1. Manuals
  2. Brands
  3. AXIS OFF-ROAD Manuals
  4. Offroad Vehicle
  5. 500cc
  6. Owner's manual

AXIS OFF-ROAD 500cc Owner's Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 500cc and is the answer not in the manual?

Questions and answers

Donna Harlan
April 16, 2025

Where is the dip stick located

0
1 comments:
Mr. Anderson
May 8, 2025

The dipstick on the AXIS OFF-ROAD 500cc is located in the engine oil filler hole, which is accessible after removing the engine oil filler cap.

This answer is automatically generated

0
gerald reynolds
January 28, 2025

were is the winch control switch on the axis 700

0

Subscribe to Our Youtube Channel

Related Manuals for AXIS OFF-ROAD 500cc

Summary of Contents for AXIS OFF-ROAD 500cc

  • Page 2: Important Safety Messages

    Owner Manual INTRODUCTION Congratulations on your purchase of the AXIS 500/700cc. This Owner’s / Operator’s manual will provide you information regarding safe operation, operational instructions, maintenance and care. Fully understanding this manual and following all of the instructions herein will provide the knowledge needed to have safe and enjoyable UTV operation.

  • Page 3: Important Manual Information

    Owner Manual IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY Particularly important information is distinguished in this manual by the following OR DEATH. notations: The Safety Alert Symbol means ATTENTION! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the machine operator, bystander or a person inspecting or repairing the machine.

  • Page 4: Important Notice

    Owner Manual 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 arrestor laws and regulations in effect at the time of manufacture.
  • Page 5 Owner Manual Location of the Warning and Switches Specification Labels Accelerator Pedal 4-14 Brake Pedal 4-15 Safety Information Parking Brake Lever 4-15 Drive Select Lever 4-16 Description and Vehicle Fuel Tank Cap 4-17 Identification Seats 4-17 Identification Number Records Seat Belts 4-18 Vehicle Identification Number Glove Compartment...
  • Page 6 Owner Manual Brake Fluid Level How to Measure Tire Pressure 5-12 Brake Fluid Leakage Tire Wear Limit 5-13 Brake Operation Fuel Operation Gasohol Starting the Engine in Low Engine Oil Temperatures Coolant Starting the Engine Final Gear Oil Warming Up Differential Gear Oil Drive Select Lever Operation and Throttle Pedal...
  • Page 7 Owner Manual Learning to Operate Your Vehicle To Change the Engine Oil 8-12 Turning your Vehicle Final Gear Oil 8-15 Braking Changing the Final Gear Oil 8-17 Going Uphill Differential Gear Oil 8-18 Going Downhill 7-10 Changing The Differential Gear Oil 8-19 Crossing Through Shallow Water Coolant...
  • Page 8 Owner Manual Parking Brake Lever Free Play Troubleshooting 8-51 Adjustment 8-35 Solution to Common Problems in Brake Light Switch Adjustment 8-37 the Vehicle 8-52 Cable Inspection and Lubrication 8-37 Brake Pedal and Accelerator Pedal Cleaning and Storage Lubrication 8-38 Cleaning Rear Knuckle Upper and Lower Storage Pivot Lubrication...
  • Page 9 Warning and Safety Labels Read and understand all of the labels on your vehicle. They contain important information for safe and proper operation of your vehicle. Never remove any labels from your vehicle. If a label becomes difficult to read or comes off, a replacement label is available by contacting your dealer.

  • Page 10: Warning And Safety Labels

    Warning and Safety Labels...
  • Page 11 Warning and Safety Labels...
  • Page 12 Warning and Safety Labels...
  • Page 13 Warning and Safety Labels...

  • Page 14: Safety Information

    Safety Information SAFETY INFORMATION This off-highway utility vehicle handles differently from other vehicles including cars and UTVs. SEVERE INJURY OR DEATH can result if you do not follow these instructions: Read this manual and all labels carefully and follow the operating procedures described. ●...
  • Page 15 Safety Information Never attempt jumps or other stunts. ● Always inspect your vehicle each time you use it to be sure it is in safe operating condition, Always ● follow the inspection and maintenance procedures and schedules described in this manual. Always keep hands, arms, feet, and legs inside the vehicle at all times during operation.
  • Page 16 Safety Information Never operate on hills that are slippery or ones where you will not be able to see far enough ahead of ● you. Never go over the top of a hill at speed if you cannot see what is on other side. Always follow proper procedures for going uphill.

  • Page 17: What Can Happen

    Safety Information WARNING POTENTIAL HAZARD Improper handling of gasoline. WHAT CAN HAPPEN Gasoline can catch fire and you could be burned. HOW TO AVOID THE HAZARD Always turn off the engine when refueling. Do not refuel right after the engine has been running and is still very hot.
  • Page 18 Safety Information WARNING POTENTIAL HAZARD Starting or running the engine in a closed area. WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. HOW TO AVOID THE HAZARD Always operate your vehicle in an area with adequate ventilation.

  • Page 19: Description And Vehicle Identification

    Description and Vehicle Identification Headlights Spark arrester Front shock absorber assembly adjusting ring Passenger seat belt Brake fluid reservoir Passenger seat Air filter element(engine and air intake duct) Oil filter cartridge V-belt case Engine oil dipstick Driver seat Battery Driver seat belt Fuses Spark plug Coolant reservoir...
  • Page 20 Description and Vehicle Identification Light switch Steering wheel Starter Main switch On-Command four-wheel-drive and differential lock switches Multi-function meter unit Auxiliary DC jack Drive select lever Parking brake lever Accelerator pedal Brake pedal NOTE: The vehicle you have purchased may differ slightly from those in the figures of this manual.

  • Page 21: Vehicle Identification Number

    Description and Vehicle Identification Identification Number Records Record the Vehicle Identification Number and Vehicle Identification Number model label information in spaces provided for The Vehicle Identification Number (VIN) is assistance when ordering spare parts from a stamped into the frame. service center or for reference in case the vehicle is stolen.

  • Page 22: Control Functions

    Control Functions Functions of the respective switch positions CONTROL FUNCTIONS are as follows: Main switch All electrical circuits are supplied with power, and the headlights and taillights illuminate when the light switch is on. OFF: All electrical circuits are switched off. The key can be removed in this position.

