READ THIS MANUAL CAREFULLY! It contains important safety information. 500/600UTV 500L/600LUTV OWNER’S MANUAL 4×4 This UTV should not be ridden by anyone under 16 years of age.
INTRODUCTION Congratulations on your purchase of the 500/600UTV. With the purchase of this UTV, you can now appreciate the high degree of craftsmanship. This manual will provide you with a good basic understanding of the features and operation of this UTV. This manual includes important safety information. It provides information about special techniques and skills necessary to ride your UTV. It also includes basic maintenance and inspection procedures.
INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander or a person inspecting or repairing the machine.
IMPORTANT NOTICE This UTV is designed and manufactured for OFF-ROAD use only. It is illegal 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 manufacture. Please check your local riding laws and regulations before operating this UTV.
TABLE OF CONTENTS Introduction……………………………………………………………………………………1 SAFETY………………………………………………………………………………………3 Features and Controls…………………………………………………………………………21 Component Locations…………………………………………………………………………21 Indicator 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………………………………………………………………………………………
Throttle Pedal…………………………………………………………………………………34 OPERATION…………………………………………………………………………………35 Vehicle break-in period………………………………………………………………………35 Pre-ride inspection……………………………………………………………………………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 w
Driving through water…………………………………………………………………………48 Driving over obstacles…………………………………………………………………………49 Driving in 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 ………………………………………
Brakes…………………………………………………………………………………………73 Steering wheel inspection ……………………………………………………………………75 Shock spring adjustment ……………………………………………………………………75 Tires……………………………………………………………………………………………76 Vehicle immersion……………………………………………………………………………77 Battery…………………………………………………………………………………………78 Clearing and storage…………………………………………………………………………81 Malfuncation analysis and elimination ………………………………………………………83 WARRANTY………………………………………………………………………98 SPECIFICATIONS…………………………………………………………………………101 Circuit Diagram…………………………………
INTRODUCTION Failure to follow the warnings and safety precautions contained in this manual can result in severe injury or death. Your vehicle is not a toy and can be hazardous to operate. This vehicle handles differently than cars, trucks or other off-road vehicles. A collision or rollover can 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.
INTRODUCTION Identification number records Record 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 identification number is used to identify your machine.
SAFETY Equipment Modifications Your vehicle is designed to provide safe operation when used as directed. Modifications to your vehicle may negatively impact vehicle stability. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power. This vehicle may become less stable at speeds higher than those for which it is designed. Loss of control may occur at higher speeds.
SAFETY Safe Riding Gear Always wear appropriate clothing when riding this vehicle. Wear protective clothing for comfort and to reduce the chance of injury.
SAFETY Safe Riding Gear Helmet Wearing a helmet can prevent a severe head injury. Whenever riding this vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S. Department 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 helmet face shield.
SAFETY Safety Warnings Failure to operate this vehicle properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Be sure to read all of the following warnings about driving hazards and how to avoid them. These warnings are provided for your safety. Operating Without Instruction Operating this vehicle without proper instruction increases the risk of an accident.
SAFETY Safety Warnings Failure to Inspect Before Operating Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect the 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.
SAFETY Safety Warnings Protective Apparel Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of serious injury in the event of an accident. Operator and passenger must always wear an approved helmet that fits properly and eye protection (goggles or face shield). Seat Belts Riding in this vehicle without wearing 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.
SAFETY Safety Warnings Carrying a Passenger Never carry a passenger until you have operated this vehicle for at least four hours. Carrying Multiple Passengers Carrying more than one passenger in the 500/600UTV or carrying more than three passengers in the 500L/600LUTV can affect the operator’s ability to steer and operate the controls, which increases the risk of loss of control and accident or overturn. Never carry more than stipulate passenger in this vehicle.
SAFETY Safety Warnings Operating at Excessive Speeds Operating this vehicle at excessive speeds increases the operator's risk of losing control. Always operate at a speed that's appropriate for the terrain, the visibility and operating conditions, your skills and your passenger’s skills. Turning Improperly Turning improperly could cause loss of traction, loss of control, accident or overturn. Never turn abruptly or at sharp angles. Never turn at high speeds.
