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UTV500CC User’s Manual www.UTVsFactory.com
500CC Utility Vehicle
User Manual
Vision 2007-1.0
UTVs Factory
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Table of contents
I、 Notices
II、 Technical parameters
III、 Placement drawing for whole vehicle
IV、 Inspection before driving
V、 Driving operation
VI、 Running-in of new vehicle
VII、 Maintenance and repair
VIII、Trouble diagnosis and elimination
IX、 Screwing moment of important bolts
X、 Specification and dosage table for fuel, Lubricating oil and brake liquid
XI、 Circuit diagram
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I、、、、Notes
1. Please read this operating instruction carefully before using this vehicle, and
drive, check and repair it by the requirement in this manual to keep vehicle at good
technical status and prolong its using lifetime.
2. Initial running for 1000km of vehicle is period. In this period, it is necessary to
accord with the regulation of period(see the chapter—for new vehicle). After period
expires, it is necessary to make vehicle maintenance by regulation.
3. Quality warrant term of vehicle: in normal using situation, it is three months or
3000km mileage after buying this vehicle, if one of these two exceeds regulated value,
quality warrant term expires. In quality warrant term, for those malfunctions caused by
design, manufacture, assembly quality which influence your usage, our company will
repair them freely.
4. Damaged parts in following items could not be repaired freely, they should be
paid, please forgive:
(1) Damages caused b y wrong usage, maintenance and storage which do not accord
with this operating instruction.
(2) Damages caused by force majeure, chemical sub stance, bad substance or other
natural disasters.
(3) Consumed parts in normal usage, such as: bulbs, fuse(pipe), air filter core,
engine oil filter core, gasoline filter core, brake friction sheet(drum), spark plug, tyre,
transmission belt, appliqué, rubber parts, standard fastening parts, lubricating oil(grease),
brake liquid and so on.
(4) Damages caused by improper assembly or repair, such as self-dismantling or
changing this vehicle without approval of our company and chartered sal e(repair) store,
or sending chartered sale(repair) store for repair which is not appointed by our company.
(5) Vehicles which could not provide warrant card or vehicle purchase credential.
(6) Malfunctions caused by using other parts or accessories which are not provided
by our company.
(7) Various overhead expenses caused by repairing vehicle(such as telephone fee,
vehicle fare, freightage, work missing fee, rep air fee out of repair store appointed b y our
company).
(8) Abnormal abrasions and damages caused by wrong using gasoline, lubricating
oil and brake liquid.
(9) Feeling phenomenon which could not influence mechanical performance, such
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as: noise, vibration, heat and so on.
(10) Damages caused by that you do not check and maintain vehicle periodically by
our requirements.
II、、、、Technical parameters
(I)、Common technical data
1、Mass parameters(kg)
Mass of whole equipments(not including driver)： 590Kg
Front shaft： 260Kg
Rear shaft ： 330Kg
2、Dimension parameter(mm)
Total length×total width×total height:2600×1280×1960
Minimal clearance apart from ground： 210
Wheelbase： 1730
Tread： front wheel：1036 rear wheel： 1040
Approach angle(°)：47
Removed angle(°)：82
(II)、Using data
1、High running speed(km/h)：H gear : 70
2、Small steering semi-diameter(m)： 4.65
3、Brake performance (No-load brake distance m).
When V０=30km/h：4.
When V０=40km/h：5.5
When V０=50km/h：9
4、0—50Km/h accelerating time（H）：7.9”
0—50Km/h accelerating time（L）：8.4”
5、Oil consumption for 100 kilometers (L)：10
6、Exhaust：Reach Euro II exhaust standard.
7、Loading capacity:： 300Kg
(III)、Engine
Type：CF188
Form：single cylinder, four-stroke, water cooling, 4 valves, top camshaft, single equal
shaft, Carburetor type.
Cylinder diameter(mm)： 87.5
Travel(mm)： 82
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Engine displacement: 493
Compressed ratio： 10.2：1
Maximal power (kw/r/min)： 24/6500 (EEC model less than 15kw)
Maximal torque(N·m/r/min)： 38.8/5500 (EEC model: 30N.M/4500r/min)
Lowest fuel consuming rate (g/Kw·h)： 340
Idling speed (r/min)： 1300±100%
Start type： electronic start
Ignition type： non-touch CDI DC start
Plug type: DPR7EA-9(NGK)
Magneto type: ever-mag DC motor, ex-rotor flywheel type.
Lubricating oil category： SAE 15W—40/SF
Engraved position of factory number： Upper surface on rear part of left crankcase
Ignition ahead angle(°/r/min)： 10/1500
32/1500
Lubricating type： Pressure and splash lubricating type
Engine oil pump type： TOTOR type
Engine oil filter type: whole filtering with paper element
Carburetor style: vacuum film
Air filter: Sponge element filtering
Fuel type: higher class than RQ-93
Transmission: V-belt with teeth on, auto stepless gear change, plus gear change cam
with change gear transmission.
Gear change type: gear lever with hand
Clutch type： wet, hoof centrifugal type
Primary speed change ratio (stepless speed change): 0.703—2.88
Speed change ratio： Total speed reduce ratio:
H Gear：3.514 2.47—10.12
L Gear： 5.857 4.12—16.87
R Gear： 3.828 2.69—11.02
Cooling style: Closed cooling fluid circulating.
Cooling fluid type: antifreeze with prevent rust
Out dimension: 610 x 568 x 519
Net weight: 70kg
Output type: front and rear shaft output
Shaft running direction: clockwise (from back of engine).
