UTV500CC User’s Manual www.UTVsFactory.com 500CC Utility Vehicle User Manual Vision 2007-1.
UTV500CC User’s Manual www.UTVsFactory.
UTV500CC User’s Manual www.UTVsFactory.com I、 、Notes 1. Please read this operating instruction carefully before using this vehicle, and drive, check and repair it by the requirement in this manual to keep vehicle at good technical status and prolong its using lifetime. 2. Initial running for 1000km of vehicle is period. In this period, it is necessary to accord with the regulation of period(see the chapter—for new vehicle). After period expires, it is necessary to make vehicle maintenance by regulation.
UTV500CC User’s Manual www.UTVsFactory.com as: noise, vibration, heat and so on. (10) Damages caused by that you do not check and maintain vehicle periodically by our requirements.
UTV500CC User’s Manual www.UTVsFactory.com Engine displacement: 493 Compressed ratio： 10.2：1 Maximal power (kw/r/min)： 24/6500 (EEC model less than 15kw) Maximal torque(N·m/r/min)： 38.8/5500 (EEC model: 30N.M/4500r/min) Lowest fuel consuming rate (g/Kw·h)： 340 Idling speed (r/min)： 1300±100% Start type： electronic start Ignition type： non-touch CDI DC start Plug type: DPR7EA-9(NGK) Magneto type: ever-mag DC motor, ex-rotor flywheel type.
UTV500CC User’s Manual www.UTVsFactory.com 2. Main Driver： Main driver： Tapered arc gear transmission，transmission rate： 33/9 3. Driving type： 4×4 front and rear wheels drive; Rear wheel is the normal drive. Front wheel can be took off the driving. They are all the shaft transmission。 4. Suspension： Front suspension： swing arm type independent suspension. Rear suspension： co-length double swing arm independent suspension, two shock absorbers on each side of rear wheel. 5.
UTV500CC User’s Manual www.UTVsFactory.com 4.
UTV500CC User’s Manual www.UTVsFactory.
UTV500CC User’s Manual www.UTVsFactory.com 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、Reinforce pole.
UTV500CC User’s Manual www.UTVsFactory.
UTV500CC User’s Manual www.UTVsFactory.com Warning：Engine oil quantity should be between upper and lower position, over more or less oil would burn out or damage engine.. Oil drain plug（bottom of engine） Warning： Oil drain plugs of engine and gear box should be tightened， ，otherwise engine would burned for oil leakage. Should use the correct gear box oil and quantity. More or less oil can cause the gear box burned out..
UTV500CC User’s Manual www.UTVsFactory.com Rear main speed reducer lube-check lube-check Front main speed reducer Warning：Fill up the stipulated lube in main reducer. The lube level should be a little bit lower than intake , more will cause leakage and less will cause the main reducer burnt. IV、 、Check before drive 1. Check the leakages on engine, such as oil, cooling fluid, fuel, lube and so on should have no leakage. 2.
UTV500CC User’s Manual www.UTVsFactory.com 6. Check engine supporting frame, bolts, transmission system and running system. 7. When starting engine, listen and check whether there is any abnormal noise, and observe whether each meter is normal. 8. Check whether steering is flexible and reliable; check brake free travel length and its reliability (including parking brake). 9.
UTV500CC User’s Manual www.UTVsFactory.com 1. Safety driving notes for farmer vehicle To guarantee your driving safe, please accord with following items： —Tie safety belt— Safety belt could avoid you are thrown out of vehicle when happening sudden swerve and accidents, and guarantee running safe effectively. —Inspection before driving — Careful inspection before driving is necessary to guarantee running safe and enjoy driving pleasure.
UTV500CC User’s Manual www.UTVsFactory.com ③ Meter 1、Thermometer 2.3.、Indicators 4、Fuel 7、Speed indicator 5、High beam 6、kilometer mark 8、2 and 4 wheel drive （ａ）、Speedometer 7：Display the speed of vehicle. （ｂ）、Kilometer mark 6 ：Display the accumulated driving distance. （ｃ）、High-beam 5：Light when high-beam is on. （ｄ）、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.
UTV500CC User’s Manual www.UTVsFactory.com （ａ）、When ignition switch is at “ON” position and lamplight main switch is ”position, front and rear small light are lightened. turned to “ （ｂ）、When ignition switch is at “ON” position and lamplight main switch is turned to “ ”position, front headlight and rear small light are lightened.
