Power Max 500 Rough-Rider User manual

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500 ROUGH-RIDER UTV
Maintenance Manual

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Catalogue
General Information……………………………...5
1 Description…………………………………………………..5
1.1 Identification code…...6
1.1.1. Frame No. …………………………………………………6
1.1.2. Engine No.…………………………………………………7
1.2 Special tools, instruments and meters…………………7
1.3 Periodic maintenance chart……………………………….9
Engine………………………………………………………….11
2. Inspection and adjustment of engine…………….11
2.1 Inspection of cylinder head, intake
And exhaust valve………………………………………….11
2.2 Inspection of spark Plug………………………………….12
2.3 Inspection of cylinder, piston and piston ring…….14
2.4 Inspection of crankshaft………………………………….17
2.5 Inspection of clutch……………………………………….18
2.6 Inspection of carburetor………………………………….18
2.7 Inspection of air filter………………………………….19
2.8 Inspection of oil filter………………………………….20
2.9 Inspection of lubrication system……………………….20
2.10 Lubrication of engine…………………………………….21
2.11 Inspection of cylinder head…………………………….21

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3. Disassembly of engine……………………………………27
3.1 Cylinder head and block …………………… …………… .27
4. Chassis
4.1 Direction system…...42
4.2 Brake system…………………………………………...….57
4.3 Wheels and tires……………………………………...….77
4.4 Transmission system…………………………….…...….81
4.5．Reverse mechanism parts………………………………89
4.6 Suspension……....91
4.7 Cooling System of Engine………………..97
3. Disassembly of engine……………………………………27
3.1 Cylinder head and block………………………………….27
3.2 Piston and connecting rod……………………………….31
3.3 Manual starting mechanism……………………………….32
3.4 Sensor………………………………………………….…….32
3.5 Left crankcase cover……………………………….…….33
3.6 Magneto…………………………………………………..….33
3.7 Oil pump………………………………………….……..….34
3.8 Clutch…………………………………………………...….35
3.9 Carburetor……………………………………………...….36
3.9.1 Structure of carburetor…...36
3.9.2 Inspection and adjustment of carburetor…....….37
3. Disassembly of engine……………………………………273. Disassembly of engine……………………………………273. Disassembly of engine……………………………………27
3. Disassembly of engine...................................................................27

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4.8 Lubrication points……….102
5. Electrical system…....105
5.1 Ignition system…....108
5.2 Magneto and charging system…....109
5.3 Battery…....110
5.4 Lighting system…....111
5.5 Meter and signal system…………………………..……112
5.6 Electrical starting system…………….……..…….113
6. Appendix…...115
6.1 Specification…....115
6.2 Requirements for torque of fastener……………….121
6.3 Electrical circuits……………………………....….122

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General Information
1 Description

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1.1 Identification code
1.1.1. Frame No.
The frame No. is engraved in the right bottom of the supporting
frame. See Figure 1-1
1-1
1.1.2. Engine NO.
The engine No. is engraved in the right side of the engine. See
figure 1-2

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1-2
1.2 Special tools, instruments and meters
1.2.1 Oil filter detacher
To fasten and detach the oil filter
1.2.2 Height gauge
To gauge the height of various components
1.2.3 Venire
To measure the length of various components
1.2.4 尺Outside micrometer
To accurately measure external
Diameter of a column
1.2.5 inside micrometer
To accurately measure internal

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Diameter of a hole
1.2.6 Dial indicator
To accurately measure a small distance
1.2.7 Torque Spanner
To measure torque force
1.2.8 Feeler gauge
To measure gap-width
1.2.9 Multimeter
To check electrical circuits and parts
1.2.10 Barometer
To measure pressure of the tire
1.2.11 Magneto drawing device

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To detach the magneto
1.2.12 Snap ring clamp to install
And detach snap rings
1.3 Periodic maintenance chart
ITEM
ROUTINE
Which ever
comes first
EVERY
INITAL
month
1
3
6
6
12
km
320
1,200
2,400
2,400
4,800
(mi)
(200)
(750)
(1,500)
(1,500)
(3,000)
hours
20
75
150
150
300
Valves
●Check valve clearance.
●Adjust if necessary.
○
○
○
○
Sparkplug
●Check condition.
●Adjust gap and clean.
●Replace if necessary.
○
○
○
○
○
Air filter
element
●Clean.
●Replace if necessary.
Every20-40hours
（More often in wet of dusty areas.）
Carburetor*
●Check and adjust idle speed/starter
operation.
●Adjust if necessary.
○
○
○
○
Crankcase
breather system*
●Check breather hose for cracks of
damage.
●Replace if necessary.
○
○
○
Exhaust system*
●Check for leakage.
●Tighten if necessary.
●Replace gasket(s) if necessary.
○
○
○
Spark arrester
●Clean.
○
○
○
Fuel line*
●Check fuel hose for cracks or damage.
●Replace if necessary.
○
○
○
Engine oil
●Replace.(Warm engine before draining.)
○
○
○
○
Engine oil filter
cartridge
●Replace.
○
○
○
○
Engine oil strainer*
●Clean.
○
○
○
○

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Final gear oil
●Check for oil leakage.
●Replace even 12 months.
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○
Differential gear oil
Front brake*
●Check operation/fluid leakage. (See
NOTE page 8).
●Correct if necessary.
○
○
○
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Rear brake*
●Check operation.
●Adjust if necessary.
○
○
○
○
○
Select lever safety
system cable
●Check operation.
●Adjust if necessary.
○
○
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V-belt*
●Check operation.
●Check for cracks or damage.
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○
○
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Wheel
●Check balance/damage/
●Repair if necessary.
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○
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Wheel bearing*
●Check bearing assemblies for loosened/
Damage.
●Replace if necessary.
○
○
○
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Front and rear
suspension*
●Check operation.
●Correct if necessary.
○
○
Steering system*
●Check operation./Replace if damaged
●Check toe-in. /Adjust if necessary.
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○
○
○
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Drive shaft universal
joint*
●Lubricate with lithium–soap–based
grease.
○
○
○
Axle boots*
●Check operation.
●Replace if damaged.
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○
○
○
○
Fittings and
fasteners*
●Check all chassis fittings and fasteners.
●Correct if necessary.
○
○
○
○
○
Lights and
switches*
●Check operation.
●Adjust headlight beams.
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○
○
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○
Engine
2. Inspection and adjustment of engine
2.1.1 Inspection cylinder head, intake and exhaust system
Check the pressure of cylinder
Preheat the engine, then misfire and unplug the spark plug.
Fix pressure gauge into the hole.