SAFETY Safety Warnings Jumps and Stunts Exhibition driving increases the risk of an accident or overturn. DO NOT do power slides, “donuts”, jumps or other driving stunts. Avoid exhibition driving. Driving Downhill Improperly Driving down a hill improperly could cause loss of control or overturn. Always 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 in neutral.
SAFETY Safety Warnings Improper Hill Climbing Improper hill climbing could cause loss of control or overturn. Use extreme caution when operating on hills. Always follow proper procedures for hill climbing as described in the owner's manual. Stalling While Climbing a Hill Stalling or rolling backwards while 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.
SAFETY Safety Warnings Operating in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn. Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn. Travel slowly and use extra caution when operating on unfamiliar terrain. Always be alert to changing terrain conditions.
SAFETY Safety Warnings Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures as outlined in this manual. Before shifting into reverse gear, always check for obstacles or people behind the vehicle. When it's safe to proceed, back slowly. Operating Over Obstacles Improperly operating over obstacles could cause loss of control or overturn. Before operating in a new area, check for obstacles.
SAFETY Safety Warnings Operating Through Water Operating through deep or fast-flowing water can cause loss of traction, loss of control, overturn or accident. Never operate in fast-flowing water or in water that exceeds the floor level. Always follow 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 driving slowly. The friction will help dry out the pads.
SAFETY Safety Warnings Operating a Damaged Vehicle Operating a damaged vehicle can result in an accident with serious injury or death. After any overturn 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 Operating on frozen bodies of water can result in the vehicle and/or riders falling through the ice. Never operate this vehicle on a frozen body of water.
SAFETY Safety Warnings Handling Gasoline Gasoline is highly flammable and is explosive under certain conditions. Always exercise extreme caution whenever handling gasoline. ● Never allow a child to refuel or handle gasoline. ● Always stop the engine when refueling. ● Always refuel outdoors or in a well ventilated area. ● Do not smoke or allow open flames or sparks in or near the refueling area or where gasoline is stored. ● Never refuel while a person is in the vehicle. ● Do not over fill the tank.
SAFETY Safety Warnings Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle. Hot components can cause burns and fire. Do not touches hot exhaust system components. Always keep combustible materials away from the exhaust system. Use caution when traveling through tall grass, especially dry grass. Always inspect the underside of the vehicle and areas near the exhaust system after driving through tall grass, weeds, brush and other tall ground cover.
SAFETY Safety Labels and Locations Warning Label WARNING Improper vehicle use can result in SEVERE INJURY or DEATH NEVER allow vehicle to be operated: ● Without all occupants first viewing and understanding safety warning labels. ● With more than stipulate passenger. ● On hills steeper than 15 degrees. ● On paved surfaces - pavement may seriously affect handling and control. ● With non-approved accessories, they may seriously affect stability.
SAFETY Safety Labels and Locations Warning Label WARNING Operation of this vehicle by children age 16 and under increases the risk of severe injury or death. NEVER permit children age 16 and under to operate or ride in this vehicle. WARNING VEHICLE OVERTURN could cause severe injury or death. The cab frame is not designed or intended to provide rollover protection. TIRE PRESSURE IN PSI (KPa): Front: 21±1(145±6.9) Rear: 28±1(193±6.9) LOADING CAPACITY：660 lbs.
FEATURES AND CONTROLS Component Locations 21
FEATURES AND CONTROLS Component Locations 22
FEATURES AND CONTROLS Indicator and warning lights 1、Thermometer 2.3.、Turning Indicators 4、Fuel indicator 5、High beam 6、odometer 7、Speed indicator 8、2 and 4 wheel drive. 9. Brake liquid warning light. 10. Reverse over speed alarm light 11.Parking brake light 12.engine oil warning light 13.Engine trouble light 14. Battery conditional warming light 15. Tachometer (ａ)Speedometer 7：Display the speed of vehicle. (ｂ) Odometer 6 ：Display the accumulated driving distance.
FEATURES AND CONTROLS （ｄ）.Turning Indicators 2, 3 ：Blink when the relative direction indicators light. Blink in same times when warning light is on. （ｅ）.Fuel meter 4 ：Display the quantity of fuel. （ｆ）.Gear display：The corresponding indicating (L, H, N, R) will be displayed when the gear changed. （g）.Thermometer 1：Display the temperature of engine coolant.. （h）. 2WD/4WD transfer and differential lock display 8: When single axle indicator lights, it is only the rear axle is in driving.