(IV)、Chassis
1. Clutch and transmission： wet hoof auto-centrifugal clutch. V belt, auto-stepless
transmission plus gear change cam transmission.
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2. Main Driver：
Main driver： Tapered arc gear transmission，transmission rate： 33/9
3. Driving type： 4×4 front and rear wheels drive; Rear wheel is the normal
drive. Front wheel can be took off the driving. They are all the shaft
transmission。
4. Suspension：
Front suspension： swing arm type independent suspension.
Rear suspension： co-length double swing arm independent suspension, two
shock absorbers on each side of rear wheel.
5. Front Wheel alignment parameter：
Front wheel extroversion angle： 0° ±1°
Main pin inner obliquity： 11°50’ ±3°
Main pin back obliquity： 4°±1°
Front toe-in： -3—3mm
6. Tyre：
Front wheel： Front wheel type 25×8.00—12 Air inflating pressure：
250Kpa
Rear wheel：Tyre type 25×10.00—12 Air inflating pressure：
300Kpa
7. Steering system：
Adopt gear rack type redirector, total circle number of steering plate：3.75；
total swing angle of steering wheel：75°.
Maximum turning left: 37.5°.
Maximum turning right: 37.5°.
8. Brake：
Brakes adopt front and rear placement dual-pipeline hydraulic pressure brake
system, front and rear wheels adopt disk type brake. And parking brake adopts
mechanical transmission disk to work on the flange of the main axle of rear wheels.
9. Loading Dump Bed：
Dump Bed adopts slope backward by electric powered pump. Dumping a ngle
is 49°.
10. Winch:
Electric powered winch. Traction is 2000 pounds.
(V)、Electric apparatuses
1. Pipeline system： pipeline system adopts single-line system，Minus ground
strap， pipeline voltage is 12V。
2. Generator：out-rotor flywheel AC magneto，rated power is 325W。
3. Battery：voltage is 12V，capacity is 36A·h。
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4. Starting engine type：12V forever magnetic DC electric engine。
III、、、、Placement drawing for whole vehicle
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1. Top roof. 2. Safe belt. 3. Frame. 4. Steering wheel. 5. Rear mirror.
6. Engine hood. 7. Indicator. 8. Bumper. 9. Headlight. 10. Winch
11. Wheel. 12. Seat. 13. Side cover. 14. Rear mudguard. 15. Dump bed
16、Reinforce pole. 17、Head rest
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Engine
1、Carburetor 2、Start 3、Water temperature sensor 4Hand-pill staring handle 5、Left
cover
6、Rear shaft flange 7、Front shaft flange 8、Oil filter 9、water outlet（temperature
adjuster）
10、CVT case 11、CVT inlet 12 、CVT inlet 13、Plug
VIN number location（on frame of right rear wheel） Rear suspension
Oil Intake Dipstick
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Oil drain plug（bottom of engine）
Fuel tank intake（in left side） Coolant, Brake liquids intakes
Warning：Engine oil quantity should be between upper and lower position, over more or less oil
would burn out or damage engine..
Warning： Oil drain plugs of engine and gear box should be tightened，
，，
，otherwise engine would
burned for oil leakage. Should use the correct gear box oil and quantity. More or less oil can
cause the gear box burned out..
Warning：Brake liquid should be filled by regulated trademark, it could not mix
different brake liquids from different factories and trademarks, and it is necessar
y
to keep enough brake liquid height; otherwise it will incur brake disables, even
heavy result.
Warning： it is very dangerous to unscrew radiator or coolant cap when engine is
hot，for steam and water will spurt by the pressure to hurt people at this time. It is
necessary to unscrew radiator or coolant cap after engine becomes cool.
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Rear main speed reducer lube-check Front main speed reducer
lube-check
IV、、、、Check before drive
1. Check the leakages on engine, such as oil, cooling fluid, fuel, lube and so on should
have no leakage.
2. Check the levels of engine oil, brake liquid and cooling liquid, if necessary, add
more.
3. Check the air pressure in tyre.
4. Check the function of safety belt.
5. Check whether steering transmission organization has been loosened.
Warning：Fill up the stipulated lube in main reducer.
The lube level should be a little bit low er than intake , more will cause leakage and less wil
l
cause the main reducer burnt.
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6. Check engine supporting frame, bolts, transmission system and running system.
7. When starting engine, listen and check whether there is any abnormal noise, and
observe whether each meter is normal.
8. Check whether steering is flexible and reliable; ch eck brake free t ravel length and it s
reliability (including parking brake).
9. Check whether lighting system (steering light, brake light, warning light, small light,
dipped headlight, high beam and so on) is complete and workable.
10. Check whether vehicle dump box works well. And winch works normally.
11. Check fuel quantity.
V、、、、Driving operation
Warning：
(1) Driver must accord with the legal driving age and requirement.
(2) Fasten the safety belt before driving.
(3) Driver should buy person safety insurance。
(4) Driver should limit the speed and try his best to keep vehicle run at economical
speed (35—45km/h). Overspeed driving will cause accident.
(5) Driver should control speed strictly by the size of swerve when turn around
(the highest speed could not exceed 20Km/h).
(6) Do not load the goods over the height of the box. The loadings must be
fastened if it is higher than box, in order to avoid being hurt some one by the
goods rushing forward when driving or stopping.
(7) The antifreeze in radiator is only suitable in using in temperature bellow -15
degree centigrade. Please change the correct antifreeze when below -15℃.
