XINYANG XY POWERSPORTS XY500UTV XY500LUTV 4X4 Shop Manual

Service Manual XY500UTV/XY500LUTV XY500UE/XY500UEL 4×4 ZHEJIANG XINYANG INDUSTRY CO.,LTD.

FOREWORD This service manual is designed primarily for use by certified XINYANG Master Service Dealer technicians in a properly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator's perspective when seated in a normal riding position. Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper tools as specified. This manual contains an introductory description of procedures for inspection，maintenance, overhaul ， disassembly & assembly ， removal and installation of components and parts, troubleshooting and service data together with illustrations of our UTV Model XY500 and XY500L. CONTENTS Vehicle Service Information 1 Vehicle Body, Muffler 2 Inspection & Adjustment 3 Cooling & Lubricating System 4 Removal and Installation of Engine，Transmission System & Gearshift 5 Removal, Inspection and Assemble of Engine 6 Carburetor、Fuel System, Air Intake System 7 Front Wheel, Front Brake, Suspension, Steering 8 Rear Wheel, Rear Brake, Suspension 9 Front and Rear Axle 10 Electric System 11 Lighting & Switches 12 Troubleshooting 13 The manufacturer reserves the right to make improvements or modifications to the products without prior notice. Overhaul and maintenance should be done according to the actual state and condition of the UTV.

1. SERVICE INFORMATION 1-1 A few Words About Safety ……………1-1 Tightening Torque………………………1-9 VIN Number Engine Number…………1-3 Lubricating oil, and brake liquid ……1-12 Main Data Table………………………1-4 Cables Pipes, Cable Routing ……………1-13 Overhaul Datasheet……………………1-6 A Few Words About Safety Service Information The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others, It could also damage the vehicle or create an unsafe condition. This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service procedure or a tool that is not recommended by XinYang, must determine the risks to their personal safety and the safe operation of the vehicle. If you need to replace a part, use genuine XinYang parts with the correct part number or an equivalent part. We strongly recommend that you do not use replacement parts of inferior quality. For Your Customer is Safety Proper service and maintenance are essential to the customer is safety and the reliability of the vehicle. Any error or oversight while servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others. For Your Safety Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety practices (e.g., Hot parts-wear gloves). If you have not received shop safety training or do not feel confident about your knowledge of safe servicing practice, we recommended that you do not attempt to perform the procedures described in this manual. Some of the most important general service safety precautions are given below. However, we cannot warn you of every conceivable hazard that can arise in performing service and repair and procedures. Only you can decide whether or not you should perform a given task, can cause you to be seriously hurt or killed. Important Safety Precautions Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and using safety equipment. When performing any service task, be especially careful of the following: ● Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills required to perform the tasks safely and completely. 1

1. SERVICE INFORMATION 1-2 ● Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection. ● Use other protective wear when necessary, for example gloves or safety shoes. Handing hot or sharp parts can cause severe burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves. ● Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack, make sure that it is always securely supported. Use jack stands. Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will help eliminate several potential hazards; ● Carbon monoxide poisoning from engine exhaust, Be sure there is adequate ventilation whenever you run the engine. ● Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas. ● Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way. Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when working around gasoline or batteries. ● Use only a nonflammable solvent, not gasoline, to clean parts. ● Never drain or store gasoline in an open container. ● Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts. Conversion Table Item Example Conversion Pressure 200Kpa(2.00kgf/cm 2 ) 33kpa(250mmHg) 1kgf/cm 2 =98.0665kpa 1kpa=1000pa 1mmHg=133.322Pa=0.133322Kps Torque 18N· m(1.8kgf-m) 1kgf· m=9.80665N· m Volume 419ml 1ml=1 cm 3 =1cc 1l=1000cm 3 Force 12N(1.2kgf) 1kgf=9.80665N

1. SERVICE INFORMATION 1-3 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. Vehicle Identification Number (500UTV): LCXRSTS1~ Vehicle Identification Number (500LUTV): LCXLSTS1~ Vehicle Identification Number (500UE): LCXRSTS3~ Vehicle Identification Number (500UEL): LCXLSTS3~ Engine Number: CF188 Engine Number（EFI）: CF188-B NOTE: The vehicle identification number is used to identify your machine. 1

