Owner's manual | UTVs Factory UTV500CC Owner`s manual

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. If you have any questions regarding the operation or maintenance of your UTV, please consult you dealer.

AN IMPORTANT SAFETY MESSAGE:

● READ THIS MANUAL FOR THE UTV RIDER CAREFULLY AND COMPLETELY

BEFORE OPERATING YOUR UTV. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS.

● PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE UTV.

● NEVER OPERATE A UTV WITHOUT PROPER TRAINING OR INSTRUCTION.

FREE

TRAINING IS AVAILABLE TO ANYONE WHO BUYS A NEW UTV.

● THIS UTV, AND ANY OTHER UTV OVER 90cc, SHOULD NOT BE RIDDEN BY

ANYONE UNDER 16 YEARS OF AGE.

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.

A CAUTION indicates special precautions that must be taken to avoid damage to the machine.

NOTE: A NOTE provides key information to make procedures easier or clearer.

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……………………………………………………………………………………………30

Driver’s seat adjustment……………………………………………………………………30

Seat Belts………………………………………………………………………………………30

Seat Belt Inspection……………………………………………………………………………30

Fuel cap …………………………………………………………………………………31

Ignition Switch ………………………………………………………………………………32

Gear Selector…………………………………………………………………………………33

Parking Brake………………………………………………………………………………33

Brake Pedal…………………………………………………………………………………34

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 with a passenger………………………………………………………………………43

Driving on slippery surface……………………………………………………………………44

Driving uphill…………………………………………………………………………………46

Driving on a sidehill…………………………………………………………………………47

Driving downhill………………………………………………………………………………47

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 ………………………………………………61

Filter system …………………………………………………………………………………63

Cooling system …………………………………………………………………………………65

Throttle system ………………………………………………………………………………68

Carburetor ……………………………………………………………………………………70

Throttle body………………………………………………………………………………72

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

W A R R A N T Y … … … … … … … … … … … … … … … … … … … … … … … … … … … 9 8

SPECIFICATIONS…………………………………………………………………………101

C i r c u i t D i a g r a m … … … … … … … … … … … … … … … … … … … … … … … … … 1 0 8

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. Understand all safety warnings, precautions and operating procedures before driving the vehicle. Keep this manual with the vehicle.

● Never operate this vehicle without proper instruction.

● Always follow the age guidelines for your vehicle. Operation is prohibited for anyone age 16 and under. Never operate with a passenger age 12 and under.

1

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.

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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. Do not install on 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 vehicle create a substantial safety hazard and increase the risk of bodily injury. The warranty on your vehicle is terminated if any equipment has been added to the vehicle, or if any modifications have been made to the vehicle, that increases its speed or power.

The addition of certain accessories may change the handling characteristics of the vehicle. Use only our company approved accessories, and familiarizes yourself with their function and effect on the vehicle.

3

SAFET

Y

Safe Riding Gear

Always wear appropriate clothing when riding this vehicle. Wear protective clothing for comfort and to reduce the chance of injury.

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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.

Gloves

Wear gloves for comfort and for protection from sun, cold weather and other elements.

Boots

Wear sturdy footwear. Do not ride a vehicle with bare feet.

Clothing

Wear long sleeves and long pants to protect arms and legs.

5

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. The operator must understand how to operate the vehicle properly in different situations and on different types of terrain.

Age Restrictions

Operation is prohibited for anyone age 16 and under. Never operate with a passenger age 12 and under. Make sure any passenger is tall enough to comfortably and safely reach the hand holds and place both feet on the floor.

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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.

Accessories

Installing non-approved accessories may seriously affect vehicle handling and stability, which could result in loss of control or an accident. Never install accessories not approved by our company for use on this vehicle.

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SAFETY

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. Seat belts reduce the severity of injury in the event of a sudden stop or accident. Always make sure the seat belts are secured for both the operator and passenger before riding.

Using Alcohol or Drugs

Riding in this vehicle after consuming alcohol or drugs could adversely affect operator judgment, reaction time, balance and perception. Never consume alcohol or drugs before or while operating or riding in this vehicle.

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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.

Operating on Pavement

Operating this vehicle on paved 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 designed for off-road use only, not for use on pavement. Avoid operating the vehicle on pavement. If you must operate on a paved surface, travel slowly and do not make sudden turns or stops.

Operating on Public Roads

Operating this vehicle on public streets, roads or highways could result in a collision with another vehicle. Never operate this vehicle on any public street, road or highway, including dirt and gravel roads. In many areas it's unlawful to operate vehicles of this type on public streets, roads and highways.

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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. Practice turning at slow speeds before attempting to turn at faster speeds.

Physical Control of the Vehicle

Removing hands from the steering wheel or hand holds or removing feet from the floor while riding increases the risk of loss of control and accident or overturn. The operator should always keep both hands on the steering wheel during operation. A passenger should always be seated in the passenger seat with both feet on the floor and with both hands securely grasping the hand holds. Always keep hands and feet inside the vehicle at all times.

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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.

● Never operate the vehicle on hills steeper than 15 degrees.

● Always check the terrain carefully before driving down a hill

● Never travel down a hill at high speed.

● Avoid traveling down a hill at an angle, which would cause the vehicle to lean sharply to one side.

Travel straight downhill.

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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.

Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed.

Crossing Hillsides

Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary.

12

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.

Operating on Sand or Slippery Terrain

Operating on sand or on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or overturn. Always use extra caution when operating on sand or on rough, slippery or loose terrain. Do not operate on excessively rough, slippery or loose terrain.

13

SAFETY

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. Never attempt to operate over large obstacles such as rocks or fallen trees.

Always follow the proper procedures outlined in this manual when operating over obstacles.