FEATURES AND CONTROLS Main switch of lights down“ ”, headlight(low beam), meter light and tail light is on. (c). When ignition switch is at “ON”, “ACC”or“ON”position, press down“ (d). When ignition switch is at “ACC” or “ON” position, press down“ indicator lights. 25 ”, alarm light blinks.
FEATURES AND CONTROLS Dump Bed and winch When need to dump, firstly, open the rear door of cargo box, then press main switch to“ON” position, and press “DUMP” to “UP”, cargo box will be up backwards; And stop after releasing the press; While press “DUMP”to” DOWN”, the cargo box will be back. And 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.
FEATURES AND CONTROLS 4×2、4×4WD and differential locking exchangeable When select “4X2”, it is rear wheel drive mode (this is the normal driving mode). When select “4X4”, the front and rear wheels will be drove at same times( normally, this drive mode will be used on muddy and rugged road. When select “4X4 lock” mode, it is 4 wheel drive mode and also the front differential locked (this drive mode only used on very rough road or when the car got stuck). Warning: 1.
FEATURES AND CONTROLS The Other Switch Cigarette light The cigarette light installed on the vehicle. The socket also can be used for phone charging and external power supply. Note: The voltage of the socket is 12V, DC. sure the voltage matches your electro-set’s. Please make 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 the second step, the wiping speed is high.
FEATURES AND CONTROLS The Other Switch CHOKE When start the vehicle in cold weather, pull out the “CHOKE SWITCH” a little bit. Push it back after the engine started. Note: Once the engine started, push the SWITCH back in time. Never leave the SWITCH out when driving. Or it might reduce the power and increase more fuel consumption and pollution. REVERSE OVER SPEED BUTTON The engine has the speed limit for the safety when gear is on “R” and/or differential lock.
FEATURES AND CONTROLS Seats Driver’s Seat Adjustment If you want to adjust the backrest of the seat forward or rearward, rotate the 1 which locates at the inneredge of the seat in clockwise or anticlockwise direction . Seat Belts This vehicle is equipped with three-point lap seat belts for the operator and passenger. Always make sure the seat belts are secured for both the operator and passenger before riding. To wear the seat belt properly, follow this procedure: 1.
FEATURES AND CONTROLS 2. Push the red release latch in the middle of the buckle to make sure it releases freely. 3. Inspect the full length for any damage, including cuts, wear, fraying or stiffness. If any damage is found, or if the seat belt 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 use bleach, dye or household detergents.
FEATURES AND CONTROLS Ignition Switch Ignition switch has four positions： “OFF”（close）position：All circuits are turnoff except emergency light, electric fan and cigarette lighter. “ACC” position: lights, MP3, horn, 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 circuit, and start engine. Handle returns to “ON” position automatically after engine starts.
FEATURES AND CONTROLS Gear Selector L: Low gear H: High gear N: Neutral R: Reverse The gear selector is located between the seats. To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear. Do not attempt to shift gears with engine speed above idle or while the vehicle is moving. Tip: Maintaining shift linkage adjustment is important to assure proper transmission function. See your dealer if you experience any shifting problems.
FEATURES AND CONTROLS Tip: Always set the parking brake whenever the vehicle is left unattended. Operating the vehicle while the parking brake is engaged could cause an accident resulting in serious injury or death. It could also result in driveline or engine damage. Always be sure to disengage the parking brake before operating the vehicle. Brake Pedal Depress the brake pedal to slow or stop the vehicle. Apply the brakes while starting the engine.
OPERATION Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual. Vehicle Break-in Period The break-in period for your new vehicle is defined as the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as a proper break-in period.
OPERATION Vehicle Break-in Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. Always exercise extreme caution whenever handling gasoline. Never allow a child to handle gasoline. 2. Check the oil level. See page 56. Add the recommended oil as needed to maintain the oil level in the safe operating range. 3. Complete the New Operator Driving Procedures outlined on pages41-42. 4. Avoid aggressive use of the brakes. See Brake System Break-in below. 5. Vary throttle positions.
OPERATION Pre-Ride Inspection Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition.
