XY Powersports XY500UTV Manuals

XY Powersports XY500UTV Manuals

Manuals and User Guides for XY Powersports XY500UTV. We have 1 XY Powersports XY500UTV manual available for free PDF download: Service Manual

XY Powersports XY500UTV Service Manual

XY Powersports XY500UTV Service Manual (260 pages)

Brand: XY Powersports | Category: Utility Vehicle | Size: 16.62 MB

Table of Contents

Table of Contents
3
Important Safety Precautions
4
Service Information
4
- A few Words about Safety
  4
- Conversion Table
  5
- Identification Number Records
  6
- Main Data Table
  7
- Overhaul Datasheet
  9
- Lubricating Device
  9
- Air Inlet System
  10
- Cooling Device
  10
- Front/Rear Wheel
  10
- Cables, Pipes, Cable Routing
  16
- Tightening Torque
  22
- Vehicle Body，Muffler
  22
- Operation Cautions
  22
- Overhaul Information
  22
- Center Cover, Steering Wheel
  23
- Decorate Cover, Steering Stem
  23
Vehicle Body, Muffler
23
- Holder, Meter
  24
- Front Side Support(LH)
  26
- Front Side Support (RH)
  26
- Front Vent Cover
  26
- Seat, Driver
  27
- Seat, Passenger
  27
- Gearshift Knob
  28
- Decorate Cover，Gearshift
  28
- Gearshift Unit
  28
- Handle, Parking Brake
  29
- Skid Plate (L)
  29
- Rear Fender (L)
  30
- Rear Fender(R)
  30
- Fender, Cargo Box（L）
  30
- Cargo Box
  31
- Fender, Cargo Box
  31
- Side Door (LH)
  32
- Side Door (RH)
  32
- Bumper
  33
- Fuel Tank
  33
- Headrest, Driver
  34
- Headrest, Passenger
  34
- Backrest, Passenger (500L/500UEL)
  34
- Safety Belt, Driver
  35
- Safety Belt, Passenger
  35
- Safety Belt Fastener
  35
- Rear Mirror (RH)
  36
- Rear Mirror(LH)
  36
- Roll-Over Bar(500UTV/500UE)
  36
- Roll-Over Bar(500LUTV/500UEL)
  37
- Bumper Protector
  38
- Winch Cable and Motor
  38
- Muffler
  40
- Description of Visible Parts
  41
- Inspection & Adjustment
  42
- Overhaul Info
  42
- Replace Parts Regularly
  42
- Regular Maintenance Table
  43
Inspection & Adjustment
43
- Steering Stem
  47
- Brake Disc, Brake Pad
  48
- Change the Brake Fluid
  48
- Master Cylinder
  48
- Front Toe-In Size
  49
- Wheels
  49
- Tire Pressure
  50
- Tire Tread
  50
- Lift the Front Wheel
  51
- Suspension System
  51
- Sway of Wheel Bearing
  51
- Wheel Nut and Wheel Axle
  51
- Adjusting the Absorber
  52
- Fuel Device
  52
- Gear Shifting
  52
- Throttle Pedal Check
  53
- Valve Clearance
  54
- Engine Idle Speed
  55
- Spark Plug
  55
- Air Filter
  56
- Spark Plug Gap
  56
- Drive Belt
  57
- Special Tool: Rotor Holder
  57
- Check Engine Oil Level
  59
- Inspection of Lubrication System
  59
- Replacing Engine Oil
  59
- Inspection of External Oil Pipe
  60
- Replacing Oil Filter
  60
- Tool: Oil Filter Wrench
  60
- Inspection of Cooling System
  61
- Replacing Coolant
  61
- Inspection of Radiator Hose
  62
- Testing Cylinder Pressure
  62
- Inspection of Oil Pressure
  63
- Oil Pressure Is too High
  63
- Oil Pressure Is too Low
  63
- Testing Oil Pressure
  63
- Clutch Lock-Up Inspection
  64
- Initial Engagement Inspection
  64
