Hisun HS800 Service Manual
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Hisun HS800 Service Manual

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Forth version , May, 2014
Published by Chongqing
Huansong Industries
(Group) Co., Ltd and
Hisun Motors Corp USA.
Chongqing Huansong
Industries (Group)
Co., Ltd and Hisun
Motors Corp USA
holds the copy right.
No publishing and
reprinting without
permission
READ THIS
MANUAL
CAREFULLY
For questions regarding
this UTV, please
contact HISUN at:
(877) 838-6188
www.hisunmotors.com
REV. 06051401
SERVICE
MANUAL
HS800

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  • Page 1 Forth version , May, 2014 Published by Chongqing Huansong Industries (Group) Co., Ltd and Hisun Motors Corp USA. Chongqing Huansong Industries (Group) Co., Ltd and Hisun Motors Corp USA holds the copy right. No publishing and reprinting without permission READ THIS...
  • Page 2 Foreword Brief introduction to maintenance handbook of HS800UTV The handbook is edited by Technical Center of Chongqing Huansong Industries (Group) Co., Ltd., and is supplied to dealers and technicians as a document of technique. This manual gives methods to check, maintain and repair utility terrain vehicles (UTV’s), and supplies some relevant techniques and performance data.
  • Page 3 INDEX Index Chapter 1 General Chapter 2 Chapter 3 Specifications Periodic Maintenance and Adjustments Chapter 4 Chapter 5 Engine Chassis Chapter 6 Chapter 7 Electrical Engine Management System Chapter 8 Wiring Troubleshooting Diagrams...
  • Page 4 INDEX...

  • Page 5: Table Of Contents

    INDEX Chapter 1 General Information Spark Arrester 3-13 Brake Pedal 3-14 Warnings, Cautions, Notes Brake Pads 3-15 Description, Location Shift Lever Adjustment 3-16 Identification Code, Frame Final Gear Oil 3-17 Number, Engine Number Steering System 3-18 Safety Shock absorbers 3-19 Handling Gasoline, cleaning parts Tires 3-19...
  • Page 6 INDEX Gear Shift Assembly 5-36 Chapter 8 Troubleshoot Front Swing Arm 5-39 Front Suspension 5-40 Rear Anti-roll Bar 5-43 Troubleshoot Basics Rear Swing Arm 5-44 Principles and Requirements Radiator and Oil Cooler 5-47 Special Faults Water Pump 5-51 Flooded Engine Seat 5-56 Engine will not start...
  • Page 7 General Information Warnings, Cautions, Notes Shop Supplies, Lubricants, 1-10 Engine Oils Description, Location Greases, Brake Fluid, Coolant 1-11 Identification Code, Frame Number, Engine Number Cleaners, Degreasers and 1-12 Solvents Safety Basic Tools 1-12 Handling Gasoline, cleaning parts Precision Measuring Tools 1-19 Warning Labels, Serial Numbers, Compression Gauge,...
  • Page 8 General Information...

  • Page 9: Warnings, Cautions, Notes

    General Information This manual provides complete information on maintenance, tune-up, repair and overhaul. Hundreds of photographs and illustrations created during the complete disassembly of Utility Terrain Vehicles (UTV) guide the reader through every job. All procedures are in step by step format and designed for the reader who may be working on the UTV for the first time.
  • Page 10 General Information Description 1. Headlights/Front turning lights/ Position lights 2. Front shock absorber spring preload Adjusting ring 3. Rear Brake Fluid Reservoir 4. Parking Brake Lever 5. Driver Seat 6. Battery 7. Fuses 8. Left shoulder protection plate 9. Driver’s seat belt 10.

  • Page 11: Identification Code, Frame

    General Information Identification Code Frame No. Frame No. is stamped on the right side of the main frame. Engine No. Engine No. is stamped on the right side of the engine.

  • Page 12: Vehicle Identification Number

    General Information Vehicle Identification Number 123456 Manufacturer UTV below 750 cc UTV above 750 cc ATV below 750 cc ATV above 750 cc 400 cc 500 cc 700 cc 800 cc DOT Check Digits 2010 Model Year 2011 Model year 2012 Model Year 2013 Model Year 2014 Model Year...

  • Page 13: Safety

    General Information same size and strength as the Safety original ones. 9. Keep your work area clean and Professional mechanics can work for organized. many years and never sustain a serious 10. Wear eye protection anytime the injury or mishap. Follow these safety of the eyes is in question.
  • Page 14 General Information fire and makes it more difficult to Handling Gasoline put out. Use a class B, BC or ABC fire extinguisher to safely extinguish the fire. 8. Always turn off the engine before Gasoline is a volatile flammable liquid refueling.