OPERATION Safe Operation Practices 1. Complete the New Operator Driving Procedures outlined on pages41-42. 2. Do not ride at night or when visibility is poor (rain, fog, dusk). Your vehicle doesn't have lights that are designed for driving in these conditions. 3. Engine exhaust fumes are poisonous. Never start the engine or let it run in an enclosed area. Never allow a child to handle gasoline. 4. Never install accessories not approved by our company for use on this vehicle. 5.
OPERATION Starting the Engine 1. Sit in the driver's seat and fasten the seat belt. 2. Place the transmission in neutral. Set the parking brake. 3. Apply the brakes. 4. Do not press the throttle pedal while starting the engine. 5. Turn the ignition key to the “ST” position. Engage the starter for a maximum of five seconds. Release the key when the engine starts. NOTICE: Operating the vehicle immediately after starting could cause engine damage.
OPERATION Stopping the Engine 1. Release the throttle pedal completely and brake to a complete stop. 2. Place the transmission in neutral. 3. Set the parking brake. 4. Stop the engine. 5. Turn the fuel valve off. Braking 1. Release the throttle pedal completely. (When the throttle pedal is released completely and engine speed slows to near idle, the vehicle has no engine braking.) 2. Press on the brake pedal evenly and firmly.
OPERATION New Operator Driving Procedures 1. Read and understand the owner's manual and all warning and instruction labels before operating this vehicle. 2. Review the section of this owner’s manual about starting the engine, stopping the engine, braking and parking (pages39-40). 3. Perform the 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.
OPERATION 13. Check your surroundings. Make sure the area is clear of people and obstacles. 14. Keeping both hands on the steering wheel, slowly release the brakes and press the throttle with your right foot to begin driving. 15. Drive slowly at first. Practice starting, stopping, turning, using the throttle and brakes and driving in reverse. 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.
OPERATION Driving with a Passenger 1. Complete the New Operator Driving Procedures outlined on Pages 41-42. 2. Perform the pre-ride inspection. See page 37. 3. Do not carry a passenger until you have at least four hours 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 secured, put both feet on the floor and grasp the hand holds. 5.
OPERATION 7. Make sure the passenger is wearing appropriate riding gear, including an approved helmet and eye protection. See page 5. 8. Make sure the passenger secures the seat belt. 9. Tell your passenger to always keep hands and feet inside the vehicle at all times. 10. Drive slowly. Vehicle handling may change with a passenger on board. Always travel at a speed appropriate for your skills, your passenger's skills, and operating conditions.
OPERATION Follow these precautions when driving in 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 direction of the skid. Never apply the brakes during a skid.
OPERATION Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always check the terrain carefully before ascending a hill. 2. Avoid steep hills (15° maximum). 3. Drive straight uphill. 4. Never climb hills with excessively slippery or loose surfaces. 5. Drive 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.
OPERATION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Driving on a sidehill improperly cause loss of control or overturn. If crossing a hill is unavoidable, follow these precautions: 1. Drive slowly and use extreme caution. 2. If the vehicle begins to overturn, or if it feels as if it may overturn, immediately turn downhill. 3. Avoid obstacles and changes in terrain that may lower or raise one side of the vehicle or cause the vehicle to slide. 4.
OPERATION Driving Through Water Your vehicle can drive through shallow water. Make sure the water is no deeper than the floor of the vehicle. Follow these precautions when driving through water: 1. Check water depth. Never drive through water that is deeper than the floor level. 2. After driving through water, test the brakes. Apply them lightly several times while driving slowly. The friction will help dry out the pads.
OPERATION Driving Over Obstacles Follow these precautions when driving over obstacles: 1. Always check for obstacles before driving in a new area. 2. Look ahead and watch the terrain. Always be alert for hazards 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 as rocks and fallen trees. If it’s unavoidable, use extreme caution and drive slowly. 5.
OPERATION Driving in Reverse Follow 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 lightly for stopping. 5.
OPERATION Parking on an Incline A rolling vehicle can result in 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 fuel valve off. 5. Always block the rear wheels on the downhill side.
MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine parts available from your dealer. Service and adjustments are important for proper vehicle operation.
MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first. Maintenance Interval (whichever comes first) Item Ⅱ Ⅰ Hours Calendar Miles(Km) Steering － Daily － Tires － Daily － － Daily － － Daily － Brake fluid level Brake system Remarks Check each day before driving the vehicle. Make adjustments as needed. See the Pre-Ride Checklist on page37.