(8)
The sudden brake is not allowed when the speed is over 50km/h (except the
emergency situation). Otherwise it might cause the vehicle damaged, or sideslip or
turn over.
(9) The two wheel drive is suggested to be used on normal road. The four wheel
drive can cause the over wearing on tyre and parts.
(10) The stepless automatic clutch used on engine. Gear chan ge i s not nece ssary in
the most time. Make sure the vehicle must be stopped when change reverse gear.
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1. Safety driving notes for farmer vehicle
To guarantee your driving safe, please accord with following items：
—Tie safety belt—
Safety belt could avoid you are thrown out of vehicle when happening sudden
swerve and accidents, and guarantee running safe effectively.
—Inspection before driving —
Careful inspection before driving is necessary to guarantee running safe and enjoy
driving pleasure.
—Be familiar with your farmer vehicle—
Your driving technique and mechanical common sense are base o f safety driving. We
advise you practice driving on open location before driving on road.
—Accord with highway code —
According with highway code will guarantee your running safe furthest.
—It is necessary to keep aware when driving in rain—
Rain weather will drop the brake performance and operation performance of your
farmer vehicle, and bring bad influence for your running safe, so it is necessary to note.
2. Operation
① Key
Keys can be used on ignition and fuel box. There are two keys, one of them
should be preserved carefully for spare.
② Ignition switch
Ignition switch has four positions：
“OFF”（close）position： All circuits are turnoff except emergency light,
electric fan and cigarette lighter.
“ON”（open）position： All circuits ex cept engine are connected, and they
could start at any moment or make engine keep running status 。
“START”（start）position： Connect engine and ignition circuit, and start
engine. Handle returns to “ON” position automatically after engine starts。
“LOCK”（lock）position： The steering wheel is locked after pulling out the
key (key could be pulled out only at this position).
Warning: Ignition key can not be turned to “LOCK” position and pull out before vehicle
is stopped stably. This could causes the vehicle lost control when the steering wheel is
locked.
N
ote: You only can start the engine when gear is in “N” position. The engine can not be started
up when gear is in “H”, “L” and “R” positions.
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③ Meter
1、Thermometer 2.3.、Indicators 4、Fuel 5、High beam 6、kilometer mark
7、Speed indicator 8、2 and 4 wheel drive
（ａ）、Speedometer 7：Display the speed of vehicle.
（ｂ）、Kilometer mark 6 ：Display the accumulated driving distance.
（ｃ）、High-beam 5：Light when high-beam is on.
（ｄ）、Indicators 2, 3 ：Blink when the relative direction indicators light. Blink
in same times when warning light is on.
（ｅ）、Fuel meter 4 ：Display the quantity of fuel.
（ｆ）、Gear display：The corresponding indicating (L, H, N, R, P) 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.
④ Main switch of lights
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（ａ）、When ignition switch is at “ON” position and lamplight main switch is
turned to “ ”position, front and rear small light are lightened.
（ｂ）、When ignition switch is at “ON” position and lamplight main switch is
turned to “ ”position, front headlight and rear small light are
lightened.
（ｃ）、When ignition switch is at “ON” position and lamplight main switch is
turned to “ ”position, press down lamplight main switch handle,
headlight changes to far light from close light; raise lamplight main
switch handle, headlight changes to close light from far light;
（ｄ）、When ignition switch is at “ON” position and lamplight main switch is at
“OFF” position, raise lamplight main switch handle(feeling elastic), high
beam illumines, and high beam extinguishes after releasing the handle.
（ｅ）、When ignition switch is at “ON” position, press the red button switch at
the front of combination switch cover, warning light will flash; and pull
out button switch, warning light will extinguish.
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（ｆ）、When ignition switch is at “ON” position, turn lamplight main switch
handle anticlockwise, left steering light will flash; and turn lamplight
main switch handle clockwise, right steering light will flash.
（ｇ）、When ignition switch is at “ON” position, step down brake pedal, brake
light will illumine.
⑤ Horn button
Press down horn button on steering wheel (anyone of these two), loudspeaker will
hoot.
⑥ Accelerator pedal and brake pedal
At the front of driver’s right foot, the left one is brake pedal, right one is
accelerator. farmer vehicle will start going or accelerating by stepping down the
accelerating pedal when gear pole is in “L”,“H”or“R” position.
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⑦ Parking brake handle
When pulling up parking brake handle, rear wheels will produce brake force to
prevent vehicle from sliding when vehicle is parked.
⑧ Dump Bed
When need to dump, firstly, open the rear door of cargo box, then press main switch
to“O” position, and press down“UP” of “TRAILER” switch, at this time, cargo
box will be up backwards; And stop after releasing the press; while press down
“
““
“DOWN”””” on “TRAILER” switch, th e cargo box will be back. And stop after
when release the press.
Warning：After parking the vehicle, pull up the hand b rake bar. Push down the
handle before start moving. The hand brake can not be used to stop vehicle when
moving(except emergency).
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, please stop pushing the button at onc e in case to
damage the motor and switch.
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⑨4×2、4×4WD and differential locking exchangeable
When select “4X2”, it is rear wheel drive mode (this is the normal driving
mode). When select “4X4”, the front and rear wheels will be drove at same
times( normally, this drive mode will be used on muddy and rugged road. When select
“4X4 lock” mode, it is 4 wheel drive mode and also the front differential locked (this
drive mode only used on very rough road or when the car got stuck).
⑩ Windshield and wiper（optional）
Clockwise turning the switch is the “Low” and “High” wiping speed. Anti-clockwise
turning to the bottom is “Off”.
N
ote：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.
