Xingyun XY40EV Service Manual

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XY40EV

SERVICE MANUAL

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Summary of Contents for Xingyun XY40EV

Page 1 XY40EV SERVICE MANUAL...
Page 2: Important Information
NOTICE This manual was produced by the XINGYUN Group primarily for use by XINGYUN dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on XINGYUN vehicle has a basic understanding of the mechanical ideas and the procedures of vehicle repair.
Page 3 CONTENTS CHAPTER1 ……………………………………………………….General Information CHAPTER2 ………………………………………….……………………Maintenance CHAPTER3…………………………………….……….….…… ………… Electrical CHAPTER4…………………………………………..…………………………Chassis CHAPTER5………………………………………………….……………….Final Drive CHAPTER6………………………………………………………………………Brakes Never run an engine in an enclosed area. Carbon monoxide exhaust gas is...
Page 4 poisonous and can cause severe injury or death. Always start engines outdoors. Gasoline is extremely flammable and explosive under certain conditions. Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Always keep alert and wear protection. Exhaust system components are very hot during and after use of UTV.
Page 5: General Information
CHAPTER 1 GENERALINFORMATION SERVICE MANUAL CHAPTER 1 GENERAL INFORMATION The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each UTV model for spare parts information and service. 1.1 IMPORTANT INFORMATION 1.2 V.I.N AND MOTOR SERIAL NUMBER 1.3 VEHICLE DIMENSIONS...
Page 6 CHAPTER 1 GENERALINFORMATION SERVICE MANUAL 1.1 IMPORTANT INFORMATION PREPARATION FOR REMOVAL PROCEDURES 1. Remove all dirt, mud, dust and foreign material before removal and disassembly. 2. Use proper tools and cleaning equipment. 3. When disassembling the machine, always keep mated parts together. Mated part must always be reused or replaced as an assembly.
Page 7 CHAPTER 1 GENERALINFORMATION SERVICE MANUAL CHECKING OF CONNECTIONS Dealing with stains, rust, moisture, etc. on the connector. 1. Disconnect: Connector 2. Dry each terminal with an air blower. 3. Connect and disconnect the connector two or three. 4. Pull the lead to check that it will not come off. 5.
Page 8 CHAPTER 1 GENERALINFORMATION SERVICE MANUAL CONVERSION TABLE How to use the CONVERSION TABLE Use this table to convert METRIC unit data to IMPERIAL unit data. METRIC MULIPLIER **mm 0. 3937 **in **cm 0.03937 **in CONVERSION TABLE METRIC TO IMP Known Multiplier Result Torque...
Page 9 CHAPTER 1 GENERALINFORMATION SERVICE MANUAL V.I.N AND MOTOR SERIAL NUMBER The vehicle identification number ① is stamped into the left side of the rear frame tube. The motor serial number ② is stamped into left side of motor crankcase. CHAPTER 1 GENERAL PAGE.
Page 10: Vehicle Dimensions
CHAPTER 1 GENERALINFORMATION SERVICE MANUAL VEHICLE DIMENSIONS Note. The on-road equipments (rear view mirror, turn lights, etc.) are not Standard Equipment for USA. CHAPTER 1 GENERAL PAGE. 1- 6...
Page 11 CHAPTER 1 GENERALINFORMATION SERVICE MANUAL NOTES CHAPTER 1 GENERAL PAGE. 1- 7...
Page 12: Maintenance
CHAPTER 2 MAINTENANCE SERVICE MANUA CHAPTER 2 MAINTENANCE CAUTION Due to the nature of the adjustments marked with a D on the following chart, it is recommended that service be performed by an authorized dealer.  More often under severe use, such as dirty or wet conditions to purge water or dirt contamination from grease fittings and other critical components.
Page 13 CHAPTER 2 MAINTENANCE SERVICE MANUA Item Hours When Remarks  Brake System Pre-ride Pre-ride Pre-ride inspection item Electronic Accelerator Pre-ride Pre-ride Pre-ride inspection item pedal Tires Pre-ride Pre-ride Inspect daily, pre-ride inspection  item Front and Rear Wheels/ Pre-ride Pre-ride Pre-ride inspection item ...