  • Page 23: Indicator And Warning Lights

    Control Functions Indicator and Warning Lights CAUTION: Do not operate the electric starter ● continuously for more than 5 seconds at a time or starter damage could occur. Wait at least 5 seconds between each start attempt. Do not turn the key to the “START” ●...
  • Page 24 Control Functions Reverse Indicator Light “R” Low-Range Indicator Light “L” This indicator light comes on when the drive This indicator light comes on when the drive select lever is in the “R” reverse position. select lever is in the “L” position. Coolant Temperature Warning Light “...
  • Page 25 Control Functions  After restarting, make sure that the light Meter works together with EPS system and is out. Continuous use while the light is monitors working condition of EPS system. on may cause damage to the engine. Fault can be displayed by fault indicator light High beam indicator and fault indicator of EPS system, so the The light being on means headlight is at high...
  • Page 26 Control Functions Speedometer Unit  Check the meter. If fault indicator light of EPS system does not be lit, ECU can be for regular use.  If fault indicator light of EPS system is lit, that means EPS system find out some fault during ECU self-checking process, then you should consult your local dealer for maintenance in time.
  • Page 27 Control Functions Speedometer unit functions: from the odometer, to the tripometer, and  a speedometer (which shows the speed) then to the hours meter; then it starts the  an odometer (which shows the total cycle over. distance covered) The odometer displays the total distance ...
  • Page 28 Control Functions button on the display. This will also change circle on the front axle when the grey and displayed mileage from miles yellow 4WD selector buttons are pressed in kilometers. indicating the “4WD” function has been Clock time adjustment activated.
  • Page 29 Control Functions When riding on a flat road at a comparatively CAUTION: high speed, adjust settings If the display indicators flash or the “2WD/UNLOCK” and there are no symbols speedometer does not show the speed while in either of the 4WD indicators. the UTV is in motion, Ask a dealer to check Riding an UTV while the differential the speed sensor and circuits.
  • Page 30 Control Functions fixed, will the time show automatically. Switches The description for the fault codes are shown in Chapter 11 of this manual. Fuel level indicator The fuel level display will indicate the fuel volume. When the fuel is getting low the fuel pump symbol will flash.
  • Page 31 4-10 Control Functions On-Command Four-Wheel–Drive and CAUTION: Differential Gear Lock Switches Do not use the headlights with the engine turned off for an extended period of time. The battery may discharge to the point that the starter motor will not operate properly. If this happens, remove the battery and recharge it.

  • Page 32: What Can Happen

    Control Functions 4-11 conditions.  Two-wheel drive (”2WD”): Power is sup- WARNING plied to the rear wheels only. POTENTIAL HAZARD Changing from 2WD to 4WD or from 2WD  Four-wheel drive (“4WD’): Power is to 2WD-Differential UNLOCK, or supplied to the rear and front wheels. vice-versa while the vehicle is moving.
  • Page 33 4-12 Control Functions the select lever is set to positionⓐ, and On-Command four-wheel-drive switch then set the switch to “2WD”. “2WD/4WD” On-Command Differential Gear Lock Switch “4WD”/”LOCK” Select lever On-Command four –wheel-drive switch “2WD/4WD” To change from 2WD to 4WD ,stop the vehicle, and then set the switch to On-Command differential gear lock switch “4WD”/ “LOCK”...
  • Page 34 Control Functions 4-13 set the switch to “LOCK”. When the differential gear is locked, the differential HOW TO AVOID THE HAZARD gear lock indicator light will come on along Always ride at a slow speed when the with the differential gear lock indicatorin the vehicle is in 4WD-LOCK, and allow extra multifunction meter unit display .To release time and distance for maneuvers.
  • Page 35 4-14 Control Functions will cause the engine speed to be limited until engagement is complete. Accelerator pedal Press the accelerator pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check that the accelerator pedal returns normally before staring the engine.
  • Page 36 Control Functions 4-15 Brake pedal Press the brake pedal to slow or stop the vehicle. WARNING POTENTIAL HAZARD Malfunction of the accelerator pedal. WHAT CAN HAPPEN A faulty pedal that makes it difficult to speed up or slow down could cause loss of control.
  • Page 37 4-16 Control Functions lever, press the release button, and then Drive select lever push the lever all the way down. Spring The drive select lever is used to shift you pressure helps return the lever to the vehicle into the low, high, neutral and reverse released position.
  • Page 38 Control Functions 4-17 Fuel tank cap Seats Remove the fuel tank cap by turning it To remove a seat, pull its seat lock lever counterclockwise. upward, lift the front of the seat, and then slide the seat forward and up. 1.
  • Page 39 4-18 Control Functions To install a seat, insert the projection on the rear of the seat into the seat holders and push down on the seat at the front. WARNING POTENTIAL HAZARD A loose seat. WHAT CAN HAPPEN The operator could lose control or the operator or passenger could fall if the seat is loose during operation.
  • Page 40 Control Functions 4-19 2. Push the latch plate into the buckle until it clicks. Pull up on the latch plate to make sure it is secure. 1. Seat belt (×2) 2. Latch plate (×2) 3. Buckle (×2) To wear the seat belt properly, do the 1.
  • Page 41 4-20 Control Functions shoulder belt should fit against your chest. If it is loose, pull the belt out all the WARNING way and then let it retract. POTENTIAL HAZARD 5. To release the buckle, firmly press the Not wearing the seat belt or wearing the release button.
  • Page 42 Control Functions 4-21 Glove compartment Cargo bed CAUTION: To protect from damage, do not put metal products, like tools or sharply edged products directly in the glove compartment. If they must be stored, wrap them in appropriate cushion material. 1. Cargo bed 2.
  • Page 43 4-22 Control Functions Opening and closing the tailgate Lifting and lowering the cargo bed 1. Tailgate 2. Latch (×2) 1. Cargo bed release lever To lift To open Push down cargo bed release lever on left or Unhook the latches, and then lower the right side of the vehicle;...
  • Page 44 Control Functions 4-23 WARNING WARNING POTENTIAL HAZARD POTENTIAL HAZARD Overloading the cargo bed Pinch points. WHAT CAN HAPPEN WHAT CAN HAPPEN Could cause changes in vehicle handling You or someone else could be pinched which could lead to an accident. between the cargo bed and the frame HOW TO AVOID THE HAZARD when the bed is being lowered.
  • Page 45 4-24 Control Functions Front and Rear Shock Adjustment(Option 1) The spring preload can be adjusted to suit WARNING the operating conditions. POTENTIAL HAZARD You can reduce preload for a softer ride, or Carrying a passenger in the cargo bed increase preload if frequent bottoming out of WHAT CAN HAPPEN the UTV occurs.
  • Page 46 Control Functions 4-25 Standard position: B A-Minimum(soft) E-Maximum(hard) 1. Spring preload adjusting ring 2. Position indicator NOTE: A special wrench can be obtained at a service center to make this adjustment. 1. Special wrench...
  • Page 47 4-26 Control Functions Front and Rear Shock Adjustment(Option 2) WARNING WARNING POTENTIAL HAZARD These shock absorber assemblies Improper shock absorber adjustment. contain highly pressurized nitrogen gas, WHAT CAN HAPPEN read understand following Uneven adjustment can cause poor information before handling the shock handling and loss of stability, which absorber assemblies.
  • Page 48 Control Functions 4-27 Spring preload ·Do not dispose of a damaged or worn 1. Loosen the locknut. 2. Turn the spring preload adjusting nut in out shock absorber assembly yourself. direction ⓐ to increase the spring Take the shock absorber assembly to a preload thereby harden...
  • Page 49 4-28 Control Functions · A special wrench can be obtained at a Spring travel setting(Front) HSUN dealer to make this adjustment. · The spring preload setting is determined Minimum(soft): 412mm(16.22 in) Maximum(hard): 426mm(16.77 in) by measuring distance A, shown in the illustration.
  • Page 50 Control Functions 4-29 damping, and in direction F to decrease the Compression damping force rebound damping force and thereby soften Turn compression damping force the damping. adjusting screw (use 3.0 allen wrench) in direction ⓐ to increase the compression damping force and thereby harden the damping, and in direction ⓑ...
  • Page 51 4-30 Control Functions Trailer hitch bracket This vehicle is equipped with a 1 ¼ in WARNING ·Suspension components become hot receiver bracket for a standard trailer hitch. Trailer towing equipment can be obtained at during operation. Never touch a service center. (See pages 6-12 - 6-14 for compression damping force adjusting precaution information.) screw,...
  • Page 52 Control Functions 4-31 jack. Auxiliary DC jack The auxiliary DC jack is located at the right side of the front panel. The auxiliary DC jack can be used for suitable work lights, radios, etc. The auxiliary DC jack should only be used when the engine is running.
  • Page 53 4-32 Control Functions 4. When the auxiliary DC jack is not being used, cover it with the cap. CAUTION:  Do not use accessories requiring more than the above maximum capacity. This may overload the circuit and cause the fuse to blow. ...