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 ch ange 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）.
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VI、、、、Running-in of new vehicle
Cooperation between the surfaces of each part of new vehicle is locating adjusting
and running-in phase, for surface friction of each part is big, the result of running-in
quality influences greatly using lifetime of farmer vehicle. In running-in period, please
implement strictly the regulation about speed limit, load limit and periodic maintenance
to reduce
1. Highest speed:
Running mileage Highest limit speed
Initial 800Km 40Km/h
800～1600Km 50Km/h
Exceed 1600Km 60Km/h
2. Accelerate and decelerate
It is necessary to avoid sudden and frequent acceleration and deceleration and
keep running in even speed in running-in period.
3. Heating engine before running
In running-in period, it is necessary to run at idling speed for 3-5 minutes after
starting engine to pre-heat engine, then start running after lubricating oil flows
on each friction surface.
4. Note engine cooling
In running-in period, it is necessary to note water temperature in engine to avoid
running in low temperature for long time and in high temperatu re without water,
this will strengthen abrasion and drag cylinder.
5. Check the loosing situation on each linking part of all bolts usually
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For fastening bolts on each part of new vehicle are easy to loosen, it is necessary
to note the fixed situation of each bolt, especially the bolts of transmission
organization and fixed equipment.
6. First maintenance of vehicle
In running-in period, after running for 1000km, it is necess ary to complete first
maintenance, maintenance details could refer to “Maintenance and repair”.
Warning：First maintenance is necessary to implement best performance of
farmer vehicle, prolong using lifetime and insure safe.
VII、、、、Maintenance and repair
1、1. First maintenance item table:
Sequence
number
Category Checking item Adjusting content
1 Engine Change engine oil and oil
filter.
Check coolant.
Adjust idling speed ：
1300±100r/m listen whether
there is any abnormal noise
in engine; clean air filter
core.
2 Brake Front and rear wheel arrester;
parking arrester; brake
performance
Brake liquid height； Brake
pedal free travel ： 15 ～
20mm； Travel of parking
arrester is 2～3 tooth.
3 Steering
organization
Operate flexibly without any
block phenomenon
Fastening bolts on redirector
and steering transmission
organization which could
influence safety
performance
4 Transmission
box
Stepless shift performance and
belt abrasion
5 Gear Box Change gear lube.
6 Front/Rear
main driver
Change gear lube
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7 Tyre Tyre pressure and thread depth Check front tie-in ： -3 ～
3mm
8 Transmission
organization
Whether the bolts, flange nuts
on transmission shaft and the
bolts on main driver are
tightened.
9 Lamplight Illumination and signal Every kind of lamplights,
signal switches and buttons,
etc
10 Storage cell Liquid height in storage
cell(except the
maintenance-free battery)
Liquid surface should be
between upper and lower
limit marked, it is necessary
to note only distilled water
could be filled in storage
cell
11 Meter Display is normal and correct
12 Dump bed
and
self-saving
winch
Work normally
2、Routine maintenance item table (checked by consumer)
Sequence
number
Category Checking item Adjusting content
1 Engine Engine oil level; leakage
situation, cooling water level
Oil level is between
upper and lower limit;
engine oil, cooling
liquid, fuel and other
mediums do not have
any leakage; clean filter
periodically
2 Steering
organization
Operate flexibly without any
block phenomenon
Each linking drag pole,
ball head and locking
nut are tightened.
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3 Brake Brake liquid height; brake
pedal travel and free travel;
brake performance
The thickness of pad
must not be less than
4.5mm.
4 Gear box Gear oil level, any noise Oil level must in the
limitation.
5 F/R main
driver
Gear oil level, any noise Oil level shoud be to the
intake.
6 Tyre Air pressure, thread, crack
and wound
Tyre air pressure：front
wheel 0.20Mpa。 rear
wheel 0.25Mpa
Thread depth ：no less
than 1.6mm
7 Lamplight Illumination, signal and
loudspeaker
Every kind of
lamplights, signal
switches and buttons,
etc
8 Battery Liquid height in storage
cell(except the
maintenance-free battery)
Liquid surface should be
between upper and
lower limit marked, it is
necessary to note only
distilled water could be
filled in storage cell
9 Meter Display is normal and correct
10 Dump bed and
self-saving
winch
Work normally
11 Transmission
organization
Each bolt of transmission
organization has not been
loosened.
Periodic maintenance item table for UTV
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Checking Kilometers
term
Checking
Item month
First 1000Km
first 3 months
Every
3000Km
Every 3
months
Every 6000Km
Every 3 months
Brake soft pipe
Check Check —
Change once every three years
Brake liquid Change once every one and half year
Brake Check Check —
Steering organization Check Check —
Accelerator cable Check Check —
Brake pedal free travel Check Check —
Carburetor Check Check —
Tyre Check Check —
Spark plug — Check —
Engine oil Change Change —
Air filter(filter core)
— Clean —
Change if necessary（ usually change once every
10000Km）
Valve clearance — Check —
Shift driving belt — Check —
Fuel pipe
Check Check —
Change once every three years
Gear oil in Gear box change change —
Gear oil in F/R main driver change change —
Front and rear absorber — — Check
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Main driver, reverse gear
device (including gear oil)
Check Check —
Battery Check Check —
Redirector and steering
transmission organization
Check Check —
Transmission organization Check Check —
Lamplight and meter
Check Check —
Brake pipeline and branch
pump
Check Check —
Engine suspension Check Check —
Front and rear axle
suspension
— Check —
Note：①
：①：①
：①Period maintenance term takes the first reached value of mileage and
time as standard.