Skidding or Sliding

Skidding or sliding can cause loss of control or overturn (if tires regain traction unexpectedly).

Always follow proper procedures for operating on slippery surfaces as described in the owner's manual. When operating on slippery surfaces such as ice or loose gravel, reduce speed and use extra caution to reduce the chance of skidding or sliding. Do not operate on excessively slippery surfaces.

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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.

Overloading the Vehicle

Overloading the vehicle may cause changes in stability and handling, which could cause loss of control or an accident.

● Never exceed the maximum weight capacity for this vehicle.

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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.

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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. Do not fill the tank neck.

● If gasoline spills on your skin or clothing, immediately wash it off with soap and water and change clothing.

● Turn the fuel valve off whenever the vehicle is stored or parked.

Exposure to Exhaust

Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time.

Never start the engine or let it run in an enclosed area. Operate this vehicle only outdoors or in well-ventilated areas.

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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. Promptly 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 or overturn. Always remove the ignition key when the vehicle is not in use.

Safety Labels and Locations

Warning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully. If any of the labels shown in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle. If an informational or graphic label becomes illegible or comes off, contact your dealer to purchase a replacement.

18


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.

● At speeds that are too fast for the operator’s skills, the conditions and/or the terrain.

ALWAYS require operator and passenger to:

● Wear seat belts, grab hand holds (passenger) and plant feet firmly

on the floor.

● Keep hands and feet inside vehicle.

● Avoid quick turns of the steering wheel and driving stunts such as

jumps, donuts or power slides.

● Reduce speed and use extra caution when carrying a passenger.

● Watch for branches or other hazards that could enter vehicle.

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SAFETY

SAFETY


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. (300 Kg)

INCLUDES WEIGHT OF OPERATOR, PASSENGER AND ACCESSORIES.

LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND

WARNINGS. IF OWNER’S MANUAL IS MISSING, CONTACT YOUR DEALER FOR

A REPLACEMENT.

20

Component Locations

FEATURES AND CONTROLS

21


Component Locations

22


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) O dometer 6 ：Display the accumulated driving distance.

(ｃ) High beam 5：Light when high beam is on.

23


（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. When two axles indicator lights, the both front and rear axles are in driving. 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 when brake fluid level is lower (need add more) .

( j）.Low range over speed alarm light 10: The light will be on when press down the over speed button.

Main switch of lights

(a). When ignition switch is at “ACC” or “ON” position, press down at the first step, front and rear small light and meter light is on. Press down at the second step, headlight, meter light and tail light is on.

(b). When ignition switch is at “ACC” or “ON” position, press down at the second step, press down “ ” at same time, The headlight (high beam), meter light, and tail light is on. Press

24


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“ ”, alarm light blinks.

(d). When ignition switch is at “ACC” or “ON” position, press down“ ”or“ ”,The left or right indicator lights.

25


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.

Press “SWITCH” to “ON” position, and then press “WINCH” to “OUT” or “IN”, the winch cable can be strech out and in.

Warning: Set the main switch back to “OFF” when finish dumping and winching in void being power wasting.

When cargo box reaches the top or bottom, or the winch cable to the ends, please stop pushing the button at once in case to damage the motor switch.

26


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. Engine is matched with stepless automatic clutch. There is no any assistant unit in gear changing. So the vehicle must be stopped when change 2WD from 4WD.

2. The corresponding gear position will be displayed on meter when change gears. But sometimes this is not the meaning that the gear is in its position.

You just need step on the accelerator pedal lightly, and then the gear will be in its position. (Please note that better do not step on pedal hard before the gear is in its position in case to damage the transmission gear）.

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 only be used on muddy, slippery, snow or up-slope road.

27


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. Please make sure the voltage matches your electro-set’s.

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.

at

28


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. Press the button you can release the limitation.

Note: Normally do not press down the button to 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 socket is under the meter .

CHOCK SWITCH

29

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. 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 diagonally across your chest. Make sure the belt is not twisted.

2. Push the latch plate into the buckle until it clicks.

3. Press the red release latch on the buckle to release the seat belt.

Seat Belt Inspection

Inspect all seat belts for proper operation before each use of the vehicle.

1.Push the latch plate into the buckle until it clicks. The latch plate must slide smoothly into the buckle. A click indicates that it's securely latched.

30


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.

Fuel Cap

Never allow a child to refuel or handle gasoline.

The fuel tank filler cap is located on the left-hand side of the vehicle behind the operator seat. When refueling, always use unleaded gasoline.

31


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.

Note: You can start the engine when gear is in “N” position or step down the brake pedal when gear is in “H”, “L” and “R” positions.

32


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.

NOTICE: Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission could result. Always shift when the vehicle is stationary and the engine is at idle.

Parking Brake

1. Apply the brakes.

2. When the vehicle is fully stopped, pull the parking brake lever rearward as far as possible to set the parking brake.

3. Stop the engine.

4. To release the parking brake, apply the brakes and push the lever toward the passenger seat and forward.

33


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.

Throttle Pedal

Push the pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check that the throttle pedal returns normally before starting the engine. Make sure there's adequate throttle pedal freeplay.

See page 68 for throttle pedal adjustment procedures.

If the throttle cable should stick in an open position when the operator releases the throttle pedal, the engine will stop and power to the rear wheels will cease.

34

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. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components. Perform the following procedures carefully.

NOTICE: Excessive heat build-up during the first three hours of operation will damage close-fitted engine parts and drive components. Do not operate at full throttle or high speeds during the first three hours of use.

Mixing brands or using a non-recommended oil may cause serious engine damage. Always use the recommended oil. Never substitute or mix oil brands.

35

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. Do not 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.

