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Xingyun XY500U Operator's Manual

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OWNER'S/OPERATOR'S
WARNING：
Read this Manual, and any Supplements Carefully Before
Operating Vehicle.
Assembly
Operation
Maintenance
THIS VEHICLE IS NOT DESIGNED FOR USE ON RENTAL
TRACKS OR RACING
BEFORE OPERATING THIS VEHICLE, THE OWNER AND EACH
OPERATOR MUST HAVE READ AND HAVE AN UNDERSTANDING OF
ALL THE INSTRUCTIONS FOR PROPER ASSEMBLY AND SAFE
OPERATION, AS WELL AS THE INSTRUCTIONS CONCERNING THE
ENGINE AND ALL OTHER PORTIONS OF THE VEHICLE.
MANUAL
XY500U

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  • Page 1 Operation Maintenance THIS VEHICLE IS NOT DESIGNED FOR USE ON RENTAL TRACKS OR RACING XY500U  BEFORE OPERATING THIS VEHICLE, THE OWNER AND EACH OPERATOR MUST HAVE READ AND HAVE AN UNDERSTANDING OF ALL THE INSTRUCTIONS FOR PROPER ASSEMBLY AND SAFE OPERATION, AS WELL AS THE INSTRUCTIONS CONCERNING THE ENGINE AND ALL OTHER PORTIONS OF THE VEHICLE.
  • Page 2 NOTE: A storage area/toolbox has been provided on the UTV for storage of this manual. Please keep this manual in the storage box so that it can be found easily and referenced when needed.

  • Page 4: Table Of Contents

    CONTENTS 1. INTRODUCTION · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·1.1 2. UNDERSTANDING WARNINGS · · · · · · · · · · · · · · · · ·2.1 3.

  • Page 5: Introduction

    OWNER’S/OPERATOR’S MANUAL 1. INTRODUCTION Introduction Congratulations on the purchase of your Utility Task Vehicle (UTV). We take pride in offering you this product engineered and manufactured to the highest performance and quality standards. We are sure that you will enjoy superior levels of performance, reliability, riding comfort, and safety.

  • Page 6: Important Safety Notice

    OWNER’S/OPERATOR’S MANUAL 1. INTRODUCTIOPN Important Safety Notice ● This vehicle is designed and manufactured for off-road use only. It is illegal to operate this vehicle on any public street, road, or highway. Such use is prohibited by law. ● Check the local laws and regulations before choosing where to operate this vehicle.
  • Page 7 OWNER’S/OPERATOR’S MANUAL 1. INTRODUCTIOPN A UTV CAN BE HAZARDOUS TO OPERATE. A UTV handles differently from other vehicles including motorcycles, ATVs and cars. A rollover can occur quickly, even during routine maneuvers such as turning and driving on hills or over obstacles, if you fail to take proper precautions.
  • Page 8 OWNER’S/OPERATOR’S MANUAL 1. INTRODUCTIOPN safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual.  Always keep both hands, arms, feet, and legs inside the vehicle at all times during operation. Keep your feet on the floorboard. Never hold onto the enclosure except when using the handgrip inside the enclosure.
  • Page 9 OWNER’S/OPERATOR’S MANUAL 1. INTRODUCTIOPN Avoid crossing the side of a steep hill if possible.  Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual.

  • Page 10: Understanding Warnings

    OWNER’S/OPERATOR’S MANUAL 2. UNDERSTANDING WARNINGS ATTENTION: This is an ADULT VEHICLE ONLY! Not a toy! READ AND UNDERSTAND WARNINGS AND OWNER’S MANUAL BERORE OPERATION. KNOW YOUR VEHICLE BEFORE YOU BEGING RIDING! Read this manual thoroughly referring to the various areas which are being discussed on your machine.
  • Page 11 OWNER’S/OPERATOR’S MANUAL 2. UNDERSTANDING WARNINGS SAFETY ALERT WARNINGS identify special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life. Read all WARNINGS in this manual carefully. Follow their instructions to remain safe. The following precautionary signal words are used throughout this manual to convey the following messages: This is the safety alert symbol.

