Hisun HS500UTV HS700UTV HS800UTV

hisun%20hs500utv,%20hs700utv,%20hs800utv%20-%20service%20manual.gif

HISUN HS500UTV, HS700UTV, HS800UTV- WORKSHOP, REPAIR, SERVICE, PARTS, OWNERS MANUAL

- English Workshop 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 - Workshop Manual.pdf
- Hisun HS700UTV - Engine Parts Manual.pdf
- Hisun HS800UTV - Owners Manual.pdf
- Hisun HS800UTV - Workshop 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 - WORKSHOP 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 - WORKSHOP 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

Hisun HS500UTV HS700UTV HS800UTV - Workshop Manual

inicio - index

coche - car

moto

4x4

quad - buggy

camión - truck

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