UTVs Factory UTV500CC Owner's Manual

MASSIMO ALLIGATOR 500 & MSU 500 Owner’s Manual

Location of the Warning and Safety Labels 1-1 ` ⑭ ⑬

Periodic Maintenance and Adjustment 8-2 WARNING POTENTIAL HAZARD Servicing an engine while it is running. WHAT CAN HAPPEN Moving parts can

8-3 Periodic Maintenance and Adjustment Periodic Maintenance Chart for the Emission Control System ● For vehicles not equipped with an odometer

Periodic Maintenance and Adjustment 8-4 General maintenance and lubrication chart INITIAL EVERY Month 1 3 6 6 12 Miles (Km) 200 (320)750(1,200)

8-5 Periodic Maintenance and Adjustment INITIAL EVERY Month 1 3 6 6 12 Miles (Km) 200 (320)750(1,200)1,500 (2,400)1,500 (2,400) 3,000 (4,800)

Periodic Maintenance and Adjustment 8-6 NOTE:

8-7 Periodic Maintenance and Adjustment Hood To open Unhook the hood latches, and then slowly tilt the hood up until it stops. 1. Latch (×2)

Periodic Maintenance and Adjustment 8-8 1. Projection (×2) 2. Slot (×2) 3. Slot (×2) 4. Projecti

8-9 Periodic Maintenance and Adjustment 2. Install the parking brake lever boot. 3. Install the seats. CAUTION:

Periodic Maintenance and Adjustment 8-10 1. Maximum level mark 2. Minimum level mark 3. Dipstick 4. Engi

8-11 Periodic Maintenance and Adjustment 1. Engine oil drain bolt NOTE: Skip ste

1-2 Location of the Warning and Safety Labels Read and understand all of the labels on your vehicle. They contain important information for safe

Periodic Maintenance and Adjustment 8-12 1. O-ring 6. Install the new oil filter cartridge with an oil filter wrench, and then tight

8-13 Periodic Maintenance and Adjustment Recommended engine oil: See page 10-2. Oil quantity: Without oil filter cartridge replaceme

Periodic Maintenance and Adjustment 8-14 1. Speedometer sensor 2. final gear oil 3. Correct oil level NOTE:

8-15 Periodic Maintenance and Adjustment Changing the final gear oil 1. Place the vehicle on a level surface. 2. Place a container under the f

Periodic Maintenance and Adjustment 8-16 Tightening torque: Final gear oil filler bolt: 17 ft·lbf (23 Nm, 2.3 m·kgf) 7. Check for oil

8-17 Periodic Maintenance and Adjustment Changing the differential gear oil 1. Place the vehicle on a level surface. 2. Place a container un

Periodic Maintenance and Adjustment 8-18 Tightening torque: Differential gear oil filler bolt: 17 ft·lbf (23Nm, 2.3m·kgf) 7. Check f

8-19 Periodic Maintenance and Adjustment the hood. Coolant reservoir capacity (up to the maximum level mark): 0.37 qt (0.35L) CAUTION:

Periodic Maintenance and Adjustment 8-20 1.Front axle boot (×2 each side) 1. 1. Rear axle boot (×2 each side)

8-21 Periodic Maintenance and Adjustment 1. Spark plug wrench Inspection The spark plug is an important engine component and is easy to insp

Location of the Warning and Safety Labels 1-3

Periodic Maintenance and Adjustment 8-22 a. Spark plug gap 2. Clean the surface of the spark plug gasket and its mating surface

8-23 Periodic Maintenance and Adjustment 1. Air filter check hose 1. Remove the seats. (See pages 4-17 - 4-18 for seat removal and insta

Periodic Maintenance and Adjustment 8-24 1. Air filter element 1. Air filter frame 2. Sponge material 3. Element retaining plat

8-25 Periodic Maintenance and Adjustment CAUTION: Do not twist the sponge material when squeezing it.