Page 14 CHAPTER 2 MAINTENANCE SERVICE MANUA Rear Prop Shaft, Shaft 50 hrs 6 months Check for/ boots/ looseness/  Yoke ＆ Boots damage. Front Suspension 50 hrs 6 months Inspect-lubricate,  tighten fasteners  Rear Suspension 50 hrs 6 months Inspect, tighten fasteners Brake fluid 200 hrs Change every two years...
Page 15 CHAPTER 2 MAINTENANCE SERVICE MANUA NOTE: 1. More often under severe use, such as wet or dusty conditions . 2. Grease: Light weight lithium-soap grease. 3. Grease M：molybdenum disulfide(MoS ) grease(water resistant). 4. *When suspension action becomes stiff or after washing. 5.
Page 16 CHAPTER 2 MAINTENANCE SERVICE MANUA The following items should be checked occasionally for tightness; or if they have been loosened for maintenance service. WHEEL NUT TORQUE SPECIFICATIONS Bolt Size Specification M12X1.25 50Ft.Lbs 69N.m NOTE: All nuts that have a cotter pin installed must be serviced by an authorized Dealer. Rear Tapered nuts: install with tapered side against wheel AXLE BOOTS ●Front Shaft Boots,...
Page 17 CHAPTER 2 MAINTENANCE SERVICE MANUA STEERING Steering Inspection The steering assembly of the machine should be checked periodically for loose nuts and bolts, worn tie rod ends, worn boots, and damage. Checking routing of all cables, hoses, and wiring to be sure the steering mechanism is not restricted or limited.
Page 18 CHAPTER 2 MAINTENANCE SERVICE MANUA The recommended toe alignment is 1/8”to 1/4”(3to6mm) toe out. 1. Set the steering wheel in a straight ahead position and hold them in this position. 2. Measure A and B, B minus A should be 1/16” to 1/8” (1.5 to 3mm). 3.
Page 19 CHAPTER 2 MAINTENANCE SERVICE MANUA  Check brake for excessive travel or spongy feel.  Check friction pads for wear, damage and loosened.  Check security and surface condition of the disc.  Pads should be changed when friction material is worn to 3/64”(1mm).(A) Rear Brake ...
Page 20: Headlight Lamp Replacement
CHAPTER 2 MAINTENANCE SERVICE MANUA LIGHTS WARNING Keep your headlights and taillights clean. Poor light while riding can result in an accident causing severe injury or death. CAUTION Do not service while headlight is hot. Serious burns may result. Do not touch a halogen lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot which will shorten the life of the lamp.
Page 21 CHAPTER 2 MAINTENANCE SERVICE MANUA High Beam Headlight Adjustment The headlight beam can be adjusted up and down. 1. Place the vehicle on a level surface with the headlight approximately 10’’(3m) from a wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.
Page 22: Electrical
CHAPTER 3 ELECTRICAL 3.1 PARTS INSPECTION AND SERVICE 3.2 BATTERY 3.3 Drive System 3.4 Drive System Common Malfunction 3.5 LIGHTING SYSTEM 3.6 LCD Meter 3.7 WIRING DIAGR...
Page 23 PARTS INSPECTION AND SERVICE HEADLIGHT ADJUSTMENT 1. Use bulb 12V 35W/35W. 2. Remove the black sheath, turning the socket counterclockwise and take it out. Turning the bulb counterclockwise and Remove it from the socket. Change the bulb. HEADLIGHT ADJUSTMENT 1. The headlight beam can be adjusted vertically. 2.
Page 24 position. 7. Tighten nut and bolt / screw. To turn the two adjusting screws backward is to lower the beam. To turn the two adjusting screws forward is to heighten the beam. TAILLIGHT / BRAKELIGHT LAMP REPLACEMENT 1. From the rear of the taillight remove two screws holding lens cover in place and remove lens cover.
