UTVs Factory UTV500CC User manual
UTV500CCUser’sManual www.UTVsFactory.com
500CC Utility Vehicle
User Manual
Vision 2007-1.0
UTVs Factory
UTV500CC User’sManual www.UTVsFactory.com
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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 by wrong usage, maintenance and storage which do not accord
with this operating instruction.
(2) Damages caused by force majeure, chemical substance, bad substance or other
natural disasters.
(3) Consumed parts in normal usage, such as: 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 sale(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, repair fee out of repair store appointed by 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：Totalspeedreduceratio:
H Gear：3.514 2.47—10.12
LGear：5.857 4.12—16.87
RGear：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 angle
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
Table of contents