Periodic Maintenance and Adjustment 8-26 element rubber joint to the fuel system and manifold fittings securely to avoid the possibility of unfi

8-27 Periodic Maintenance and Adjustment V-belt case drain plug The V-belt case drain plug is located under the driver seat. (See pages 4-17 -

Periodic Maintenance and Adjustment 8-28 1. Bolt(×3) 2. Remove the tailpipe by pulling it out of the muffler. 3. Tap the tailpipe lightly,

8-29 Periodic Maintenance and Adjustment WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester. Hot exhaust system WHAT CAN HAPPE

Periodic Maintenance and Adjustment 8-30 1. Brake pad wear indicator groove NOTE:

8-31 Periodic Maintenance and Adjustment Checking the brake fluid level Insufficient brake fluid may let air enter the brake system, possibly

1-4 Location of the Warning and Safety Labels

Periodic Maintenance and Adjustment 8-32 the fluid and may result in vapor lock. z Brake fluid may deteriorate painted surfaces or plastic part

8-33 Periodic Maintenance and Adjustment WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN Yo

Periodic Maintenance and Adjustment 8-34 1.Parking brake lever free play NOTE: The parking brake lev

8-35 Periodic Maintenance and Adjustment Brake light switch adjustment The brake light switch, which is activated by the brake pedal, is properl

Periodic Maintenance and Adjustment 8-36 WARNING POTENTIAL HAZARD Damaged control cables. WHAT CAN HAPPEN Corrosion can result when the o

8-37 Periodic Maintenance and Adjustment Rear knuckle upper and lower pivot lubrication Lubricate the knuckle upper and lower pivots with a gr

Periodic Maintenance and Adjustment 8-38 Wheel removal Loosen the wheel nuts . Elevate the vehicle and place a suitable stand under the frame. R

8-39 Periodic Maintenance and Adjustment 1. Tapered nut 2. Lower the vehicle so that the wheel is on the ground. 3. Tighten the wheel nuts

Periodic Maintenance and Adjustment 8-40 WARNING POTENTIAL HAZARD Failure to handle batteries or battery electrolyte carefully. WHAT CA

8-41 Periodic Maintenance and Adjustment Battery maintenance 1. When the vehicle is not used for a month or longer, remove the battery and sto

Location of the Warning and Safety Labels 1-5

Periodic Maintenance and Adjustment 8-42 by lifting it up and pulling it out. 1. Battery compartment cover 2. Turn the key to “OFF” and turn

8-43 Periodic Maintenance and Adjustment Specified fuse: Main fuse: Headlight fuse: Auxiliary DC jack fuse: Signaling system fuse: Fuel system

Periodic Maintenance and Adjustment 8-44 1. Cover at the rear of the headlight 3. Remove the headlight bulb holder cover by pul

8-45 Periodic Maintenance and Adjustment 1. Headlight bulb holder 5. Remove the defective bulb by pulling it out. WARN

Periodic Maintenance and Adjustment 8-46 1. Do not touch the glass part of the bulb. CAUTION: Do not to

8-47 Periodic Maintenance and Adjustment 1. Headlight beam adjusting screw Tail/brake light bulb replacement If a tail/brake ligh

Periodic Maintenance and Adjustment 8-48 1. Quick fastener（×8） 2. Bolt（×2） 3. Panel A 2. Remove the bulb holder（together with the

8-49 Periodic Maintenance and Adjustment Tightening torque: Panel bolt: 4.7 ft·lbf (6.5N·m, 0.65 m·kgf） Troubleshooting Although vehicles rece

Periodic Maintenance and Adjustment 8-50 Solution to Common Problems in Vehicle The below tables show some common problems that may come up when

8-51 Periodic Maintenance and Adjustment Table 2：Solution of Common Problems in Brake System. S/N Problems Solutions 1. Check if the handle of

1-6 Location of the Warning and Safety Labels 9 10

Periodic Maintenance and Adjustment 8-52 fasteners of calipers are deformed. 1. Check if left and right brake force deviation of front brake

