The provided information does not include specific part numbers for the Massimo 500UTV. It lists compatible parts and accessories but does not assign part numbers to them. Therefore, part numbers cannot be determined from the given context.

This answer is automatically generated

May 12, 2025

my e break doesnt work

1 comments:

Mr. Anderson

May 20, 2025

Common issues causing the e-brake to not work on a Massimo 500UTV include:

- Excessive clearance due to component wear or improper adjustment.
- Concaved or damaged brake pipeline.

These issues can reduce braking efficiency or cause the e-brake to fail.

This answer is automatically generated

Dee

June 6, 2025

Fuse box location

Summary of Contents for Massimo 500UTV

Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. 500UTV 500LUTV OWNER’S MANUAL 4×4 This UTV should not be ridden by anyone under 16 years of age.
Page 2 INTRODUCTION Congratulations on your purchase of the 500UTV. With the purchase of this UTV, you can now appreciate the high degree of craftsmanship. This manual will provide you with a good basic understanding of the features and operation of this UTV. This manual includes important safety information.
Page 3 INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander or a person inspecting or repairing the machine.
Page 4: Important Notice
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 arrester laws and regulations in effect at the time of manufacture.
Page 5: Table Of Contents
TABLE OF CONTENTS Introduction……………………………………………………………………………………1 SAFETY………………………………………………………………………………………3 Features and Controls…………………………………………………………………………21 Component Locations…………………………………………………………………………21 Indicator and warning lights…………………………………………………………………23 Main stitch of light……………………………………………………………………………24 Dump Bed and winch……………………………………………………………………26 4×2,4×4WD and differential locking exchangeable……………………………………27 The Other Switch……………………………………………………………………………28 Seats……………………………………………………………………………………………30 Driver’s seat adjustment……………………………………………………………………30 Seat Belts………………………………………………………………………………………30 Seat Belt Inspection……………………………………………………………………………30 Fuel cap …………………………………………………………………………………31 Ignition Switch ………………………………………………………………………………32 Gear Selector…………………………………………………………………………………33 Parking Brake………………………………………………………………………………33...
Page 6 Throttle Pedal…………………………………………………………………………………34 OPERATION…………………………………………………………………………………35 Vehicle brake-in period………………………………………………………………………35 Pre-ride inspection……………………………………………………………………………37 Safe operation practices………………………………………………………………………38 Starting the engine……………………………………………………………………………39 Stopping the engine……………………………………………………………………………40 Braking…………………………………………………………………………………………40 Parking the vehicle……………………………………………………………………………40 New operator driving procedures……………………………………………………………41 Driving with a passenger………………………………………………………………………43 Driving on slippery surface……………………………………………………………………44 Driving uphill…………………………………………………………………………………46 Driving on a sidehill…………………………………………………………………………47 Driving downhill………………………………………………………………………………47...
Page 7 Driving through water…………………………………………………………………………48 Driving over obstacles…………………………………………………………………………49 Driving in reverse………………………………………………………………………………50 Parking on an incline…………………………………………………………………………51 MAINTENANCE………………………………………………………………………………52 Periodic maintenance chart …………………………………………………………………52 Engine oil ……………………………………………………………………………………55 Transmission (main gearcase)………………………………………………………………59 Spark plugs……………………………………………………………………………………60 Constant variable transmission (CVT)system ………………………………………………61 Filter system …………………………………………………………………………………63 Cooling system …………………………………………………………………………………65 Throttle system ………………………………………………………………………………68 Carburetor ……………………………………………………………………………………70 Brakes…………………………………………………………………………………………72...
Page 8 Steering wheel inspection ……………………………………………………………………74 Shock spring adjustment ……………………………………………………………………74 Tires……………………………………………………………………………………………75 Vehicle immersion……………………………………………………………………………76 Battery…………………………………………………………………………………………77 Clearing and storage…………………………………………………………………………80 Malfuncation analysis and elimination ………………………………………………………82 W A R R A N T Y … … … … … … … … … … … … … … … … … … … … … … … … … … … 9 7 SPECIFICATIONS…………………………………………………………………………100 C i r c u i t D i a g r a m …...
Page 9: Introduction