MAINTENANCE Periodic Maintenance Chart Maintenance Interval (whichever comes first) Item Hours Calendar Remarks Miles(Km) Ⅰ Rear Suspension 50H 6M 500 (800) Ⅰ Spark plug 100 12M 600 (1000) Inspect; replace as needed Ⅱ Front wheel bearings 100 H 12M － Inspect; replace as needed 50H 6M 500 (800) Shift Linkage Battery Ⅱ Ⅱ Ⅰ 25 Monthly 250 (400) Lubricate Inspect, lubricate, adjust Check terminals; clean; test Toe adjustment － Inspect periodically; adjust when parts are replace
MAINTENANCE 3.If you vehicle often operate on rough terrain ,you must maintenance to maintain your vehicle’s performance. 4.Change every two years , have a qualified dealer perform these operations. Engine Oil Always check 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.
MAINTENANCE Engine Oil Oil Check Maintain the oil level within the safe range on the dipstick. Do not overfill. 1. Position the vehicle on a level surface. 2. Remove the dipstick. Wipe it dry with a clean 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 moisture collecting in the crankcase. If the oil level is over the full/safe mark, change the oil immediately.
MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 53 .Always change the oil filter wheneven changing oil. The engine drain plug is located on the bottom of the crankcase. 1. Position the vehicle on a level surface. Set the parking brake. 2. Start the engine. Allow it to idle for two to three minutes, Stop the engine. 3. Clean the area around the drain plug. CAUTION: Hot oil can cause burns to skin.
MAINTENANCE Engine Oil Oil and Filter Change 9. Install the new oil filter cartridge with an oil filter wrench ,and then tighten it to the specifiec torque with a torque wrench .Oil filter cartridge tightening torque:17N·m (17m·kgf,12ft·lbf). 10. 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 one to two minutes. 14. Stop the engine.Inspect for leaks. 15.
MAINTENANCE Transmission (Main Gearcase) Fluid Check The fill plug is located on the rear of the gearcase. Access the fill plug through the left rear wheel well. Maintain the fluid level at the bottom of the fill plug hole. 1. Position the vehicle on a level surface. 2. Remove the fill plug. 3. Check the fluid level. 4. Add the recommended 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.
MAINTENANCE Spark Plugs Spark Plug Gap/Torque Plug Tightening Torque Electrode Gap 0.8-0.9 mm 12.5 ft. lbs. (17.5 Nm) NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use our company recommended spark plugs. Spark plug condition is indicative of engine operation. The spark plug firing 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.
MAINTENANCE Constant Variable Transmission (CVT) System WARNING Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the CVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The CVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components.
MAINTENANCE CVT Drying There may be some instances when water is accidently ingested into the CVT system. Use the following instructions to dry it out before operating. The drain plug is located on the bottom of the CVT cover. 1. Remove the drain plug. Allow the water to drain. Reinstall the drain plug. 2. Shift the transmission to neutral. 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.
MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. 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. 3.Remove the filter element of the air filter 4 from the air box 4.Wash the filter element in warm soapy water, then rinse and let dry. If the filter element is damaged, install a new filter. 1. Fixed card 2. Cover 3.Screw 4.
MAINTENANCE Filter Systems Air Filter 5. Clean away 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, causing rapid wear and severe damage to the engine.
MAINTENANCE Cooling system 1.Place the vehicle on a level surface. 2.Check the coolant level in the coolant reservoir when the engine is cold as the coolant level will vary with engine temperature. 3.If the coolant is at or below the minimum level mark, open the cover 1 which locates on the engine cover ,you will see the coolant cap , remove the cap, add coolant to the maximum level mark, install the reservoir cap. NOTE: The coolant should be between the minimum and maximum level marks.
MAINTENANCE Cooling system Correctly fill up the coolant and release the air inside: 1. Under the situation of whole empty As showed in the picture, pull out the small circulating pipe on the temperature adjusting set. Full up the coolant from the intake of radiator. Connect back the pipe when coolant overflew. Continue filling up untill the coolant is full. Cap the radiator, Tighten the hoop of the pipe. 2.Add more coolant.
MAINTENANCE Cooling system The trobleshooting method of coolant circulation: Touch the in 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 circulation is ok. If the temperature is cold there, this means the circulation is not working.