  • Page 15: Warning Labels

    General Information 9. Thoroughly clean all oil, grease same requirements as the originals. and cleaner residue from any part Many screws, bolts and studs are that must be heated. combined with nuts to secure particular 10. Use a nylon brush when cleaning components.

  • Page 16: Cotter Pins

    General Information become distorted after the initial shortest pin. installation and removal. Discard and replace self-locking fasteners after removing them. Do not replace self- Snap Rings and E-clips locking fasteners with standard fasteners. Snap rings (Figure 1) are circular- shaped metal retaining clips. External Washers type snap rings are used to retain items on shafts.

  • Page 17: Shop Supplies, Lubricants

    General Information ring in a thrust application, install the Shop Supplies sharp edge facing away from the part producing the thrust. Lubricants and Fluids Periodic lubrication help ensure a long service life for any type of equipment. Using the correct type of lubricant is as important as performing the lubrication service.

  • Page 18: Brake Fluid

    General Information Always use oil with a classification its own definite characteristics. Do not recommended by the manufacturer, mix different types of brake fluid as this using an oil with a different classification may cause brake system failure. DOT 5 can cause engine damage.

  • Page 19: Cleaners, Degreasers And Solvents

    General Information tool. Most of these types of products are Cleaners, Degreasers very caustic. Follow the gasket remover manufacturer’s instructions for use. and Solvents Thread locking Many chemicals are available to remove oil, grease and other residue from the Compound UTV.
  • Page 20 General Information is devoid of sharp edges and carefully polished. They have an easy-to-clean Phillips-head screws are often damaged finish and are comfortable to use. by incorrectly fitting screwdrivers. Quality tools are a good investment. Quality Phillips screwdrivers are Some of the procedures in this manual manufactured with their crosshead tip specify special tools.

  • Page 21: Adjustable Wrenches

    General Information Wrenches Adjustable Wrenches Open-end, box-end and combination An adjustable wrench or Crescent wrenches (figure 5) are available in a wrench (Figure 6) can fit nearly any nut variety of types and sizes. or bolt head that has clear access The box-end wrench is an excellent tool around its entire perimeter.
  • Page 22 General Information Socket Wrenches, Ratchets and Handles Sockets that attach to a ratchet handle (Figure 7) are available with 6-point or 12-point openings (Figure 8) and different drive sizes. The drive size indicates the size of the square hole that accepts the ratchet handle.

  • Page 23: Impact Drivers

    General Information socket bolts. Impact Drivers An impact driver provides extra force for removing fasteners by converting the impact of a hammer into a turning motion. This makes it possible to remove stubborn fasteners without damaging them. Impact drivers and interchangeable bit (Figure 10) are available from most tool suppliers.

  • Page 24: Torque Adapters

    General Information Torque Adapters Torque adapters or extensions extend or reduce the reach of a torque wrench. The torque adapter,(Figure 13), is used to tighten a fastener that cannot be reached because of the size of the torque wrench head, drive, and socket. Locking pliers (Figure 16), sometimes If a torque adapter changes the effective called Vise- Grips, are used to hold...

  • Page 25: Ignition Grounding Tool

    General Information engine and suspension components Snap Ring Pliers because damage occurs in most cases. Always wear eye protection when using Snap ring pliers are specialized pliers hammers. Make sure the hammer face with tips that fit into the ends of snap is in good condition and the handle is rings to remove and install them.

  • Page 26: Precision Measuring Tools

    General Information Precision Measuring Feeler Gauge Tools The ability to accurately measure components is essential to perform many of the procedures described in this manual. Equipment is manufactured to close tolerances, and obtaining consistently accurate measurements is essential to determine which components require replacement or further service.
  • Page 27 General Information establish the first number by the location Calipers of the 0 line on the movable scale in relation to the first line to the left on the Calipers (Figure 20) are excellent tools fixed scale. is 10 mm. To determine the for obtaining inside, outside and depth next number, note which of the lines on measurements.
  • Page 28 General Information Follow the manufacturer’s instructions to adjust the micrometer. To check a micrometer larger than 1 in. or 25 mm use the standard gauge supplied by the manufacturer. A standard gauge is a steel block, disc or rod that is machined to an exact size. Place the standard gauge between the spindle and anvil, and measure its outside diameter or length.