②
②②
②Inspection in table includes: if necessary, need more w ash, lubrication
or change.
③“
③“③“
③“————”
””
”shows no requirement.
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VIII、、、、Malfunction analysis and elimination
（I）Engine malfunction
Malfunction
phenomenon
Malfunction system Reason Solving method
Start
difficultly or
could not start
1. pressure in
cylinder is too
low.
Cylinder wear out
Piston wear out.
Leakage on Washer of
cylinder.
Wearing on Pipe of air valve
or seat of valve is not
suitable.
plug is loose.
Starting motor is too slow.
Air circulation is not right.
Gap of valve is not suitable.
change
change
change
Repair or change
Tighten
Check electric system.
Adjust
Adjust
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2. No ignition
generated from plug
① Dirt on spark plug
② Wet on plug
③ Ignition coil problem
④ Touch loop got open or
short circuit
⑤ Magneto problem
⑥ CDI problem
Clean or change
Clean, dry or
Change
Change
Change
Change
Change
3. No fuel in
carburetor
Vent hole on tank jammed
Problem or blocked in fuel
pipe.
Problem on needle valve of
carburetor
Blocked in fuel tank
Blocked in fuel filter
Clean or change
Clean or change
Change
Change
Clean or Change
Start
difficultly or
could not
start
4. Miscellaneous Gear is not in neutral Put gear on neutral
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1. Mechanic problem Valve gap no suitable
Valve base is not suitable
Problem on air pipe
Broken on bush of swing
arms
Fuel level of bobber cab is
not right
⑥ Jam on muzzle of
carburetor
⑦ Fuel pipe problem
⑧ Adjust screw of idle sets
wrong.
Adjust
Repair or Change
Change
Change
Adjust the height of
bobber
Clean
Change
Adjust
Engine has no
idle speed or
uneven
2. Electric parts
problem
① Dirt on plug
② Gap of plug not correct
③ Ignition loop problem
④ CDI problem
⑤ Magneto problem
Clean or Change
Change or Adjust
Change
Change
Change
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29
Engine
middle and
high rotate
speed is
uneven
Mechanical problem
① The force o f Valve sprin g 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
Change
Change
Clean or Change
Adjust or change
Adjust or change
Change
Adjust the height of
floater
Clean or change
Clean
Change
Exhaust blue
smoke
Mechanical fault
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
Drain the extra lube
Change
Change
Change
Change
Change
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30
1. Fuel supply system
fault
① Jam in muzzle of carburetor
② Level of Floater not correct
③ Air filter is dirty
④ Leakage on air intake pipe
⑤ Too many lube
Clean or change
Adjust the height
Clean or change
Tighten or change
Drain the extra lube
2. Electrical parts
problem
① Dirt on plug
② Gap of plug not correct
③ Ignition loop problem
④ CDI problem
⑤ Magneto problem
Clean or Change
Change or Adjust
Change
Change
Change
Engine power
is not enough
3.Mechanical
problem
Gap of Valve is not correct
The force of valve spring is
weak.
③ Air circulation is not right.
④ Cylinder worn out
⑤ Piston Ring worn out
⑥ Valve base not correct
⑦ Swing arm or cam shaft
worn out
Change operation
method
Check, remove or
change
Adjust
Change
Change
Change or repair
Change
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31
1. Fuel system fault ① Octane number is lower
② Fuel pass blocked
③ Fuel pump problem
④ Fuel level in floater is
lower
Use the right fuel
Clean the fuel pass
Change
Adjust the height of
floater
2. Electric System
problem
Ignition time is late or early
②Spark is weak or no spark
Adjust ignition time
Check from plug to
magneto
3. Air pass problem 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
Adjust carburetor
Repair
Clean or change filter
Repair or change
Repair or change
Dredge
Repair or change
Engine
overheats
4. Engine cooling
system
Block in water channel or
radiator
② Air in Cooling system or
coolant is 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
Clear
Release air, refill
coolant
Change
Change
Change
Change
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32
5. Miscellaneous ① Carbon a ccumulated on top
of piston
② Too many or less lube
③ Unsuitable lube used
Clear
Drain or Refill
Change
Noise on air valve Gap on valve is too big
Spring on valve is broken
Swing arm or cam shaft
worn out
Adjust
Change
Change
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
Change
Change
Clean
Change
Change
Noise from chain of
circulation
Chain elongated
Chain worn out
Adjustor of chain problem
Change chain &
sprocket
Repair & Change
Noise from clutch ① Spline of crankshaft
damaged
② Spline of clutch damaged
Change crankshaft
Change clutch
Noise from
Crankshaft
① Bearing noise
② Needle bearing damaged
③ Gap too big
Change
Change
Change
Noise from
engine
Noise from CVT ① Belt loose or worn out
② Roller or main wheel
damage
Change
Change
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33
Noise from
transmission system
① Gear damaged
② Input and output shaft
damaged
③ Bearing worn out
④ Bush worn out
Change
Change
Change
Change
1.Fuel system
happens malfunction
Octane number is too low
Oil routine is blocked and oil
supply is not smooth
Change with gasoline
whose Octane number
accords with regulation
Clean oil routine
Gasoline
engine lacks
power and
accelerating
Clutch
skiding
Transmission system ① Hoof of clutch worn out
② Spring on clutch is weak
③ Out wheel worn out
④ Belt worn out & loose
Change
Change
Change
Change
Gear change
not smooth or
got stuck
Gear box or Gear
change system
① Operating gear damaged
② Shift rod twisted
③ Shift drum worn out
④Shift pulling stick unsuitable
Change
Change
Change
Adjust
Carburetor
works not
properly
Starting problem ① Blocked in muzzle
② Blocked in muzzle channel
③ Leakage on connecting part
of carburetor and starting part
④ Starting pin not work
properly
Clean
Clean
Tighten, Adjust or
change
Adjust
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34
Idle and low speed
not stable
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
Not stable in high and
middle speed
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
Clean
Clean
Clean
Adjust
Clean or change
Adjust
Adjust
Spill over or fuel
level fluctuated
① Needle valve worn out or
damaged
② Spring on valve broken
③ Floater not work well
④ Dirt or scale in valve
Change
Change
Adjust or change
Clean
Engine
coolant
temperature is
lower
Cooling System ① Fault on heat sensor switch
on fan
② Cold weather
③ problem on constant
temperature meter
Change
Cover the radiator
Change
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35
Spark weak Ignition System 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
Change
Change
Change
Change
Change
（II）Malfunction in transmission system
Vehicle speed
does not
increase by
engine speed
Transmission system Shift belt slips
Speed adjusting plate
abrasion is too much
Speeding adjusting plate
slipping is blocked
Spring force of adjuster is
short
Change
Change
Repair or Change
Repair or Change
Out of gear Gear Box or Gear
shifting system
① Speed changing drum
groove worn out
② Right and Left gear
changing rods bended
③High and Low driven gear
groove wear to taper
④ Speed changing principal
and countershaft worn out
⑤Sector gear tooth worn out
⑥The force of spring of sector
gear is weak or broken.