Brake System Break-in

Apply only moderate braking force for the first 50 stops. Aggressive or overly forceful braking when the brake system is new could damage brake pads and rotors.

CVT Break-in (Clutches/Belt)

A proper break-in of the clutches and drive belt will ensure a longer life and better performance.

Break in the clutches and belt by operating at slower speeds during the break-in period as recommended. Avoid aggressive acceleration and high speed operation during the break-in period.

36

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.

Item Remarks

Brake Ensure proper operation

Page

73

Steering

Engine oil

Air filter

Ensure free operation

Ensure proper levels

Inspect, clean

75

56 57 58

63 64

Seat Belts

Brake fluid

Check length of belt for damage, check latches for proper operation

Ensure proper level

30 31

74

76

Throttle system Ensure proper operation 68 69

Gearcase fluid

Spark plug

Ensure proper levels

Inspect condition

59

60

37

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.

Never operate the vehicle on pavement or on any public street, road or highway, including dirt and gravel roads.

6. Drive in a 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 wheel at all times.

7. Never consume alcohol or drugs before or while operating this vehicle.

8.Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure.

9.Never operate a damaged vehicle. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage.

10. Never operate the vehicle on a frozen body of water.

11. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.

12. Always remove the ignition key when the vehicle is not in use to prevent unauthorized use.

38

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. Allow the engine to warm up for several minutes before operating the vehicle.

6. 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 point where it does not readily start, intermittent use of the choke (pulled half way out) may be necessary. If the engine is over-choked when warm, depress the throttle lever fully while cranking to aid in starting. Release the throttle lever immediately after the engine starts. If the engine does not start and all conditions are favorable, change the spark plug and try again.

7. Vary the engine RPM slightly with the throttle to aid in warm-up until the engine idles smoothly.

8. Release the parking brake before driving.

39

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. 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. When parking inside a garage or other structure, be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks, including any appliance with pilot lights.



4. Stop the engine.

5. Remove the ignition key to prevent unauthorized use.

40

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. Sit in the driver's seat and fasten the seat belt.

7. Do not carry a passenger until you have at least four hours of driving experience with this vehicle.

(See page43).



10. Start the engine.

11. Apply the brakes and shift into gear.

12. Release the parking brake.

41

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. After you become skilled at making turns and begin to operate at faster speeds, follow these precautions:

● Avoid sharp turns. Make turns gradually.

● Never turn while applying heavy throttle.

● Never turn the steering wheel abruptly.

● Operate at speeds appropriate for your skills, the conditions and the terrain.

● Do not attempt to do power slides, “donuts”, jumps or other driving stunts.

42

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. Never carry more than one passenger in the 500/600UTV or carrying more than three passengers in the 500L/600LUTV.

6. Never allow a passenger to ride on the cargo box. Allow passenger to ride only in the passenger seat.

43

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. Avoid unexpected or aggressive maneuvers that could 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 such as wet trails, loose gravel, sand or ice, be alert for the possibility of skidding and sliding.

Skidding or sliding can cause loss of control or overturn, especially if tires regain traction unexpectedly. When operating on slippery surfaces such as ice or loose gravel, slow down and use extra caution to help prevent skidding or sliding. Always use extra caution when operating on sand or on rough, slippery or loose terrain. Do not operate on excessively rough, slippery or loose terrain.

44

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.

45

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. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.

8. If the vehicle stalls while climbing a hill, apply the brakes. Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying the brakes lightly to control speed.

46

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. 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 steep hills (15° maximum).

2. Slow down. Never travel down a hill at high speed.

3. Always check the terrain carefully before driving down a hill.

4. Always drive down a hill with the transmission in forward gear. Never “coast” or drive down a hill with the transmission in neutral.

5. Avoid driving down a hill at an angle, which would cause the vehicle to lean sharply to one side.

Always drive straight downhill.

6. Apply the brakes lightly to keep speed slow.

47

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.

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 53-54. Give special attention to engine oil, transmission oil and all grease fittings. If your vehicle is operated in water deeper than the floor level, take it to your dealer for service before starting the engine.

If it's impossible to bring the vehicle to your dealer before starting the engine, perform the service outlined on page 77, and take the vehicle to your dealer as soon as possible.

48

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. Always have a passenger dismount and move away from the vehicle before driving over an obstacle that could cause an overturn.

49

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. Avoid making sharp

50

OPERATION

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:



3. Stop the engine.

4. Turn the fuel valve off.

5. Always block the rear wheels on the downhill side.

51

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. If you're not familiar with safe service and adjustment procedures, have a qualified 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 subjected to severe use must be inspected and serviced more frequently.

Severe Use Definition

● Frequent immersion in mud, water or sand

● Racing or race-style high RPM use

● Prolonged low speed operation

● Extended idle

● Short trip cold weather operation

Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause or see your dealer.

52

MAINTENANCE


Perform all services at whichever maintenance interval is reached first.

Item

Maintenance Interval

(whichever comes first)

Hours Calendar Miles(Km)

Ⅱ

Ⅰ

Steering

Tires

Brake fluid level

Brake system

Ⅰ Brake pedal travel

Ⅰ Engine oil level

Ⅰ Engine oil change

Remarks

－ Daily －

－ Daily －

－ Daily －

－ Daily －

－ Daily －

－ Daily －

30 6 M

Check each day before driving the vehicle. Make adjustments as needed. See the Pre-Ride Checklist on page37.