Page 25 3.2 BATTERY SPECIFICATIONS DC 60V 100Ah (5×12V) Lead acid battery Check for appearance and connection 1.The shell, cover of the battery has no swelling, acid leakage or damage. 2, Check whether the battery is dirt; 3. Check whether the connection wire or terminal is rusty 4.
Page 26 water stains, to prevent short circuits. There has a charging indicator on instrument panel to indicates charging capacity. charging capacity: RED (<80%) YELLOW(>80%) GREEN (100%) Maintain 1.Do not allow the battery to be in a state of loss for a long time, it will decrease the capacity of the battery and affect the service life seriously.
Page 27 3.3 Drive System Drive system configuration: Motor rated power: 4KW Motor type: BLDC Battery: 12V100Ah*5 Maximum Speed: 40km/h Mileage: 50km 3.3.1 Electronic shift lever Have 3 gears : Front Neutral Reverse When select reverse, reverse buzzer will be working. Schematic Diagram...
Page 28 3.3.2Electronic accelerator pedal working voltage:5V (Provided by the motor controller) output voltage:0.9~4.0V Initial voltage: ＜1V （If the initial voltage > 1V, the motor cannot working） You can use a multimeter to measure the voltage between Blue line and Yellow line which is the pedal output voltage. 3.3.3 Motor controller 1.Controller Number 2.Power indicator light...
Page 29 A1：Accelerator pedal - B1：60V power supply A2：DC converter input + B2：DC contactor coil- C2；DC converter input - A3；Accelerator pedal + B3；Accelerator pedal OUTPUT A4：Ground enable B4：Reverse C4：Front B6: Motor speed signal A7: Hall sensor C B7: Hall sensor B C7: Hall sensor A A8: Hall sensor power supply+ B8: Motor temperature signal C8: Hall sensor power supply-...
Page 30 3.3.5 Car charger input voltage:100~240Vac Input frequency:47~63Hz charger current: 15A If the indicator light not work, check the voltage red/blue/brown line to green line. There have voltage, replace the indicator light, otherwise, car charger is fault. Charging abnormal check the car charger output voltage (60V), if the voltage is normal , battery is fault , otherwise check the input power and charging line.
Page 31 Switch to reverse gear, check the motor controller terminal B4 whether connect to negative of battery, if not, check the stroke switch in electronic shift lever Switch to front gear, check the motor controller terminal C4 whether connect to negative of battery, if not, check the stroke switch in electronic shift lever If terminal B4, C4 no fault, step on the accelerator pedal and measuring the voltage between terminal B3 and A1 (should between 1.0V~4.0V) .If the voltage is not normal, check the accelerator pedal.
Page 32 controller is fault. Otherwise, observe whether the accelerator pedal is returned and check the voltage between terminal A3 and A1,the initial voltage should be less than 1V. (4) green light on, red light twinkle Flicker mode: 0.25s on----0.25s off----0.25s on----0.25s off ----0.25s on----2s off(loop) check the plug which for motor hall sensor (4) green light on, red light twinkle Flicker mode:...
Page 33 3.3.5 LIGHTING SYSTEM FOR USA MODEL TROUBLESHOOTING Procedure Check: 1. Fuse (Main) 4.Lights switch\ 2. Battery 5.Distance light switch 3. Main switch 6. Wiring connection (entire lighting system)
Page 34 1.fuse NO CONTINUITY Replace the fuse 2.Battery NO CONTINUITY Check the battery condition. Clean battery terminals 3. Main switch NO CONTINUITY CHECK SWITCHES Replace the main switch 4. Light switch NO CONTINUITY CHECK SWITCHES Replace the light switch 5. Distance light switch CHECK SWITCHES Replace the H/L demo light switch...
Page 35 6.Wiring connection POOR CONNECTIONS Check the connection of the entire lighting system correct 7.check the condition of each lighting system. LIGHT SYSTEM CHECK 1. If the headlight fail to come on NO CONTINUITY 1.Blub and bulb socket CHECK SWITCHES Replace the bulb and/ or bulb socket 2.