INTRODUCTION Failure to follow the warnings and safety precautions contained in this manual can result in severe injury or death. Your vehicle is not a toy and can be hazardous to operate. This vehicle handles differently than cars, trucks or other off-road vehicles. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.
Page 10: Identification Number Records
INTRODUCTION Identification number records Record the vehicle identification number and engine number in the spaces provided for assistance when ordering spare parts from your dealer or for reference in case the vehicle is stolen. NOTE:The vehicle identification number is used to identify your machine.
Page 11: Safety
SAFETY Equipment Modifications Your vehicle is designed to provide safe operation when used as directed. Modifications to your vehicle may negatively impact vehicle stability. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power. This vehicle may become less stable at speeds higher than those for which it is designed.
Page 12 SAFETY Safe Riding Gear Always wear appropriate clothing when riding this vehicle. Wear protective clothing for comfort and to reduce the chance of injury.
Page 13 SAFETY Safe Riding Gear Helmet Wearing a helmet can prevent a severe head injury. Whenever riding this vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label. Eye Protection Do not depend on eyeglasses or sunglasses for eye protection.
Page 14 SAFETY Safety Warnings Failure to operate this vehicle properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Be sure to read all of the following warnings about driving hazards and how to avoid them. These warnings are provided for your safety. Operating Without Instruction Operating this vehicle without proper instruction increases the risk of an accident.
Page 15 SAFETY Safety Warnings Failure to Inspect Before Operating Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the owner's manual.
Page 16 SAFETY Safety Warnings Protective Apparel Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of serious injury in the event of an accident. Operator and passenger must always wear an approved helmet that fits properly and eye protection (goggles or face shield).
Page 17 Never carry a passenger until you have operated this vehicle for at least four hours. Carrying Multiple Passengers Carrying more than one passenger in the 500UTV or carrying more than three passengers in the 500LUTV can affect the operator’s ability to steer and operate the controls, which increases the risk of loss of control and accident or overturn.
Page 18 SAFETY Safety Warnings Operating at Excessive Speeds Operating this vehicle at excessive speeds increases the operator's risk of losing control. Always operate at a speed that's appropriate for the terrain, the visibility and operating conditions, your skills and your passenger’s skills. Turning Improperly Turning improperly could cause loss of traction, loss of control, accident or overturn.
Page 19 SAFETY Safety Warnings Jumps and Stunts Exhibition driving increases the risk of an accident or overturn. DO NOT do power slides, “donuts”, jumps or other driving stunts. Avoid exhibition driving. Driving Downhill Improperly Driving down a hill improperly could cause loss of control or overturn.
Page 20 SAFETY Safety Warnings Improper Hill Climbing Improper hill climbing could cause loss of control or overturn. Use extreme caution when operating on hills. Always follow proper procedures for hill climbing as described in the owner's manual. Stalling While Climbing a Hill Stalling or rolling backwards while climbing a hill could cause an overturn.
Page 21 SAFETY Safety Warnings Operating in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn. Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn. Travel slowly and use extra caution when operating on unfamiliar terrain.
Page 22 SAFETY Safety Warnings Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures as outlined in this manual. Before shifting into reverse gear, always check for obstacles or people behind the vehicle. When it's safe to proceed, back slowly.
Page 23 SAFETY Safety Warnings Operating Through Water Operating through deep or fast-flowing water can cause loss of traction, loss of control, overturn or accident. Never operate in fast-flowing water or in water that exceeds the floor level. Always follow proper procedures for operating in water as described in the owner's manual.