300 (480) Perform a break-in oil change at one month

－

Weekly

－

Drain water as needed,check often if driving in wet conditions

CVT housing (if equipped)

Ⅰ Air filter, main element

Ⅰ

Ⅱ

Brake pad wear

Ⅰ

Idle speed

Front Suspension

－

10

50H

Weekly

Monthly

6M

－

500 (800)

Inspect; replace as needed

Lubricate

53

MAINTENANCE


Item

Maintenance Interval

(whichever comes first)

Hours Calendar Miles(Km)

Ⅰ Rear Suspension 50H 6M 500 (800)

100

100 H

12M

12M

Remarks

Lubricate

600 (1000) Inspect; replace as needed

－ Inspect; replace as needed

Ⅰ Spark plug

Ⅱ Front wheel bearings

Shift Linkage

Ⅱ

Battery

Toe adjustment

Headlight aim

－ Inspect periodically; adjust when parts are replaced

－ needed

Ⅱ Choke

Ⅰ Main gearcase oil

Ⅰ

Ⅱ

25 Monthly 250 (400) Inspect level; change yearly

Perform these procedures more often for vehicles subjected to severe use.

Have an authorized dealer perform these services.

Remark：1.If the Odometer indication is large, please repeat this maintenance.

2.If operate this vehicle at special wet or dusty area, you had better shorten the maintenance interval.

54

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.

Oil Recommendations

NOTICE:

Mixing brands or using a non-recommended oil may cause serious engine damage. Always use the recommended oil. Never substitute or mix oil brands.

Engine oil classification of the UTV

55

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.

5. Add the recommended oil as needed.

6. Reinstall the dipstick.

56

MAINTENANCE

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. 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 completely.

NOTE:The sealing surfaces on drain plug and crankcase should be clean and free of burrs or scratches.

6. Using a cap-style oil filter wrench,turn the oil filter cartridge to remove it.

7. Using a clean dry cloth,clean the filter sealing surface on the crankcase.

8. Lubricate the o-ring on the new filter with a film of fresh engine oil.Check to make sure the o-ring is in good condition.

57

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. Re-check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick.

16. Dispose of used filter and oil properly.

58

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.


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. Place a drain pan under the drain plug.

3. Remove the drain plug. Allow the fluid to drain completely.

4. Clean the drain plug.

5. Reinstall the drain plug with a new o-ring.

6.

Add SAE15W/40 SF or SAE 80W/90 GL-4 of the recommended fluid to the fill hole. Maintain the fluid level at the bottom of the fill plug hole. Do not overfill.

7. Reinstall the fill plug.

8. Check for leaks.

9. Discard used fluid properly.

59

MAINTENANCE

Spark Plugs

Spark Plug Gap/Torque

Electrode Gap Plug Tightening Torque

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.

A hot exhaust system and engine can cause burns. Wear protective gloves when removing a spark plug for inspection.

Specified spark plug: DPR7EA-9.

Spark Plug Removal and Replacement

1.Remove the spark plug cap.

2.Using the spark plug wrench provided in the tool kit, remove the plug by rotating it counterclockwise.

3.Reverse the procedure for spark plug installation.

60

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. The CVT system rotates at high speeds, creating large amounts of force on clutch components. Extensive enginee- ring and testing has been conducted to ensure the safety of this product. However, as the owner, you have the following responsibilities to make sure this system remains safe:

● This CVT system is intended for use on our company products only. Do not install it in any other product.

● Always make sure the CVT housing is securely in place during operation.

61

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. Do not hold the throttle wide open for more than 10 seconds.

4. Allow the engine RPM to settle to idle speed.

5. Test for belt slippage. If the belt slips, repeat the process.

6. Take the vehicle to your dealer for service as soon as possible.

NOTICE: Exposure to salt water will cause corrosion to metal components. If your vehicle is operated in salt water areas, rinse it off frequently with fresh water.

62

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. 1.

Fixed card

3.Remove the filter element of the air filter 4 2. Cover from the air box 3.Screw

4.Wash the filter element in warm soapy 4.

Filter Element

water, then rinse and let dry. If the filter element is damaged, install a new filter.

63

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.

64

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.

Don’t removing the radiator cap when the engine and radiator are still hot, or you could be burned by hot fluid nd steam blown out under pressure. Wait for the engine to cool before removing the radiator cap. Always use a thick rag over the cap. Allow any remaining pressure to escape before completely removing the cap.

65

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.

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 the radiator is full, also the water pump, Temperature Adjusting Set (TAS), fan is working properly. So it might be some air in pipe.

The method of releasing the air is: pull out the small circulating pipe, keep adding coolant from intake of radiator. Connect back the pipe when the coolant spilled out from the pipe.

Then fill up the radiator till it is full. Cap the radiator and tighten the hoop on the pipe.

66

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.

67

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.

Throttle Freeplay

If the throttle pedal has excessive play or misadjustment, it will cause a delay in throttle response, especially at low engine speed. The throttle may also not open fully. If the throttle pedal has no freeplay, the throttle may be hard to control, and the idle speed may be erratic. Check the throttle pedal freeplay at the intervals outlined in the

Periodic Maintenance Chart beginning on page 53.

Adjust the freeplay if necessary.

68

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).

69

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. 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 circle

range.

3. Regularly inspect the carburetor, cleaning and maintenance, under normal circumstances,

should be looking for an experienced professional service personnel better, should not have

their own repair arbitrary random tune.

4. Long time (a week or more) do not use your vehicle, be sure to let the residual net carburetor

to prevent the corrosion of copper parts residual oil deterioration, resulting in carburetor

failure.

70

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.



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.

71

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.

72

MAINTENANCE

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.

Operating the vehicle with a spongy brake pedal can result in loss of braking, which could cause an accident resulting in severe injury or death. Never operate the vehicle with a spongy-feeling brake pedal.