  • Page 12: Safety Warning

    OWNER’S/OPERATOR’S MANUAL 3. SAFETY WARNINGS NOTE： Warning decals have been placed on the vehicle for your protection. Read and follow the instructions on each decals carefully. In the event any decal becomes illegible or comes off, contact your dealer for a replacement.
  • Page 13 OWNER’S/OPERATOR’S MANUAL 3. SAFETY WARNINGS 3- 2...
  • Page 14 OWNER’S/OPERATOR’S MANUAL 3. SAFETY WARNINGS 6&7 3- 3...
  • Page 15 OWNER’S/OPERATOR’S MANUAL 3. SAFETY WARNINGS 3- 4...
  • Page 16 OWNER’S/OPERATOR’S MANUAL 3. SAFETY WARNINGS 3- 5...
  • Page 17 OWNER’S/OPERATOR’S MANUAL 3. SAFETY WARNINGS 3- 6...

  • Page 18: Daily Pre-Ride Inspection

    OWNER’S/OPERATOR’S MANUAL 4. DAILY PRE-RIDE INSPECTION WARNING You must inspect your UTV each time before riding to ensure it is in proper working order. If a proper inspection is not done, injury or death could result. Use the following checklist to verify your machine is in proper working order each time you ride.
  • Page 19 OWNER’S/OPERATOR’S MANUAL 4. DAILY PRE-RIDE INSPECTION released. Have an authorized dealer repair as necessary for proper operation. 5. Headlight / Taillight / Brake light— check operation of all indicator lights and switches. 6. Engine stop switch— check for proper function. 7.

  • Page 20: Operation Warning

    OWNER’S/OPERATOR’S MANUAL 5. OPERATION WARNINGS WARNING POTENTIAL HAZARD Malfunction of the accelerator pedal. WHAT CAN HAPPEN The accelerator pedal could be hard to operate, making it difficult to speed up or slow down when you need. This could cause an accident. HOW TO AVOID THE HAZARD Check the operation of the accelerator pedal before you start the engine.
  • Page 21 OWNER’S/OPERATOR’S MANUAL 5. OPERATION WARNINGS WARNING POTENTIAL HAZARD Pinch points. WHAT CAN HAPPEN You or someone else could be pinched between the cargo bed and the frame when the bed is being lowered. HOW TO AVOID THE HAZARD Before closing the bed, be sure others are standing away from the vehicle.
  • Page 22 OWNER’S/OPERATOR’S MANUAL 5. OPERATION WARNINGS POTENTIAL HAZARD Driving with improperly operating brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD Always check the brakes before every ride. Do not operate the vehicle if you find any problem with the brakes.
  • Page 23 OWNER’S/OPERATOR’S MANUAL 5. OPERATION WARNINGS Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident. HOW TO AVOID THE HAZARD Never modify this vehicle through improper installation or use of accessories.
  • Page 24 OWNER’S/OPERATOR’S MANUAL 5. OPERATION WARNINGS POTENTIAL HAZARD Operating this UTV at excessive speeds. WHAT CAN HAPPEN Increases your chances of losing control of the UTV, which can result in an accident. HOW TO AVOID THE HAZARD Always travel at a speed which is proper for the terrain, visibility and operating conditions, and your experience.
  • Page 25 OWNER’S/OPERATOR’S MANUAL 5. OPERATION WARNINGS time to react. Could result in the UTV overturning or losing control. HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the UTV. WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery...
  • Page 26 OWNER’S/OPERATOR’S MANUAL 5. OPERATION WARNINGS overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Use extreme caution when riding over large obstacles, such as large rocks or fallen trees. If you cannot avoid obstacles, always follow proper procedures as described in the Owner’s Manual.
  • Page 27 OWNER’S/OPERATOR’S MANUAL 5. OPERATION WARNINGS increases the risk of an accident. HOW TO AVOID THE HAZARD Always use the size and type tires specified in the Owner’s Manual for this vehicle. Always maintain proper tire pressure as described in the Owner’s Manual.
  • Page 28 OWNER’S/OPERATOR’S MANUAL 6. V.I.N. #, ENGINE SERIAL NUMBER, AND KEY Record these numbers in the graphical position 1. Frame VIN (On the right side of the square tube under the cargo bed) 2. Engine Serial Number (Left side of engine crankcase) 6- 1...

  • Page 29: Control And Functions

    OWNER’S/OPERATOR’S MANUAL 7. CONTROL AND PARTS FUNCTIONS Dashboard 1. Hood unlock switch 2. TFT Meter 3. Key Switch 4. Horn Switch 5. Accessory Socket HOOD UNLOCK SWITCH: Pull the switch upward to open the hood KEY SWITCH: The key switch has 4 gears: Steering lock→OFF→OPEN→Ignition 7- 1...