Page 24 SAFETY Safety Warnings Operating a Damaged Vehicle Operating a damaged vehicle can result in an accident with serious injury or death. After any overturn or accident, have a qualified service dealer inspect the entire vehicle for possible damage, including (but not limited to) brakes, throttle and steering systems. Operating on Frozen Bodies of Water Operating on frozen bodies of water can result in the vehicle and/or riders falling through the ice.
Page 25 SAFETY Safety Warnings Handling Gasoline Gasoline is highly flammable and is explosive under certain conditions. Always exercise extreme caution whenever handling gasoline. ● Never allow a child to refuel or handle gasoline. ● Always stop the engine when refueling. ● Always refuel outdoors or in a well ventilated area. ●...
Page 26 SAFETY Safety Warnings Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle. Hot components can cause burns and fire. Do not touches hot exhaust system components. Always keep combustible materials away from the exhaust system. Use caution when traveling through tall grass, especially dry grass.
Page 27 SAFETY Safety Labels and Locations Warning Label WARNING Improper vehicle use can result in SEVERE INJURY or DEATH NEVER allow vehicle to be operated: ● Without all occupants first viewing and understanding safety warning labels. ● With more than stipulate passenger. ●...
Page 28 SAFETY Safety Labels and Locations Warning Label WARNING Operation of this vehicle by children age 16 and under increases the risk of severe injury or death. NEVER permit children age 16 and under to operate or ride in this vehicle. WARNING VEHICLE OVERTURN could cause severe injury or death.
Page 29: Features And Controls
FEATURES AND CONTROLS Component Locations...
Page 30 FEATURES AND CONTROLS Component Locations...
Page 31: Indicator And Warning Lights
FEATURES AND CONTROLS Indicator and warning lights indicator odometer 1、Thermometer 2.3.、Turning Indicators 4、Fuel 5、High beam 6、 warming light 7、Speed indicator 8、2 and 4 wheel drive. 9. Brake liquid 10. Reverse over speed alarm light (ａ)Speedometer 7：Display the speed of vehicle. dometer (ｂ) O 6 ：Display the accumulated driving distance.
Page 32: Main Stitch Of Light
FEATURES AND CONTROLS （ｄ） .Turning Indicators 2, 3 ： Blink when the relative direction indicators light. Blink in same times when warning light is on. （ｅ）.Fuel meter 4 ：Display the quantity of fuel. （ｆ）.Gear display：The corresponding indicating (L, H, N, R) will be displayed when the gear changed.
Page 33 FEATURES AND CONTROLS Main switch of lights down“ ”, headlight(low beam), meter light and tail light is on. (c). When ignition switch is at “ON”, “ACC”or“ON”position, press down“ ”, alarm light blinks. (d). When ignition switch is at “ACC” or “ON” position, press down“ ”or“...
Page 34: Dump Bed And Winch
FEATURES AND CONTROLS Dump Bed and winch When need to dump, firstly, open the rear door of cargo box, then press main switch to“ON” position, and press “DUMP” to “UP”, cargo box will be up backwards; And stop after releasing the press; While press “DUMP”to”...
Page 35: 4×2,4×4Wd And Differential Locking Exchangeable
FEATURES AND CONTROLS 4×2、4×4WD and differential locking exchangeable When select “4X2”, it is rear wheel drive mode (this is the normal driving mode). When select “4X4”, the front and rear wheels will be drove at same times( normally, this drive mode will be used on muddy and rugged road. When select “4X4 lock”...
Page 36: The Other Switch
FEATURES AND CONTROLS The Other Switch Cigarette light The cigarette light installed on the vehicle. The socket also can be used for phone charging and external power supply. Note: The voltage of the socket is 12V, DC. Please make sure the voltage matches your electro-set’s. Windshield and wiper（optional）...
Page 37: The Other Switch
FEATURES AND CONTROLS The Other Switch CHOKE When start the vehicle in cold weather, pull out the “CHOKE SWITCH” a little bit. Push it back after the engine started. Note: Once the engine started, push the SWITCH back in time. Never leave the SWITCH out when driving.
Page 38: Seats
FEATURES AND CONTROLS Seats Driver’s Seat Adjustment If you want to adjust the backrest of the seat forward or rearward, rotate the 1 which locates at the inneredge anticlockwise of the seat in clockwise or direction . Seat Belts This vehicle is equipped with three-point lap seat belts for the operator and passenger. Always make sure the seat belts are secured for both the operator and passenger before riding.
Page 39: Fuel Cap
FEATURES AND CONTROLS 2. Push the red release latch in the middle of the buckle to make sure it releases freely. 3. Inspect the full length for any damage, including cuts, wear, fraying or stiffness. If any damage is found, or if the seat belt does not operate properly, have the seat belt system checked and/or replaced by an authorized dealer.
