HS500UTV, HS700UTV, HS800UTV
WORKSHOP, REPAIR, SERVICE, PARTS, OWNERS MANUAL
HISUN HS500UTV, HS700UTV, HS800UTV- WORKSHOP, REPAIR, SERVICE, PARTS, OWNERS MANUAL - English Service Manuals, to UTV Hisun HS500UTV, HS700UTV, HS800UTV FILES INCLUDED ON THE CD: - Hisun HS500UTV - Engine Parts Manual.pdf - Hisun HS500UTV, HS700UTV - Owners Manual.pdf - Hisun HS500UTV, HS700UTV - Service Manual.pdf - Hisun HS700UTV - Engine Parts Manual.pdf - Hisun HS800UTV - Owners Manual.pdf - Hisun HS800UTV - Service Manual.pdf Bonus (Parts): - 500UTV (A,B) (E-mark).xls - 500UTV.xls - 700UTV-2 (A,B,C) (EPA).xls - 700UTV-4 (A,B) (E-mark).xls - 700UTV-4 (A,B) EFI (E-mark).xls - 700UTV-4 (A,B,C) (EPA).xls - 700UTV.xls - 800UTV (E-mark) 2010.xls - 800UTV (EPA) 2010.xls CONTENTS: HISUN HS500UTV, HS700UTV - SERVICE MANUAL GENERAL INFORMATION - 1 Description..5 - Identification code....6 - Frame No. 6 - Engine No.7 - Special tools, instruments and meters7 - Periodic maintenance chart.10 ENGINE - 2. Inspection and adjustment of engine.11 - 2.1 Inspection of cylinder head, intake and exhaust valve.11 - 2.2 Inspection of spark Plug.14 - 2.3 Inspection of cylinder, piston and piston ring.15 - 2.4 Inspection of crankshaft.18 - 2.5 Inspection of clutch.19 - 2.6 Inspection of carburetor.19 - 2.7 Inspection of air filter.20 - 2.8 Inspection of oil filter.21 - 2.9 Inspection of lubrication system.21 - 2.10 Lubrication of engine.22 - 2.11 Inspection of cylinder head.22 DISASSEMBLY OF ENGINE27 - 3.1 Cylinder head and block.27 - 3.2 Piston and connecting rod.32 - 3.3 starting mechanism..33 - 3.4 Sensor..33 - 3.5 Left crankcase cover..33 - 3.6 Magneto...34 - 3.7 Oil pump....34 - 3.8 Clutch....36 - 3.9 Carburetor....36 - 3.9.1 Structure of carburetor.....36 - 3.9.2 Inspection and adjustment of carburetor.....37 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 parts89 - 4.6 Suspension.....91 - 4.7 Cooling System of Engine..97 - 4.8 Iubrication points...102 ELECTRICAL SYSTEM - 5.1 Ignition system.......108 - 5.2 Magneto and charging system.......109 - 5.3 Battery.......110 - 5.4 Lighting system.......111 - 5.5 Meterand signal system..112 - 5.6 Electrical starting system....113 APPENDIX - 6.1 Specification.........115 - 6.2 Requirements for torque of fastener.121 - 6.3 Electrical circuits.....122 HISUN HS800UTV - SERVICE MANUAL GENERAL INFORMATION - General information1 - Watnings, cautions and notes1 - Description2 - Identification code 3 - Frame no. 3 - Engine no. 3 - Safety 4 - Handing gasoline safely 4 - Cleaning parts 5 - Warning labels 5 - Serial numbers 6 - Fasteners 6 - Torque specifications 6 - Self-locking fasteners 6 - Washers 6 - Cotter pins 7 - Snap rings and e-clips 7 - Shop supplies 8 - Lubricants and fluids 8 - Engine oils 8 - Greases 8 - Brake fluid 9 - Coolant 9 - Cleaners, degreasers and solvents 9 - Gasket sealant 9 - Gasket remover 10 - Thread locking compound 10 - Basic tools 10 - Screwdrivers 11 - Wrenches 11 - Adjustable wrenches 12 - Socket wrenches, ratchets and handles 12 - Impact drivers 13 - Allen wrenches 13 - Torque wrenches 14 - Torque adapters 14 - Pliers 15 - Snap ring pliers 15 - Hammers 16 - Ignition grounding tool 16 - Precision measuring tools 16 - Feeler gauge 17 - Calipers 17 - Micrometers 18 - Adjustment 18 - Care 19 - Metric micrometer 19 - Standard inch micrometer 20 - Telescoping and small bore gauges 21 - Dial indicator 21 - Compression gauge 22 - Multimeter 22 - Electrical system fundamentals 22 - Voltage 22 - Resistance 23 - Amperage 23 - Basic service methods 23 - Removing frozen fasteners 24 - Removing broken fasteners 25 - Repairing damaged threads 25 - Stud removal/installation 25 - Removing hoses 26 - Bearings 26 - Removal 26 - Installation 27 - Interference fit 28 - Seal replacement 29 - Storage 30 - Storage area selection 30 - Preparing the motorcycle for storage 30 - Returning the utv to service 30 - Trovbleshooting 31 - Engine principles and operating requirements 32 - Starting the engine 32 - Engine is cold 32 - Engine is warm 32 - Starting the engine after a fall or after the engine stalls 33 - Flooded engine 33 - Engine cold with air temperature 33 - Engine cold with air temperature above 35.(95°f) 33 - Cold engine with air temperature below 10.