8-53 Periodic Maintenance and Adjustment Table 3: Solution of Common Problems in Electrical System S/N Problems Solutions 1. Check if the headl

Periodic Maintenance and Adjustment 8-54 Table 4: Solution of Common Problems in Running System S/N Problems Solutions 1. Check the fasteners c

8-55 Periodic Maintenance and Adjustment 3. Check the inner splines of rear wheel hubs and outer splines of rear wheel axles to find out if th

Periodic Maintenance and Adjustment 8-56 Table 5: Solution of Common Problems in Engine System S/N Problems Solutions 1. Check the battery vol

8-57 Periodic Maintenance and Adjustment 4. Check the coolant drain tube for with air. 1. Check the battery charge. 2. Check the battery

Periodic Maintenance and Adjustment 8-58 NOTE: If it is difficult

9-1 Cleaning and Storage Cleaning Frequent, thorough cleaning of your vehicle will not only enhance its appearance but also will improve its gen

Cleaning and Storage 9-2 chamois, clean towel or soft absorbent cloth. 6. Clean the seats with vinyl upholstery cleaner to keep the cover pli

9-3 Cleaning and Storage Storage Long-term storage (60 days or more) of your vehicle will require some preventive procedures to guard against de

Location of the Warning and Safety Labels 1-7 11 14 12 13

Cleaning and Storage 9-4 6. Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering. 7. If storing in a humid or s

10-1 Specifications Model HS500UTV Dimensions: Overall length Overall width Overall height Seat height Wheelbase Ground clearance Minimum turn

Specifications 10-2 Model HS500UTV Engine oil: Type Recommended engine oil classification Quantity: Without oil filter c

10-3 Specifications Model HS500UTV Final gear case oil: Type Quantity: SAE80 API GL-4 Hypoid gear oil 0.25L (0.26 qt ) Differential gear case

Specifications 10-4 Model HS500UTV Spark plug: Type Spark plug gap DR8EA 0.6-0.7 mm (0.023-0.027 in) Clutch type: Wet, centrifugal automatic

10-5 Specifications Model HS500UTV Tire: Type Size front rear Tubeless 25×8-12 25×1

Specifications 10-6 Model HS500UTV Wheel travel: Front wheel travel Rear wheel travel 130mm (5.12in) 150mm (5.91in) Electrical: Ignition syst

10-7 Specifications Model HS500UTV High-range/ Low-range indicator light LED Specified fuses: Main fuse Headlight fuse Auxiliary DC jack fuse

Fault Code of Electronic Injection System 11-1 Fault Code of Electronic Injection System DTC NumberDTC Description Related Calibration HEX

11-2 Fault Code of Electronic Injection System P0132 O2S 1 Circuit High Voltage KsDGDM_O2_1_ShortHigh 132 306 P0031 O2S Heater Cir

2-1 Safety Information This off-highway utility vehicle handles differently from other vehicles including cars and UTVs. SEVERE INJURY OR DEA

Fault Code of Electronic Injection System 11-3 P0563 System Voltage High KsDGDM_SysVoltHigh 563 1379 P0650 MIL Circuit Malfunction

Hisun Motors Corp., U.S.A. Emission Control System Warranty Statement 12-1 YO

Hisun Motors Corp., U.S.A. Emission Control System Warranty Statement 12-2 As the vehicle owner, you should be aware that HISUN may deny your

Hisun Motors Corp., U.S.A. Emission Control System Warranty Statement 12-3 (2

Hisun Motors Corp., U.S.A. Emission Control System Warranty Statement 12-4 C. No dealer is authorized to modify this Limited Emission Control

Safety Information 2-2 ● Never attempt jumps or other stunts. ● Always inspect your vehicle each time you use it to be sure it is in safe operat

2-3 Safety Information ● Never operate on hills that are slippery or ones where you will not be able to see far enough ahead of you. Never go