UTV500CC User’s Manual www.UTVsFactory.com （ｆ）、When ignition switch is at “ON” position, turn lamplight main switch handle anticlockwise, left steering light will flash; and turn lamplight main switch handle clockwise, right steering light will flash. （ｇ）、When ignition switch is at “ON” position, step down brake pedal, brake light will illumine. ⑤ Horn button Press down horn button on steering wheel (anyone of these two), loudspeaker will hoot.
UTV500CC User’s Manual www.UTVsFactory.com ⑦ Parking brake handle When pulling up parking brake handle, rear wheels will produce brake force to prevent vehicle from sliding when vehicle is parked. Warning：After parking the vehicle, pull up the hand brake bar. Push down the handle before start moving. The hand brake can not be used to stop vehicle when moving(except emergency).
UTV500CC User’s Manual www.UTVsFactory.com ⑨4×2、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.
UTV500CC User’s Manual www.UTVsFactory.com VI、 、Running-in of new vehicle Cooperation between the surfaces of each part of new vehicle is locating adjusting and running-in phase, for surface friction of each part is big, the result of running-in quality influences greatly using lifetime of farmer vehicle. In running-in period, please implement strictly the regulation about speed limit, load limit and periodic maintenance to reduce 1.
UTV500CC User’s Manual www.UTVsFactory.com For fastening bolts on each part of new vehicle are easy to loosen, it is necessary to note the fixed situation of each bolt, especially the bolts of transmission organization and fixed equipment. 6. First maintenance of vehicle In running-in period, after running for 1000km, it is necessary to complete first maintenance, maintenance details could refer to “Maintenance and repair”.
UTV500CC User’s Manual 7 Tyre 8 www.UTVsFactory.com Tyre pressure and thread depth Check front tie-in ： -3 ～ 3mm Transmission Whether the bolts, flange nuts organization on transmission shaft and the bolts on main driver are tightened.
UTV500CC User’s Manual www.UTVsFactory.com 3 Brake Brake liquid height; brake The thickness of pad pedal travel and free travel; must not be less than brake performance 4.5mm. 4 Gear box Gear oil level, any noise Oil level must in the limitation. 5 F/R driver main Gear oil level, any noise Oil level shoud be to the intake. 6 Tyre Air pressure, thread, crack Tyre air pressure：front and wound wheel 0.20Mpa 。 rear wheel 0.25Mpa Thread depth ：no less than 1.
UTV500CC User’s Manual Checking Kilometers www.UTVsFactory.
UTV500CC User’s Manual www.UTVsFactory.
UTV500CC User’s Manual www.UTVsFactory.com VIII、 、Malfunction analysis and elimination （I）Engine malfunction Malfunction phenomenon Malfunction system 1. pressure in Start cylinder is too difficultly or low. could not start Reason Solving method Cylinder wear out change Piston wear out. change Leakage on Washer of change cylinder. Wearing on Pipe of air valve or seat of valve is not Repair or change suitable. plug is loose. Starting motor is too slow. Air circulation is not right.
UTV500CC User’s Manual www.UTVsFactory.com 2. No ignition ① Dirt on spark plug generated from plug ② Wet on plug ③ Ignition coil problem Clean or change Clean, Change dry or Change ④ Touch loop got open or short circuit Change 3. No fuel carburetor in ⑤ Magneto problem Change ⑥ CDI problem Change Vent hole on tank jammed Clean or change Problem or blocked in fuel pipe. Clean or change Problem on needle valve of carburetor Start difficultly or could not start 4.
UTV500CC User’s Manual www.UTVsFactory.com Engine has no 1. Mechanic problem idle speed or uneven Valve gap no suitable Adjust Valve base is not suitable Repair or Change Problem on air pipe Change Broken on bush of swing Change arms Fuel level of bobber cab is Adjust the height of not right bobber ⑥ Jam on muzzle of Clean carburetor ⑦ Fuel pipe problem Change ⑧ Adjust screw of idle sets Adjust wrong. 2.
UTV500CC User’s Manual Engine Mechanical problem middle and high rotate speed is uneven www.UTVsFactory.com ① The force of Valve spring is Change weak. ② Cam axle worn out Change ③ Plug is dirty. Clean or Change ④ Gap of plug is too small. Adjust or change ⑤ Air circulation is not right. Adjust or change ⑥ Ignition loop problem ⑦ Floater of carburetor is too Change lower. ⑧ Air filter is dirty.
UTV500CC User’s Manual www.UTVsFactory.com 1. Fuel supply system ① Jam in muzzle of carburetor Clean or change fault ② Level of Floater not correct ③ Air filter is dirty Adjust the height ④ Leakage on air intake pipe Clean or change ⑤ Too many lube Tighten or change Drain the extra lube Engine power 2. Electrical is not enough problem 3.