  • Page 30: Accessory Socket

    OWNER’S/OPERATOR’S MANUAL 7. CONTROL AND PARTS FUNCTIONS ACCESSORY SOCKET The accessory socket (1) is attached to the left side of the front cover. You can use the accessory socket to power a trouble light, spotlight, CB radio, or cell phone etc. CAUTION Do not plug in any heat-generating accessories such as an automobile cigarette lighter because it will damage the socket.

  • Page 31: Rocker Switch

    OWNER’S/OPERATOR’S MANUAL 7. CONTROL AND PARTS FUNCTIONS Rocker switch 1. Light Switch: Turn off the daytime running lights and headlights Turn on the daytime running lights Turn on the daytime running lights and headlights 2. Hi/ Lo Beam Switch –Switches between the high and low beam headlights.
  • Page 32 OWNER’S/OPERATOR’S MANUAL 7. CONTROL AND PARTS FUNCTIONS LCD Meter 1. Left Turn Indicator 13. Neutral indicator 2. EFI fault indicator 14. Reverse indicator 3. Function button “SET” 15. Engine RPM 4. Parking indicator 16. Gear indication 5. Low fuel level warning indicator 17. Speed 6.

  • Page 33: Driving Mode

    OWNER’S/OPERATOR’S MANUAL 7. CONTROL AND PARTS FUNCTIONS Driving mode 4WD-FRONT DIFFERENTIAL LOCK REAR DIFFERENTIAL LOCK Key function: Short Press Button SET: Adjust backlight brightness; Short Press Button SEL: Trip A, Trip B switch; Long Press Button SEL: Trip A or Trip B reset; Long Press Button SET&SEL : Clock setting mode 7- 5...
  • Page 34 OWNER’S/OPERATOR’S MANUAL 7. CONTROL AND PARTS FUNCTIONS Clock setting mode: short press SEL：adjust the flashing position short press SET：switch flashing position After setting the minute position, short press the Button SET to save and exit. DTC number DTC Descriptor P0107 Map Open/GND P0108 Map Short V...

  • Page 35: Accelerator Pedal

    OWNER’S/OPERATOR’S MANUAL 7. CONTROL AND PARTS FUNCTIONS ACCELERATOR PEDAL WARNING Before starting the engine, check the accelerator pedal to be sure it is operating smoothly. Make sure the accelerator pedal fully returns to the idle position as soon as it is released.

  • Page 36: Brake Pedal

    OWNER’S/OPERATOR’S MANUAL 7. CONTROL AND PARTS FUNCTIONS BRAKE PEDAL 1.Brake peda Press the brake pedal to slow or stop the vehicle. WARNING Never operate the UTV with a spongy feeling brake pedal. Operating the UTV with a spongy brake pedal can result in loss of braking. Loss of braking could cause an accident.
  • Page 37 OWNER’S/OPERATOR’S MANUAL 7. CONTROL AND PARTS FUNCTIONS AUTOMATIC TRANSMISSION GEAR SELECTOR OPERATION The transmission gear selector is located at the right side of the steering wheel. The transmission selector lever has five positions: high gear, low gear, neutral, reverse, and parking brake. AUTOMATIC TRANSMISSION GEAR SELECTOR OPERATION The transmission gear selector is located at the right side of the steering wheel.

  • Page 38: Fuel Tank Cap

    OWNER’S/OPERATOR’S MANUAL 7. CONTROL AND PARTS FUNCTIONS Always place the transmission in gear with the parking brake locked whenever the vehicle is left unattended. Maintaining the shift linkage adjustment is important to assure proper transmission function. Should you experience any shifting problems see your dealer for assistance.

  • Page 39: Seat Belts

    OWNER’S/OPERATOR’S MANUAL 7. CONTROL AND PARTS FUNCTIONS SEATS 1. Driver seat 2. Passenger seat To remove the seat, lift the front of the seat, and then slide the seat up and forward. To install the seat, insert the projections on the rear of the seat into the seat holders and push down on the seat at the front.

  • Page 40: Trailer Hitch Bracket

    OWNER’S/OPERATOR’S MANUAL 7. CONTROL AND PARTS FUNCTIONS 1. Buckle 2. Latch plate 1. Buckle 2. Release button CAUTION To protect from damage, do not put metal products, like tools or sharp-edged products directly in the glove compartment. If they must be stored, wrap them in an appropriate cushion material first.
  • Page 41 OWNER’S/OPERATOR’S MANUAL 7. CONTROL AND PARTS FUNCTIONS 1.Trailer hitch; 2.Trailer hitch bracket. FUEL AND OIL SYSTEM WARNING Gasoline is highly flammable and explosive under certain conditions.  Always exercise extreme caution whenever handling gasoline.  Always refuel with the engine stopped and outdoors or in a well-ventilated area.