Change
Change
Change
Repair or Change
Repair or Change
Change
（III）Malfunction in running system, suspension and steering organization
Running is
leaning
Running system Air pressure in left and right
wheel is different
Adjust air pressure in
tyre
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36
Running is
leaning
Running system
Load of left and right wheel
is different
Spring force of left and right
absorbing spring
Front wheel location is
wrong
One side wheel is locked or
brake could not release
Front and rear suspension
parts have been loosened,
bent or damaged
Adjust load
Adjust or Change
Check or adjust
Repair arrester
Screw or Change
suspension parts
Tyre is
abraded
abnorma
lly or
greatly
Steering organization,
running system,
suspension
Left and right absorber has
been damaged, spring force
is short
Tyre is not balance, and
wheel hub is distorted
Front wheel location is
wrong
Vehicle is over-load
Tyre has not change its
position
Wheel hub bearing has been
damaged or adjustment is
wrong
Wheel assembly jump (axial,
radial) is too great
Air pressure in tyre is too hig
or too low
Adjust or Change
Change
Check or adjust
Check load
Change
Adjust or Change
Change
Adjust air pressure in
tyre
Front wheel
shakes,
swing or
jump
Steering organization,
running system
Tyre and wheel is not balance
Wheel hub bearing has been
damaged or adjustment is
Balance wheel or
Change tyre
Change or adjust
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37
Front wheel
shakes, swing
or jump
Steering organization,
running system
wrong
Left and right swing arm ball
head has been abraded or
loosened
Drag pole tie-in has been
abraded or loosened
Front wheel location is
wrong
Wheel (axial, radial)jump is
too big
Tyre has tympanic bag
Free travel of redirector is too
big
Fixed bolts on each part of
steering organization has been
loosened
Change
Change
Check、adjust
Change tyre or wheel
hub
Change tyre
Change or adjust
Fasten
Steering is
heavy
Steering organization
running system
Air pressure in tyre is short
Ball head of left and right
swing arm and drag pole is
blocked
Front wheel location is
wrong
Steering pole pipe is blocked
Mesh clearance of redirector
is too small
Charge the tyre to
applicable air pressure
Change
Check and adjust
Repair or Change
Adjust
（IV）Malfunction in brake system
Brake is not
hard enough
Brake system Brake pipeline leaks oil
Brake disk and brake hoof
contacts badly or dirt on
surface
Brake drum and brake hoof
wear badly
Repair
Repair or clean the
dust
Change
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38
Brake main pump is damaged
or leaks oil
⑤ Brake branch pump is
damaged or leaks oil
⑥Brake liquid is short
⑦Brake pipeline has air
⑧Arrester is too hot
Repair or change
Repair or Change
Add
Eliminate air
Repair or Change
Brake is
leaning
Brake system
suspension
Some brake drums and hoof
pads have oil stain
Individual brake branch
pump leaks oil or is blocked
The air pressure in right and
left tyre is not even
Front wheel adjustment is
wrong
⑤ Vehicle frame is distorted,
and left and right wheelbase
is different
⑥Some brake pipelines is not
smooth
⑦Individual brake drum and
brake hoop contacts badly
⑧Suspension parts loose
⑨Vehicle is leaning
⑩Thread abrasion of left and
right wheel is different
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
Brake clip
block
Brake system
Brake main pump could not
return correctly
Brake hoop return spring is
too soft
Parking brake adjustment is
Repair main pump
Change
Adjust
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39
Brake clip
block
Brake system
wrong
Parking brake drag line could
not return
Brake branch clip block
Abrasion of brake drum and
brake hoop is too big, and
clearance is too great
Brake pipeline has been
concaved
Lubricate or Change
Repair or Change
Change
Change
（V）Malfunction in lamplight, circuit and meter system
Front
headlight
does not
illuminate
Lighting system Bulb has been damaged
Adjuster has been
damaged(adjusting voltage is
too high to burn bulb）
Fuse has been burned
Headlight relay has been
damaged
Lead or grounding happens
malfunction
Combination switch has been
damaged
Storage cell has been
damaged(incur bulb is
burned)
Change bulb
Change adjuster
Check、Change
Change
Repair circuit
Repair、Change
Change
Only one
front
headlight
does not
illuminate
Lighting system Bulb has been damaged
Lead or grounding happens
malfunction
Change
Repair circuit
Steering light
does not
illuminate
Steering relay has been
damaged
Individual steering bulb has
burned
Change
Change
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40
③ Grounding is bad
④ Fuse burn out
⑤ Switch damaged
Repair
Change
Change
Starter does
not rotate
when starting
Starter has been damaged
Starting relay has been
damaged
Grounding of starter is bad
Ignition switch has been
damaged
Repair or Change
Change
Repair
Change
All electric
apparatuses
do not work
Circuit system Total fuse has been burned
Ignition switch has been
damaged
General wire or grounding
wire has been cut off
Electric bottle contacts badly
or happens oxygenation
Check and Change
Change
Repair circuit
Repair
Some kind of
lamplight is
bad or
complete
lamplights are
damaged (not
including
headlight)
Lamplight、circuit
Lamplight、circuit
Switch has been damaged
Bulb has been burned
Circuit has been cut off,
linking parts contact badly
Fuse has been burned.