UTV500CC User’s Manual Engine overheats www.UTVsFactory.com 1. Fuel system fault ① Octane number is lower Use the right fuel ② Fuel pass blocked Clean the fuel pass ③ Fuel pump problem Change ④ Fuel level in floater is Adjust the height of lower floater 2. Electric problem System Ignition time is late or early ②Spark is weak or no spark 3.
UTV500CC User’s Manual www.UTVsFactory.com ① Carbon accumulated on top Clear of piston Drain or Refill ② Too many or less lube Change ③ Unsuitable lube used 5.
UTV500CC User’s Manual www.UTVsFactory.com Noise from ① Gear damaged Change transmission system ② Input and output shaft Change damaged Change ③ Bearing worn out Change ④ Bush worn out Gasoline 1.
UTV500CC User’s Manual www.UTVsFactory.
UTV500CC User’s Manual Spark weak Ignition System www.UTVsFactory.
UTV500CC User’s Manual www.UTVsFactory.
UTV500CC User’s Manual www.UTVsFactory.
UTV500CC User’s Manual www.UTVsFactory.
UTV500CC User’s Manual www.UTVsFactory.
UTV500CC User’s Manual Starter does not rotate when starting www.UTVsFactory.
UTV500CC User’s Manual www.UTVsFactory.com IX、 、Screwing moment of important bolts Engine Sequence Item Quantity Thread diameter number mm 1 Sensor of reverse gear 1 M10x1.25 2 Spark plug 1 M12x1.25 3 Sensor of water 1 R/c1/8 temperature 4 Adjust nuts of air valve 4 M5 gap 5 Nut of driving disk 1 M20x1.5 6 Nut of driven disk 1 M20x1.5 7 Round nut of driven 1 M30x1 disk 8 Nut of front output axle 1 M14X1.5 9 Nut of driving prick 1 M22X1 gear 10 Nut of driven prick 1 M16X1.
UTV500CC User’s Manual 24 25 26 27 gear cover Gear positioning bolt Bolt on hand start disk Bolts on crankcase 28 Bolt on Gear changing sector gear Bolt on oil filter 29 30 31 32 Bolt on oil filter Bolts on start motor Bolts on cylinder cover Nuts on cylinder cover 33 34 Bolts on cylinder Bolt on cover of cylinder Bolts on chain adjuster 35 36 37 38 39 40 41 Nuts on chain adjuster Bolts on fan motor Bolts on constant temperature unit Bolts on pump cover Bolts on pump Bolts on circulationunit 42
UTV500CC User’s Manual 7 8 9 10 11 12 13 14 www.UTVsFactory.
UTV500CC User’s Manual www.UTVsFactory.com Specification Other screws（8.8 grade） M6 M8 M10 M12 Tightening moment 10N·m 25N·m 50N·m 80N·m X、 、Specification and usage quantity for fuel, lubricating oil and brake liquid Category Fuel Specification Capacity Remark RQ-90 or upper 27L Content of grade lead-free fuel box gasoline Lubricating oil SAE15W—40/SF or 1900ml(change oil) （engine, Gear box） SC 2000ml(change filter) 2200ml(repair engine) Lubricating oil（front SAE15W—40/SF or First 0.
UTV500CC User’s Manual www.UTVsFactory.com UTV 500CC Circuit Map XY500-S农夫车电路总图 黄 绿 0.75 器 刹车 近光 远光 灯 灯 灯 白 0.75 喇叭 右转 左转 向灯 向灯 红 黑 0. 75 蓝 0.75 电 源 大 点 雨 远 近 喇 仪 转 小 烟 刮 光 光 叭 表 向 灯 器 点火 刹 2/4WD 车 蓝 红 0.75 黑 棕 0. 75 红 1.5 浅蓝 1.5 浅绿 棕 0.75 点烟 器 油泵 浅绿 绿 0.75 电锁 4 绿 0.75MP3 棕绿0.75 绿 1.5 组合 黑 白 0. 75 开关 黄 绿 0.75 电锁 2 刹车 电锁 1 粉 红 0.75 红 棕 0.75 紫 0.75 高档 开关 速度 信号 LOCK 低档 刹车 开关 空档 停车 档 倒档 点火器 电源+ 电源- 辅助继 电器 触发- 点火 点火 触发+ 辅助继 线圈 电器 左音箱 黑 0.75 黄白0.