MAINTENANCE Throttle System WARNING Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation. Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal. Immediately contact your dealer for service if throttle problems arise. Always check the pedal for free movement and return before starting the engine and occasionally during operation.
MAINTENANCE Throttle System Throttle Freeplay Inspection 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 speed. Freeplay should be 1/16 to 1/8 inches (1.5-3 mm).
MAINTENANCE Carburetor Common sense: Install the carburetor, the carburetor must ensure that engine to connect with sealing flange department, in order to avoid leakage, resulting in engine starts hard, no idling or idling unstable failure. 1. Carburetor Idle Adjustment: carburetor factory has been idle mixture screw fine adjustment, the general initial use, the user without the need for any adjustments, so as to avoid unnecessary trouble. 2.
MAINTENANCE Carburetor Carburetor/Engine Idle RPM Adjustment If the engine idle speed is not satisfactory, and 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 minutes. 4. Turn the carburetor idle screw in (clockwise) to raise RPM. Turn the screw out (counterclockwise) to lower RPM.
MAINTENANCE Throttle body Connect air filer and engine, control the throttle switch angle of valve through throttle cable, Corner from the throttle position sensor signals to ECU. NOTE: The idle speed limit screw does not allow the adjustment, the engine idle speed depend on the EFI system adjustment completely, does not hand adjust the idle speed limit screw.
MAINTENANCE Brakes Always check brake pedal travel and the brake fluid reservoir level before each use of the vehicle. When applied, the brake pedal should feel firm. Any sponginess would indicate a possible fluid leak or low brake fluid level, which must be corrected before riding. See page 74 for brake fluid information. If you discover any irregularities in brake system operation, including excessive pedal travel, contact your dealer for proper diagnosis and repairs.
MAINTENANCE Brakes Brake Fluid Inspect the level of the brake fluid before each operation. If the Alarm light 9 is on add DOT 3 or DOT 4 brake fluid. After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, 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 severe injury.
MAINTENANCE Steering Wheel Inspection 1. Position the vehicle on level ground. 2. Lightly turn the steering wheel left and right. 3. There should be 0.8"-1.0" (20-25 mm) of freeplay. 4. If there is excessive freeplay or strange noises, or the steering feels rough or catchy, have the steering system inspected by an authorized dealer. Shock Spring Adjustment The front and rear shock absorber springs are adjustable to increase or decrease spring tension.
MAINTENANCE Tires Operating your vehicle with worn tires will increase the possibility of skidding, loss of control and an accident, which could result in serious injury or death. Always replace tires when the tread depth measures 1/8" (3 mm) or less. Improper tire inflation or the use of non-standard size or type of tires may adversely affect vehicle handling, which could result in vehicle damage or personal injury. Always maintain proper tire pressure.
MAINTENANCE Vehicle Immersion NOTICE: If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it's impossible to take your vehicle to a dealer before starting it, follow the steps outlined below. 1. Move the vehicle to dry land. 2. Check the air box. If water is present, dry the air box and replace the filter with a new filter. Thoroughly dry the air filter. See page 63. 3.
MAINTENANCE Battery This machine is equipped with a sealed-type battery. Therefore it is not necessary to check the electrolyte or add distilled water in the battery. If the battery seems to have discharged, consult your dealer. It is locate under the passenger seat. CAUTION: Do not try to remove the sealing caps of the battery cells. You may damage the battery. Failure to handle batteries or battery electrolyte carefully.
MAINTENANCE Battery CAUTION:A special battery charger (constant voltage/ampere or constant voltage) is required for recharging a sealed type battery. using a conventional battery charger may shorten the battery life. Fuse replacement 1.The fuses are under the meter cover. 2. If a fuse is blown, 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.
MAINTENANCE Battery 1. When the machine is not used for a month or longer, removes the battery and stores it in a cool, dark place. Completely recharge the battery before reinstallation. 2. Always make sure 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 fire. Always use a fuse of the specified rating. Never use a material in place of the proper fuse.
MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your vehicle clean will not only improve its appearance but it can also extend the life of various components. Before washing the vehicle, locate the CVT inlet and outlet duct. The inlet duct is located under the passenger seat and the outlet duct is located at the right side of the vehicle. Avoid spraying water directly toward the ducts when washing the vehicle from the rear.