Grounding wire contacts
badly
Change
Change
Repair circuit
Change
Repair
Meter works
badly
Meter and wire Fuse has been burned.
Route has been cut off, tie-in
contacts badly
Instrument has been damaged
Sensor has been damaged
Change
Repair route
Change
Change
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41
IX、、、、Screwing moment of important bolts
Engine
Sequence
number
Item Quantity Thread diameter
mm
Torque（Nm）
1 Sensor of reverse gear 1 M10x1.25 20
2 Spark plug 1 M12x1.25 18
3 Sensor of water
temperature
1 R/c1/8 8
4 Adjust nuts of air valve
gap
4 M5 10
5 Nut of driving disk 1 M20x1.5 115
6 Nut of driven disk 1 M20x1.5 115
7 Round nut of driven
disk
1 M30x1 100
8 Nut of front output axle 1 M14X1.5 97
9 Nut of driving prick
gear
1 M22X1 145
10 Nut of driven prick
gear
1 M16X1.5 150
11 Fixed nut of clutch 1 M18X1.5 70
12 Nut of position
limitation of driven
gear
1 M60 110
13 Nut of position
limitation of front
output bearing
1 M55 80
14 Bolts of swing arm axle 2 M14X1.25 28
15 Drain bolt 1 M12X1.5 30
16 Clutch installing bolts 6 M8 26
17 Stator of magneto Bolts 3 M6 10
18 Screws on CVT
stopping wind board
3 M6 10
19 Oil pipe connecting
bolts
2 M14X1.5 18
20 Oil pump installing
bolts
3 M6 10
21 Bolts on pressure
limiting valve
2 M6 10
22 Bolts on principal prick
gear cover
4 M8 32
23 Bolts on driven prick 4 M8 25
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42
gear cover
24 Gear positioning bolt 1 M14X1.5 18
25 Bolt on hand start disk 1 M10X1.25 55
14 M6 10 26 Bolts on crankcase
3 M8 25
27 Bolt on Gear changing
sector gear
1 M6 12
28 Bolt on oil filter 1 M20X1.5 63
29 Bolt on oil filter 1 M20X1.5 63
30 Bolts on start motor 2 M6 10
31 Bolts on cylinder cover 4 M10 38
2 M6 10 32 Nuts on cylinder cover
1 M8 25
33 Bolts on cylinder 4 M6 10
34 Bolt on cover of
cylinder
12 M6 10
35 Bolts on chain adjuster 2 M6 10
36 Nuts on chain adjuster 1 M8 8
37 Bolts on fan motor 3 M6 10
38 Bolts on constant
temperature unit
2 M6 10
39 Bolts on pump cover 3 M6 6
40 Bolts on pump 2 M6 10
41 Bolts on circulationunit 2 M6 15
M5 4.5—6
M6 8—12
42 Other Bolts
M8 18--25
FRONT, REAR SUSPENSION：
s.q. Item Qty.