  • Page 42: Starting The Engine

    OWNER’S/OPERATOR’S MANUAL 8. STARTING THE ENGINE Procedure for Starting a Cold Engine WARNING Never run an engine in an enclosed area. Carbon monoxide exhaust gas is poisonous and can cause severe injury or death. Always start engines outdoors. WARNING POTENTIAL HAZARD Freezing control cables in cold weather.

  • Page 43: Jump-Starting

    OWNER’S/OPERATOR’S MANUAL 8. STARTING THE ENGINE Jump-starting Jump-starting the vehicle should be avoided. The battery should be removed and charged instead. However, if the vehicle must be jump started, proceed as follows. 1. Turn the key to “OFF”. 2. Connect the positive end of a full charged 12V battery to the positive end of battery in the car by using the jumper cable.

  • Page 44: Vehicle Break-In Period

    OWNER’S/OPERATOR’S MANUAL 9. VEHICLE BREAK-IN PERIOD The break-in period for your new UTV is defined as the first 50 hours of operation. No single action on your part is as important as a proper break in period. Careful treatment of new engine will result in more efficient performance and longer life for the engine.

  • Page 45: Riding Wear

    OWNER’S/OPERATOR’S MANUAL 10. RIDING GEAR Always wear clothing suited to the type of riding you are doing. UTV riding requires special protective clothing which will make you feel more comfortable and reduce chances of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding. Select an approved off-road motorcycle-type helmet that fits properly to prevent a severe head injury.

  • Page 46: What Can Happen

    OWNER’S/OPERATOR’S MANUAL 10. RIDING GEAR WARNING POTENTIAL HAZARD Operating this vehicle without wearing an approved motorcycle helmet, eye protection, and protective clothing. WHAT CAN HAPPEN Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident.

  • Page 47: Carrying Loads

    OWNER’S/OPERATOR’S MANUAL 07.0 11. CARRYING LOADS CARRYING LOADS Cargo or a trailer can change the stability and handling of a vehicle. You must use common sense and good judgment when carrying cargo or towing a trailer. Keep the following points in mind: ...
  • Page 48 OWNER’S/OPERATOR’S MANUAL 07.0 11. CARRYING LOADS  Avoid making sharp turns unless at very slow speeds.  Avoid hills and rough terrain. Choose terrain carefully. Added weight affects the stability and handling of the vehicle. WARNING POTENTIAL HAZARD Overloading this vehicle or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident.
  • Page 49 OWNER’S/OPERATOR’S MANUAL 07.0 11. CARRYING LOADS 1.Cargo bed release lever To lift: Push down the cargo bed release lever on the left or right side of the vehicle, and then slowly lift the cargo bed until it stops. To lower: Lower the cargo bed slowly to its original position and be sure that it is locked into place.
  • Page 50 OWNER’S/OPERATOR’S MANUAL 07.0 11. CARRYING LOADS 11-4...

  • Page 51: Cvt System

    OWNER’S/OPERATOR’S MANUAL 12. CVT SYSTEM WARNING The CVT system rotates at high speeds. Creating large amounts of force on the clutch components. Do not modify any components of the CVT system. Any modification will damage the system; and cause the system to be out of balance. The CVT housing must be securely in place during operation.

  • Page 52: Exhaust System

    OWNER’S/OPERATOR’S MANUAL 13. EXHAUST SYSTEM SYSTEM REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED! CAUTION Exhaust system components are very hot during and after use of the UTV.  Do not touch exhaust system components. Serious burns can result.  Be especially careful when traveling through tall grass. The potential for fire exists.
  • Page 53 OWNER’S/OPERATOR’S MANUAL 13. EXHAUST SYSTEM WARNING When cleaning the spark arrestor, you must follow the safeguards listed below to avoid serious injury.  Do not perform this operation immediately after the engine has been run because the exhaust system becomes very hot. Keep combustible materials away from exhaust system, otherwise it ...
  • Page 54 OWNER’S/OPERATOR’S MANUAL 14. BATTERY WARNING Whenever removing the battery, disconnect the negative (black) cable first. When reinstalling the battery, connect the negative (black) cable last or an explosive situation could result causing serious injury or death. WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes, or clothing.
  • Page 55 OWNER’S/OPERATOR’S MANUAL 14. BATTERY Battery Installation and Connections WARNING To avoid the possibility of explosion, always connect the battery cables in the order specified. Red (positive) cable first; black (negative) cable last. An exploding battery can cause serious injury or death. WARNING Battery terminals and connections should be kept free of corrosion.
  • Page 56 OWNER’S/OPERATOR’S MANUAL 14. BATTERY CAUTION Your UTV is equipped with a 30Ah Battery. This may not be sufficient to provide power for optional equipment. When installing optional equipment please upgrade your battery, as necessary. See your dealer for the proper battery. 14-3...