Brake Inspection

1. Check the brake system for fluid leaks.

2. Check the brake pedal for excessive travel or a spongy feel.

3. Check the friction pads for wear, damage and looseness.

4. Inspect the brake pad wear surface for excessive wear.

5. Change pads when worn to

3/64" (1 mm).

73

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.

Change the brake fluid every two years and any time the fluid becomes contaminated. Alarm light of brake fluid level 9 on the meter will on if the brake fluid is lower (need add more). Open the cover 1 which locates on the engine cover, you will see the brake fluid intake.

74

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. Rotate the adjuster either clockwise or counterclockwise to make adjustments. Always apply the same adjustment setting to all four wheels.

WARNING! Uneven adjustment may cause poor handling of the vehicle, which could result in an accident. Always adjust both the left and right spring preloads equally or have your dealer perform the adjustments.

75

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. 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 bearing tightness and spindle nut retention are critical component operations.

All service must be performed by your authorized dealer.

Wheel Removal


2. Place the transmission in neutral. Set the parking brake. Stop the engine.

3. Loosen the wheel nuts slightly.

4. Elevate the side of the vehicle by placing a suitable stand under the frame.

5. Remove the wheel nuts. Remove the wheel.

76

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. 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. Dry the spark plugs and reinstall them, or install new plugs.

7. Tighten the carburetor drain screw.

8. Attempt to start the engine. If necessary, repeat the drying procedure.

9. Take the vehicle to your dealer for service as soon as possible, whether you succeed in starting it or not.

10. If water has been ingested into the transmission follow the procedure on page 61 for drying.

77

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.

You could be poisoned and severely burned by the 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 children.

If contract with you body, take the follow measures:

1. Negative battery terminal

2. Positive battery terminal

EXTERNAL: Flush with water

INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Get prompt medical attention.

EYES: Flush with water for 15 minutes and get prompt medical attention.

Keep batteries away from sparks, flames, cigarettes or other sources of ignition. Ventilate when charging or using in a closed.

78

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.

Specified fuses:

Battery fuse: 30A Cigarett light fuse:15A Fuel pump fuse:10A

Fan fuse: 10A Winch/dump pump fuse:10A High beam fuse:10A

Brake light Fuse: 10A Turning light fuse:5A Low beam fuse:10A

Light power fuse: 15A Horn fuse:5A Wiper fuse:15A

Ignition fuse:10A 2/4 WD fuse:5A MP3 fuse:5A

79

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.

CAUTION: To prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse.

80

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.

NOTICE:

Water in the CVT system could cause the drive belt to become 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 recommend washing the vehicle by hand or with a garden hose, using mild soap.

Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle.

The best and safest way to clean your vehicle is with a garden hose and a pail of mild soap and water.

1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts last.

2. Rinse with clean water frequently.

3. Dry surfaces with a chamois to prevent water spots.

81

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. Block up the frame to raise all wheels off the ground.

4. Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering.

5. If storing in a humid or salt-air atmosphere, coat all exposed metal surfaces with a light film of oil.

Do not apply oil to any rubber parts or the seat cover.

6. Remove the battery and charge it. Store it in a dry place and recharge it once a month. Do not store the battery in an excessively warm or cold place (less than 0 °C (30 °F) or more than 30 °C (90 °F)).

82

Malfunction analysis and elimination

（ I）Engine malfunction

Reason Malfunction phenomenon

Start difficultly or could not start

Malfunction system

1. pressure in cylinder is too low.

2. No ignition generated from plug

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.

① Dirt on spark plug

② Wet on plug or smudge

③ Ignition coil problem

④ Touch loop got open or short circuit

⑤ Magneto problem

⑥ CDI problem

Solving method change change change

Repair or change

Tighten

Check electric system.

Adjust

Adjust

Clean or change

Clean, dry or Change

Change

Change

Change

Change

83

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.

③ Problem on needle valve of carburetor

④ Blocked in fuel tank

⑤ Blocked in fuel filter

Clean or change

Clean or change

Change

Change

Clean or Change

① Vent hole on tank jammed

② Problem or blocked in Injector

③ Hight-pressure fuel pump do not

Clean or change

Clean or change work.

④ Low-pressure in hight-pressure

Clean or change fuel pump Clean or change

⑤ blocked in hight-pressure fuel pump strainer Clean or change

Gear is not in neutral Put gear on neutral

① Valve gap no suitable

② Valve base is not suitable

③ Problem on air pipe

④ Broken on bush of swing arms

⑤ IAC valve blocked in inlet 、

Adjust

Repair or Change

Change

Change

84

Engine middle rotate speed is uneven exhaust pipe.

⑥ Fuel level of bobber cab is not right

⑥ Jam on muzzle of carburetor

⑦ Adjust screw of idle sets wrong.

Adjust or Change

Adjust the height of bobber

Clean

Clean

Adjust

2. Electric parts

① Dirt on plug

② Gap of plug not correct problem

③ Ignition loop problem

Mechanical

Clean or Change

Change or Adjust

Change

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.

⑧ Air filter is dirty.