INTRODUCTION Congratulations on your purchase of the Massimo Alligator 500 or MSU 500 UTV. With the purchase of this vehicle, you can now appreciate

Safety Information 2-4 WARNING POTENTIAL HAZARD Improper handling of gasoline. WHAT CAN HAPPEN Gasoline can catch fire and you could be burned

2-5 Safety Information WARNING POTENTIAL HAZARD Starting or running the engine in a closed area. WHAT CAN HAPPEN Exhaust fumes are poisonou

Description and Vehicle Identification 3-1 1. Headlights2. Front shock absorber assembly adjusting ring 3. Brake fluid reservoir 4.

3-2 Description and Vehicle Identification 23. Light switch 24. Steering wheel 25. Starter (choke) 26. Main switch 27. On-Command f

Description and Vehicle Identification 3-3 Identification Number Records Record the Vehicle Identification Number and model label information in

4-1 Control Functions CONTROL FUNCTIONS Main switch 1. Main switch Functions of the respective switch positions are as follows: ON: Al

Control Functions 4-2 CAUTION: ● Do not operate the electric starter continuously for

4-3 Control Functions Low-Range Indicator Light “L” This indicator light comes on when the drive select lever is in the “L” position. Mechanic

Control Functions 4-4 is out. Continuous use while the light is on may cause damage to the engine. High beam indicator The light bein

4-5 Control Functions z Check the meter. If fault indicator light of EPS system does not be lit, ECU can be for regular use. z If fault indica

Control Functions 4-6 Speedometer unit functions: z a speedometer (which shows the speed) z an odometer (which shows the total distance covere

4-7 Control Functions button on the display. This will also change the displayed mileage from miles to kilometers. Clock time adjustment Pres

Control Functions 4-8 When riding on a flat road at a comparatively high speed, adjust the settings to “2WD/UNLOCK” and there are no symbols in

4-9 Control Functions fixed, will the time show automatically. The description for the fault codes are shown in Chapter 11 of this manual. Fuel

Control Functions 4-10 CAUTION: Do not use the headlights with the engine turned off for an extended period o

4-11 Control Functions conditions. z Two-wheel drive (”2WD”): Power is sup- plied to the rear wheels only. z Four-wheel drive (“4WD’): Power i

Control Functions 4-12 On-Command four-wheel-drive switch “2WD/4WD” 1. Select lever 2. On-Command four –wheel-drive switch “2WD/4WD” To cha

4-13 Control Functions set the switch to “LOCK”. When the differential gear is locked, the differential gear lock indicator light will come on a

Control Functions 4-14 will cause the engine speed to be limited until engagement is complete. Acceler

4-15 Control Functions Brake pedal Press the brake pedal to slow or stop the vehicle. WARNING POTENTIAL HAZARD Malfunction of the accelerato

Owner Manual IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Particularl

Control Functions 4-16 lever, press the release button, and then push the lever all the way down. Spring pressure helps return the lever to the

4-17 Control Functions Fuel tank cap Remove the fuel tank cap by turning it counterclockwise. 1. Fuel tank cap Seats To remove a sea

Control Functions 4-18 To install a seat, insert the projection on the rear of the seat into the seat holders and push down on the seat at the f

4-19 Control Functions 1. Seat belt (×2) 2. Latch plate (×2) 3. Buckle (×2) To wear the seat belt properly, do the followi

Control Functions 4-20 shoulder belt should fit against your chest. If it is loose, pull the belt out all the way and then let it retract. 5. T

4-21 Control Functions Glove compartment CAUTION: To protect from damage, do not put metal products, like too

Control Functions 4-22 Opening and closing the tailgate 1. Tailgate 2. Latch (×2) To open Unhook the latches, and then low

4-23 Control Functions WARNING POTENTIAL HAZARD Pinch points. WHAT CAN HAPPEN You or someone else could be pinched between the cargo bed a