Page 40: Ignition Switch
FEATURES AND CONTROLS Ignition Switch Ignition switch has four positions： “OFF”（close）position：All circuits are turnoff except emergency light, electric fan and cigarette lighter. “ACC” position: lights, MP3, horn, windshield wiper “ON”（open）position：All circuits except engine are connected, and they could start at any moment or make engine keep running status.
Page 41: Gear Selector
FEATURES AND CONTROLS Gear Selector L: Low gear H: High gear N: Neutral R: Reverse The gear selector is located between the seats. To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear. Do not attempt to shift gears with engine speed above idle or while the vehicle is moving.
Page 42: Brake Pedal
FEATURES AND CONTROLS Tip: Always set the parking brake whenever the vehicle is left unattended. Operating the vehicle while the parking brake is engaged could cause an accident resulting in serious injury or death. It could also result in driveline or engine damage. Always be sure to disengage the parking brake before operating the vehicle.
Page 43: Operation
OPERATION Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual. Vehicle Break-in Period The break-in period for your new vehicle is defined as the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline.
Page 44 OPERATION Vehicle Break-in Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. Always exercise extreme caution whenever handling gasoline. Never allow a child to handle gasoline. 2. Check the oil level. See page 56. Add the recommended oil as needed to maintain the oil level in the safe operating range.
Page 45: Pre-Ride Inspection
OPERATION Pre-Ride Inspection Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition. Item Remarks Page Brake...
Page 46: Safe Operation Practices
OPERATION Safe Operation Practices 1. Complete the New Operator Driving Procedures outlined on pages41-42. 2. Do not ride at night or when visibility is poor (rain, fog, dusk). Your vehicle doesn't have lights that are designed for driving in these conditions. 3.
Page 47: Starting The Engine
OPERATION Starting the Engine 1. Sit in the driver's seat and fasten the seat belt. 2. Place the transmission in neutral. Set the parking brake. 3. Apply the brakes. 4. Do not press the throttle pedal while starting the engine. 5.
Page 48: Stopping The Engine
OPERATION Stopping the Engine 1. Release the throttle pedal completely and brake to a complete stop. 2. Place the transmission in neutral. 3. Set the parking brake. 4. Stop the engine. 5. Turn the fuel valve off. Braking 1. Release the throttle pedal completely. (When the throttle pedal is released completely and engine speed slows to near idle, the vehicle has no engine braking.) 2.
Page 49: New Operator Driving Procedures
OPERATION New Operator Driving Procedures 1. Read and understand the owner's manual and all warning and instruction labels before operating this vehicle. 2. Review the section of this owner’s manual about starting the engine, stopping the engine, braking and parking (pages39-40). 3.
Page 50 OPERATION 13. Check your surroundings. Make sure the area is clear of people and obstacles. 14. Keeping both hands on the steering wheel, slowly release the brakes and press the throttle with your right foot to begin driving. 15. Drive slowly at first. Practice starting, stopping, turning, using the throttle and brakes and driving in reverse.
Page 51: Driving With A Passenger
OPERATION Driving with a Passenger 1. Complete the New Operator Driving Procedures outlined on Pages 41-42. 2. Perform the pre-ride inspection. See page 3. Do not carry a passenger until you have at least four hours of driving experience with this vehicle. 4.
Page 52: Driving On Slippery Surface
OPERATION 7. Make sure the passenger is wearing appropriate riding gear, including an approved helmet and eye protection. See page 5. 8. Make sure the passenger secures the seat belt. 9. Tell your passenger to always keep hands and feet inside the vehicle at all times. 10.
Page 53 OPERATION Follow these precautions when driving in slippery conditions: 1. Slow down before entering slippery areas. 2. Be alert, watch the path ahead and avoid quick turns, which can cause skids. 3. Correct a skid by turning the steering wheel in the direction of the skid. Never apply the brakes during a skid.
Page 54: Driving Uphill