  • Page 54: Pre-Operation Checks

    Pre Operation Checks Before using this vehicle, check the following items: ITEM ROUTINE PAGE Check operation, free play, fluid level and fluid leakage ● Brakes 5-2 - 5-3， 8-32 Fill with DOT 3 brake fluid if necessary ● Check for proper operation, condition and free play ●...
  • Page 55 Pre Operation Checks Brakes WARNING Check for correct brake pedal free play. If the POTENTIAL HAZARD brake pedal free play is incorrect, have a Failure to inspect the vehicle before service center adjust it. (See pages 8-34 - operating. Failure to properly maintain the 8-35.) vehicle.
  • Page 56 Pre Operation Checks Brake fluid leakage Check to see if any brake fluid is leaking out of WARNING the pipe joints or the brake fluid reservoir. Apply POTENTIAL HAZARD the brakes firmly for one minute. If there is any Driving with improperly operating brakes. leakage, have the vehicle inspected by a WHAT CAN HAPPEN service center.
  • Page 57 Pre Operation Checks Your engine has been designed to use regular Fuel Make sure there is sufficient gasoline in the unleaded gasoline with a pump octane number tank. ([R+M] /2) of 91 or higher, or research octane number of 91 or higher. If knocking or pinging Recommended fuel: occurs, use a different brand of gasoline or Unleaded gasoline only...
  • Page 58 Pre Operation Checks Engine oil Make sure the engine oil is at the specified level. WARNING Add oil as necessary. (See pages 8-10) POTENTIAL HAZARD Improper care when refueling. CAUTION: WHAT CAN HAPPEN  In order to prevent clutch slippage Fuel can spill, which can cause a fire and (since the engine oil also lubricates the severe injury.
  • Page 59 Pre Operation Checks CAUTION: Recommended engine oil type and Hard water or salt water is harmful to the engine. quantity: You may use soft water if you cannot get See page 10-2 distilled water. Coolant Coolant reservoir capacity Check the coolant level in the coolant reservoir (up to the maximum level mark): when the engine is cold.
  • Page 60 Pre Operation Checks Final gear oil Make sure the final gear oil is at the specified WARNING level. Add oil as necessary. (See pages 8-14 - POTENTIAL HAZARD 8-15 for details) Removing the radiator cap when the engine and radiator are still hot. Recommended oil: WHAT CAN HAPPEN SAE 80 API GL-4 Hypoid gear oil...
  • Page 61 Pre Operation Checks WARNING Recommended oil: Failure to check or maintain proper SAE 80 API GL-5 Hypoid gear oil operation of the throttle system can result in an accident and lead to serious injury or Throttle Pedal death if the throttle pedal sticks during Check to see that the accelerator pedal operation.
  • Page 62 Pre Operation Checks Throttle Freeplay Throttle Freeplay Adjustment 1. Remove both seats. Remove the middle If the throttle pedal has excessive play due to cover of the engine. (see PAGE 8-9 ) cable stretch or mis-adjustment, it will cause a 2.
  • Page 63 5-10 Pre Operation Checks 4. Resume the center cover and seat to their when pulled out and retract on its own when position released. The latch plate should click securely into the buckle and release when the release button is pushed firmly. Wash off any dirt or Steering Wheel Inspection Check the steering wheel for specified freeplay mud which could affect operation.
  • Page 64 Pre Operation Checks 5-11 as necessary for proper operation. Tires WARNING Switches POTENTIAL HAZARD Operating this vehicle with improper tires, or with Check the operation of all switches. Have a improper or uneven tire pressure. service center repair as necessary for proper WHAT CAN HAPPEN operation.
  • Page 65 5-12 Pre Operation Checks be incorrect. 2. Tire pressure below the minimum specified could cause the tire to dislodge from the rim under severe riding conditions. 3. Use no more than the following pressures when seating the tire beads. Higher pressures may cause the tire to burst. Inflate the tires very slowly and carefully.
  • Page 66 Pre Operation Checks 5-13 Tire wear limit When the tire groove decreases to 0.12 in (3 mm) due to wear, replace the tire. a. Tire wear limit...
  • Page 67 Operation WARNING WARNING POTENTIAL HAZARD POTENTIAL HAZARD Operating vehicle without being familiar Freezing control cables due to cold with all controls. weather conditions. WHAT CAN HAPPEN WHAT CAN HAPPEN Loss of control, which could cause an Loss of vehicle control, which could accident or injury.
  • Page 68 Operation service center to inspect the electric Starting the Engine circuit. The engine can be started in any gear if CAUTION: ● See the “Engine Break-In”section prior to the brake is applied. However, it is recommended to shift into neutral ”N” operating the engine for the first time.
  • Page 69 Operation Continue warming up the engine until it idles smoothly before riding. 2500RPM to charge the battery for 5-10 minutes; when the voltage of battery is over 12V, the idle speed will be normal. If the WARNING idle speed is still high, please contact your POTENTIAL HAZARD service center.
  • Page 70 Operation Otherwise, go on with the third step. Shifting: Neutral to High and High to Low 3. Continue warming up the engine until it 1. Stop the vehicle. Keep your foot off the idles smoothly. accelerator pedal. 2. Apply the brakes, and then shift by CAUTION: See the “Engine break-in”...