(50°f) 33 - Engine is hot 34 - Starting the engine after a fall or after the engine stalls 34 - Flooded engine 34 - Engine will not start 35 - Identifying the problem 35 - Spark test 36 - Starter does not turn over or turns over slowly 37 - Poor engine performance 37 - Engine starts but stalls and is hard to restart 37 - Engine backfires, cuts out or misfires during acceleration 37 - Engine backfires on deceleration 38 - Poor fuel mileage 38 - Engine will not idle or idles roughly 38 - Low engine power 38 - Poor idle or low speed performance 40 - Poor high speed performance 40 - Fuel system 41 - Rich mixture 41 - Lean mixture 41 - Engine 42 - Engine smoke 42 - Black smoke 42 - Blue smoke 42 - White smoke or steam 42 - Low engine compression 42 - High engine compression 43 - Engine overheating (cooling system) 43 - Engine overheating (engine) 43 - Preignition 43 - Detonation 44 - Power loss 44 - Engine noises 44 - Englne lubrication 45 - High oil consumption or excessive 45 - Exhaust smoke 45 - Low oil pressure 45 - High oil pressure 45 - No oil pressure 45 - Oil level too low 46 - Oil contamination 46 - Cylinder leak down test 46 - Electrical testing 48 - Preliminary checks and precautions 48 - Intermittent problems 49 - Electrical component replacement 50 - Test equipment 50 - Ammeter 50 - Self-powered test light 50 - Ohmmeter 51 - Jumper wire 51 - Test procedures 52 - Voltage test 52 - Voltage drop test 52 - Peak voltage test 53 - Continuity test 53 - Testing for a short with a self-powered test light or ohmmeter 54 - Testing for a short with a test light or voltmeter 54 - Brake system 54 - Soft or spongy brake lever or pedal 54 - Brake drag 55 - Hard brake lever or pedal operation 56 - Brake grabs 56 - Brake squeal or chatter 56 - Leaking brake caliper 57 - Leaking master cylinder 57 SPECIFICATIONS - How to use conversion table of unit 58 - How to use conversion table 58 - Definition of unit 58 - Geberar specifications 59 - Engine specifications 62 - Chassis specifications 68 - Electrical specifications 70 - Tightening torques 72 - Engine tightening torques 72 - Chassis tightening torques 75 - General tightening torque specifications 77 - Lubrication pionts and lubricant types 78 - Engine 78 - Chassis 79 - Hydrographic chart 80 - Engine gearbox lubrication oil parth circuit 81 MAINTENCE AND ADJUSTMENT OF THE UTV - Maintenance schedule 83 - Engine - Adjusting the valve clearance 85 - Checking the spark plug 88 - Checking the ignition timing 89 - Measuring the compression pressure 90 - Checking the engine oil level 91 - Changing the engine oil 92 - Chassis - Cleaning the air filter 94 - Checking the coolant level 95 - Changing the coolant 96 - Checking the coolant temperature warning light 99 - Checking the v-belt 100 - Cleaning the spark arrester 101 - Adjusting the brake pedal 102 - Checking the brake fluid level 103 - Checking the front brake pads 104 - Checking the rear brake pads 104 - Checking the brake hoses and brake pipes 105 - Bleeding the hydraulic brake system 105 - Adjusting the select lever shift rod 107 - Adjusting the brake light switch 107 - Checking the final gear oil level 108 - Changing the final gear oil 108 - Checking the differential gear oil 109 - Changing the differential gear oil 109 - Checking the constant velocity joint dust boots 110 - Checking the steering system 111 - Adjusting the toe-in 112 - Adjusting the front and rearshock absorbers 113 - Checking the tires 114 - Checking the wheels 116 - Checking and lubricating the cables 116 - Electrical - Checking and charging the battery 117 - Checking the fuses 123 - Adjusting the headlight beam 125 - Changing the headlight bulb 125 - Changing the tail/brake light bulb 126 ENGINE - Engine note 128 - Engine removal 129 - Cylinder head and cylinder head cover 131 - Rocker arms and camshaft 136 - Valves and valve springs 139 - Cylinder and piston 144 - Engine left crankcase cover a.c. Magneto148 - Starter motor and oil filter152 - Primary and secondary sheaves156 - Crankcase cover and oil pump 160 - Crankcase and middle driven shaft 164 - Output shaft170 - Gearcase - Shift lever and oil pump 174 - Gearcase transmission 176 CHASSIS - Malfunction inspection 181 - Direction system - The structure of the steering 184 - The structure of steering wheel part 188 - Diassembling the parts of the steering wheel 188 - Checking the parts of the steering wheel 188 - Diassembling the steering column parts 189 - Checking and service the steering column parts 190 - Diassembling the steering drive axle 190 - Checking and service the steering drive axle 191 - The machine parts 192 - The structure of the steering 192 - Brake system 193 - Preparation for checking before the maintenance of the brake system 193 - Disk brake components 194 - Front brake caliper 196 - Checking