Page 36 This circuit is not faulty 2. the taillight fails to come on 1. Bulb and bulb socket CHECK SWITCHES NO CONTINUIT Replace the bulb and /or bulb socket CONTINUITY 2. Voltage Connect the pocket tester (DC20V) to the bulb socket connector. Tester (+) lead →...
Page 37 3.6 LCD Meter 1. Turn Left Indicator 9. Light switch indication 2. Low voltage indication 10. Vehicle speed meter 3. Low voltage indication 11. Short mileage 4. Turn Right Indicator 12. Total mileage 5. High beam indicator light 13. LCD display 6.
Page 38 3.7 WIRING DIAGR...
Page 39: Chassis
CHAPTER 4 CHASSIS SERVICE MANUAL CHAPTER 4 CHASSIS WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each CUV model for spare parts information and service. 4.1 FRONT A-ARM REPLACEMENT 4.2 REAR A-ARM REPLACEMENT 4.3 REAR STABILIZER BAR REMOVA L/INSTALLATION...
Page 40 CHAPTER 4 CHASSIS SERVICE MANUAL 4.1 FRONT A-ARM REPLACEMENT 1. Elevate and safely support vehicle with weight removed from front wheel(s). 2. Remove cotter pin from ball joint stud at wheel end of A- arm and loosen nut until it is flush with end of stud.
Page 41 CHAPTER 4 CHASSIS SERVICE MANUAL 4.2 REAR A-ARM REPLACEMENT 1. Elevate and safely support vehicle with weight removed from the rear wheel(s). 2. Remove the wheel nuts and wheel. NOTE: To ease the removal of the spindle bolt, remove the hub cap and loosen the spindle bolts before removing the wheel.
Page 42 CHAPTER 4 CHASSIS SERVICE MANUAL 3. Remove the hub cap, cotter pin, spindle bolt, and washer. 4. Remove the brake caliper. Suspend the brake caliper from the frame with a wire. NOTE: Do not let the brake caliper hand from the brake line or damage may occur.
Page 43 CHAPTER 4 CHASSIS SERVICE MANUAL 9. Remove the bottom stabilizer bar nut. 10. Loosen two bolts that secure the A –arm bushing to frame by alternating each about 1/3 of the way until the A-arm can be removed. The lower A-arm should now be free to remove. 11.
Page 44 CHAPTER 4 CHASSIS SERVICE MANUAL 1. Elevate and safely support vehicle with weight removed from the rear wheel(s). 2. Remove the rear wheel to gain access to the stabilizer bar, each side. 3. Remove the stabilizer bar nut from the lower A-arm, each side.
Page 45 CHAPTER 4 CHASSIS SERVICE MANUAL 4.4 FRONT STRUT REPLACEMENT 1. Hold strut rod with wrench and remove top nut. 2. Compress spring. 3. Remove upper strut pivot assembly. 4. Remove coil spring and collapse strut body. 5. Remove two pinch bolts from strut body. 6.
Page 46 CHAPTER 4 CHASSIS SERVICE MANUAL 8. Install pinch bolts with clamp(s). Torque pinch bolts to 15ft.lbs.(21Nm). 9. Reassemble spring and top pivot assembly. Be sure all parts are installed properly and seated fully. 10. Torque strut rod nut to specification. Do not over torque nut. Strut Rod Nut Torque :15 ft.
Page 47 CHAPTER 4 CHASSIS SERVICE MANUAL 4.6 BOX REMOVAL/INSTALLATION Box Removal 1. Disconnect the license light coupler. 2. Lift the box into the dump position. 3. Remove the box shock pin from the frame (both sides). 4. Remove the shocks from the shock brackets. Let the shocks fully extend.
Page 48 CHAPTER 4 CHASSIS SERVICE MANUAL 4.7 STEERING ASSEMBLY REMOVAL/INSTALLATION 1. With the steering wheel cover bolts removed, remove the steering wheel cover and the steering wheel. 2. With the steering wheel holder nut removed, remove the steering wheel holder. 3. Remove the steering column bolts. 4.
Page 49 CHAPTER 4 CHASSIS SERVICE MANUAL NOTES CHAPTER 4 CHASSIS PAGE. 4- 11...