⑨ Block in fuel pipe cause fuel supply problem

⑩ Fuel pipe problem

⑾ Underpressure in hight-pressure

Change

Change

Change

Change

Clean or Change

Adjust or change

Adjust or change

Change

Adjust the height of floater

Clean or change

Clean

Change

85

Exhaust blue smoke

Mechanical fault

1. Fuel supply system fault fuel pump

① too many lube

② Piston ring worn out

③ Valve pipe worn out

④ Cylinder wall scratched

⑤ Valve rod worn out

⑥ Seal of valve rod broken

① Blocked 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

⑥ Problem or blocked in Injector

⑦ Low-pressure in hight-pressure fuel pump

Adjust or change

Drain the extra lube

Change

Change

Change

Change

Change

Clean or change


Clean or change

Tighten or change

Drain the extra lube

Clean or Change

Adjust or Change

Engine power is not enough

2. Electrical parts problem

3.Mechanical problem

① Dirt on plug

② Gap of plug not correct

③ Ignition loop problem

④ CDI problem

⑤ Magneto problem

① Gap of Valve is not correct

② The force of valve spring is

Clean or Change

Change or Adjust

Change

Change

Change

Change operation method

Check, remove or change

86

Engine overheats

1. Fuel system fault

2. Electric System problem 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

① Octane number is lower

② Fuel pass blocked

③ Fuel pump problem

④ Fuel level in floater is lower

① Ignition time is late or early

② Spark is weak or no spark

Adjust

Change

Change

Change or repair

Change

3. Air pass problem ① Air mixture is too thick or thin

② Leakage on engine

③ Air filter is dirty

④ Cylinder, piston, ring worn out

⑤ Leakages on connecting face

⑥ Block in exhaust pipe

⑦ Leakage on Air inlet pipe

4. Engine cooling system

① Block in water channel or radiator

② Air in Cooling system or coolant is

Use the right fuel

Clean the fuel pass

Change


Adjust ignition time

Check from plug to magneto

Adjust carburetor

Repair

Clean or change filter

Repair or change

Repair or change

Dredge

Repair or change

Clear

Release air, refill

87

engine not enough

③ Water pump problem

④ Unsuitable coolant

⑤ Constant temperature unit problem

⑥ Fault on motor of fan or switch of heat-sensor coolant

Change

Change

Change

Change

5. Miscellaneous ① Carbon accumulated on top of piston

② Too many or less lube

③ Unsuitable lube used

Clear

Drain or Refill

Change

Noise on air valve ① Gap on valve is too big

② Spring on valve is broken

③ Swing arm or cam shaft worn out

Noise from piston ① Piston worn out

② Cylinder worn out

③ Carbon gathered in firebox

④ Piston pin or pin hole worn out

⑤ Piston ring or ring notch worn out

Noise from chain of circulation

① Chain elongated

② Chain worn out

③ Adjustor of chain problem

Noise from clutch ① Spline of crankshaft damaged

② Spline of clutch damaged

Adjust

Change

Change

Change

Change

Clean

Change

Change

Change chain & sprocket

Change chain & sprocket

Repair & Change

Change crankshaft

Change clutch

88

Crankshaft ② Needle bearing damaged

③ Gap too big

Noise from CVT ① Belt loose or worn out

② Roller or main wheel damage transmission system

② Input and output shaft damaged

③ Bearing worn out

④ Bush worn out

Gasoline engine lacks accelerating

Clutch skiding happens

② Oil routine is blocked and oil supply is not smooth

Clutch skiding

Gear change not smooth or got stuck

Transmission system

Gear box or Gear change system

① Hoof of clutch worn out

② Spring on clutch is weak

③ Out wheel worn out

④ Belt worn out & loose

① Operating gear damaged

② Shift rod twisted

③ Shift drum worn out

④ Shift pulling stick unsuitable

Starting problem ① Blocked in muzzle

89

Change

Change

Change

Change

Change

Change

Change

Adjust

Clean

Change

Change

Change

Change

Change

Change

Change

Change

Change

Change with gasoline whose Octane number accords with regulation

Clean oil routine

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 Clean

③ Leakage on connecting part of Tighten, Adjust or carburetor and starting part

④ Starting pin not work properly change

Adjust

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

Clean or tighten

Clean

Clean

Clean

Adjust

Adjust

Adjust

① Muzzle blocked

② Main air channel blocked

③ Needle valve blocked

④ Throttle not work well

⑤ Fuel filter blocked

⑥ Height of floater not right

⑦ Starting pin not closed

① Needle valve worn out or damaged

② Spring on valve broken

③ Floater not work well

④ Dirt or scale in valve

Clean

Clean

Clean

Adjust

Clean or change

Adjust

Adjust

Change

Change

Adjust or change

Clean

90

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

Out of gear

Transmission system

Gear Box or Gear shifting system

① Shift belt slips

② Speed adjusting plate abrasion is too much

③ Speeding adjusting plate slipping is blocked

④ Spring force of adjuster is short

Change

Change

Repair or Change

Repair or Change

① Speed changing drum groove Change worn out

② Right and Left gear changing rods Change

91

bended

③ High and Low driven gear groove Change wear to taper

④ Speed changing principal and Repair or Change countershaft worn out

⑤ Sector gear tooth worn out

⑥ The force of spring of sector gear is weak or broken.

Repair or Change

Change

（ III）Malfunction in running system, suspension and steering organization leaning