Control Functions 4-24 WARNING POTENTIAL HAZARD Carrying a passenger in the cargo bed WHAT CAN HAPPEN The passenger could fall, be thrown

4-25 Control Functions 1. Spring preload adjusting ring 2. Position indicator NOTE:

Owner Manual IMPORTANT NOTICE This UTV is designed and manufactured for OFF - ROAD use only. It is illegal and unsafe to operate this UTV on any pu

Control Functions 4-26 WARNING POTENTIAL HAZARD Improper shock absorber adjustment. WHAT CAN HAPPEN Uneven adjustment can cause poor handl

4-27 Control Functions Auxiliary DC jack The auxiliary DC jack is located at the right side of the front panel. The auxiliary DC jack can be use

Control Functions 4-28 4. When the auxiliary DC jack is not being used, cover it with the cap. CAUTION: z D

5-1 Pre Operation Checks Before using this vehicle, check the following items: ITEM ROUTINE PAGE Brakes ● Check operation, free play, fluid le

Pre Operation Checks 5-2 WARNING POTENTIAL HAZARD Failure to inspect the vehicle before operating. Failure to properly maintain the vehicle

5-3 Pre Operation Checks Brake fluid leakage Check to see if any brake fluid is leaking out of the pipe joints or the brake fluid reservoir. App

Pre Operation Checks 5-4 Fuel Make sure there is sufficient gasoline in the tank. Recommended fuel: Unleaded gasoline only Fuel tank capacity

5-5 Pre Operation Checks WARNING POTENTIAL HAZARD Improper care when refueling. WHAT CAN HAPPEN Fuel can spill, which can cause a fire and

Pre Operation Checks 5-6 Recommended engine oil type and quantity: See page 10-2 Coolant Check the coolant level in the coolant reservoir wh

5-7 Pre Operation Checks WARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot. WHAT CAN HAPPEN Yo

Owner Manual Location of the Warning and Specification Labels 1-1 Safety Information 2-1 Description and Vehicle Identification 3-1 Id

Pre Operation Checks 5-8 Recommended oil: SAE 80 API GL-5 Hypoid gear oil Throttle Pedal Check to see that the accelerator pedal operate

5-9 Pre Operation Checks Throttle Freeplay If the throttle pedal has excessive play due to cable stretch or mis-adjustment, it will cause a dela

Pre Operation Checks 5-10 4. Resume the center cover and seat to their position Steering Wheel Inspection Check the steering wheel for specifi

5-11 Pre Operation Checks as necessary for proper operation. Switches Check the operation of all switches. Have a service center repair as nece

Pre Operation Checks 5-12 3. The tires should be set to the recommended pressure: Front 10psi (70kpa, 0.7 kgf/cm2) Rear 10psi (70kpa, 0.7 kgf/

5-13 Pre Operation Checks Set pressure with tires cold. Set tire pressures to the following specifications: RecommendedPressure Minimum Maximum

Operation 6-1 WARNING POTENTIAL HAZARD Operating vehicle without being familiar with all controls. WHAT CAN HAPPEN Loss of control, whi

6-2 Operation Starting the Engine CAUTION: See the “Engine Break-In”section prior to operating the engine f

Operation 6-3 5. Continue warming up the engine until it idles smoothly before riding. WARNING POTENTIAL HAZA

6-4 Operation Otherwise, go on with the third step. 3. Continue warming up the engine until it idles smoothly. CAUTION:

Owner Manual Brake Fluid Level 5-2 Brake Fluid Leakage 5-3 Brake Operation 5-3 Fuel 5-4 Gasohol 5-4 Engine Oil 5-5 Coolant 5-6 Final Gear Oil 5-7

Operation 6-5 1. Drive select lever 3. Release the brakes and press the accelerator pedal gradually. Shifting: Neutral to Revers

6-6 Operation 1. Drive select lever NOTE: ● When in reverse, the reverse indicator l

Operation 6-7 WARNING POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN You could hit an obstacle or person behind y

6-8 Operation Parking a) When parking, stop the engine and shift the drive select lever into the neutral position. b) Push the brake pedal

Operation 6-9 1．parking handbar NOTE: Like many other vehicles, the parking brake a

6-10 Operation of use. ● Use of any engine oil not mentioned in this manual will cause severe damage to the engine.