  • Page 29: Metric Micrometer

    General Information Metric Micrometer The standard metric micrometer (Figure 24) is accurate to one one-hundredth of a millimeter (0.01 mm). The sleeve line is graduated in millimeter and half millimeter increments. The marks on the upper half of the sleeve line equal 1.00 mm.
  • Page 30 General Information Telescoping and Small Bore Gauges Use telescoping gauges (Figure 28) and small bore gauges (Figure 29) to measure bores. Neither gauge has a scale for direct readings. Use an outside micrometer to determine the reading. To read a standard inch micrometer, perform the following steps and refer to Figure 27 1.

  • Page 31: Dial Indicator

    General Information knurled end of the gauge to carefully expand the gauge fingers to the limit within the bore. Do not over tighten the gauge because there is no built-in release. Excessive tightening can damage the bore surface and damage the tool.

  • Page 32: Compression Gauge

    General Information Compression Gauge A compression gauge (Figure 33) measures combustion chamber (cylinder) pressure, usually in PSI or kg/ . The gauge adapter is either inserted or screwed into the spark plug hole to obtain the reading. Disable the engine so it does not start and hold the throttle in the wide-open position when performing a compression test.

  • Page 33: Electrical Basics

    General Information Clip-on ammeter Electrical System Fundamentals 1. Clip-on ammeter (Figure 35) is the basic tool for electrical system diagnosis which is used A thorough study of the many types of to measure the current of electrical systems used in today’s UTV’s charging system and other is beyond the scope of this manual.

  • Page 34: Basic Service Methods

    General Information circuit and measures how difficult it is to component is the end closest to the push the current through the circuit. An front the UTV. The left and right ohmmeter, although useful, sides refer to the position of the parts always a good indicator of a circuit’s as viewed by the rider sitting on the actual ability under operating conditions.
  • Page 35 General Information 8. To prevent objects or debris from CAUTION falling into the engine cover all Do not direct high pressure water openings. at steering bearings, fuel hoses, wheel bearings, suspension and 9. Read each procedure thoroughly electrical components. Water may and compare the illustrations to the force grease out of the bearings actual components before starting...
  • Page 36 General Information 21. Use grease to hold small parts in If the head breaks off flush, use a screw place if they tend to fall out during extractor. To do this, center punch the assembly. Do not apply grease to exact center of the remaining portion of electrical or brake components.

  • Page 37: Removing Hoses

    General Information Note Unless otherwise specified, install bearings with the manufacturer’s mark or number facing outward. Removing Bearings While bearing are normally removed only when damaged, there may be times when it is necessary to remove a Removing Hoses bearing that is in good condition. However, improper bearing removal will When removing stubborn hoses, do not damage the bearing and possibly the...
  • Page 38 General Information 3. The ideal method of bearing removal Installation is with a hydraulic press. Note the following when using a press. 1. When installing a bearing in a housing, apply pressure to the outer Always support the inner and outer bearing race (Figure 43).

  • Page 39: Interference Fit

    General Information installation. Be careful not to overheat the bearing. Follow this step when installing a bearing in a housing. Bearings are general installed in a housing with a slight interference fit Driving the bearing into the housing using normal methods may damage the housing or cause bearing damage.

  • Page 40: Storage

    General Information slightly larger due to heat expansion. Pack waterproof grease in the seal lips This makes bearing installation easier. before the seal is installed. Note In most cases, install seals with the Always install bearings with the manufacturer’s numbers or marks facing manufacturer’s mark or number out.
  • Page 41 General Information for each type of product being Preparing the UTV for used. 8. Place the UTV on a work stand Storage with both wheels off the ground. 9. Cover the UTV with old bed The amount of preparation a motorcycle sheets or something similar.
  • Page 42 Specifications Conversion Tables Engine Torques 2-17 General Specs Chassis Torques 2-20 Engine Specs General Torques 2-22 Suspension Specs 2-13 Lubrications 2-23 Electrical Specs 2-15...
  • Page 43 Specifications...

  • Page 44: Conversion Tables

    Specifications How to Use the Conversion Table All the specified documents in this manual are taken in Standard and Metric measurements. With the following conversion table, metric measurements can be converted into Standard measurements. Sample: METRIC MULTIPLY STANDARD 0.03937 × 0.03937 =0.08in Conversion Table...