MAINTENANCE Cleaning and Storage Storage Long term storage (60 days or more) of your machine will require some preventive procedures to guard against deterioration. After thoroughly cleaning the machine, prepare for storage as follows: 1. Drain the fuel system. 2. Remove the spark plug, pour about one tablespoon of SAE 10W30 or 20W40 motor oil in the spark plug hole and reinstall the spark plug. Ground the spark plug wire and turn the engine over several times to coat the cylinder wall with oil. 3.
Malfunction analysis and elimination （I）Engine malfunction Malfunction Malfunction phenomenon system Start 1. pressure in difficultly or cylinder is too could not start low. 2. No ignition generated from plug Reason Solving method ① Cylinder wear out ② Piston wear out. ③ Leakage on Washer of cylinder. ④ Wearing on Pipe of air valve or seat of valve is not suitable. ⑤ plug is loose. ⑥ Starting motor is too slow. ⑦ Air circulation is not right. ⑧ Gap of valve is not suitable.
Start difficultly or could not start 3. No fuel in carburetor 4. No fuel in Throttle body Engine has no idle speed or uneven 5.Miscellaneous 1. Mechanic problem ① Vent hole on tank jammed ② Problem or blocked in fuel pipe.
2. Electric problem Engine middle and high rotate speed is uneven Mechanical problem parts exhaust pipe. ⑥Fuel level of bobber cab is not right ⑥ Jam on muzzle of carburetor ⑦ Adjust screw of idle sets wrong. ① Dirt on plug ② Gap of plug not correct ③ Ignition loop problem ④ CDI problem ⑤ Magneto problem ① The force of Valve spring is weak. ② Cam axle worn out ③ Plug is dirty. ④ Gap of plug is too small. ⑤ Air circulation is not right. ⑥ Ignition loop problem ⑦ Floater of carburetor is too lower.
Exhaust blue smoke Mechanical fault 1. Fuel supply system fault Engine power is not enough 2. Electrical parts problem 3.
1. Fuel system fault Engine overheats 2. Electric System problem 3. Air pass problem 4. Engine cooling system weak. ③ Air circulation is not right.
5.
Noise Crankshaft from Noise from CVT Noise from transmission system Gasoline engine lacks power and accelerating Clutch skiding 1.
Carburetor works not properly Idle and low speed not stable Not stable in high and middle speed Spill over or fuel level fluctuated ② Blocked in muzzle channel ③Leakage on connecting part of carburetor and starting part ④ Starting pin not work properly ① Reducer valve blocked or loose ② Valve channel Blocked ③ Air inlet channel blocked ④ Air inlet bypass Blocked ⑤ Starting pin not closed completely ⑥ Idle screw not suitable ⑦ Height of floater not correct ① Muzzle blocked ② Main air channel blocked ③ Nee
Engine coolant temperature is lower Spark weak Cooling System Ignition System ① Fault on heat sensor switch on fan ② Cold weather ③ problem on constant temperature meter ① Fault on starter ② problem on spark plug ③ Magneto problem ④ Voltage of battery is weak ⑤ Ignition loop problem ⑥ Starting loop problem Change Cover the radiator Change Change Change Change Change Change Change （II）Malfunction in transmission system Vehicle speed does not increase by engine speed Transmission system Out of gear Ge
bended ③High and Low driven gear groove wear to taper ④Speed changing principal and countershaft worn out ⑤Sector gear tooth worn out ⑥The force of spring of sector gear is weak or broken.