  • Page 57: Troubleshooting

    OWNER’S/OPERATOR’S MANUAL 15. TROUBLESHOOTING LOW BATTERY Possible Cause Solutions See ”8. STARTING THE ENGINE” Starting a faulty engine for and check the fuel/ air/ ignition/ a long time. compression system. Left the ignition switch When stopping the engine, turn (key) on while parking the off the ignition switch (key) off at UTV.
  • Page 58 OWNER’S/OPERATOR’S MANUAL 15. TROUBLESHOOTING NOTE: The following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection, adjustment, and replacement of parts. Adjustment and replacement must be done by your dealer.
  • Page 59 OWNER’S/OPERATOR’S MANUAL 15. TROUBLESHOOTING IGNTION SYSTEM Battery Ignition system Improperly charged battery Faulty ignitor unit Faulty battery Faulty pick up coil Broken magneto woodruff key Fuse Burnt out, improper connection Spark plug Switch Improper plug gap Faulty main switch Worn electrodes Faulty brake switch Wire between terminals broken...

  • Page 60: Poor Medium And High-Speed Performance

    OWNER’S/OPERATOR’S MANUAL 15. TROUBLESHOOTING POOR MEDIUM AND HIGH-SPEED PERFORMANCE Air cleaner Improperly adjusted fuel level Clogged air cleaner element Clogged main nozzle Fuel tank Low fuel pressure due to the fuel pump clogged POOR SPEED PERFORMANCE Ignition system Compression system Dirty spark plug Worn cylinder Improper heat range...
  • Page 61 OWNER’S/OPERATOR’S MANUAL 15. TROUBLESHOOTING OVER HEATING Fuel system Ignition system Improperly spark plug gap setting  Improper spark plug heat rang incorrectly Faulty igniter unit  Improper fuel level adjustment  Clogged air cleaner element Compression system Engine oil Heavy carbon deposit build- ...

  • Page 62: Poor Starting Performance

    OWNER’S/OPERATOR’S MANUAL 15. TROUBLESHOOTING Oily V-belt Cam, slider Roller weight Worn/damaged  Worn/improper operation primary/secondary/sheave Compression spring Damage Gears Damage CLUTCH SLIPPING Clutch weight spring Uncorrect Primaty Clutch Position Worn/loose Uncorrect engine mount Clutch shoe (see 12. CVT system) Worn/ damaged Primary sliding sheave Seized POOR STARTING PERFORMANCE...
  • Page 63 OWNER’S/OPERATOR’S MANUAL 15. TROUBLESHOOTING Air in brake fluid Broken brake hose Leaking brake fluid Oily or greasy brake disc 15-7...

  • Page 64: Specifications

    OWNER’S/OPERATOR’S MANUAL 16. SPECIFICATIONS Dimensions & Capacities L × W × H 3070mm×1622mm×2060mm Seat height 460mm Wheelbase 1930mm Ground Clearance 230mm Fuel capacity 30L (7.93 Gal.) Engine Oil Capacity 2.3 L Dry Weight 669 kg (1475 lbs.) Load Capacity 350 kg (772 lbs.) (Combined Rider&...

