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UTV500CC User’s Manual www.UTVsFactory.com

1. Fuel supply system
fault

①

Jam in muzzle of carburetor

②

Level of Floater not correct

③

Air filter is dirty

④

Leakage on air intake pipe

⑤

Too many lube

Clean or change

Adjust the height

Clean or change

Tighten or change

Drain the extra lube

2. Electrical parts
problem

①

Dirt on plug

②

Gap of plug not correct

③

Ignition loop problem

④

CDI problem

⑤

Magneto problem

Clean or Change

Change or Adjust

Change

Engine power
is not enough

3.Mechanical
problem

Gap of Valve is not correct

The force of valve spring is

weak.

③

Air circulation is not right.

④

Cylinder worn out

⑤

Piston Ring worn out

⑥

Valve base not correct

⑦

Swing arm or cam shaft

worn out

Change operation
method

Check, remove or
change

Adjust

Change

Change or repair

Change

Содержание UTV500CC

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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