  • Page 45: General Specs

    Specifications General Specifications Item Metric Standard Dimensions : 2,700mm (106.3in) Overall length 1,360mm (53.5 in) Overall width 1,840mm (72.4in) Overall height 800mm (31.50in) Seat height 1,940mm (76.4in) Wheelbase 260 mm (10.2 in) Minimum ground clearance 6,730mm (265.0 in) Minimum turning radius Basic weight : 547kg (1,206 lb)
  • Page 46 Specifications Item Metric Standard Ignition system Type Spark plug Type/manufacturer DCPR7E / 1 (NGK) Spark plug gap 0.8-0.9 mm (0.031-0.035 in) Clutch type Dry ,centrifugal automatic Transmission Primary reduction system V-belt Secondary reduction system Shaft drive Transmission type V-belt automatic Operation Right hand operation Single speed automatic...
  • Page 47 Specifications Item Metric Standard Suspension Front suspension Double wishbone Rear suspension Double wishbone Shock absorber Front shock absorber Coil spring/oil damper Rear shock absorber Coil spring/oil damper Wheel travel Front wheel travel 130mm (5.12 in) Rear wheel travel 150mm (5.91 in) Electrical Ignition system Generator system...

  • Page 48: Engine Specs

    Specifications Engine Specifications Item Metric Standard Service Wear Limit Cylinder head Warp limit * 0.03 mm(0.0012 in) Cylinder Bore size 91.016 – 91.030mm (3.544- 3.584 in) Measuring point * 50 mm (1.97 in) Camshaft Drive method Cam dimensions Intake 31.95 ~ 32.11mm (1.258~ 1.264 in) “A”...
  • Page 49 Specifications Item Metric Standard Service Wear Limit Cam chain No. of links Cam chain adjustment method Automatic Rocker arm/rocker arm shaft Rocker arm inside 12.011-12.018 mm (0.4729-0.4731in) diameter Shaft outside diameter 11.982-11.989 mm (0.4717-0.4720 in) Arm-to-shaft clearance 0.022-0.036 mm (0.0009-0.0014 in) Valve dimensions margin thickness head diameter...
  • Page 50 Specifications Item Metric Standard Service Wear Limit Stem-to-guide clearance 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) 0.08 mm(0.0031 in) 0.025 ~ 0.052 mm (0.0010 ~ 0.0020 in) 0.10 mm(0.0039 in) Stem runout limit 0.01 mm(0.0004 in) Valve seat width 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 0.9 ~ 1.1 mm...
  • Page 51 Specifications Item Metric Standard Service Wear Limit Piston Piston to cylinder 0.050 - 0.070 mm (0.0020 ~ 0.0028 in) 0.15 mm(0.0059 in) clearance Piston size “D” 90.940- 90.955mm (3.5803 ~3.5809 in) Measuring point “H” 4.0 mm (0.15 in) Piston off-set Off-set direction 0.5mm (0.0394 in)
  • Page 52 Specifications Item Metric Standard Service Wear Limit Oil ring Dimensions (B×T) 4.0×3.40mm (0.1575×0.1339in) End gap (installed) 0.20 ~ 0.70 mm (0.0079 ~ 0.0276 in) Side clearance 0.06 ~ 0.15 mm (0.0024 ~ 0.0059 in) Crankshaft 90.523- 90.577mm (3.5639 - 3.5660in) Crank width “A”...
  • Page 53 Specifications Item Metric Standard Service Wear Limit Shifter Shifter type Shift drum and guide bar Air filter oil grade Engine oil Oil pump Oil filter type Spin on Oil pump type Trochoid Tip clearance 0.15 mm (0.0059 in) Side clearance 0.03 - 0.10 mm (0.0012 - 0.0039 in) Body clearance 0.09 - 0.17 mm (0.0035 - 0.0067 in)
  • Page 54 Specifications Item Metric Standard Service Wear Limit Steering system Type Rack and pinion Front suspension Shock absorber travel 64 mm (2.52 in) Spring free length 320 mm (12.60 in) Spring fitting length 245 mm (9.65in) Spring rate 28 N/mm (2.8kg/mm, 156.80lb/in) Stroke 75-165 mm (2.95 - 6.49in)
  • Page 55 Specifications Item Metric Standard Service Wear limit Front disc brake Type Dual Disc outside diameter × 200 × 3.5 mm (7.87 × 0.14 in) thickness Pad thickness inner 9.0 mm (0.35 in) Pad thickness outer 9.0 mm (0.35 in) Master cylinder inside 19.0mm (0.75in) diameter...