Tyre is abraded system

Steering organiza-

① Air pressure in left and right wheel is different

② Load of left and right wheel is different

③ Spring force of left and right absorbing spring

④ Front wheel location is wrong

⑤ One side wheel is locked or brake could not release

⑥ Front and rear suspension parts have been loosened, bent or damaged

① Left and right absorber has been damaged, spring force is short

Adjust air pressure in tyre

Adjust load

Adjust or Change

Check or adjust

Repair arrester

Screw or Change suspension parts

Adjust or Change

92

abnormally or greatly tion, running system, suspension

Front wheel Steering shakes, organization,

② Tyre is not balance, and wheel hub is distorted

③ Front wheel location is wrong

④ Vehicle is over-load

⑤ Tyre has not change its position

⑥ Wheel hub bearing has been damaged or adjustment is wrong

⑦ Wheel assembly jump (axial, radial) is too great

⑧ Air pressure in tyre is too hig or too low

Change

Check or adjust

Check load

Change

Adjust or Change

Change

Adjust air pressure in tyre jump

① Tyre and wheel is not balance

② Wheel hub bearing has been damaged or adjustment is wrong

③ Left and right swing arm ball head has been abraded or loosened

④ Drag pole tie-in has been abraded or loosened

⑤ Front wheel location is wrong

⑥ Wheel (axial, radial)jump is too big

Balance wheel or

Change tyre

Change or adjust

Change

Change

Check、adjust

Change tyre or wheel hub

93

Steering is heavy

Steering organization running system

⑦ Tyre has tympanic bag

⑧ Free travel of redirector is too big

⑨ Fixed bolts on each part of steering organization has been loosened

① Air pressure in tyre is short

② Ball head of left and right swing arm and drag pole is blocked

③ Front wheel location is wrong

④ Steering pole pipe is blocked

⑤ Mesh clearance of redirector is too small

（ IV）Malfunction in brake system

Brake is not hard enough

Brake system

① Brake pipeline leaks oil

② Brake disk and brake hoof contacts badly or dirt on surface

③ Brake drum and brake hoof wear badly

④ Brake main pump is damaged or leaks oil

⑤ Brake branch pump is damaged or leaks oil

⑥ Brake liquid is short

⑦ Brake pipeline has air

⑧ Arrester is too hot

Change tyre

Change or adjust

Fasten

Charge the tyre to applicable air pressure

Change

Check and adjust

Repair or Change

Adjust

Repair

Repair or clean the dust

Change

Repair or change

Repair or Change

Add

Eliminate air

Repair or Change

94

Brake is leaning

Brake system suspen

-sion

① Some brake drums and hoof pads have oil stain

② Individual brake branch pump leaks oil or is blocked

③ The air pressure in right and left tyre is not even

④ Front wheel adjustment is wrong

⑤ Vehicle frame is distorted, and left and right wheelbase is different

⑥ Some brake pipelines is not smooth

⑦ Individual brake drum and brake hoop contacts badly

⑧ Suspension parts loose

⑨ Vehicle is leaning

⑩ Thread abrasion of left and right wheel is different

Clean or Change

Repair or Change

Equalize the air pressure

Adjust as the stipulation

Repair or Adjust

Repair or adjust

Repair

Check, repair and fasten

Verify, repair and adjust

Change block

① Brake main pump could not return correctly

② Brake hoop return spring is too soft

③ Parking brake adjustment is wrong

④ Parking brake drag line could not return

⑤ Brake branch clip block

⑥ Abrasion of brake drum and brake hoop is too big, and clearance is too great

⑦ Brake pipeline has been concaved

（ V）Malfunction in lamplight, circuit and meter system

Repair main pump

Change

Adjust

Lubricate or Change

Repair or Change

Change

Change

Change bulb

95

headlight does not illuminate system ② Adjuster has been damaged(adjusting Change adjuster voltage is too high to burn bulb）

③ Fuse has been burned Check、Change

④

⑦

Headlight relay has been damaged

⑤ Lead or grounding happens malfunction

⑥ Combination switch has been damaged

Storage cell has been damaged(incur bulb is burned)

Change

Repair circuit

Repair、Change

Change

Only one front headlight does not illuminate

Steering light does not illuminate

Lighting system

Starter does not rotate when starting

① Bulb has been damaged

② Lead or grounding happens malfunction

① Steering relay has been damaged

② Individual steering bulb has burned

③ Grounding is bad

④ Fuse burn out

⑤ Switch damaged

① Starter has been damaged

② Starting relay has been damaged

③ Grounding of starter is bad

96

Change

Repair circuit

Change

Change

Repair

Change

Change

Repair or Change

Change

Repair

All electric apparatuses do not work

Circuit system

Some kind of bad or complete lamplights are

Lamplight lamplight is circuit damaged (not including headlight)

Meter works badly

Meter and wire

④ Ignition switch has been damaged

① Total fuse has been burned

② Ignition switch has been damaged

③ General wire or grounding wire has been cut off

④ Electric bottle contacts badly or happens oxygenation

① Switch has been damaged

② Bulb has been burned

③ Circuit has been cut off, linking parts contact badly

④ Fuse has been burned.

⑤ Grounding wire contacts badly

Change

Check and Change

Change

Repair circuit

Repair

Change

Change

Repair circuit

Change

Repair

① Fuse has been burned.

② Route has been cut off, tie-in contacts badly

③ Instrument has been damaged

④ Sensor has been damaged

Change

Repair route

Change

Change

97

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. NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS

REGISTERED WITH COMPANY. Initial dealer preparation and set-up of your vehicle is very important in ensuring trouble-free 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 cover accidental damage, normal wear and tear, abuse or improper handling.

This warranty also does not cover any vehicle that has been altered structurally, modified, neglected, improperly maintained, used for racing, or used for purposes other than for which it was manufactured, or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, this warranty does not cover physical damage to paint or finish, stress cracks, tearing or puncturing of upholstery material, corrosion, or defects in parts, components or the vehicle due to fire, explosions or any other cause beyond company' control.

98

WARRANTY


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.

HOW TO OBTAIN WARRANTY SERVICE

If your vehicle requires warranty service, you must 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). Company suggests that you use your original selling dealer; however, you may use any Company Servicing

Dealer to perform warranty service.

Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance they will contact the appropriate person at company.This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.If any of the above terms are void because of state or federal law, all other warranty terms will remain in effect.

EMISSION：

Reach Euro II emission standard.

99

WARRANTY


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.

Outside the Country where your vehicle was purchased:

If you are traveling temporarily outside the country where 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 warranty repair.

Notice

If your vehicle is registered outside of the country where it was purchased, and you have not followed the procedure set out above, your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind. (Vehicles registered to Government officials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty.)