abnormally or greatly Front wheel shakes, swing or jump tion, running system, suspension ②Tyre is not balance, and wheel hub is distorted ③Front wheel location is wrong ④Vehicle is over-load ⑤Tyre has not change its position ⑥Wheel hub bearing has been damaged or adjustment is wrong ⑦Wheel assembly jump (axial, radial) is too great ⑧Air pressure in tyre is too hig or too low Steering organization, running system ①Tyre and wheel is not balance ②Wheel hub bearing has been damaged or adjustment is wrong ③
Steering is heavy Steering organization running system ⑦Tyre has tympanic bag ⑧Free travel of redirector is too big ⑨Fixed bolts on each part of steering organization has been loosened Change tyre Change or adjust Fasten ①Air pressure in tyre is short Charge the tyre to applicable air pressure Change ②Ball head of left and right swing arm and drag pole is blocked ③Front wheel location is wrong ④Steering pole pipe is blocked ⑤Mesh clearance of redirector is too small （IV）Malfunction in brake system Br
Brake is leaning Brake block Brake system suspen -sion clip ①Some brake drums and hoof pads have oil stain ②Individual brake branch pump leaks oil or is blocked ③The air pressure in right and left tyre is not even ④Front wheel adjustment is wrong ⑤Vehicle frame is distorted, and left and right wheelbase is different ⑥Some brake pipelines is not smooth ⑦Individual brake drum and brake hoop contacts badly ⑧Suspension parts loose ⑨Vehicle is leaning ⑩Thread abrasion of left and right wheel is different Br
headlight does not illuminate Only one front headlight does not illuminate Steering light does not illuminate Starter does not rotate when starting system Lighting system ②Adjuster has been damaged(adjusting voltage is too high to burn bulb） ③Fuse has been burned ④Headlight relay has been damaged ⑤Lead or grounding happens malfunction ⑥Combination switch has been damaged ⑦Storage cell has been damaged(incur bulb is burned) Change adjuster Check、Change Change Repair circuit Repair、Change Change ①Bulb h
All electric apparatuses do not work Circuit system Some kind of lamplight is bad or complete lamplights are damaged (not including headlight) Lamplight 、circuit Meter works badly Meter and wire ④Ignition switch has been damaged ①Total fuse has been burned ②Ignition switch has been damaged ③General wire or grounding wire has been cut off ④Electric bottle contacts badly or happens oxygenation ①Switch has been damaged ②Bulb has been burned ③Circuit has been cut off, linking parts contact badly ④Fuse has
WARRANTY LIMITED WARRANTY Company gives a SIX MONTH LIMITED WARRANTY on all components of your vehicle against defects in material or workmanship. This warranty is transferable to another consumer during the warranty period through a company dealer. REGISTRATION At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to company within ten days. Upon receipt of this registration, Company will record the registration for warranty.
WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. COMPANY FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you if inconsistent with controlling state law.
WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES In the Country where your vehicle was purchased: Warranty or Service Bulletin repairs must be done by an authorized Company dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Company dealer who sells the same line as your vehicle.
SPECIFICATIONS MODEL 500/600UTV 500L/600LUTV Dimensions: Overall length 2600 mm (102.4in) 3200 mm(126in) Overall width 1280mm (50.4in) 1300mm(51.2in) Overall height 1960mm (77.2in) 1880mm(74.0in) Seat height 870mm Wheelbase 1760mm （69.3in） Minimum ground clearance 210mm Minimum turning radius 4200mm Maximum speed 80 km/h (34.3in) 830mm(32.7in) 2440mm(96.0in) （8.3in） (165.4in) 4900mm(192.
MODEL Starting system Lubrication system 500/600UTV 500L/600LUTV Electric 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.
MODEL Periodic oil change 500/600UTV 500L/600LUTV 0.25L(0.26 US qt) Front gear case oil: Type SAE15W-40/SF or SAE 80W-90/GL-4 Quantity: Periodic oil change Air filter: 0.28L(0.30 US qt) 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 Manufacturer Vacuum Film MIKUNI EFI System : Type/quantity MSE 3.
MODEL 500/600UTV Spark plug gap 0.8-0.9 mm (0.032–0.035 in) Clutch type: wet, hoof centrifugal type Transmission: Primary reduction system V-belt Secondary reduction system Shaft drive Transmission 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 Size Tubeless front 25×8.00-12 rear 25×10.
MODEL 500/600UTV 500L/600LUTV Brake: Front brake Rear brake type Dual disc brake operation Left foot operation type operation Dual disc brake Left foot operation Suspension: Front suspension McPherson independent suspension Rear suspension Double swing arm independent suspension, two shock absorbers on each side Shock absorber: Front shock absorber Coil spring / oil damper Rear shock absorber Coil spring / oil damper Electrical: Ignition system DC. C.D.I./ECU Generator system A.C.
MODEL 500/600UTV Headlight 12 V 35 W/35.0 W × 2 Tail/brake light 12 V 5 W/21.
MODEL 500/600UTV 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 107 500L/600LUTV