  • Page 71: Operation

    Operation the shift guide. NOTE: ● Please kick the brake pedal first, before place gearshifts lever to“reverse”position. ● In the brake pedal, there is a cable, which is connected to a position pin located on the gearshift assembly. Only when the brake pedal is depressed, the position pin will be retracked, and gearshifts can be removed to “reverse”...
  • Page 72 Operation until the vehicle starts moving. 4. Check behind for people or obstacles, and then release the brake pedal. 5. Press the accelerator pedal gradually and continue to watch to the rear while backing up. 1. Drive select lever NOTE: When in reverse, the reverse indicator ●...
  • Page 73 Operation WARNING WARNING POTENTIAL HAZARD POTENTIAL HAZARD Parking on a hill or other incline. Improperly operating in reverse. WHAT CAN HAPPEN WHAT CAN HAPPEN The vehicle could roll out of control, You could hit an obstacle or person increasing the chance of an accident. behind you, resulting in serious injury.
  • Page 74 Operation Parking Parking on a Slope a) When parking, stop the engine and shift the drive select lever into the neutral position. b) Push the brake pedal down, and pull the parking brake to top position to park the vehicle 1.
  • Page 75 Operation Vehicle Break-in Period The break-in period for your new UTV vehicle is the first 25 hours of operation, or the time it takes to use the first three tanks full 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...
  • Page 76 Operation 6-10 momentary (2-3 seconds maximum) full of use. Use of any engine oil not mentioned in throttle operation under load does not harm ● this manual will cause severe damage to the engine. the engine. Each full throttle acceleration sequence should be followed with a substantial rest period for the engine by cruising at lower Engine Break-In...
  • Page 77 6-11 Operation performance. Break in the clutches and belt 10-25 Hours: Avoid prolonged operation above 3/4 throttle. by operating at slower speeds during the Rev the vehicle freely but do not use full break-in period as recommended. Pull only throttle at any time. light loads.
  • Page 78 Operation 6-12 test all nonstandard accessories, nor with accessories. The vehicle may have any control over the quality or handle differently than it does without suitability of them. Choose a genuine accessories. accessory, or one that is equivalent in design and quality. Loading Accessories should be rigidly and Cargo or a trailer can change the stability...
  • Page 79 6-13 Operation the loaded trailer on the scale with the Load cargo in the cargo bed as close to ● tongue at hitch height. Adjust the load in the center of the vehicle as possible and the trailer, if necessary, to reduce the tie it down using the cargo hooks weight on hitch.
  • Page 80 Operation 6-14 trailer. Allow more braking distance. A heavier WARNING ● vehicle takes longer to stop. POTENTIAL HAZARD Avoid making sharp turns unless at very ● Overloading this vehicle or carrying or slow speeds. towing cargo improperly. Avoid hills and rough terrain. Choose ●...

  • Page 81: Driving Your Vehicle

    Your Vehicle DRIVING YOUR VEHICLE WARNING GETTING TO KNOW YOUR VEHICLE POTENTIAL HAZARD This off-highway utility vehicle will handle Not wearing the seat belt. and maneuver differently form an ordinary Wearing the seat belt improperly. passenger car or other vehicle. WHAT CAN HAPPEN Before you begin to use your vehicle, be sure There is increased risk of being killed or...
  • Page 82 Your Vehicle The total weight of operator, passenger, WARNING accessories, cargo, trailer tongue weight, POTENTIAL HAZARD and the vehicle itself must not exceed 2,400 Carrying a passenger in the cargo bed. lbs (1090Kg). WHAT CAN HAPPEN The passenger could fall or be struck by objects in the cargo bed.
  • Page 83 Your Vehicle The driver and passenger must always wear a seat belt, an approved motorcycle helmet, WARNING eye protection and protective clothing, POTENTIAL HAZARD Overloading this vehicle or carrying or including over-the-ankle boots, gloves, a towing cargo improperly. long-sleeved shirt or jacket, and long pants. WHAT CAN HAPPEN Keep hands and feet inside the vehicle at all Could cause changes in vehicle...
  • Page 84 Your Vehicle WARNING HOW TO AVOID THE HAZARD POTENTIAL HAZARD Always wear an approved motorcycle Operating this vehicle without wearing an helmet that fits properly. You should also approved motorcycle helmet, eye wear: protection, and protective clothing. WHAT CAN eye protection HAPPEN (goggles or face shield) Operating without...

  • Page 85: Learning To Operate Your Vehicle

    Your Vehicle Perform the Pre-Operation Checks on pages LEARNING TO OPERATE YOUR VEHICLE 5-1 - 5-11. Set the parking brake, shift to You should become familiar with the neutral, and follow the instructions on page performance characteristics of the vehicle in 6-1 to start the engine.

  • Page 86: Turning Your Vehicle

    Your Vehicle maneuvers on slope. Position your hands on the steering wheel so CAUTION: that your thumbs and fingers do not wrap Do not shift from low to high or vice versa around the wheel. This is particularly important without coming to a complete stop and when driving in rough terrain.
  • Page 87 Your Vehicle Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Apply the throttle lightly. Never open the throttle suddenly. 3. Back up slowly. 4. Apply the brakes lightly for stopping. 5.

  • Page 88: Going Uphill

    Your Vehicle BRAKING Braking ability is affected by the type of terrain. In most cases, gradual application of the brakes is more effective than abrupt braking, particularly on loose surfaces like gravel. Always allow for greater braking distance on rough, loose, or slippery surfaces.
  • Page 89 Your Vehicle some hills are too steep for you to climb. WARNING Maximum slope angle:15° POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle can over turn more easily on extremely steep hills than on level surfaces or small hills. HOW TO AVOID THE HAZARD Never operate your vehicle on hills too steep for it or your abilities.

  • Page 90: Going Downhill

    Your Vehicle 7-10 Before climbing the hill, first be sure you are around. With your foot on the brake, look operating in low range 4WD or, if necessary, behind you and plan your descent. Shift the with 4WD. To climb a hill, you need traction, drive select lever in reverse so you can use momentum, and steady throttle.
  • Page 91 7-11 Your Vehicle Before starting downhill, make sure the you will be able to react to obstacles that may vehicle is in low-range 4WD. On most slopes, appear. this will let you use engine braking to help you go downhill slowly. Go as slowly as WARNING possible.

  • Page 92: Crossing Through Shallow Water

    Your Vehicle 7-12 CROSSING THROUGH SHALLOW WATER WARNING If you must cross shallow, slow moving water POTENTIAL HAZARD up to the depth of the vehicle’s floorboards, Operating this vehicle through deep or choose your path carefully to avoid sharp fast-flowing water. drop-offs, large rocks, or slippery surfaces WHAT CAN HAPPEN Loss of control, which could result in an...
  • Page 93 7-13 Your Vehicle Vehicle Immersion CAUTION: CAUTION: After riding your vehicle in water, be sure to If your vehicle becomes immersed, major drain the trapped water by removing the engine damage can result if the machine is check hose at the bottom of the air filter case, not thoroughly inspected.
  • Page 94 Your Vehicle 7-14 5. Dry the spark plugs and reinstall them, or install new plugs. CAUTION: 6. Attempt to start the engine. If necessary, Make sure all components that are washed repeat the drying procedure. and assembled are coated lightly with 7.