OPERATION Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always check the terrain carefully before ascending a hill. 2. Avoid steep hills (15° maximum). 3. Drive straight uphill. 4. Never climb hills with excessively slippery or loose surfaces. 5. Drive at a steady rate of speed. Never press the throttle suddenly.
Page 55: Driving On A Sidehill
OPERATION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Driving on a sidehill improperly cause loss of control or overturn. If crossing a hill is unavoidable, follow these precautions: 1. Drive slowly and use extreme caution. 2.
Page 56: Driving Through Water
OPERATION Driving Through Water Your vehicle can drive through shallow water. Make sure the water is no deeper than the floor of the vehicle. Follow these precautions when driving through water: 1. Check water depth. Never drive through water that is deeper than the floor level.
Page 57: Driving Over Obstacles
OPERATION Driving Over Obstacles Follow these precautions when driving over obstacles: 1. Always check for obstacles before driving in a new area. 2. Look ahead and watch the terrain. Always be alert for hazards such as logs, rocks and low hanging branches.
Page 58: Driving In Reverse
OPERATION Driving in Reverse Follow these precautions when driving in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Apply the throttle lightly. Never apply the throttle suddenly. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5.
Page 59: Parking On An Incline
OPERATION Parking on an Incline A rolling vehicle can result in serious injury. Avoid parking on an incline. If parking on an incline is unavoidable, follow these precautions: 1. Place the transmission in neutral. 2. Set the parking brake. 3. Stop the engine. 4.
Page 60: Maintenance
MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine parts available from your dealer.
Page 61 MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first. Perform these operations more often for vehicles subjected to severe use. I: means inspect 、clear、 adjust、 lubricate or change if needed；C: means clear; R: means change；A: means adjust；L: means lubricate...
Page 62 MAINTENANCE Periodic Maintenance Chart * If you're not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations. ** For safety, we recommend that have a qualified dealer perform these operations. Remark：1.If the Odometer indication is large, please repeat this maintenance. 2.If operate this vehicle at special wet or dusty area, you had better shorten the maintenance interval.
Page 63: Engine Oil
3.If you vehicle often operate on rough terrain ,you must maintenance to maintain your vehicle’s performance. 4.Change every two years , have a qualified dealer perform these operations. Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 53.
Page 64 Engine Oil Oil Check Maintain the oil level within the safe range on the dipstick. Do not overfill. 1. Position the vehicle on a level surface. 2. Remove the dipstick. Wipe it dry with a clean cloth. 3. Reinstall the dipstick completely. 4.
Page 65 Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 53 .Always change the oil filter wheneven changing oil. The engine drain plug is located on the bottom of the crankcase. 1.
Page 66 Oil and Filter Change 9. Install the new oil filter cartridge with an oil filter wrench ,and then tighten it to the specifiec torque with a torque wrench .Oil filter cartridge tightening torque:17N·m (17m·kgf,12ft·lbf). 10. Reinstall the sealing washer on the drain plug 11.
Page 67: Transmission (Main Gearcase)
MAINTENANCE Transmission (Main Gearcase) Fluid Check The fill plug is located on the rear of the gearcase. Access the fill plug through the left rear wheel well. Maintain the fluid level at the bottom of the fill plug hole. 1. Position the vehicle on a level surface. 2.
Page 68: Spark Plugs
MAINTENANCE Spark Plugs Spark Plug Gap/Torque Electrode Gap Plug Tightening Torque 0.8-0.9 mm 12.5 ft. lbs. (17.5 Nm) Using non-recommended spark plugs can result in serious engine damage. Always use our NOTICE company recommended spark plugs. Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds.
Page 69: Constant Variable Transmission (Cvt)System
MAINTENANCE Constant Variable Transmission (CVT) System WARNING Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the CVT system. Doing so may reduce its strength so that a failure may occur at a high speed.
Page 70 MAINTENANCE CVT Drying There may be some instances when water is accidently ingested into the CVT system. Use the following instructions to dry it out before operating. The drain plug is located on the bottom of the CVT cover. . Remove the drain plug. Allow the water to drain. Reinstall the drain plug. 2.