  • Page 65: Electrical Equipment

    OWNER’S/OPERATOR’S MANUAL 16. SPECIFICATIONS Engine Engine Type XY192MR 4Stroke, Single Cylinder, SOHC Bore x Stroke 92mmx75mm Displacement 499cc Starter System Electric Starter Engine Cooling Liquid -Cooled Lubrication System Wet Sump Ignitions Spark Plug Type K6RTC Electrical Equipment Battery 12V 30AH Head light （Low beam）...
  • Page 66 OWNER’S/OPERATOR’S MANUAL 17. WIRNING DIAGRAM 17-1...
  • Page 67 OWNER’S/OPERATOR’S MANUAL 17. WIRNING DIAGRAM Battery Battery 17-2...
  • Page 68 OWNER’S/OPERATOR’S MANUAL 17. WIRNING DIAGRAM Battery Battery Head Head Light Light Head Head Light Light Turn Turn signal signal Light(F,L) Light(F,L) Turn Turn signal signal Light(F,R) Light(F,R) Turn Turn signal signal Light(F,L) Light(F,L) Turn Turn signal signal Light(F,R) Light(F,R) Parking Switch Belt Switch 17-3...
  • Page 69 OWNER’S/OPERATOR’S MANUAL 17. WIRNING DIAGRAM Battery Battery Water Water temperature temperature sensor sensor REC/REG REC/REG Spark Spark Plug Plug 17-4...

  • Page 70: Maintenance

    OWNER’S/OPERATOR’S MANUAL 18. MAINTENANCE To keep the performance good, the vehicle should be checked and maintained at certain interval. The meanings of capital in following table are: I: Inspection, including check, clean, lubricate, refuel, repair or replacing if necessary. A: Inspection, adjusting if necessary C: Cleaning R: Replacing L: Lubricate...

  • Page 71: Periodic Maintenance Schedule

    OWNER’S/OPERATOR’S MANUAL 18. MAINTENANCE If you want to know more about maintenance details, please refer to the following table. Due to the nature of the adjustments marked with a D on the following chart, it is recommended these services be performed by an authorized dealer.
  • Page 72 OWNER’S/OPERATOR’S MANUAL 18. MAINTENANCE Item Hours When Remarks  Brake System Pre-ride Pre-ride Pre-ride inspection item Inspect –adjust, lubricate, replace Accelerator pedal Pre-ride Pre-ride if necessary; pre-ride inspection item Check for leaks at tank cap, lines, Fuel System Pre-ride Pre-ride fuel valve, filter, and carburetor.
  • Page 73 OWNER’S/OPERATOR’S MANUAL 18. MAINTENANCE Item Hours When Remarks Throttle Cable/ Accelerator Inspect –adjust, lubricate, replace if 20 hrs monthly necessary; pre-ride inspection item pedal Shift linkage 50 hrs 6 months Inspect, adjust Drive belt 50 hrs 6 months Inspect, replace if necessary Check operation and for looseness, worn, damage, binding feeling / Steering system...

  • Page 74: Lubrication Recommendations

    OWNER’S/OPERATOR’S MANUAL 18. MAINTENANCE LUBRICATION RECOMMENDATIONS Item Lube Rec Method Frequency 1.Engine Oil SAE 15W/40SG Add to proper level on dipstick Check level daily  2.Front/Rear axle Front axle：250ml Change annually Rear axle：450ml Gear case Oil 80W/90GL5 or at 100 hours As required, change Maintain level between fill lines.

  • Page 75: Wheel Nut Torque Specifications

    OWNER’S/OPERATOR’S MANUAL 18. MAINTENANCE 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.

  • Page 76: Rear Spring Adjustment

    OWNER’S/OPERATOR’S MANUAL 18. MAINTENANCE REAR SPRING ADJUSTMENT The rear shock absorber spring is adjusted by rotating the adjuster in the direction required to increase or decrease spring tension. Rear Spring Adjustment AIR FILTER SERVICE 1.Lift the seat asst. (See 7.CONTROL AND PARTS FUNCTIONS in this manual for bed lifting and lowering.) ○...

  • Page 77: Camber And Caster

    OWNER’S/OPERATOR’S MANUAL 18. MAINTENANCE Park on level ground. Turn the steering wheel right and left. Check for excessive free play, abnormal noises, or a rough feeling. Have an authorized dealer repair as necessary for proper operation. Lubricate the pivoting parts. Recommended lubricant: Lithium-soap-based grease CAMBER AND CASTER...
  • Page 78 OWNER’S/OPERATOR’S MANUAL 18. MAINTENANCE WARNING If the tie rod is positioned incorrectly or adjusted incorrectly, it will not pivot, may break, and may separate. Severe injury or death can result. BRAKES fill reservoir indicated Always whenever the cover is loosened or removed to insure proper diaphragm operation.

  • Page 79: Parking Brake

    OWNER’S/OPERATOR’S MANUAL 18. MAINTENANCE system leakage. If the brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage.  The brake fluid reservoir is located under the hood.  When checking the fluid level, make sure the top of the brake fluid reservoir is level.