  • Page 56: Electrical Specs

    Specifications ELECTRICAL SPECIFICATIONS Item Metric Standard Service Wear Limit Voltage 12 V Ignition system Ignition timing (BTDC) 15°±1°before TDC Advancer type ECU Digital type Ignition coil Minimum spark gap 6 mm (0.24 in) Primary winding resistance 0.18 ~ 0.28 Ωat 20 °C (68 °F) Secondary winding 6.32 ~ 9.48 kΩat 20 °C (68 °F) resistance...
  • Page 57 Specifications Item Metric Standard Service Wear Limit Radiator fan Running rpm 2,950 r/min Electric starter system Type Constant mesh type Starter motor Output 0.8 kW Armature coil resistance 0.025 ~ 0.035 Ωat 20 °C (68 °F) Brush overall length 12.5 mm (0.49 in) 5 mm(0.20 in) Spring force 7.65 ~ 10.01 N...

  • Page 58: Engine Torques

    Specifications Engine Torques Component Name Thread Ft-lb Remarks Size Cylinder head Bolt Bolt Spark plug — Cylinder head (exhaust pipe) Stud bolt Cylinder head cover Bolt Tappet cover (exhaust) — Tappet cover (intake) Bolt Oil gallery bolt — Camshaft end cap Bolt Cylinder Bolt...
  • Page 59 Specifications Component Name Thread Ft-lb Remarks size Crankcase Bolt Bearing housing (clutch housing Bolt assembly) Air duct assembly 1 bracket Bolt Oil seal (engine cooling fan pulley) Bolt Retainer Drive belt case Bolt Drive belt cover Bolt Engine cooling fan Bolt Air shroud 1 and air shroud 2 Bolt...
  • Page 60 Specifications Component Name Thread Ft-lb Remarks Size Shift arm Bolt Shift rod locknut (select lever unit) Shift rod locknut (shift arm side) Select lever unit Bolt Plug (right crankcase) Water pump assembly Bolt Water pump housing cover Bolt Coolant drain bolt Coolant inlet joint Bolt Coolant outlet joint...

  • Page 61: Chassis Torques

    Specifications Chassis Torques Component Thread Ft-lb Remarks Size Rubber connecting bracket 1(or 2) and frame Engine and Rubber connecting bracket 2 (front) Engine and Rubber connecting bracket 2 (front) Rear upper arm and frame Rear lower arm and frame Rear knuckle and rear upper arm Rear knuckle and rear lower arm Rear shock absorber and frame Rear shock absorber and rear lower arm...
  • Page 62 Specifications Component Thread Ft-lb Remarks Size Steering knuckle and tie-rod Front lower arm protector board and front lower arm Seat belt and frame Seat belt and ceiling (enclosure) 7/16 Front wheel and front wheel hub Front wheel hub and constant velocity joint of half Stake Shaft Steering knuckle and brake disc guard...

  • Page 63: General Torques

    Specifications General Torque Specifications This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached.

  • Page 64: Lubrications

    Specifications Lubrication Points and Type Used Engine Lubrication points Lubricant Oil seal lips Apply lithium-soap-based grease Bearings Apply engine oil O-rings Apply lithium-soap-based grease Piston, piston ring Apply engine oil Piston pin Apply engine oil Buffer boss and balancer drive gear Apply engine oil Crankshaft seal and spacer Apply engine oil...
  • Page 65 Specifications Chassis con”t Joint of front brake cable Light lithium-base grease Front brake lever axle and rear brake lever axle Light lithium-base grease Adjusting nut and pin of front brake cable Light lithium-base grease Adjusting nut and pin of rear brake cable Light lithium-base grease Rear brake pedal pivot and brake pedal axle hole Light lithium-base grease...
  • Page 66 Periodic Maintenance Maintenance schedule Brake Pedal 3-14 Valve Adjustment Brake Pads 3-15 Compression test Shift Lever Adjustment 3-16 Engine Oil Final Gear oil 3-15 Air filter Steering system 3-17 Coolant level 3-10 Shock absorbers 3-19 V-Belt 3-13 Tires 3-19 Spark arrester 3-13 Headlight adjustment 3-20...
  • Page 67 Periodic Maintenance...

  • Page 68: Maintenance Schedule

    Periodic Maintenance Maintenance and Adjustment of the UTV Maintenance Schedule...
  • Page 69 Periodic Maintenance Maintenance Schedule cont’ Note Recommended brake fluid: DOT 4 When disassembling the master cylinder or caliper, replace the brake fluid. Check the brake fluid level and condition regularly and add or replace as necessary. On inner parts of the master cylinder and caliper, replace the seals every two years. Replace brake hoses every four years, or if cracked or damaged.