Page 71: Filter System
MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. Access the air box through left rear wheel well. 1.Remove the air filter fixed card 1 and the cover 2 . 2.
Page 72 MAINTENANCE Filter Systems Air Filter 5. Clean away any oil or sediments in the air box. 6. Reinstall the filter element and air box cover. Secure the fixed card. Never operate the vehicle with the filter element removed. Dirt will enter the engine, NOTICE causing rapid wear and severe damage to the engine.
Page 73: Cooling System
MAINTENANCE Cooling system 1.Place the vehicle on a level surface. 2.Check the coolant level in the coolant reservoir when the engine is cold as the coolant level will vary with engine temperature. 3.If the coolant is at or below the minimum level mark, open the cover 1 which locates on the engine cover ,you will see the coolant cap , remove the cap, add coolant to the maximum level mark, install the reservoir cap.
Page 74 MAINTENANCE Cooling system Correctly fill up the coolant and release the air inside: 1. Under the situation of whole empty As showed in the picture, pull out the small circulating pipe on the temperature adjusting set. Full up the coolant from the intake of radiator.
Page 75 MAINTENANCE Cooling system The trobleshooting method of coolant circulation: Touch the in and out coolant pipe by hand (make sure do not burn your hand), if the temperature is close to the engine’s, and also the temperature of coolant-in pipe is higher than coolant-out pipe, this means the circulation is ok.
Page 76: Throttle System
MAINTENANCE Throttle System WARNING Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation. Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal. Immediately contact your dealer for service if throttle problems arise.
Page 77 MAINTENANCE Throttle System Throttle Freeplay Inspection 1. Place the transmission in neutral. Set the parking brake. 2. Start the engine. Allow it to warm up thoroughly. 3. Measure the distance the throttle pedal moves before the engine begins to pick up speed. Freeplay should be 1/16 to 1/8 inches (1.5-3 mm).
Page 78: Carburetor
MAINTENANCE Carburetor Common sense: Install the carburetor, the carburetor must ensure that engine to connect with sealing flange department, in order to avoid leakage, resulting in engine starts hard, no idling or idling unstable failure. 1. Carburetor Idle Adjustment: carburetor factory has been idle mixture screw fine adjustment, the general initial use, the user without the need for any adjustments, so as to avoid unnecessary trouble.
Page 79 MAINTENANCE Carburetor Carburetor/Engine Idle RPM Adjustment If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted. 1. Place the transmission in neutral. 2. Set the parking brake. 3. Start the engine and allow it to warm up for approximately five minutes. 4.
Page 80: Brakes
MAINTENANCE Brakes Always check brake pedal travel and the brake fluid reservoir level before each use of the vehicle. When applied, the brake pedal should feel firm. Any sponginess would indicate a possible fluid leak or low brake fluid level, which must be corrected before riding. See page 73 for brake fluid information. If you discover any irregularities in brake system operation, including excessive pedal travel, contact your dealer for proper diagnosis and repairs.
Page 81 MAINTENANCE Brakes Brake Fluid Inspect the level of the brake fluid before each operation. If the Alarm light 9 is on add DOT 3 or DOT 4 brake fluid. After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle.
Page 82: Steering Wheel Inspection
MAINTENANCE Steering Wheel Inspection 1. Position the vehicle on level ground. 2. Lightly turn the steering wheel left and right. 3. There should be 0.8"-1.0" (20-25 mm) of freeplay. 4. If there is excessive freeplay or strange noises, or the steering feels rough or catchy, have the steering system inspected by an authorized dealer.
Page 83: Tires
Tires Operating your vehicle with worn tires will increase the possibility of skidding, loss of control and an accident, which could result in serious injury or death. Always replace tires when the tread depth mea- sures 1/8" (3 mm) or less. Improper tire inflation or the use of non-standard size or type of tires may adversely affect vehicle handling, which could result in vehicle damage or personal injury.
Page 84: Vehicle Immersion