  • Page 95: Your Vehicle

    7-15 Your Vehicle 1. Drive select lever box check hose 1．V-belt cooling duct check hose 1．V-belt case drain plug Riding Over Rough Terrain Operating over rough terrain should be done with caution. Look for obstacles that could cause damage to the vehicle or could lead to a rollover accident.
  • Page 96 Your Vehicle 7-16 vehicle could occur. WARNING POTENTIAL HAZARD Failure to use extra care when operating this vehicle on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the vehicle overturning or going out of control.
  • Page 97 7-17 Your Vehicle thoroughly. Look from both your approach Riding in Brush or Wooded Areas side and the exit side. If you believe you can When operating in areas with brush or trees, continue safely, decide the path that will watch carefully on both sides and above the allow you to get over the obstacle at as close vehicle for obstacles such as branches that...
  • Page 98 Your Vehicle 7-18 WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the vehicle to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles.
  • Page 99 Periodic Maintenance and Adjustment Periodic Maintenance and Adjustment NOTE: Periodic inspection, adjustment and If you do not have a torque wrench available lubrication will keep your vehicle in the safest during a service operation requirin and most efficient condition possible. Safety g one, take your vehicle to service center to is an obligation of the vehicle owner.
  • Page 100 Periodic Maintenance and Adjustment WARNING WARNING POTENTIAL HAZARD POTENTIAL HAZARD Servicing an engine while it is running. Operating this vehicle with improper modifications. WHAT CAN HAPPEN WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body, causing injury. Improper installation of accessories or Electrical components can cause shocks modification of this vehicle may cause...

  • Page 101: Periodic Maintenance And Adjustment

    Periodic Maintenance and Adjustment CAUTION: ● Be sure you have sufficient knowledge, experience, the proper replacement parts and tools before you attempt any vehicle maintenance task. ● If you don’t have the knowledge and equipment which are necessary to perform the maintenance task, consult your local dealer.
  • Page 102 Periodic Maintenance and Adjustment MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) ITEM REMARKS Hours Frequency Miles (KM) Brake systems Pre-Ride Make adjustments as needed. Lug Nuts Pre-Ride Ensure lug nuts are torque to spec Frame fasteners Pre-Ride All fasteners are secured Engine Oil Level Pre-Ride Inspect and add if needed Coolant...
  • Page 103 Periodic Maintenance and Adjustment MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) ITEM REMARKS Hours Frequency Miles (KM) Routine Maintenance Check (performed at each interval below, whichever comes first) Air filter Inspect; replace as needed Brake pad wear 20 H Monthly 250 (402) Inspect periodically Throttle Body Intake 20 H...
  • Page 104 Periodic Maintenance and Adjustment MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) ITEM REMARKS Hours Frequency Miles (KM) Antifreeze Coolant 50 H 500 (800) Pressure Test / Add Fluid Tranmission Fluid 50 H 500 (800) Replace Engine mounts 100 H 12 M 1000 (1600) Inspect;...

  • Page 105: Lubrication Recommendations

    Periodic Maintenance and Adjustment MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) ITEM REMARKS Hours Frequency Miles (KM) Valve clearance 100 H 1000 (1600) Inspect; adjust Extreme Maintenance Check (cut the Routine Maintenance Schedule in half) *Service Note: Under extreme use, change gear case fluid every 25 hours. "Extreme Use" is defined as constant 4WD operation on hilly or mountainous terrain, or if 4WD is the primary mode of operation.

  • Page 106: Engine Oil

    Periodic Maintenance and Adjustment ENGINE OIL Always check and change the oil at the intervals outlined in the Service Interval Chart above. Always use the recommended engine oil. Always change the oil filter whenever changing oil. Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident and injury.
  • Page 107 Periodic Maintenance and Adjustment Hood To open Unhook the hood latches, and then slowly tilt the hood up until it stops. Hood To close Lower the hood slowly to its original position, 1. Latch (×2) and then hook the hood latches. Secure projections on the underside of the ①...
  • Page 108 Periodic Maintenance and Adjustment 8-10 Console To remove 1. Remove the seats. (See pages 4-17─ 4-18 for seat removal and installation procedures.) 2. Remove the parking brake lever boot. 3. Pull the console upward (the drive select lever boot will come loose.) 1.
  • Page 109 8-11 Periodic Maintenance and Adjustment 2. Remove the console. (See page 8-9 for To install console removal and installation 1. Place the console in its original position. 2. Install the parking brake lever boot. procedures.) 3. Check the engine oil level on a cold 3.
  • Page 110 Periodic Maintenance and Adjustment 8-12 8. Install the console. To change the engine oil (with or without oil filter cartridge replacement) 1. Remove the console. (See page 8-9 for console removal and installation procedures.) 2. Place an oil pan under the engine to collect the used oil, and then remove the engine oil filler cap.
  • Page 111 8-13 Periodic Maintenance and Adjustment 1. Engine oil drain bolt 1. Oil filter cartridge 2. Oil filter wrench NOTE: NOTE: Skip steps 4-6 if the oil filter cartridge is not An oil filter wrench is available at a nearby being replaced. service center.
  • Page 112 Periodic Maintenance and Adjustment 8-14 1. Oil filler cartridge 2. Torque wrench 1. O-ring 7. Install the engine oil drain bolt, and then 6. Install the new oil filter cartridge with an tighten it to the specified torque. oil filter wrench, and then tighten it to the specified torque with a torque wrench.
  • Page 113 8-15 Periodic Maintenance and Adjustment several minutes while checking it for oil Recommended engine oil: leakage. If oil is leaking, immediately turn See page 10-2. the engine off and check for the cause. Oil quantity: 10. Turn the engine off, wait at least ten Without oil filter cartridge replacement minutes, and then check the oil level and 2.01 qt (1.9L)
  • Page 114 Periodic Maintenance and Adjustment 8-16 CAUTION: 1. Be sure no foreign material enters the final gear case. 2. Please clean the sensor every 320 mile period. 3. Install the oil filler bolt, and then tighten it to the specified torque. 1.
  • Page 115 8-17 Periodic Maintenance and Adjustment Changing the final gear oil Tightening torque: 1. Place the vehicle on a level surface. Final gear oil drain bolt: 2. Place a container under the final gear 14 ft·lbf (20 Nm, 2.0 m·kgf ) case to collect the used oil.
  • Page 116 Periodic Maintenance and Adjustment 8-18 Tightening torque: Final gear oil filler bolt: 17 ft·lbf (23 Nm, 2.3 m·kgf) 7. Check for oil leakage. If oil leakage is found, check for the cause. Differential gear oil Checking the differential gear oil level 1.
  • Page 117 8-19 Periodic Maintenance and Adjustment Changing the differential gear oil 1. Place the vehicle on a level surface. Tightening torque: 2. Place a container under the differential Differential gear oil drain bolt: gear case to collect the used oil. 7.1 ft·lbf (9.8Nm, 0.98 m·kgf) 3.
  • Page 118 Periodic Maintenance and Adjustment 8-20 NOTE: Tightening torque: The coolant should be between the minimum Differential gear oil filler bolt: and maximum level marks. 17 ft·lbf (23Nm, 2.3m·kgf) 7. Check for oil leakage. If oil leakage is found, check for the cause. Coolant The coolant level should be checked before each ride.
  • Page 119 8-21 Periodic Maintenance and Adjustment possible. Coolant reservoir capacity The radiator fan is automatically ● (up to the maximum level mark): switched on or off according to the 0.37 qt (0.35L) coolant temperature in the radiator. CAUTION: Axle boots Mix anti freeze with distilled water only. Check the protective boots for holes or tears.
  • Page 120 Periodic Maintenance and Adjustment 8-22 Spark plug inspection Removal 1. Lift the cargo bed up. (See pages 4-21 - 4-22 for cargo bed lifting and lowering procedures.) 2. Remove the spark plug cap. 1.Front axle boot (×2 each side) 1. Spark plug cap 3.
  • Page 121 8-23 Periodic Maintenance and Adjustment Do not attempt to diagnose such problems yourself. Instead, take the vehicle to a service center. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. If electrode erosion becomes excessive, or if carbon and other deposits are excessive, you should replace the spark plug with the specified...
  • Page 122 Periodic Maintenance and Adjustment 8-24 Tightening torque: Spark plug: 12.7 ft·lbf (17.5 Nm, 1.75 m·kgf) NOTE: If a torque wrench is not available when you are installing the spark plug, a good estimate of the correct torque is 1/4 to 1/2 turn past finger tight.
  • Page 123 8-25 Periodic Maintenance and Adjustment 1. Air filter check hose 1. Holder (×4) 2. Air filter case cover 1. Remove the seats. (See pages 4-17 - 4. Remove the air filter element. 4-18 for seat removal and installation 5. Remove the sponge material from its procedures.) frame.