Operation 6-11 10-25 Hours: Avoid prolonged operation above 3/4 throttle. Rev the vehicle freely but do not use full throttle at any time. A

6-12 Operation test all nonstandard accessories, nor have any control over the quality or suitability of them. Choose a genuine accessory, or on

Operation 6-13 the loaded trailer on the scale with the tongue at hitch height. Adjust the load in the trailer, if necessary, to reduce the w

6-14 Operation Make sure cargo in the trailer cannot move around. A shifting load can cause an accident. ● Make sure the load does not interfer

Owner Manual Learning to Operate Your Vehicle 7-5 Turning your Vehicle 7-6 Braking 7-8 Going Uphill 7-8 Going Downhill 7-10 Crossing Through Shal

Operation 6-15 WARNING POTENTIAL HAZARD Overloading this vehicle or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause ch

7-1 Your Vehicle DRIVING YOUR VEHICLE GETTING TO KNOW YOUR VEHICLE This off-highway utility vehicle will handle and maneuver differently form an

Your Vehicle 7-2 WARNING POTENTIAL HAZARD Carrying a passenger in the cargo bed. WHAT CAN HAPPEN The passenger could fall or be struck b

7-3 Your Vehicle WARNING POTENTIAL HAZARD Overloading this vehicle or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause cha

Your Vehicle 7-4 WARNING POTENTIAL HAZARD Operating this vehicle without wearing an approved motorcycle helmet, eye protection, and protecti

7-5 Your Vehicle LEARNING TO OPERATE YOUR VEHICLE You should become familiar with the performance characteristics of the vehicle in a large,

Your Vehicle 7-6 CAUTION: Do not shift from low to high or vice versa without coming t

7-7 Your Vehicle Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or person. Always

Your Vehicle 7-8 BRAKING Braking ability is affected by the type of terrain. In most cases, gradual application of the brakes is more ef

7-9 Your Vehicle some hills are too steep for you to climb. Choose carefully which hills you attempt to climb. Avoid hills with slippery surface

Owner Manual Brake Fluid Replacement 8-32 Checking the Brake Pedal 8-32 Parking Brake Lever Free Play Adjustment 8-33 Brake Light Switch Adjustme

Your Vehicle 7-10 Before climbing the hill, first be sure you are operating in low range 4WD or, if necessary, with 4WD. To climb a hill, you ne

7-11 Your Vehicle you will be able to react to obstacles that may appear. WARNING POTENTIAL HAZARD Going down a hill improperly. W

Your Vehicle 7-12 CROSSING THROUGH SHALLOW WATER If you must cross shallow, slow moving water up to the depth of the vehicle’s floorboards, choo

7-13 Your Vehicle CAUTION: After riding your vehicle in water, be sure to drain the trapped water by remov

Your Vehicle 7-14 5. Dry the spark plugs and reinstall them, or install new plugs. 6. Attempt to start the engine. If necessary, repeat the dr

7-15 Your Vehicle 1．V-belt cooling duct check hose 1. Drive select lever box check hose 1．V-belt case drain plug Riding Over R

Your Vehicle 7-16 vehicle could occur. WARNING POTENTIAL HAZARD Failure to use extra care when operating this vehicle on unfamiliar terrain.

7-17 Your Vehicle Riding in Brush or Wooded Areas When operating in areas with brush or trees, watch carefully on both sides and above the vehic

Your Vehicle 7-18 WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision.

8-1 Periodic Maintenance and Adjustment Periodic Maintenance and Adjustment Periodic inspection, adjustment and lubrication will keep your vehi