Vehicle Immersion NOTICE: If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it's impossible to take your vehicle to a dealer before starting it, follow the steps outlined below. 1.
Page 85: Battery
MAINTENANCE Battery This machine 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 your dealer. It is locate under the passsenger seat. CAUTION: Do not try to remove the sealing caps of the battery cells.
Page 86: Fuse Replacement
MAINTENANCE Battery :A special battery charger (constant voltage/ampere or constant voltage) is required for CAUTION recharging a sealed type battery. using a conventional battery charger may shorten the battery life. Fuse replacement 1.The fuses are under the meter cover. 2. If a fuse is blown, turn off the main switch and the switch of the circuit in question. then, install a new fuse of the specified amperage.
Page 87: Battery Maintenance
MAINTENANCE Battery 1. When the machine is not used for a month or longer, removes the battery and stores it in a cool, dark place. Completely recharge the battery before reinstallation. 2. Always make sure the connections are correct when putting the battery back in the machine. : Do not use an improper fuse, because an improper fuse can cause damage to the WARNING...
Page 88: Cleaning And Storage
MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your vehicle clean will not only improve its appearance but it can also extend the life of various components. Before washing the vehicle, locate the CVT inlet and outlet duct. The inlet duct is located under the passenger seat and the outlet duct is located at the right side of the vehicle.
Page 89 MAINTENANCE Cleaning and Storage Storage Long term storage (60 days or more) of your machine will require some preventive procedures to guard against deterioration. After thoroughly cleaning the machine, prepare for storage as follows: 1. Drain the fuel system. 2. Remove the spark plug, pour about one tablespoon of SAE 10W30 or 20W40 motor oil in the spark plug hole and reinstall the spark plug.
Page 90: Malfunction Analysis And Elimination
Malfunction analysis and elimination （I）Engine malfunction Malfunction Malfunction Reason Solving method phenomenon system ① Cylinder wear out change Start 1. pressure in ② Piston wear out. change difficultly or cylinder is too ③ Leakage on Washer of cylinder. change could not start low.
Page 91 ① Vent hole on tank jammed Clean or change Start 3. No fuel in ② Problem or blocked in fuel pipe. Clean or change difficultly or carburetor ③ Problem on needle valve of could not start carburetor Change ④ Blocked in fuel tank Change ⑤...
Page 92 Engine middle Mechanical ① The force of Valve spring is Change high problem weak. rotate speed is ② Cam axle worn out Change uneven ③ Plug is dirty. Clean or Change ④ Gap of plug is too small. Adjust or change ⑤...
Page 93 Engine power 2. Electrical parts ① Dirt on plug Clean or Change is not enough problem ② Gap of plug not correct Change or Adjust ③ Ignition loop problem Change ④ CDI problem Change ⑤ Magneto problem Change 3.Mechanical ① Gap of Valve is not correct Change operation method problem ②...
Page 94 3. Air pass problem ① Air mixture is too thick or thin Adjust carburetor ② Leakage on engine Repair ③ Air filter is dirty Clean or change filter ④ Cylinder, piston, ring worn out Repair or change ⑤ Leakages on connecting face Repair or change ⑥...
Page 95 Noise from piston ① Piston worn out Change ② Cylinder worn out Change ③ Carbon gathered in firebox Clean ④ Piston pin or pin hole worn out Change ⑤ Piston ring or ring notch worn out Change Noise from chain ①...
Page 96 Clutch skiding Transmission ① Hoof of clutch worn out Change system ② Spring on clutch is weak Change ③ Out wheel worn out Change ④ Belt worn out & loose Change Gear change Gear box or Gear ① Operating gear damaged Change not smooth or change system...
Page 97 Not stable in high ① Muzzle blocked Clean and middle speed ② Main air channel blocked Clean ③ Needle valve blocked Clean ④ Throttle not work well Adjust ⑤ Fuel filter blocked Clean or change ⑥ Height of floater not right Adjust ⑦...
Page 98 （II）Malfunction in transmission system Vehicle speed Transmission ①Shift belt slips Change does not system ②Speed adjusting plate abrasion is too Change increase by much engine speed ③Speeding adjusting plate slipping is Repair or Change blocked ④Spring force of adjuster is short Repair or Change Out of gear Gear Box or Gear...