  • Page 124: What Can Happen

    Periodic Maintenance and Adjustment 8-26 1. Air filter frame 2. Sponge material 3. Element retaining plate 6. Wash the sponge material gently but thoroughly in solvent. WARNING POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the sponge material. WHAT CAN HAPPEN 1.
  • Page 125 8-27 Periodic Maintenance and Adjustment CAUTION: Do not twist the sponge material when squeezing it. 8. Inspect the sponge material and replace it if damaged. 9. Thoroughly apply foam air filter oil or other quality liquid foam air filter oil (not spray type) to the sponge material.
  • Page 126 Periodic Maintenance and Adjustment 8-28 check the air inlet to the air filter case for Check fuel line and fuel filter obstructions. Check the air filter CAUTION: element rubber joint to the fuel system and Be sure to stop the engine and remove the manifold fittings securely to avoid the key.
  • Page 127 8-29 Periodic Maintenance and Adjustment IMPORTANT ① fuel pump ② fuel line When the fuel line is disconnected for ③ Exit pipe maintenance or repair, close both ends of the To remove the in-line fuel filter clamps fuel line with a piece of clean cloth or paper (b), slide the clamps (b) away from the to prevent dust and dirt from entering.
  • Page 128 Periodic Maintenance and Adjustment 8-30 of the tailpipe and inside of the tailpipe Cleaning the spark arrester Be sure the exhaust pipe and muffler are housing. cool before cleaning the spark arrester. 1. Remove the bolts. 1. Tailpipe 2. Spark arrester 4.
  • Page 129 8-31 Periodic Maintenance and Adjustment Valve clearance Tightening torque: The correct valve clearance changes with Tailpipe bolt: 6.9 ft·lbf (9.5 Nm, 0.95 m·kgf) use, resulting in improper fuel-air supply or engine noise. To prevent this, the valve WARNING clearance must be adjusted regularly. This POTENTIAL HAZARD adjustment however, should be left to a Improper cleaning of the spark arrester.
  • Page 130 Periodic Maintenance and Adjustment 8-32 Rear brake pad check Each brake pad is provided with wear indicator grooves, which allow you to check the brake pad wear without having to disassemble the brake. To check the brake pad wear, check the wear indicator grooves. If a brake pad has worn to the point that the wear indicator grooves have almost disappeared, have a service center replace...
  • Page 131 8-33 Periodic Maintenance and Adjustment The brake fluid reservoir is located under the Checking the brake fluid level hood. (See pages 8-8- 8-9 for hood opening Insufficient brake fluid may let air enter the and closing procedures.) brake system, possibly causing the brakes to become ineffective.
  • Page 132 Periodic Maintenance and Adjustment 8-34 the fluid and may result in vapor lock. should be no free play in the brake pedal. The brakes should operate smoothly and  Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up there should be no brake drag.
  • Page 133 8-35 Periodic Maintenance and Adjustment Parking brake lever free play adjustment Periodically check the parking brake lever WARNING free play and adjust it if necessary. POTENTIAL HAZARD 1. Shift the drive select lever into low gear Operating with improperly serviced or “L”.
  • Page 134 Periodic Maintenance and Adjustment 8-36 1.Parking brake lever free play 1. Locknut 2. Adjusting nut NOTE: 6. Turn the adjusting nut in direction The parking brake lever must be released increase the free play or in direction when checking and adjusting the parking to decrease the free play.
  • Page 135 8-37 Periodic Maintenance and Adjustment Brake light switch adjustment The brake light switch, which is activated by the brake pedal, is properly adjusted when the brake light comes on just before braking takes effect. If necessary, adjust the brake light switch as follows. 1.
  • Page 136 Periodic Maintenance and Adjustment 8-38 Brake pedal and accelerator pedal WARNING lubrication POTENTIAL HAZARD Lubricate the pivoting parts. Damaged control cables. Recommended lubricant: WHAT CAN HAPPEN Lithium-soap-based grease Corrosion can result when the outer (all-purpose grease) covering of control cables becomes damaged.
  • Page 137 8-39 Periodic Maintenance and Adjustment Rear knuckle upper and lower pivot Steering shaft lubrication Lubricate the pivot points. lubrication Lubricate the knuckle upper and lower pivots Recommended lubricant: with a grease gun. Lithium-soap-based grease (all-purpose grease) Recommended lubricant: Lithium-soap-based grease...
  • Page 138 Periodic Maintenance and Adjustment 8-40 Wheel installation Wheel removal 1. Install the wheel and the nuts. Loosen the wheel nuts . Elevate the vehicle and place a suitable NOTE: The arrow mark on the tire must stand under the frame. ●...
  • Page 139 8-41 Periodic Maintenance and Adjustment Battery This vehicle 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 a service center. CAUTION: 1.
  • Page 140 Periodic Maintenance and Adjustment 8-42 WARNING POTENTIAL HAZARD Failure to handle batteries or battery electrolyte carefully. WHAT CAN HAPPEN You could be poisoned. You could be severely burned by the sulfuric acid in battery electrolyte. Batteries produce explosive gases. HOW TO AVOID THE HAZARD Avoid contact with skin, eyes or clothing.
  • Page 141 8-43 Periodic Maintenance and Adjustment Battery maintenance 1. When the vehicle is not used for a month or longer, remove the battery and store it in a cool, dark place. Completely recharge the battery before reinstallation. CAUTION: A special battery charger (constant voltage/ampere or constant voltage) is required for recharging a sealed-type battery.
  • Page 142 Periodic Maintenance and Adjustment 8-44 by lifting it up and pulling it out. 1. Battery compartment cover 1. Relay assembly 2. Turn the key to “OFF” and turn off the 2. Backup fuse 3. Relay electrical circuit in question. 4. Fuse box 5.
  • Page 143 8-45 Periodic Maintenance and Adjustment Specified Fuse: WARNING Main Fuse: 30.0A POTENTIAL HAZARD Using an improper fuse Headlight Fuse: 15.0A WHAT CAN HAPPEN ECU、Pump Fuse: 15.0A An improper fuse can cause damage to Auxiliary DC Jack Fuse: 15.0A the electrical system, which could lead to Signaling System Fuse: 10.0A a fire.
  • Page 144 Periodic Maintenance and Adjustment 8-46 1. Cover at the rear of the headlight 1. Headlight bulb holder cover 4. Remove the headlight bulb holder by 3. Remove the headlight bulb holder cover pushing it in and turning it by pulling it off. counterclockwise.
  • Page 145 8-47 Periodic Maintenance and Adjustment WARNING POTENTIAL HAZARD A headlight bulb is hot when it is on and immediately after it is turned off. WHAT CAN HAPPEN You can be burned, or a fire could start if the bulb touches something flammable. HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it.
  • Page 146 Periodic Maintenance and Adjustment 8-48 turning it clockwise. 8. Install the bulb holder cover and the cover at the rear of the headlight. CAUTION: Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly. 9.
  • Page 147 8-49 Periodic Maintenance and Adjustment 1. Panel A 1. Headlight beam adjusting screw Tail/brake light bulb replacement If a tail/brake light bulb burns out, replace it as follows: 1. Remove panel A (if replacing the left tail/brake bulb) or panel B (if replacing the right tail/brake bulb) by removing the quick fasteners and bolts.
  • Page 148 Periodic Maintenance and Adjustment 8-50 1. Quick fastener（×8） 2. Bolt（×2） 1. Tail/brake light bulb holder 3. Panel A 3. Push the defective bulb in and turn it counterclockwise to remove it from the 2. Remove the bulb holder（together with bulb holder. the bulb）by turning it counterclockwise.
  • Page 149 8-51 Periodic Maintenance and Adjustment Imitation parts may look like genuine parts, Tightening torque: but they are often inferior. Panel bolt: Consequently, they have a shorter service 4.7 ft·lbf (6.5N·m, 0.65 m·kgf） life and can lead to expensive repair bills. WARNING Troubleshooting Although vehicles receive a rigid inspection...