  • Page 70: Valve Adjustment

    Periodic Maintenance Valve Adjustment Note The valve clearance must be adjusted when the engine is cool to the touch. Adjust the valve clearance when the piston is at Top Dead Center (TDC) on the compression stroke. • Remove the Driver’s seat Check the valve clearance •...
  • Page 71 Periodic Maintenance • Check the electrode Look for color, carbon deposits and check the spark plug gap. Proper Gap 0.8 to 0.9mm Color should be light tan • Clean the spark plug with a spark Fixed nut plug cleaner and reinstall the plug. 14 Nm(1.4 m·kgf, 10 ft·lbs) 17.5 Nm(1.75 m·kgf, 12.7 ft·lbs) Install all parts in reverse order of...

  • Page 72: Engine Oil

    Periodic Maintenance Note: Note: When cranking the engine with the Do not screw in the dip stick. Check the electric starter, ground the spark plug level by resting the dipstick on the lead to prevent arcing. threads. • Read the highest reading on the •...
  • Page 73 Periodic Maintenance CHANGING THE ENGINE OIL Place the vehicle on a level surface. 1. Start the engine and let it warm up for several minutes. 2. Stop the engine and place an oil pan under the engine. 3. Remove: • Driver’s seat 4.

  • Page 74: Air Filter

    Periodic Maintenance Chassis Note: Never operate the engine with the air Cleaning the Air Filter filter element removed. This will allow unfiltered air to enter, causing rapid Note: wear and possible engine damage. There is a check hose ② at the bottom Additionally, operation without the filter element will affect tuning with of the air filter case.

  • Page 75: Coolant Level

    Periodic Maintenance Checking the coolant level The reservoir bottle can be seen behind the right front tire. The level should be kept between the minimum (b) and the maximum (a) level bars on the bottle. Note: Adding water instead of coolant lowers the antifreeze content.
  • Page 76 Periodic Maintenance Warning: Connect the water pump inlet hose, and A hot radiator is under pressure. the coolant outlet hose. Therefore, do not remove the radiator Remove the air bleed bolt (1). cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause serious injury.
  • Page 77 Periodic Maintenance Install the air bleed bolt 9 Nm (0.9 m · kg, 6.5 ft · lb) Install the radiator cap and fill the reservoir, install the reservoir cap. Start the engine and warm it up for several minutes. Then shut off the engine and check the coolant level in the reservoir.

  • Page 78: V-Belt

    Periodic Maintenance Checking the V-Belt Remove the passenger’s seat, rear right seat board, and mud guard. Remove the drive belt cover Inspect the drive belt (1) for cracks, wear, Install a New V-Belt chipping or damage. Measure the width of the drive belt (2).

  • Page 79: Brake Pedal

    Periodic Maintenance Remove the tail pipe (2) by pulling it out of Brake pedal free play the muffler. 0 mm (0.0 in) Adjust by loosening the locknut (1) and turn the brake rod in or out to obtain the correct free play. Tighten the locknut Use a wire brush to remove any carbon Locknut...

  • Page 80: Brake Pads

    Periodic Maintenance Checking the Front and Rear brake pads Remove the wheel Inspect the brake pad indicator groove (a), if it has almost disappeared replace the pads as a set. Both Front or Both Rear. Brake pad wear limit (a) 1.5 mm (0.06 in) A small c-clamp is handy for pushing the Bleeding the Brake system...
  • Page 81 Periodic Maintenance Adjusting the Select Lever Shift Rod Adjusting the Brake light switch Check the timing of the brake light. • Neutral (1) • High (2) Note: • Low (3) The brake light switch is operated by • Reverse (4) movement of the brake pedal.

  • Page 82: Final Gear Oil

    Periodic Maintenance Checking the Final Gear Oil Level Unclip the wire connector to the speed sensor and remove the speed sensor. Place the UTV on level ground. Install the Drain Plug. Unclip wire connector to the speed sensor and remove the Speed sensor 23 Nm (2.3 m ·...

  • Page 83: Steering System

    Periodic Maintenance Checking the Steering system Adjusting the Toe-In Check the steering Column for excessive Place the vehicle on a flat surface. play up and down, and side to side. If the clearance is too much replace the steering Place a white chalk mark at the center of column bearing.

  • Page 84: Shock Absorbers

    Cylinder damage will result in poor damping performance. 100 kg or 220 lbs ·Do not dispose of a damaged or worn out shock absorber assembly yourself. Take the shock absorber assembly to a HiSUN dealer for any service. 3-19...
  • Page 85 Periodic Maintenance Adjusting the Headlight Install the new bulb Turn the adjuster (1) in or out to achieve Install the new bulb into the bulb holder the desired height of the beam. Note: Avoid touching the glass part of the new bulb.
  • Page 86 Engine Special Notes Starter Motor and Oil filter 4-19 Throttle and Intake Manifold Primary and Secondary 4-21 removal Sheaves Cylinder Head Cover and Crankcase cover and Oil 4-24 Cylinder Head Pump Rocker Arms and Camshaft Crankcase and Middle Driven 4-27 Shaft Valves and Valve Springs 4-10...
  • Page 87 Engine...