  • Page 80: Throttle Free Play Inspection

    OWNER’S/OPERATOR’S MANUAL 18. MAINTENANCE Adjusting Note: The adjustment on the caliper is for the wear out of the pads. To adjust the mechanical parking brake, use the following procedure:  1. With the engine off, loosen the adjustor on the lever. ...

  • Page 81: Spark Plugs

    OWNER’S/OPERATOR’S MANUAL 18. MAINTENANCE NOTE: While adjusting free play, it is important you flip the throttle pedal back and forth. 3. Tighten locknut and slide the boots over cable adjuster. SPARK PLUGS Inspect:  Insulator ① Abnormal color: Replace. Normal color is a medium-to-light tan color.

  • Page 82: Engine Oil Level Inspection

    OWNER’S/OPERATOR’S MANUAL 18. MAINTENANCE Remove the spark plug by rotating counterclockwise. Reverse the procedure for spark plug installation. Torque to 22ft.Ibs (30N.m). WARNING Winch Warning: The winch is available as an optional accessory, please contact your dealer for more information. Maximum Winch Specs: 12V/200Amp relay needed.

  • Page 83: Engine Oil Replacement

    OWNER’S/OPERATOR’S MANUAL 18. MAINTENANCE CAUTION: 1.Do not put in any chemical additives. 2.Be sure not to use oils labeled "ENERGY CONSERVING I" or higher. Engine oil also lubricates the gear-box and additives could cause abnormal wear. 3.Be sure no foreign material enters the crankcase. 4.Start the engine and let it warm up for a few minutes.
  • Page 84 OWNER’S/OPERATOR’S MANUAL 18. MAINTENANCE 5. Install: ○  Aluminum Washer 10 2 NEW ○  Bolt M10 NOTE : Check the drain plug O-ring. If damaged, replace it with a new one. 6. Fill Oil:  Crankcase Oil quantity: 2.3L 7.
  • Page 85 OWNER’S/OPERATOR’S MANUAL 18. MAINTENANCE 5. Fill Oil: SAE 80W/90 GL5 Oil quantity: 250 ml 6. Install: ○ 2 NEW  Copper Washer ○  Oil Port Screw REAR AXLE GEAR CASE OIL REPLACEMENT 1. Place an oil pan under the gear case. 2.

  • Page 86: Optional Configuration

    OWNER’S/OPERATOR’S MANUAL 19. Optional configuration Fully enclosed cab Side Doors of UTV 1、Door unlock trigger Pull the trigger upwards to open the car door 2、Door lock When the car door is not locked, you can press the circular lock cylinder on the door handle to open the door You can insert the included door key into the lock cylinder on the door handle to...
  • Page 87 OWNER’S/OPERATOR’S MANUAL 19. Optional configuration Heater The heater is located behind the right front wheel and is actually a water tank. After the cooling water of the engine flows into the water tank, the fan on the water tank blows out hot air. 1、Heater Switch Turn on the fan on the heater;...
  • Page 88 OWNER’S/OPERATOR’S MANUAL 19. Optional configuration Multimedia display screen Button: 1. Prower When the ignition switch is in the ACC ON position, press the switch panel on the Touchscreen key to boot. 2. Off After the host starts,press the switch on the side of the touch screen button for 2 seconds,the host will perform the shutdown Attention: When there is noise, please briefly press the power button to enter the mute mode.