For questions call company Customer Assistance:

China:+86(0)579 82258522

100

SPECIFICATIONS

Dimensions:

Overall length

Overall width

Overall height

Seat height

Wheelbase

Minimum ground clearance

Minimum turning radius

Maximum speed

2600 mm (102.4in)

1280mm (50.4in)

1960mm (77.2in)

870mm (34.3in)

3200 mm(126in)

1300mm(51.2in)

1880mm(74.0in)

830mm(32.7in)

1760mm （69.3in） 2440mm(96.0in)

210mm （8.3in）

4200mm (165.4in)

80 km/h

4900mm(192.9in)

Basic weight:

Mass of whole equipments (Not include driver)

590kg 635kg

Engine:

Engine type

Cylinder arrangement

Water-cooled 4-stroke, CF188/ CF 188-B/CF196 single cylinder

Displacement

Bore × stroke

Compression ratio

500：493 ml 600：594 ml

87.5×82.0 mm (3.4×3.2 in)

10.2:1

101

Starting system

Lubrication system

Engine oil:

Type

Recommended engine oil classification

Quantity:

Without oil filter cartridge replacement

With oil filter cartridge replacement

Final gear case oil:

Type

Quantity:

Electric

Pressure spray

1.8L(1.90 US qt)

1.9L(2.01 US qt)

SAE15W-40/SF or SAE 80W-90/GL-4

102

Periodic oil change

Front gear case oil:

Type

Quantity:

Periodic oil change

Air filter:

Fuel:

Fuel tank capacity

Fuel reserve amount

Carburetor:

Manufacturer

EFI System :

Manufacturer

Spark plug:

Type/manufacturer

0.25L(0.26 US qt)

SAE15W-40/SF or SAE 80W-90/GL-4

0.28L(0.30 US qt)

Dry element

22.0 L (5.8Gal) about 4 L (1Gal)

MIKUNI

BOSCH

DPR7EA-9(NGK)

103

Spark plug gap

Clutch type:

Transmission:

Primary reduction system

Secondary reduction system

Transmission type

Operation

High gear

Low gear

Reverse gear

Chassis:

Frame type

0.8-0.9 mm (0.032–0.035 in) wet, hoof centrifugal type

V-belt

Shaft drive

V-belt automatic

Right hand operation

3.514

5.857

3.828

Steel tube frame

Caster angle

Trail

4°

Tire:

Type Tubeless

Size front 25×8.00-12 rear 25×10.00-12

104

Brake:

Front brake

Rear brake type operation type operation

Suspension:

Front suspension

Rear suspension

Shock absorber:

Front shock absorber

Rear shock absorber

Electrical:

Ignition system

Generator system

Battery type

Battery capacity

Headlight type:

Bulb voltage, wattage × quantity:

Dual disc brake

Left foot operation

Dual disc brake

Left foot operation

McPherson independent suspension

Double swing arm independent suspension, two shock absorbers on each side

Coil spring / oil damper

Coil spring / oil damper

DC. C.D.I./ECU

A.C. magneto

12V 36Ah

105

Headlight

Tail/brake light

Indicator light

Neutral indicator light

High gear indicator light

Low gear indicator light

Reverse gear indicator light

Coolant temperature warning light

4WD-Lock drive indicator light

Fuses:

Power fuse

Brake light fuse

Light power fuse

Winch/dump pump fuse

E-fan fuse

Ignition fuse

2/4WD fuse

Fuel pump fuse

12 V 35 W/35.0 W × 2

12 V 5 W/21.0 W × 2

LED × 1

LED × 1

LED × 1

LED × 1

LED × 1

LED × 1

30A

10A

15A

10A

10A

10A

5A

10A

106

Low beam fuse

High beam fuse

Wiper fuse

Turning light fuse

Cigarett light fuse

MP3 fuse

Horn fuse

10A

10A

15A

5A

15A

5A

5A

107

Owner's manual | UTVs Factory UTV500CC Owner`s manual

INTRODUCTION

TABLE OF CONTENTS

Identification number records

Equipment Modifications

Safe Riding Gear

Safe Riding Gear

Safety Warnings

Safety Warnings

Safety Warnings

Safety Warnings

Safety Warnings

Safety Warnings

Safety Warnings

Safety Warnings

Safety Warnings

Safety Warnings

Safety Warnings

Safety Warnings

Safety Warnings

Safety Labels and Locations

Safety Labels and Locations

Component Locations

Component Locations

Indicator and warning lights

Dump Bed and winch

4×2、4×4WD and differential locking exchangeable

The Other Switch

Cigarette light

Windshield and wiper（optional）

The Other Switch

Seats

Fuel Cap

Ignition Switch

Gear Selector

Brake Pedal

Throttle Pedal

Vehicle Break-in Period

Pre-Ride Inspection

Safe Operation Practices

Starting the Engine

Stopping the Engine

Braking

Parking the Vehicle

New Operator Driving Procedures

Driving with a Passenger

Driving on Slippery Surfaces

OPERATION

Driving Uphill

Driving on a Sidehill (Sidehilling)

Driving Downhill

Driving Through Water

Driving Over Obstacles

Driving in Reverse

OPERATION

OPERATION

Parking on an Incline

MAINTENANCE

Periodic Maintenance Chart

Periodic Maintenance Chart

Periodic Maintenance Chart

Engine Oil

Engine Oil

Engine Oil

Engine Oil

Transmission (Main Gearcase)

Spark Plugs

Constant Variable Transmission (CVT) System

Filter Systems

Filter Systems

Throttle System

Throttle System

Carburetor

Carburetor

Throttle body

Brakes

Brakes

Steering Wheel Inspection

Shock Spring Adjustment

Tires