Page 99 （III）Malfunction in running system, suspension and steering organization Running Running ①Air pressure in left and right wheel is different Adjust air pressure in tyre leaning system ②Load of left and right wheel is different Adjust load ③Spring force of left and right absorbing spring Adjust or Change ④Front wheel location is wrong Check or adjust...
Page 100 Front wheel Steering ①Tyre and wheel is not balance Balance wheel shakes, organization, Change tyre swing running system ②Wheel hub bearing has been damaged or Change or adjust jump adjustment is wrong ③Left and right swing arm ball head has been Change abraded or loosened ④Drag pole tie-in has been abraded or...
Page 101 （IV）Malfunction in brake system Brake is not Brake ①Brake pipeline leaks oil Repair hard enough system ②Brake disk and brake hoof contacts badly or dirt Repair or clean the dust on surface ③Brake drum and brake hoof wear badly Change ④Brake main pump is damaged or leaks oil Repair or change ⑤Brake branch pump is damaged or leaks oil...
Page 102 Brake clip Brake system ①Brake main pump could not return correctly Repair main pump block ②Brake hoop return spring is too soft Change ③Parking brake adjustment is wrong Adjust ④Parking brake drag line could not return Lubricate or Change ⑤Brake branch clip block Repair or Change ⑥Abrasion of brake drum and brake hoop is Change...
Page 103 Only one front Lighting ①Bulb has been damaged Change headlight does system ②Lead or grounding happens malfunction Repair circuit not illuminate Steering light ①Steering relay has been damaged Change does not ②Individual steering bulb has burned Change illuminate ③Grounding is bad Repair ④Fuse burn out Change...
Page 104 Meter works Meter and ①Fuse has been burned. Change badly wire ②Route has been cut off, tie-in contacts badly Repair route ③Instrument has been damaged Change ④Sensor has been damaged Change...
Page 105: W A R R A N T
WARRANTY LIMITED WARRANTY Company gives a SIX MONTH LIMITED WARRANTY on all components of your vehicle against defects in material or workmanship. This warranty is transferable to another consumer during the warranty period through a company dealer. REGISTRATION At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to company within ten days.
Page 106 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. COMPANY FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY.
Page 107 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES In the Country where your vehicle was purchased: Warranty or Service Bulletin repairs must be done by an authorized Company dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Company dealer who sells the same line as your vehicle.
Page 108: Specifications
SPECIFICATIONS MODEL 500UTV 500LUTV Dimensions: Overall length 2600 mm (102.4in) 3345 mm(131.7in) Overall width 1280mm (50.4in) 1290mm(50.8in) Overall height 1960mm (77.2in) 1865mm(73.4in) Seat height 870mm (34.3in) 830mm(32.7in) Wheelbase 1760mm （69.3in） 2450mm(96.5in) Minimum ground clearance 210mm （8.3in） Minimum turning radius 4200mm (165.4in)
Page 109 MODEL 500UTV 500LUTV Starting system Electric Lubrication system Pressure spray Engine oil: Type Recommended engine oil classification Quantity: Without oil filter cartridge replacement 1.8L(1.90 US qt) With oil filter cartridge replacement 1.9L(2.01 US qt) Final gear case oil: Type SAE15W/40 SF or SAE 80W/90 GL-4...
Page 110 MODEL 500UTV 500LUTV Periodic oil change 0.25L(0.26 US qt) Front gear case oil: Type SAE15W/40 SF or SAE 80W/90 GL-4 Quantity: Periodic oil change 0.28L(0.30 US qt) Air filter: dry element Fuel: Type UNLEADED GASOLINE ONLY Fuel tank capacity 22.0 L (5.8Gal)
Page 111 MODEL 500UTV 500LUTV Primary reduction system V-belt Secondary reduction system Shaft drive Transmission type V-belt automatic Operation Right hand operation High gear 3.514 Low gear 5.857 Reverse gear 3.828 Chassis: Frame type Steel tube frame Caster angle 4° Trail Tire:...
Page 112 MODEL 500UTV 500LUTV Rear brake type Dual disc brake operation Left foot operation Suspension: Front suspension Double wishbone Rear suspension Double wishbone Shock absorber: Front shock absorber Coil spring / oil damper Rear shock absorber Coil spring / oil damper...
Page 113 MODEL 500UTV 500LUTV Headlight 12 V 35 W/35.0 W × 2 Tail/brake light 12 V 5 W/21.0 W × 2 Indicator light Neutral indicator light LED × 1 High gear indicator light LED × 1 Low gear indicator light LED × 1 Reverse gear indicator light LED ×...
Page 114 MODEL 500UTV 500LUTV Low beam fuse High beam fuse Wiper fuse Turning light fuse Cigarett light fuse MP3 fuse Horn fuse...

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