Page 50 CHAPTER 4 CHASSIS SERVICE MANUAL CHAPTER 4 CHASSIS PAGE. 4- 12...
Page 51: Final Drive
CHAPTER 5 FINAL DRIVE SERVICE MANUAL CHAPTER 5 FINAL DRIVE WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each CUV model for spare parts information and service. 5.1 W HEEL, HUB , AND SPINDLE TORQUE TABLE 5.2 FRONT HUB EXPLODED VIEW 5.3 FRONT HUB REMOVAL/INSPECTION...
Page 52 CHAPTER 5 FINAL DRIVE SERVICE MANUAL 5.1 WH E E L , H U B , AND SPINDLE TORQUE TABLE Item Specification heel Nuts 59 Ft.Lbs 66 Nm Front W heel Nuts 59 Ft.Lbs 66 Nm Rear W Front Hub Nut on Spindle/ outer CV joint 101 Ft.Lbs 137 Nm Rear Hub Retaining Nut 101 Ft.Lbs 137 Nm...
Page 53: Brakes
CHAPTER 5 FINAL DRIVE SERVICE MANUAL 3. Grasp the top and bottom of the tire. The tire should rotate smoothly without binding or rough spots. 4. Remove wheel nuts and wheel. 5. Remove the two brake caliper mounting bolts. CAUTION: Do not hang the caliper by the brake line. Use wire to hang the caliper to prevent possible damage to the brake line.
Page 54 CHAPTER 5 FINAL DRIVE SERVICE MANUAL 7. Rotate hub. It should rotate smoothly without binding or rough spots or side play. 8. Install brake caliper using new bolts. (Apply Loctite™ 242 to threads) Tighten bolts to 18 ft.lbs (24 Nm) CAUTION: New bolts have a pre-applied locking agent which is destroyed bolts upon removal.
Page 55 CHAPTER 5 FINAL DRIVE SERVICE MANUAL 5.6 REAR HUB EXPLODED VIEW 5.7 RE AR HUB AND KNUCKLE REMOVAL/ INSPECTION 1. Elevate rear end and safely support machine under main frame area. C AUTIO N: Serious injury may result if machine tips or falls.
Page 56 CHAPTER 5 FINAL DRIVE SERVICE MANUAL 5.8 RE AR HUB AND KNUCKLE INSTALL ATION 1. Start the rear hub and knuckle assembly onto the drive shaft. 2. Align the bottom of knuckle and lower control arm. Secure with the lower control arm bolt. 3.
Page 57 CHAPTER 5 FINAL DRIVE SERVICE MANUAL 5.10 RE AR DRIVE SHAFT INSTALL ATION 1. Install a new circlip onto the rear drive shaft. Apply Anti-Seize Compound onto the rear driveshaft splines (both ends). 2. Reinstall the rear driveshaft into the rear gearcase.
Page 58 CHAPTER 5 FINAL DRIVE SERVICE MANUAL 7. Lower the vehicle. Torque the spindle retaining nut to 101 ft.lbs. (137 Nm). Install a new cotter key and the hub cap. 8. Install brake caliper using new bolts. (Apply Loctite™ 242 to threads) Tighten bolts to 18 ft.lbs (24 Nm) CHAPTER 5 FINAL DRIVE.
Page 59 CHAPTER 5 FINAL DRIVE SERVICE MANUAL NOTES CHAPTER 5 FINAL DRIVE. 5-...
Page 60 CHAPTER 6 BRAKES SERVICE MANUAL CHAPTER 6 BRAKES WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each ATV model for spare parts information and service. NOTE: Also See Chapter 2 for Maintenance Information.
Page 61 CHAPTER 6 BRAKES SERVICE MANUAL 6.1 SPECIFICATIONS Front Brake Caliper Item Standard Service Limit Brake Pad Friction material 0.157"/ 4mm 0.04"/ 1mm Thickness B rake Disc Thickness 0.150- 0.164"/3.810- 4.166mm 0.140"/ 3.556mm Brake Disc Thickness Variance 0.002 "/ .051m m Between Measurements Brake Disc Runout 0.005 "/ .127mm...