  • Page 88: Special Notes

    Engine Special Notes 1. Always use the recommended components, oils, adhesives and sealants. 2. Whenever it is necessary to remove original oil seals, gaskets, O-rings or piston rings, replace them with new parts. 3. When disassembling, keep your parts orderly to help with reassembly. 4.

  • Page 89: Cylinder Head

    Engine Engine Removal Part Name Remarks Removing the throttle and intake Remove the parts in the order manifold. listed. Dampers Dampers Joint (intake manifold) Intake Manifold Temperature Sensor Cylinder Head Timing Chain tensioner cap bolt Pressure plate (TMAP) Fuel Injector Fuel Injector seat Drain Blind Nut For installation, reverse the order...
  • Page 90 Engine Cylinder Head and Cylinder Head Cover Part Name Remarks Removing the Cylinder Head Remove the parts in the order Cover and Cylinder Head listed Thermostat cover Thermostat Cylinder water outlet connector Washer O-ring Cylinder head cover Cylinder cover pad Spark plug Stud Bolt M8×45 (stainless steel ) Temperature sensor...
  • Page 91 Engine Inspection While holding the rod in wind the adjuster clockwise with a thin screwdriver until it Inspect the cylinder head cover stops. Look for cracks or damage. If replacement With the screwdriver still inserted, install is necessary replace the Cylinder Head the tensioner with a new gasket, with the and Cylinder Head cover as a set.
  • Page 92 Engine Assembly Installing the Cylinder Head Install a new cylinder head gasket Then install the cylinder head. Tighten the 9mm bolts #1 - 6 to 38 Nm or 28 ft lbs in the order shown in two stages. Ttighten the 6mm bolt #7 in two stages. 10 Nm or 7 ft lbs Install the timing chain guide (exhaust side).

  • Page 93: Rocker Arms And Camshaft

    Engine Rocker Arms and Camshaft Part Name Remarks Removing the rocker arms and Remove the parts in the order camshaft listed Cylinder Head cover Rocker arm shaft Wave washer Rocker arm (exhaust) Rocker arm (intake) Valve adjuster Locknut Camshaft sprocket Camshaft station plate Camshaft II Camshaft I...
  • Page 94 Engine Inspection Calculate the clearance by subtracting the rocker arm shaft outside diameter from the Inspect the rocker arms rocker arm inside diameter. Look at the rocker arm lobes and valve Rocker arm to shaft clearance adjusters. Look for discoloration, pitting, Service Wear Limit scratches or damage.

  • Page 95: Valves And Valve Springs

    Engine Valves and Valve Springs Part Name Remarks Removing the Valves and Valve Remove the parts in the order Springs listed Cylinder head cover Valve Keeper Valve spring retainer Intake valve spring Exhaust valve spring Intake valve Exhaust valve Valve stem seal For installation, reverse the order Valve spring seat listed...
  • Page 96 Engine Valve and Valve seat inspection Stem-to-guide clearance Service Wear Limit Pour a good quality combustion chamber Intake:0.08mm Exhaust:0.10mm cleaner into the intake and exhaust ports (1). Look for leaks at the valve sealing Measure the margin thickness. (a) areas (2). There should be no leakage. Margin thickness Intake:2 mm Exhaust:2.2 mm...
  • Page 97 Engine Measure the valve spring free length. Installing or removing the valve guide, use a valve guide remover (1) and valve guide installer (2). Valve spring free length Intake:41mm Exhaust:41mm Measure the spring squareness. After installing the valve guide it needs to be sized for the valve by using a reamer (3) to obtain proper stem to guide clearance.
  • Page 98 Engine Note: Install the valve keepers while compressing the valve spring with the valve spring compressor (1) and valve spring compressor attachment (2). 4-13...

  • Page 99: Cylinder And Piston

    Engine Cylinder and Piston Part Name Remarks Removing the Cylinder and Piston Remove the parts in the order listed Water pump outlet hose Cylinder head Dowel Pin Cylinder head gasket Cylinder Cylinder base gasket Piston pin clip Piston pin Piston For installation, reverse the order Piston Ring set listed...
  • Page 100 Engine Inspection Calculate the difference between the Inspect the cylinder and piston walls. piston outside diameter and cylinder bore Look for vertical scratches. diameter. Inspect the piston rings by inserting them Service Wear Limit into the cylinder bore and measure ring 0.10mm end gap (1).
  • Page 101 Engine Installation Install the cylinder base gasket, then install the cylinder. Install the rings onto the piston. Note: Install the cylinder with one hand while compressing the piston rings with the other hand. Caution: Be careful not to damage the timing chain guide during installation.

