Publication: PDI-010 Date: March 5, 2010 Model: UXV 500

Transcription

1 Publication: PDI-00 Date: March 5, 200 Model: UXV 500 (Orginal issue: September 25, 2008) Subject: Assembly & Pre-Delivery Instructions Proper assembly and preparation of the UXV500 is essential for the safety and satisfaction of your customers. Use this guide and other KYMCO reference materials to make sure your staff properly prepares the vehicle for delivery to the customer. Allot time when presenting the vehicle to the customer to explain its operation, maintenance requirements, and warranty coverage. Your attention to proper delivery will promote customer satisfaction, safety and future business.. Shipping crate size: 90.5 x 66. x 50 in. (2300 x 680 x 270 mm) NOTE: To avoid damage, do not store the shipping crate or the vehicle outdoors. Do not stack more than one crate upon another. Damage from improper storage is not a defect covered by the KYMCO Limited Warranty. STEPS 2-28: UNPACKING 2. The vehicle is shipped without the overhead canopy, front bumper, cargo bed, muffler, wheels and other items installed. Loose items: Canopy, front bumper, font hood bracket hardware, CV-joint guards, center console cover, cargo bed, trailer hitch receiver, seats, wheels, and exhaust. 3. Remove the outer crate top braces, corner pieces, side pieces and end pieces. Remove the protective fabric cover from the unit. Remove the contents of the bed assembly and set them aside. Remove the bed assembly and set it aside. Remove the front temporary brace that supports the bed in the shipping crate. Discard the brace. / 5

2 4. Remove the rear temporary brace that supports the bed in the shipping crate. Discard the brace. 5. Remove the metal plate 2 from the frame. Reinstall the bolts after removing the plate. Discard the plate Remove the hardware carton from the vehicle interior. Open the carton and set it aside. Remove the hardware carton from under the vehicle by sliding it out the side. Open the carton and set it aside. Remove the hood from the vehicle and set it aside. Remove the wheels and tires from the vehicle and set them aside. 7. Inside the hardware carton there are four hardware packets (with items such as bolts and nuts) plus other various parts required to mount components to the vehicle. Refer to the illustrations in the PDI Bulletin to identify hardware and components that must be mounted to the vehicle. 8. Exhaust system hardware (shown at right). 2 /5

3 9. Hood, front bumper, engine cover, shifter console and battery cover hardware (shown at right). 0. Bed mounting hardware (shown at right).. Canopy and headrest hardware (shown at right). 2. Exhaust head pipe (shown at right). NOTE: If an o-ring gasket 3 is provided with the exhaust head pipe, do not use it. Discard this gasket and use the o-ring gasket provided in the exhaust system hardware packet (see step 8). 3 3 / 5

4 3. Exhaust muffler (shown at right). 4. Exhaust bracket and bolts (shown at right). 5. Trailer hitch (receiver) and bolts (shown at right). 6. Headrests (x 2 - shown at right). 4 /5

5 7. CV boot guards and bolts (shown at right). 8. Tool kit, battery box cover, cover retaining bolts and battery strap (shown at right). 9. Battery, battery fluid and terminal hardware (shown at right). 20. Front bumper assembly (shown at right). 5 / 5

6 2. Seats (x2, shown at right). 22. Center console, shifter cover (shown at right). 23. Hood assembly (shown at right). 24. Wheels - two front and two rear with tires mounted (shown at right). 6 /5

7 25. Left and right canopy main tubes and head rest cross bar (shown at right). 26. Canopy top tubes. The rear tube includes a handle (shown at right). 27. Bags secured to each front wheel spindle, shown at right, contain wheel mounting hardware (lug nuts). 28. NOTE TO ASSEMBLER: If you plan to lift the entire vehicle to install the wheels, you must do this first before doing any other vehicle assembly. This will permit you to use the canopy mounting points to lift the vehicle (shown at right). You can then follow the assembly instructions and just ignore the section on lifting & wheel installation (step 42). 7 / 5