the front brake disc 198 - Replacing the front brake pads 199 - Disassembling the front brake calipers 201 - Assembling the front brake calipers 202 - Installing the front brake calipers 202 - Rear brake calipers 204 - Checking the rear brake disc 207 - Replacing the rear brake pads 208 - Disassembling the rear brake caliper 209 - Assembling the rear brake caliper 210 - Installing the rear brake caliper 212 - Checking the master cylinder 213 - Assembling the brake master cylinder 213 - Installing the brake master cylinder 214 - Footrest assembly 215 - Wheel and tyre parts 218 - Front wheels 218 - Rear wheels 219 - Checking the wheel tyre 220 - Checking the wheel hub 220 - Installing the wheel hub 221 - Installing the wheel tyre 221 - Specification of wheel and tyre 222 - Transmission system 223 - Front bridge 223 - Disassembling the universal joint 229 - Checking the joints 230 - Assembling the universal joint231 - Rear bridge 232 - Reverse mechanism parts 239 - Adjusting reverse mechanism parts 241 - Checking and service of reverse mechanism 242 - Suspension 243 - Front suspension 243 - Front arm 245 - Disassembling, service and assembly the supporting rocker parts 247 - Checking the stabilizer 248 - Checking the steering knuckles 248 - Checking the front arms 248 - Checking the front shock absorber 249 - Installing the front arms and front shock absorber 250 - Rear suspension 251 - Rear arm shaft 252 - Checking and service of rear suspension 254 - Checking the stabilizer 255 - Checking the steering knuckles 255 - Checking the rear arms 255 - Checking the rear shock absorber 255 - Installing the rear arms and rear shock absorber 256 - Cooling system 257 - Radiator 257 - Checking the radiator 261 - Installing the radiator 262 - Oil cooler 263 - Checking the oil cooler 265 - Water pump 266 - Disassembling the water pump 270 - Checking the water pump 271 - Assembling the water pump 272 - Seat 273 - Disassembling the seat 277 - Moving seat forward and backward 277 - Fuel tank 278 ELECTRICAL COMPONENTS - Electrical system malfunction inspection 281 - Electrical 282 - Electricalcomponents 282 - Checking the switch 284 - Checking the switch 284 - Checking the switch continuity 285 - Checking the bulbs and bulb sockets 286 - Ignition system 287 - Circuit diagram 287 - Troubleshooting 288 - Electric starting system 291 - Circuit diagram 291 - Troubleshooting 292 - Starter motor 295 - Checking the starter motor 296 - Assembling the starter motor 297 - Charging system 298 - Circuit diagram 298 - Troubleshooting 299 - Lighting system 301 - Circuit diagram 301 - Troubleshooting 302 - Checking the lighting system 303 - If the headlights fail to come on 303 - If the taillights fail to come on 304 - Signaling system 305 - Circuit diagram 305 - Troubleshooting 306 - Checking the signal system 307 - If the brake lights fail to come on 307 - If the neutral lights fail to come on 308 - If the parking brake indicator light fails to come on 309 - If the reverse indicator light fails to come on 310 - If the coolant temperature warning 311 - If the differential gear lock indicator light fails to come on 313 - If the four-wheel drive indicator light fails to come on 315 - Cooling system 317 - Circuit diagram 317 - Troubleshooting 318 - 2wd/4wd selecting system 321 - Circuit diagram 321 - Troubleshooting 322 ENGINE MANAGEMENT SYSTEM - Introduction - Ems (engine management system) 323 - Typical components of ems323 - Layout of ems components324 - Components of ems - Electronic control unit 324 - Multec 3.5 injectors 325 - Throttle body assembly(with stepper motor) 329 - Engine coolant temperature sensor 331 - Intake air pressure and temperature sensor 331 - Oxygen sensor 332 - Ignition coil 332 - Fuel pump module336 - Ems fault diagnosis - Eme fault diagnosis 342 - Fault code list342 TROUBLESHOOTING - Starting failure/hard starting 344 - Fuel system 344 - Electrical system 344 - Compression system 345 - Poor idle speed performance 345 - Poor idle speed performance 345 - Poor medium and high-speed performance 346 - Poor medium and high-speed performance 346 - Faulty gear shifting 346 - Shift lever does not move 346 - Jumps out of gear 346 - Overheating 346 - Overheating 346 - Faulty brake 347 - Poor braking effect 347 - Shock absorber malfunction 347 - Malfunction 347 - Unstable handling 347 - Unstable handling 345 - Lighting system 348 - Head light is out of work 348 - Bulb burnt out 348 HS800UTV WIRING DIAGRAM 349
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