1. SERVICE INFORMATION 1-4 Main Data Table Item Parameter Model 500UTV/500UE 500LUTV/500UEL Length 2600mm 3200mm Width 1280mm 1300 mm Height 1960mm 1880mm Wheel base 1760mm 2440mm Engine type 500UTV/500LUTV:CF188 500UE/500UEL:CF188-B Displacement 493ml Fuel type Unleaded gasoline 93octane or above Mass of whole equipments (Not include driver) 580kg 720 kg Number of Passengers 2 for 500UTV/500UE, 4 for 500L UTV/500UEL (including driver) Max. Load 300Kg Front 25×8-12 Tire Rear 25×10-12 Minimum turning radius 4200mm 4900mm Starting Electrical starting Form Single cylinder, four-stroke, liquid cooling, 4 valves, OHC Combustion Chamber Type Triangle Valve Driving Type SOHC /Chain Drive Bore × stroke 87.5×82.0 mm (3.4×3.2 in) Compression ratio 10.2:1 Lubrication Type Pressure and splash lubricating type Lowest fuel consuming rate (g/Kw·h) ≤ 340g/Kw·h Idling speed (r/min) 500UTV/500LUTV:1300±100 500UE/500UEL:1400±100 Starting system Electrical starting Spark Plug type DPR7EA-9(NGK) Lubricating oil category SAE 15W—40/SF Engine oil pump type ROTOR Engine Oil filter type Whole way paper filter element

1. SERVICE INFORMATION 1-5 Item Parameter Fuel type Higher class than RQ-93 Transmission V-belt with teeth on, auto stepless gear change, plus gear change cam with change gear transmission Gear change type Gear lever with hand Clutch type Wet, hoof centrifugal type Primary speed change ratio (stepless speed change) 0.703—2.88 Speed change ratio： Total speed reduce ratio H Gear：3.514 2.47—10.12 L Gear： 5.857 4.12—16.87 R Gear： 3.828 2.69—11.02 Cooling type Closed cooling fluid circulating Cooling fluid type Antifreeze with prevent rust Out dimension 610 × 568 ×519 Net weight 70kg Output type Front and rear shaft output Engine Shaft running direction Clockwise (from back of engine). Air Filter type Sponge element filter Type CF188-B-173000 Fuel Device Valve Diameter of mixing valve 36mm Clutch Type: Wet, Auto-Centrifugal Operation mode Automatic (CVT) + Parking & Gear shifting Gears shift Low Gear, High Gear & Reverse Gear Shift Mode/order Manual /L-H-N-R (CVT ) Transmission Ratio 2.88～ 0.70 Final Ratio 1.333（24/18，Bevel Gear） Secondary transmission 1.952（41/21） Gears Low Gear : 2.25(36 /16) ；High Gear : 1.350(27/20)； Reverse Gear : 1.471(25/17) Gear Ratio Total Low Gear5.857 ; High Gear : 3.514； Reverse Gear：3.828 Front Axle 33 / 9 = 3.667 Gearing Axle Ratio Rear Axle 33 / 9 = 3.667 1

1. SERVICE INFORMATION 1-6 Item Parameter Engine Output Mode Front/Rear Shaft Gearing Direction of Output Rotation Clockwise on forward shift Right 35° Steering device Steering angle Left 35° Front Hydraulic Disc Brake type Rear Hydraulic Disc Bumper Device Suspension Swing Arm Frame type Welded steel tube and plate Overhaul Datasheet Lubricating device Item Standard Service limit Volume when replacing 1900ml — Engine Oil Capacity Full capacity 2200ml — Recommended Oil (see original) ● Specially for 4-stroke motorcycle SAE-10W-40、20W-50 Substitutes must be used in the following range. ●API type: SE or SF grade ●SAE type: Choose from the left chart according to the environmental temperature Gap between inner and outer rotors 0.03~0.10mm 0.15mm Gap between outer rotor and body 0.03～0.10mm 0.12mm Oil pump Rotor Oil pressure 130-170KPa(18.85PSI-24.66PSI) at 3000RPM

1. SERVICE INFORMATION 1-7 Air Inlet System Item Standard Fuel Tank Capacity Full capacity 22L Valve CF188-B-173000 Inlet Pressure Sensor CF188-B-175000 Inlet Temperature Sensor CF188-B-177000 Air Bypass Valve CF188-B-172000 Injector CF188-B-171000 Idle Speed 1400±100rRPM Cooling Device Item Standard Full Capacity 2620ml Reservoir tank capacity 300 ml Coolant capacity Standard Density 45% Opening pressure of radiator cap 108kpa(1.1kgf/cm 2 ) Temperature / valve open 72±2ºC Temperature/valve full open 88ºC Thermostat Overall lift 3.5-4.5mm/95ºC Close–Open 88 (190.4F)Round ℃ 88 Round ℃ Temperature of Thermostat Open-Close 82 (179.6F)Round ℃ 82 Round ℃ Coolant Type -35℃ antifreeze, antisepsis, high-boil coolant. Front/Rear Wheel Item Standard Service Limit Vertical 1.0mm 2.0mm Play of wheel rim Horizontal 1.0mm 2.0mm Groove — 3.0mm Front Wheel Tire Pressure 21±1PSI(145±6.9KPa) — Vertical 1.0mm 2.0mm Play of wheel rim Horizontal 1.0mm 2.0mm Groove — 3.0mm Rear Wheel Tire Pressure 28±1PSI(193±6.9 KPa) — 1

XINYANG XY POWERSPORTS XY500UTV XY500LUTV 4X4 Shop Manual

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