8 29. Inflate the tires to the specified air pressure. Front tire air pressure: 0 PSI (0.7 kgf/cm 2 ) Rear tire air pressure: 4 PSI (0.98 kgf/cm 2 ) 30. Install the wheels onto the vehicle. NOTE: The arrow mark on the tire must point towards the rotating direction of the wheel. STEPS 3-55: ASSEMBLY 3. Install the nuts on the spindle s studs so the tapered side of the nut 2 faces the wheel. Tighten the wheel nuts in a chris cross pattern 3 to the specified torque 2 Wheel nuts Tighten to 40 ft-lb (5.5 kg-m/50nm) WRONG OK This KYMCO UTV is equipped with a maintenancefree (sealed) type battery that requires activation with the supplied electrolyte fluid pack (never activate with conventional battery acid or distilled water). NOTE: Perform the initial service on the battery per the recommendations in KYMCO Service Bulletin PDI Install the left and sight sides of the canopy. Using a 8mm Allen wrench and a 4mm wrench to install the canopy hardware. NOTE: Do not tighten the canopy bolts and nuts until the canopy is fully assembled 8 /5

9 34. Using a 2mm wrench, install the eight hex head bolts in the canopy head rest cross tube. Using a 2mm wrench, install the four hex head bolts in the rear canopy top rail (with handle). 35. Install the front canopy top rail (no handle) using a 2mm wrench on the hex head bolts. At this point tighten all of the canopy hardware. Front & rear cross tube hardware Tighten to 23.6 ft-lb (3.2 kg-m/32nm) Left & right canopy tube hardware Tighten to 47.2 ft-lb (6.4 kg-m/64nm) 36. Use a 7mm wrench to tighten the bolts and nuts that secure the seat belts to the canopy. Seatbelt mounting hardware Tighten to 47.2 ft-lb (6.4 kg-m/64nm) Install the head rests to the canopy using a 4mm Allen head wrench to tighten the six bolts with washers (three bolts and washers used on each head rest) 37. Use a 2mm wrench to tighten the two exhaust head pipe flange nuts. Use a 4mm wrench to tighten the nut that secures the head pipe to the bracket. NOTE: Make sure you install the exhaust port gasket before installing the exhaust head pipe. 9 / 5

10 38. Use a 4mm wrench to tighten the two exhaust muffler stay mounting bolts. Muffler stay mounting bolts Tighten to 25.8 ft-lb (3.5 kg-m/35nm) 39. Install the exhaust muffler, using a 4mm wrench to tighten the two muffler mounting bolts. Use a 6mm Allen wrench to tighten the muffler s clamp to the head pipe. Muffler mounting bolts Tighten to 22 ft-lb (3.0 kg-m/30nm) 40. Install the trailer hitch, using a 4mm wrench to tighten the two trailer receiver hitch bolts. Trailer hitch receiver bolts Tighten to 22 ft-lb (3.0 kg-m/30nm) 4. Install the front bumper assembly using a 4mm wrench to tighten the two bolts and corresponding nuts. 0 /5

11 NOTE: If the wheels were not installed in steps 28 through 30, install them at this time. Inflate the tires and install the wheels per the specification listed in steps 29 and Use a suitable hoist or jack to raise the vehicle to install the wheels. 43. To protect the tires from damage, place the shipping container s cardboard under the tires before setting the vehicle down on the metal shipping crate base. 44. With the aid of an assistant, set the cargo bed in place and align the mounting holes to the frame. 45. Insert the two large pins into the cargo bed hinge points. Insert the pins from the outside of the hinge. Place washers on the inside end of the hinge pins and secure them with the locking clips (through the holes in the hinge pins). / 5

12 46. Insert the two rubber bumpers between the cargo bed and the frame under the hinge points. Connect the two hydraulic lift-assist struts. Use a 2mm wrench to tighten the stut s mounting nuts. Lift-assist strut nuts Tighten to 22 ft-lb (3.0 kg-m/30nm) 47. Plug the tail light electrical connectors together and secure the tires to the cargo bed with cable ties. 48. Use a 4mm Allen wrench to remove the shifter handle setscrew. Remove the shifter handle. 49. Slide the center console (engine cover) in place by hooking the rear, lower portion around the seat subframe and over the top of the shift lever. 2 /5