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Note: Giving a leakage check to the pressure gauge.
Rotate the engine until the pressure gauge stop rising.
The maximum reading would be greater than0.7- 0.9Mpa
after starting for 4-6 times. See figure 2-1.
Figure 2-1
Check the valve clearance
Note: when adjust valve clearance, the engine must be
cooled. (The temperature should be less than 35℃)
Remove the seat cushion and fuel tank, unplug the vision hole
cover, round the flywheel of magneto anti-clockwise to aim “T”
At the signal of fore cover on the left.
Note: The piston must be fixed to the top dead enter.
(Figure 2-2)

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Remove cylinder valve cover, check the clearance between the
valve stem by feeler gauge.
Valve clearance: inlet and exhaust valve: 0.05～0.08mm.
See figure 2-3.
Figure 2-3
Loose the lock nut, rotate the adjusting screw until it
appears that the feeler gauge be pulled .Then fasten the
adjusting screw by valve adjuster, tighten the lock nut and
check the valve clearance .After installing the cylinder
valve cover , vision hole cover, the fuel tank and cushion. See
figure 2-4.

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Figure 2-4
2.1.2 Spark Plug checking
1. Unplug the Spark-Plug cap: remove the spark plug by
spanner, look over whether the spark-plug insulator and
electrode is damaged. If so, see figure 2-5.
Figure 2-5
1．Check the spark clearance by feeler gauge whether it is
between 0.6～0.7mm.Or adjust the gap, clean incrustation with
spark-plug cleaner and steel wire brush and check if the spark
plug sealing washer(Figure 2-6).

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Figure 2-6
3. Swirl the spark plug and tighten to 18～20N.m by spanner,
then fix the spark plug cap when assembling.
2.1.3 Cylinder, piston, piston ring
Specification

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Diagnosing and eliminating of malfunction:
●Emission of black smoke for abrasion of cylinder or piston,
1. Cylinder, piston of piston ring is worn out.
2. The piston ring is not properly assembled.
3. The piston or cylinder wall is scraped.
●overheated
1Excessive incrustation of piston.
2 Blast and abnormal noise.
3 Abrasion of cylinder or piston.
Inspection of cylinder.
item mm
standard value: mm
mm
limit value:mm
cylinder
Inner diameter of
cylinder
φ84.503～φ84.527 φ84.6
taper 0.0040 0.005
out of roundness 0.0035 0.005
degree of warp 0.04 0.10
Piston,
piston ring
and piston
pin
Outside diameter of piston φ84.47～φ84.45 φ84.35～φ84.25
Inner diameter of piston pin
hole
φ20.002～φ20.01 φ20.05～φ20.1
gap between piston pin and
piston pin hole
0.002～0.019 0.03
Piston ring
end
clearance
Top ring/the
second ring
0.2～0.4 0.5～0.7
gap between
piston ring
and piston
groove
oil ring 0.03～0.15 0.3～0.5
top ring 0.03～0.07 0.10～0.15
second ring 0.02～0.06 0.09～0.14
gap between cylinder and
piston
0.033～0.062 0.07～0.10
outside diameter of piston
pin
φ19.991～φ20 φ19.95～φ19.97
Crank shaft
Inner diameter φ20.016 ～φ
20.027
φ20.05
Gap between small end of
connecting rod and piston
pin
φ0.018～φ0.036 0.05

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1. Check whether the cylinder is damaged.
2. Measure the bore diameter of cylinder at three spots.
3. At the top, the middle and the bottom of the piston
stroke .And measure the bore diameter at directions of
right-angle intersection
Repairing limit value:
0.05 mm ，out of roundness: 0.005 mm
0.05mm taper ：0.005mm
Inspection of piston and piston ring
1. Measure the gap between piston ring and piston groove.
2. The first ring
3. The second ring
Note: It is forbidden to damaging the piston ring
when assembling. Check whether the piston and the
piston groove is cracked and abraded. See figure 2-9.

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Figure 2-9
：0.5mm。
Insert piston ring into cylinder, and measure the end gap.
Repairing limit value: the first ring/the second ring: 0.5mm
See figure 2-10.
Figure 2-10
Measure the bore diameter of piston pin hole.
Repairing limit value: see figure 2-11.

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Figure 2-11
Measure the external diameter 10mm above the bottom of the
piston skirt.
Extreme position: the gap between cylinder and piston
Repairing limit value: 0.1mm
See figure 2-12.
1、
Figure 2-12
7．Measure the external diameter of piston pin:
The gap between piston and piston pin:
0.02mm
Repairing limit value: 0.02mm .See figure 2-13.

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Figure 2-13
2.1.4 Inspection of crank and connecting rod
Check that whether crank and connecting rod can rotate without
stuck and whether the clearance between crank and connecting
rod is 0.5～0.6mm.The hop of crank shaft should be 0.05mm.If
not so, replace it. See figure 2-14-1, figure 2-14-2.
Figure 2-14-1 Figure 2-14-2