  • Page 150: Solution To Common Problems In Vehicle

    Periodic Maintenance and Adjustment 8-52 Solution to Common Problems in Vehicle The below tables show some common problems that may come up when you are driving a UTV, which will help to solve these problems. To repair a UTV requires technical skills, if you cannot repair the UTV yourself, please contact your service center.
  • Page 151 8-53 Periodic Maintenance and Adjustment Table 2：Solution of Common Problems in Brake System. Problems Solutions 1. Check if the handle of parking brake return to its position. Brake system is locked 2. Check if the brake discs are bent or deformed. 3.
  • Page 152 Periodic Maintenance and Adjustment 8-54 fasteners of calipers are deformed. 1. Check if left and right brake force deviation of front brake is with specified limit. 2. Check if the brake force of front brake goes down, which Vehicle makes odd turn causes the rear wheels to lock up before the front wheels.
  • Page 153 8-55 Periodic Maintenance and Adjustment Table 3: Solution of Common Problems in Electrical System Problems Solutions 1. Check if the headlight switch functions properly. Lights do not work. 2. Check if the wires are broken. 3. Check if the lamps or bulbs are broken. 1.
  • Page 154 Periodic Maintenance and Adjustment 8-56 Table 4: Solution of Common Problems in Running System Problems Solutions 1. Check the fasteners connecting steering rod to steering stem and knuckle to find out if they are loose or broken. Swing clearance of 2.
  • Page 155 8-57 Periodic Maintenance and Adjustment 3. Check the inner splines of rear wheel hubs and outer splines of rear wheel axles to find out if they are worn or broken. Rear wheels shake during 4. Check the lock screws of rear wheels and axles to find out use.
  • Page 156 Periodic Maintenance and Adjustment 8-58 Table 5: Solution of Common Problems in Engine System Problems Solutions Check the battery voltage for Within specified value Check the rectifier output voltage for within specified Idle speed is not stable value Check MEUI for failure Check and clean air filter.
  • Page 157 8-59 Periodic Maintenance and Adjustment Check the coolant drain tube for with air. Check the battery charge. Check the battery connection. Check the starter for damage. Check if the ignition loop is in good condition. Engine cannot start. Check if the spark plug creating sparks. Check if the ignition signal is in good condition.
  • Page 158 Periodic Maintenance and Adjustment 8-60 WARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot. WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure. HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap.
  • Page 159 Cleaning and Storage Cleaning CAUTION: Frequent, thorough cleaning of your vehicle Excessive water pressure may cause water will not only enhance its appearance but also seepage and deterioration of wheel bearings, will improve its general performance and brakes, transmission seals and electrical extend the useful life of many components.
  • Page 160 Cleaning and Storage chamois, clean towel or soft absorbent cloth. WARNING 6. Clean the seats with vinyl upholstery POTENTIAL HAZARD cleaner to keep the cover pliable and Operation with wet brakes after washing. glossy. WHAT CAN HAPPEN 7. Automotive type wax may be applied to Wet brakes may have reduced stopping all painted and chrome plated surfaces.
  • Page 161 Cleaning and Storage Storage Specified amount: Long-term storage (60 days or more) of your 1 oz of stabilizer to each gallon of fuel (or vehicle will require some preventive 7.5 ml of stabilizer to each liter of fuel) procedures to guard against deterioration. After thoroughly cleaning the vehicle, NOTE: prepare for storage as follows:...
  • Page 162 Cleaning and Storage 6. Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering. 7. If storing in a humid or salty atmosphere, coat all exposed metal surfaces with a light film of oil. Do not apply oil to any rubber parts or the seat covers.