13 50. Secure the console in place with two plastic pushpins. Reinstall the shift lever handle. 5. Carefully turn the driver and passenger seats over and checks all of the hardware on the seat base for tightness. Make sure all of the fasteners are tight and secure. Check the tightness of all of the fasteners for the seat mount and latches on the vehicle s chassis. 52. Hook the rear of the driver s seat into the catches in the sub-frame. Lock the seats into place by pressing down on the front edge of the seat. Repeat for the passenger seat. 53. Install the CV joint boot guards using a 0mm wrench to tighten the single mounting bolt for each guard. CV-joint guard bolts Tighten to 7.3 ft-lb (.0 kg-m/0nm) NOTE: If installing an accessory winch, do it at this time, as the winch mounting points are easily accessible with the front hood off of the vehicle. 3 / 5

14 54. With the aid of an assistant, set the hood in place and align the hinges between the hood and the frame. Insert the two pins into the hood hinge points. Insert the pins from the outside of the hinge. Place washers on the inside end of the hinge pins and secure them with the locking clips (through the holes in the hinge pins). 55. Plug the headlight electrical connectors together. STEPS 56-63: PRE-DELIVERY SERVICE 56. Verify that the retention clip is in place and properly positioned securing the differential engagement switch on the right side of the front differential. NOTE: Do not operate the UXV500 is the clip is missing or a fluid leak can result. Install a new clip before operating the vehicle. 57. Verify the operation of the front differential lock lever on the vehicle s dash. When engaged (the lever flipped up) the engagement plunger 2 should pull out from the right side of the front differential. When the lever is flipped back down, the plunger should retract fully into the differential case. 2 3 NOTE: If the plunger does not retract fully, the control cable 3 free play will need to be adjusted (see next page for cable free-play adjustment). 4 /5

15 58. To adjust the differential control cable free play, locate the adjuster on the cable where it is adjacent to the battery box (under the hood of the vehicle). Turn the adjuster to create a small amount of free play so the differential lock plunger retracts fully into the case when the control lever on the dash is flipped down (disengaged position). After adjustment, tighten the adjuster s lock nut 2 and slip the protective sleeve 3 back in place. NOTE: Verify the operation of the differential lock and its indicator light when test operating the vehicle before delivery to the customer Place the battery in the battery compartment and secure it with the rubber strap. Connect the battery terminal wires. NOTE: When connecting the battery to the vehicle, connect the red positive lead (+) first, then the negative lead (-). Install the battery cover using a 0mm wrench to tighten the cover s four bolts. 60. Check the engine oil level in the inspection window on the engine 4. If the level is below the L mark, add oil through the filler cap 5 until the level is at the H mark. NOTE: The recommended engine oil is rated SJ or higher under the API service classification. The standard oil viscosity is SAE 0W-40. Recheck the oil level after running the engine Add gasoline to the fuel tank. NOTE: The recommended fuel is regular unleaded gasoline with a 87 minimum octane rating. Oxygenated fuels containing up to 0% ethanol, 5% methane, or MTBE are acceptable to use. 62. Start the engine and test its operation. Test ride the unit to make sure all of the controls and features operate properly. Make sure the engine idle speed is set properly. NOTE: The idle adjustment screw is located on the carburetor. Turn the idle adjustment screw in or out until the engine idles between 400 to 600 RPM. 63. Clean the vehicle before display for sale or delivery to the customer. If you have any questions about the assembly or pre-delivery service on the UXV 500, contact your KYMCO USA technical representative. Thank you. Route this information to the following dealership personnel: Dealer Owner General Manager Sales Manager Sales Staff F & I Parts Manager Parts Staff Accessories Service Manager Service Technicians PDI Technicians Warranty 5 / 5