- Inspection of Clutch Engagement and Lock-Up
  64
- Cooling and Lubricatiing System
  65
- Cooling System Illustration
  66
- Engine Coolant
  67
- Inspection of Cooling Circuit
  67
- Inspection and Cleaning of Radiator and Water Hoses
  68
  - Radiator Cap
    68
  - Radiator Hose Inspection
    68
  - Radiator Inspection and Cleaning
    68
- Inspection of Fan Motor
  69
- Inspection of Thermoswitch
  69
- Inspection of Thermostat
  70
- Inspection of Water Temperature Sensor
  70
  - Water Temperature and Resistance
    70
  - Water Temperature Sensor
    70
- Water Pump
  71
- Mechanical Seal
  73
- Inspection of Water Pump
  73
- Bearing
  73
- Oil Seal
  74
- Water Pump Body
  74
- Impeller
  74
- Assembly and Installation of Water Pump
  74
- Removal of Engine, Transmission System and Gearshift
  79
- Inspection Information
  79
- Disassembly Engine
  80
- Cvt
  82
- Installation of Engine
  83
- Installation
  85
- Gearshift
  85
- Engine Removal/Installation Orders and the Relative Page Numbers
  86
- Engine Removal
  87
- Left Side Cover
  87
- Recoil Starter
  87
- Inspection Plug
  87
- Cylinder Head Cover
  88
- Timing Chain Tensioner
  88
- Camshaft
  88
- Cylinder Head
  89
- Cylinder
  89
- Starting Motor
  90
- Oil Filter
  91
- Tool: Oil Filter Remover
  91
- Sector Gear
  91
- Sheave Drum
  92
- Left Crankcase Cover
  92
- Magneto Rotor
  92
- Starting Motor Gear
  93
- Oil Pump Sprocket and Chain
  93
- CVT Cover
  94
- Cvt(Continuously Variable Transmission)
  94
- Timing Chain
  95
- Clutch
  95
- CVT Case
  95
- Driven Bevel Gear, Front Output Shaft
  96
- Engine Center
  96
- Gear Position Bolt
  96
- Shift Cam, Fork/Shaft
  97
- Drive Bevel Gear
  97
- Drive Shaft, Drive Shaft
  97
- Balancer Shaft
  97
- Crankshaft
  98
- Oil Bump, Relief Valve
  98
- Rocker Arm Shaft
  99
- Cylinder Head Cover Distortion
  99
- Engine Components Inspection
  99
- Rocker Arm
  100
- Cylinder Head Distortion
  102
- Valve Seat Width
  102
- Valve Stem and Valve Guide
  102
- Valve Stem O.D
  103
- Valve Stem Run-Out
  103
- Valve Head Radial Run-Out
  103
- Valve Face Wear
  103
- Valve Spring
  104
- Assembly of Cylinder Head
  104
- Camshaft Journal Wear
  107
- Automatic Decompression
  107
- Cam Wear
  107
- Camshaft Journal O.D.
  108
- Camshaft Run-Out
  108
- Timing Sprocket and Chain
  108
- Tensioner and Chain Guide
  108
- Chain Tensioner Inspection
  109
- Cylinder Distortion
  109
- Cylinder Bore
  109
- Piston
  110
- Piston Diameter
  110
- Piston Ring to Groove Clearance
  110
- Piston Ring Free End Gap and End Gap
  111
- Piston Pin and Pin Bore
  111
- Connecting Rod/Crankshaft
  112
- Connecting Rod Deflection
  112
- Connecting Rod Big End Side Clearance
  112
- Crankshaft Run-Out
  112
- Clutch Shoes
  113
- Clutch Wheel
  113
- Primary and Secondary Sheave
  114
- Primary Sliding Sheave
  115
- Primary Sliding Sheave and Fixed Sheave
  116
- Install Spacer
  117
- Secondary Sheave
  117
- O-Ring and Oil Seal
  118
- Secondary Sheave Spring
  119
- Secondary Sliding and Fixed Sheave