Page 62 CHAPTER 6 BRAKES SERVICE MANUAL  Adjust foot brake after pad service.  Test for brake drag after any brake system service and investigate cause if brake drag is evident.  Make sure caliper moves freely on guide pins (where applicable) . ...
Page 63 CHAPTER 6 BRAKES SERVICE MANUAL 1. Clean reservoir cover thoroughly. 2. Remove cover from reservoir. 3. If changing fluid, remove old fluid from reservoir with a brake fluid pump or similar tool. 4. Add brake fluid up to the indicated MAX level on the reservoir.
Page 64 CHAPTER 6 BRAKES SERVICE MANUAL Master Cylinder Fluid Level Between the MIN line and the MAX line of reservoir. 12. Install master cylinder reservoir cover. 13. Field test machine at low speed before putting into service. Check for proper braking action and pedal reserve.
Page 65 CHAPTER 6 BRAKES SERVICE MANUAL 1. Inspect the spring on the parking brake lever assembly. 2. Inspect the parking brake cable at the parking brake lever assembly on the brake caliper. 3. Inspect the brake lines and brake line connections for possible leaks or loose lines. 6.7 PARKING BRAKE ADJUSTMENT Parking Brake Inspection 1.
Page 66 CHAPTER 6 BRAKES SERVICE MANUAL will not roate. 5. Back the adjustment bolt (B) out 1/4 turn. 6. Tighten the jam nut (A) while holding the adjustment nut (B) in place. 6.8 PARKING BRAKE REAR CALIPER REMOVAL / INSTALL Park Brake Caliper Disassembly / Pad Inspection NOTE: Do not get oil, grease, or fluid on the park brake pads.
Page 67 CHAPTER 6 BRAKES SERVICE MANUAL 6.9 FRONT PAD REMOVAL / INSPECTION / INSTALLATION NOTE: The brake pads should be replaced as a set REMOVAL 1. Elevate and support front of CUV safely. CAUTION: Use care when supporting vehicle so that it does not tip or fall.
Page 68 CHAPTER 6 BRAKES SERVICE MANUAL INSPECTION Measure the thickness of the pad friction material. Replace pads if worn beyond the service limit. Service Limit 0.3/64"(1 mm) INSTALLATION 1. Lubricate mounting bracket pins with a light film of All Season Grease, and install rubber dust boots.
Page 69 CHAPTER 6 BRAKES SERVICE MANUAL 2. Measure the disc thickness at 8 different points around the pad contact surface using a 0-1" micrometer and a dial indicator. Replace disc if worn beyond service limit. Brake Disc Thickness New 0.150-0.164" (3.810 - 4.166 mm) Service Limit 0.140"...
Page 70 CHAPTER 6 BRAKES SERVICE MANUAL 1. Remove wheel, remove caliper from the strut. 2. Loosen and remove brake hose to caliper. Place a container under caliper to catch fluid draining. INSPECTION Inspect caliper body for nicks, scratches or worn. Replace caliper as an assembly if any problem exists.
Page 71 CHAPTER 6 BRAKES SERVICE MANUAL damage brake line. Support caliper so as not to kink or bend brake line. 4. Push caliper piston into caliper bore slowly using a C-clamp or locking pliers with pads installed. NOTE: Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper.
Page 72 CHAPTER 6 BRAKES SERVICE MANUAL Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls. 1. Safely support the rear of the machine. 2. Use a wrench to remove the brake line. Place a container to catch brake fluid draining from brake lines.
Page 73 CHAPTER 6 BRAKES SERVICE MANUAL micrometer and a dial indicator. Replace disc if worn beyond service limit. Brake Disc Thickness New 0.150-0.164" (3.810 - 4.166 mm) Service Limit 0.140" / 3.556 mm Brake Disc Thickness Variance Service Limit 0.002 " (0.051 mm) difference between measurements 3.
Page 74 CHAPTER 6 BRAKES SERVICE MANUAL NOTES CHAPTER 6 BRAKES PAGE. 7- 15...