Ball joint and or ball joint nut is are loose Retighten...

Page 69: ...at the same time slider shoes kit 2 Check driven pulley sliding mechanism between driven pulley outer and inner sheave Mechanism is stuck and or damaged Replace driven pulley assembly 3 Check roller s...

Page 70: ...an air intake and or outlet from contamination Fans located on drive pulley is worn or damaged Replace 2 Check if pulley sheaves are clean Oil on pulley surfaces Clean pulley sheaves and replace belt...

Page 71: ...Readjust valve clearance 4 Internal engine problem Overhaul engine to find defective parts Refer to the appropriate section in ENGINE Symptom ENGINE HARD TO START 1 Check idle bypass valve Stuck or d...

Page 72: ...intake Broken valve spring damages the cylinder head valve s rocker arm s piston piston rings and connecting rod Replace defective part s 10 Check if fuel supply is sufficient Low fuel level Clogged f...

Page 73: ...cooling system shows any failure see COOLING SYSTEM System is leaking Repair and or replace damaged part s 2 Check function of lubrication system see LUBRICATION SYSTEM Lubrication is not working prop...

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