  119
- Assembly
  119
- Transmission
  122
- Oil Pump
  126
- Oil Strainer
  127
- Relief Valve
  127
- Bevel Gear Washer Adjustment
  128
- Driven Bevel Gear
  128
- Front Output Shaft
  128
- Bevel Gear
  129
- Bevel Gear Backlash
  129
- Tooth Contact
  130
- Electric Starter Gear
  133
- Crankcase
  137
- Engine Assembly
  138
- Oil Pump and Relief Valve
  138
- Connecting Rod
  139
- Shift Cam, Shift for
  140
- Right Crankcase
  140
Carburetor、Fuel System, Air Intake System
155
- Overhaul Info
  156
- Carburetor Removal
  157
- Inspection
  158
- Measurement and Adjustment
  159
- Carburetor Assembly
  160
- Fuel Level
  160
- Carburetor Installation
  161
- Carburetor Parameters
  161
- High Pressure Fuel Line Installation
  162
- Throttle Body Disassembly
  162
- Fuel Injector Assy Disassembly
  162
- High Pressure Fuel Line Disassembly
  162
- Fuel Injector Assy Removal
  163
- Fuel Injector Assy Assembly
  163
- Idle Air Control Valve Disassembly
  163
- Idle Air Control Valve Installation
  163
- Overhaul Information Operating Cautions Notes
  164
- Maintenance Standard
  164
- Wheel Cannot Turn Freely
  165
- Troubleshooting Heavy
  165
- Vibration of Front Wheel
  165
- Shaking Steering Wheel
  165
Front Wheel, Front Brake, Suspension, Steering
165
- Front Wheel
  166
- Inspection Rim
  166
- Front Wheel Hub
  166
- Brake System
  167
- Front Brake Caliper
  167
- Brake Disc
  168
- Front Brake Master Cylinder
  168
- Brake Pedal Removal
  169
- Front Left Suspension
  170
- Front Suspension
  171
- Rocket Arm
  172
- Front Right Arm
  172
- Ball Pin
  173
- Right Steering Knuckle
  173
- Constant Velocity Drive Shaft
  174
- Left Constant Velocity Drive Shaft, Front Axle
  174
- Steering System
  175
- Rear View Mirror
  176
- Installation of Combination Switch
  178
- Installation of Rear View Mirror
  179
- Installation of Steering
  179
- Install Steering Wheel
  179
Rear Wheel, Rear Brake, Suspension
181
- Rear Wheel Wobbles
  182
- Rear Shock Absorber Is too Soft
  182
- Rear Shock Absorber Is too Hard
  182
- Poor Brake Efficiency
  182
- Rear Wheel Removal
  183
- Wheel Hub Removal
  183
- Rear Drive Shaft
  184
- Parking Caliper
  184
- Inspection Brake Disc
  184
- Rear Brake Caliper
  184
- Rear Suspension System
  185
- Rear Right Suspension
  185
- Stabilizer Bar
  186
- Right Rear Absorber
  186
- Rear Right Arm
  186
- Rear Left Suspension
  186
- Front/Rear Axle Overhaul Information
  187
- Inspection & Overhaul
  188
- Observation and Judgement
  188
Front and Rear Axle
188
- Disassembly of Front Axle
  189
- Inspection after Front Axle Disassembly
  190
- Front Axle Assembly and Adjustment
  191
- Front Axle Case Cover Assembly
  191
- Front Differential Gear Case Cover
  191
- Differential Gear Assembly
  191
- Disassembly of Rear Axle
  194
- Needle Bearing Removal
  195
- Rear Axle Inspection after Disassembly
  195
- Rear Axle Assembly and Adjustment
  196
Electric System
198

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