  • Page 89: Apple Carplay

    OWNER’S/OPERATOR’S MANUAL 19. Optional configuration 5.Volume control keys When the volume is too low, you can click to increase the volume. When the volume is too high, you can click to reduce the volume. 6. MIC , which can be adjusted in This machine has built-in MIC the setting according to the use situation.
  • Page 90 OWNER’S/OPERATOR’S MANUAL 19. Optional configuration Siri In Carplay mode, user can talk to Siri to control the CarPlay functions.Press to start the Siri function, or touch the button for 2 seconds or the HOME button of iPhone. Now you can talk to Siri for playing music,l am going..
  • Page 91 OWNER’S/OPERATOR’S MANUAL 19. Optional configuration Operations (1) Connect an Android device via USB terminal.To use the hands-free function,connect the Android device via Bluetooth.When an Android device compatible with Android Auto is connected to USB terminal the device is connected iva Bluetooth.automatically,and the Bluetooth smartphon currently conected is disconnected.
  • Page 92 OWNER’S/OPERATOR’S MANUAL 19. Optional configuration 2. Radio mode
 Touch the Radio mode icon to enter Radio. Touch FM1 to select FM1 Band. Touch AM1 to select AM1 Band. Touch to select Band,FM1>FM2>FM3>AM1>AM2 19- 7...
  • Page 93 OWNER’S/OPERATOR’S MANUAL 19. Optional configuration Short touch to prescan searching,each scanned station will be played10s. Long touch for auto searching. Touch to enter EQ settings. Touch to switch LOCAL or DX. Touch to input tune directly. Short touch to Seek-, long touch for Step- Short touch to Seek+, long touch for Step+ Preset station,6 preset store and recall station for each band.
  • Page 94 OWNER’S/OPERATOR’S MANUAL 19. Optional configuration 3. USB Plug the USB , the USB icon will be colorful. Touch the USB icon to enter the USB playback mode.The source unit default the play the Audio in the USB device. Press to list Audio ,Video, Picture files in USB. Short press to skip previous track Long press to fast reverse.
  • Page 95 OWNER’S/OPERATOR’S MANUAL 19. Optional configuration Press to switch Random is On or Off. Press to select Audio setting or set the prefer EQ of each band in custom mode. Touch to handle go to page for input the track number directly. File List browsing Touch to browse the folder and file list List of the...

  • Page 96: Bluetooth Connect

    OWNER’S/OPERATOR’S MANUAL 19. Optional configuration 4.1 Bluetooth Connect If the Bluetooth is not connected, press Re-connect the paired phone or paring to pair the new device. 19- 11...

  • Page 97: Bluetooth Audio

    OWNER’S/OPERATOR’S MANUAL 19. Optional configuration Press to skip previous track. Play or pause button. Press to skip next track. Press to switch Random is On or Off Press to select Repeat All >Repeat 1>Repeat Directory Press to select Audio setting or set the prefer EQ of each band in custom mode.
  • Page 98 OWNER’S/OPERATOR’S MANUAL 19. Optional configuration Bluetooth Audio Playback 19- 13...

  • Page 99: Bluetooth Pairing

    OWNER’S/OPERATOR’S MANUAL 19. Optional configuration 4.3 Bluetooth Pairing Pairing mode screen will be shown as below: Tum On the Bluetooth of the mobile phone or Bluetooth device, you can see the CAR-KIT, select the CAR-KIT for pairing and connection. 19- 14...

  • Page 100: Bluetooth Phone

    OWNER’S/OPERATOR’S MANUAL 19. Optional configuration 4.4 Bluetooth Phone Touch the Phone icon in main menu to go to Phone mode.After the mobile phone is connected with the source unit via Bluetooth(HFP), user can through the source unit to make a phone call.

  • Page 101: Emissions Control - System Warranty

    OWNER’S/OPERATOR’S MANUAL 20. EMISSIONS CONTROL – SYSTEM WARRANTY Emission Related Components Warranty Your new Mars Carts vehicle complies with the U.S. EPA emission regulations. Mars Carts Inc. provides the emission warranty coverage for engines in the United States and its territories. In the remainder of this Emission Related components Warranty, Mars Carts Inc.

  • Page 102: Warranty Coverage

    OWNER’S/OPERATOR’S MANUAL 20. EMISSIONS CONTROL – SYSTEM WARRANTY completed in a reasonable amount of time, not to exceed 30 days. As the vehicle owner, you should be aware that Mars Carts may deny your warranty coverage if your vehicle or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

  • Page 103: To Obtain Warranty Service

    OWNER’S/OPERATOR’S MANUAL 20. EMISSIONS CONTROL – SYSTEM WARRANTY warranty statement. Normal maintenance items, such as spark plugs and filters that are on the warranted parts list are warranted up to their required replacement interval only. Only Mars Carts approved replacement parts may be used in the performance of any warranty repairs and must be provided without charge to the owner.

  • Page 104: Exclusions And Limitations

    OWNER’S/OPERATOR’S MANUAL 20. EMISSIONS CONTROL – SYSTEM WARRANTY If you are unable to obtain warranty service, or are dissatisfied with the warranty service you received, contact the owner of the dealership involved. Normally this should resolve your problem. However, if you require further assistance, write or call the Mars Carts Inc.

  • Page 105: Parts Description

    OWNER’S/OPERATOR’S MANUAL 20. EMISSIONS CONTROL – SYSTEM WARRANTY except as specifically set forth herein. Any emission related components warranty implied by law, including any warranty of merchantability or fitness for a particular purpose, is limited to the express emission related components warranty terms stated in this warranty.

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