  • Page 163: Specifications

    10-1 Specifications Model 500/700cc Dimensions: Overall length 3010mm (118.5 in) Overall width 1460m m (57.5 in) Overall height 1940mm (76.4 in) Seat height 818mm (32.2 in) Wheelbase 1890mm (74.4 in) Ground clearance 280mm (11.0 in) Minimum turning radius 3900mm (154 in) Basic weight with oil and full fuel tank 658 kg (1,451 lb)/690 kg (1,521 lb) Engine:...
  • Page 164 Specifications 10-2 Model 500/700cc Engine oil: Type Recommended engine oil classification API-SJ & JASO/MA CAUTION: In order to prevent clutch slippage（since the engine oil also lubricates the clutch ） , do not mix any chemical additives. Do not use oils with a diesel specification of “CD”...
  • Page 165 10-3 Specifications 500/700cc Model Quantity: Without oil filter cartridge replacement 1.90L (2.01 qt) With oil filter cartridge replacement 2.10L (2.22 qt) Final gear case oil: Type SAE80 API GL-4 Hypoid gear oil Quantity: 0.25L (0.26 qt ) Differential gear case oil: Type SAE80 API GL-5 Hypoid gear oil Quantity:...
  • Page 166 Specifications 10-4 Model 500/700cc Spark plug: Type DR8EA/ DCPR7E Spark plug gap 0.6-0.7 mm (0.023-0.027 in) Clutch type: Wet, centrifugal automatic Transmission: Primary reduction system V-belt Secondary reduction system Shaft drive Secondary reduction ratio Transmission type V-belt automatic Operation Right hand operation Reverse gear 1.471 Sub transmission ratio...
  • Page 167 10-5 Specifications Model 500/700cc Tire: Type Tubeless Size front 26×9-14 rear 26×11-14 Brakes: Ⅰ: Front brake Type Dual disc brake Operation Foot operation Rear brake Type Single disc brake Operation Foot operation Ⅱ: Front brake Type Dual disc brake Operation Foot operation Rear brake Type...
  • Page 168 Specifications 10-6 Model 500/700cc Shock absorber: Front shock absorber Coil spring/oil damper Rear shock absorber Coil spring/oil damper Wheel travel: Front wheel travel 130mm (5.12in) Rear wheel travel 150mm (5.91in) Electrical: Ignition system Generator system AC magneto U1L-11 or GSU1-9 Battery type 12V32.0Ah or 12V30.0Ah Battery capacity...
  • Page 169 10-7 Specifications Model 500/700cc On-Command four-wheel-drive/differential gear lock indicator On-Command differential gear lock indicator light High-range/ Low-range indicator light Specified fuses: Main Fuse: 30.0A Headlight Fuse: 15.0A ECU、Pump Fuse: 15.0A 15.0A Auxiliary DC Jack Fuse: Signaling System Fuse: 10.0A 2WD/4WD、EPS Fuse: 10.0A...
  • Page 170 Fault Code of Electronic Injection System 11-1 Fault Code of Electronic Injection System DTC Description Related Calibration Number P0107 MAP Circuit Low Voltage or Open KsDGDM_MAP_ShortLow P0108 MAP Circuit High Voltage KsDGDM_MAP_ShortHigh P0112 IAT Circuit Low Voltage KsDGDM_IAT_ShortLow P0113 IAT Circuit High Voltage or Open KsDGDM_IAT_ShortHigh Coolant/Oil Temperature Sensor Circuit P0117...
  • Page 171 11-2 Fault Code of Electronic Injection System P0132 O2S 1 Circuit High Voltage KsDGDM_O2_1_ShortHigh P0031 O2S Heater Circuit High Voltage KsDGDM_O2_HeaterShortHigh P0032 O2S Heater Circuit Low Voltage KsDGDM_O2_HeaterShortLow P0201 Injector 1 Circuit Malfunction KsDGDM_INJ_CYL_A_Fault P0202 Injector 2 Circuit Malfunction KsDGDM_INJ_CYL_B_Fault P0230 FPR Coil Circuit Low Voltage or Open KsDGDM_FPP_CircuitShortLow...
  • Page 172 Fault Code of Electronic Injection System 11-3 P0563 System Voltage High KsDGDM_SysVoltHigh 1379 P0650 MIL Circuit Malfunction KsDGDM_MIL_Circuit 1616 P1693 Tachometer Circuit Low Voltage KsDGDM_TAC_Circuit_Low 1693 5779 P1694 Tachometer Circuit High Voltage KsDGDM_TAC_Circuit_High 1694 5780 P0137 O2S 2 Circuit Low Voltage KsDGDM_O2_2_ShortLow P0138 O2S 2 Circuit High Voltage...
  • Page 173 Hisun Motors Corp., U.S.A. Emission Control System Warranty Statement YOUR WARRANTY RIGHTS AND OBLIGATIONS The U.S. Environmental Protection Agency and Hisun Motors Corp., U.S.A. (hereinafter “HISUN”) are pleased to explain the emission control system warranty on your Off-Road vehicle. New off-road motor vehicles must be designed, built and equipped to meet U.S.

  • Page 174: Owner's Warranty Responsibilities

    Hisun Motors Corp., U.S.A. Emission Control System Warranty Statement replaced by HISUN. This is your EMISSION CONTROL SYSTEM WARRANTY. NOTICE! Use of this vehicle in any type of competitive event completely and absolutely voids this and all other warranties offered by HISUN. OWNER’S WARRANTY RESPONSIBILITIES As the vehicle owner, you are responsible for the performance of the required maintenance listed in your owner’s manual.
  • Page 175 Hisun Motors Corp., U.S.A. Emission Control System Warranty Statement coverage if your vehicle or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications. If you use your vehicle in any type of competitive event, this warranty is immediately and completely void.

  • Page 176: Your Warranty Rights And Obligations

    Hisun Motors Corp., U.S.A. Limited Warranty on Emission Control System YOUR WARRANTY RIGHTS AND OBLIGATIONS Hisun Motors Corp., U.S.A. warrants that each new off-road vehicle: A. is designed, built and equipped so as to conform at the time of initial retail purchase with all applicable regulations of the United States Environmental Protection Agency, and B.
  • Page 177 Hisun Motors Corp., U.S.A. Limited Warranty on Emission Control System II. Limitations This Emission Control System Warranty shall not cover any of the following: A. Repair or replacement as a result of (1) accident, (2) misuse, (3) repairs improperly performed or replacements improperly installed, unless performed by a HISUN authorized dealer, (4) use of improper replacement parts or accessories not conforming to specifications set forth by HISUN, which adversely...
  • Page 178 Hisun Motors Corp., U.S.A. Limited Warranty on Emission Control System C. Any vehicle equipped with an odometer or hour meter on which the odometer mileage or hour meter reading has been changed so that actual mileage cannot be readily determined. III.
  • Page 179 Hisun Motors Corp., U.S.A. Limited Warranty on Emission Control System B. No express emission control system warranty is given by HISUN except as specifically set forth herein. Any emission control system warranty implied by law, including any warranty of merchantability or fitness for a particular purpose, is limited to the express emission control system warranty terms stated in this warranty.
  • Page 180 Hisun Motors Corp., U.S.A. Limited Warranty on Emission Control System performance and durability may be used in the performance of any maintenance or repairs by the owner. However, HISUN is not liable for these parts. The owner is responsible for the performance of all required maintenance. Such maintenance may be performed at a service establishment or by any individual.

This manual is also suitable for:

700cc

Table of Contents

Save PDF