Thread diameter
mm
Torque
（N·m）
1
Bolts on front steering joint
and absorber
4 M12×50 110
2
Bolts on front and rear brake
disk
18 M10×50 60
3
Bolts on front and rear brake
grip
4 M12×50 110
4
Bolts on support frame of
front and rear break sub-pumps
4 M12×20 110
5
Bolts on front steering joint
connector and beam pin
2 M10×30 60
6
Nuts of front and rear
sub-axles
4 M18 200
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43
7 Nuts of pulling rode connector 2 M12 100
8 Locknuts of pulling rode 4 M12 60
9 Screw on Steering 4 M10×30 50
10 Bolts on steering transfer fork 2 M8×25 25
11 Screws on steering column 2 M10×20 50
12 Nuts on front absorber 2 M8 25
13 Screw of winch 4 M8×16 25
14 Screw of main brake pump 2 M10×55 55
15
Bolt on push rode of main
brake
1 M10 50
16
Bolt on beam pin of push rode
of main brake
1 M8×20 23
17 Nuts of flange of drive shaft 4 M14 100
18 Nuts on tyre 16 M12 55
19 Screws on cab roof
6
2
M12×95
M12×70
60
20 Nut of steering wheel 1 M12 70
21 Bolts on hand brake 2 M8x20 28
22 Bolts on bumper 2 M10x20 50
23 Bolts on driving axle 2 M8x25 30
24
Bolts on flange and rear wheel
upper swing arm
1 M12x90 70
25
Bolts on flange and rear wheel
lower swing arm
2 M12x175 70
26 Bolts on front axle gear box 6 M8x28 25
27 Screw on front axle motor 4 M8×20 13
28 Screw on front axle pin shaft 1 M8x10 10
29 Nut on front axle 1 M14x1.5 62
30 Bolts on differential 6 M10x1.25x18 40
31 Bolt on oil intake of front axle 1 M14x1.25x12 25
32 Drain bolt on front axle 1 M10x1.25 25
33 Bolts on rear axle box 2 M10x1.25x25 40
34 Bolts on rear axle box 4 M8x25 25
35 Nut on rear axle input shaft 1 M12x1.25 62
36
Bolts on base of rear axle
input shaft
4 M8x30 25
37 Bolt on rear axle positioning 1 M65x1.5x10 90
38 Nut 1 M8 16
39 Drain bolt on rear axle 1 M14X1.25X12 25
40 Bolt on oil intake of rear axle 1 M20X1.5X12 25
Page 44
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44
Specification
Tightening
moment
M6 10N·m
M8 25N·m
M10 50N·m
Other screws（8.8 grade）
M12 80N·m
X、、、、Specification and usage quantity for fuel, lubricating oil and brake
liquid
Category Specification Capacity Remark
Fuel RQ-90 or upper
grade lead-free
gasoline
27L Content of
fuel box
Lubricating oil
（engine, Gear box）
SAE15W—40/SF or
SC
1900ml(change oil)
2000ml(change filter)
2200ml(repair engine)
Lubricating oil（front
main driver）
First 0.33L/change
0.28
Lubricating oil ( Rear
main driver）
SAE15W—40/SF or
SAE80W—90/GL-4
First 0.30L/change0.25
Brake liquid Gb1083 JG3 1.1L
Engine coolant Distilled water:
Glycol =1:1
Page 45
UTV500CC User’s Manual www.UTVsFactory.com
UTV 500CC Circuit Map
+-
起动电机
M
点火
线圈
左转向
灯开关
右转向
灯开关
闪光
信号
小灯
开关
小灯
电源
大灯
电源
近光灯
开关
远光灯
开关
喇叭
开关
速度
信号
低档高档空档
停车
档
倒档
LOCK
刹车
开关
远光灯近光
灯
10
右转向灯左转
向灯
10
闪光
器
水温油量
电源+
刹车
灯
小灯
喇叭
雨刮
油泵
雨刮
开关
发电机
点火器低档
高档
空档
停车
档
倒档
速度
信号
刹车
开关
电源+
电源-
辅助继
电器
点火
触发+
触发-
辅助继
电器
调节器
电源-
电锁
1
至24WD
至F
红4
红
1.5
黑
0.75
仪表
仪
表
蓝
0.75
绿
0.75
紫
0.75
红6 黑6
红6
黑
0.75
黑
1.5
蓝
2.5
红
2.5
紫
0.75
绿
1.5
白
0.75
蓝
0.75
黄
绿
0.75
黄
绿
0.75
棕
0.75
棕
0.75
浅蓝
0.75
橙0.75
红白
0.75
黑白
0.75
白
棕
0.75
黑蓝
0.75红蓝0.75
黑
红
0.75
蓝白
0.75
黄白0.75
紫
0.75
黄白0.75
红
棕
0.75
粉
红
0.75
浅
绿
棕
0.75
黄Z
0.75
红4
黑
白
0.75
浅
绿
黄
0. 75
蓝
绿
0.75
浅蓝
0.75
+12
至24WD
黑
1.5
-
黑
0.75
温控
开关
风扇
电锁2电锁3电锁
4
5
10 10
10
10 5
30 10
10
10
大
小
灯
电
源
转
向
喇
叭
远光近
光
继电
器
继电
器
仪
表
雨
刮
点烟
器
点
烟
器
红
黄
0.75
刹
车
点火
2/4
WD
浅绿
棕
0.75
绿
1.5
浅蓝
1.5
红
1.5
蓝
红
0.75
黑
棕
0. 75
红
黑
0.75
黄白
0.75
黑黄
0.75
白
0.75
蓝
0.75
橙0.75
5
10
浅绿
绿
0.75
黄绿
0.75
顶泵
开关
顶泵
电机
红
1.5
黄
1.5
黄
1.5
白
绿
0.75
白
绿
0.75
黑
棕
0.75
MP3
左音箱
右音箱
制动
液位
继电器
红黑
0.75
组合
开关
5
棕绿0.75
黄
绿
0.75
灰白
0.75
浅绿
绿
0.75
牵引
电机
牵引
开关
红4
黄4 黄4
黑4
黑4
绿
0.75
20A
XY500-S农夫车电路总图
红
0.75
4WD and 4WD Transfer Circuit
K1
K2
+12 -
-
+
BA
地
C
D
E
+1 2
前桥
至
LOCK
仪表
白绿
0.75
浅
绿
棕
0.75
红
0.75
黄
0.75
浅
绿
绿
0.75
浅
绿
黄
0.75
浅绿
/红
0.75
红白
0.75
灰白
0.75
蓝白
0.75
黄白
0.75
蓝绿
0.75
红棕
0.75
红棕
0.75
灰白
0.75
XY500-S农夫车二、四驱转换电路图
黑蓝
0.75
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