  • Page 102: Left Crankcase Cover And A.c

    Engine Engine Left Crankcase Cover and A.C. Magneto Part Name Remarks Removing the engine left Remove the parts in the order listed. crankcase cover and A.C. magneto Engine oil Water Pump Assembly Left crankcase cover Inspection port cover/ O-ring Crank position sensor/ O-ring Dipstick/ O-ring A.C.
  • Page 103 Engine Inspection Turn the starter wheel gear clockwise (2) to check for smooth operation. If it is not Inspect the A.C. magneto smooth replace the starter clutch. Look at the stator coil and pickup coil. Look for damage or burnt windings or wire. Inspect the starter idle gear teeth and the starter wheel gear teeth.

  • Page 104: Starter Motor And Oil Filter

    Engine Starter Motor and Oil filter Part Name Remarks Removing the starter motor and Remove the parts in the order listed oil filter A.C. magneto rotor Starter Idle gear Starter idle gear shaft Relief valve spring/ steel ball Chain plate Timing chain guide (first cylinder) Timing chain Pump...
  • Page 105 Engine Inspection Installation Inspect the starter idle gear. Look for Install the starter motor, oil filter cartridge, cracks, wear or damage. starter idle gear shaft and the starter idle gear. Use molybdenum disulfide grease to assist in assembly. Inspect the timing chain and guides. Look for cracks or stiffness in the chain.

  • Page 106: Primary And Secondary Sheaves

    Engine Primary and Secondary sheaves Part Name Remarks Removing the primary and Remove the parts in the order listed secondary sheaves Drive belt cover Rubber gasket Drain plug Grommet V-belt Secondary fixed sheave Secondary sliding sheave Compression spring Guide base, Driven gear Driving flyweight Primary fixed sheave Compression spring/spring seat...
  • Page 107 Engine Inspection Install the weights (1). Inspect the primary pulley slider and the primary sliding sheave splines. Look for wear, cracks or damage. Inspect the spacer and primary pulley cam. Look for cracks or damage. Inspect the primary sliding sheave and the Note: primary fixed sheave.
  • Page 108 Engine Tighten the primary sheave nut (1) using the sheave holder (3) to 70 Nm or 51 ft lbs Then tighten the secondary sheave nut (2) 50 Nm or 36 ft lbs 4-23...

  • Page 109: Crankcase Cover And Oil Pump

    Engine Crankcase Cover and Oil Pump Part Name Remarks Removing the crankcase cover Remove the parts in the order listed and Oil Pump Crankcase separation Crankshaft cover Gasket Dowel pin Crankcase vent pipe Crankcase block Oil seal Oil pump gasket Oil pump Outer rotor Inner rotor...
  • Page 110 Engine Crankcase cover and Oil pump Part Name Remarks Shaft/pin Water pump gear/washer Oil pump middle gear Shaft Bearing Fuel and air separator assy V-ring Shaft Valve piece plate Valve piece Chain plate Timing chain guide Timing chain For installation, reverse the order Right crankcase listed 4-25...
  • Page 111 Engine Inspaction Inspect the oil pump housing and rotor cover for cracks, wear or damage. Inspect the operation of the oil pump for smoothness. Tip clearance Limit: 0.23 mm Inspect the timing chain for stiffness or Side clearance Limit: 0.25 mm cracks and the timing chain guides for Body clearance Limit: 0.20 mm wear or damage.

  • Page 112: Crankcase And Middle Driven Shaft

    Engine Crankcase and Middle Driven Shaft Part Name Remarks Remove the crankcase and Remove the parts in the order listed middle drive shaft Crankcase separation Right crankcase Crankcase gasket Dowel pin Crankshaft Shaft Connecting Rod cap/rod bushing Universal joint Oil seal Bearing retainer Bearing seat dowel pin Bearing...
  • Page 113 Engine Inspection Runout (b) (C) Inspect the middle drive gear O-ring for Runout limit (b): 0.03 mm （0.0012 in） damage or wear. (C): 0.03 mm （0.0012 in） Inspect the bearings for pitting or damage. Clean and lubricate the bearing, then The crankshaft (1) and the crank pin (2) oil rotate the inner race with a finger.
  • Page 114 Engine Install the middle driven shaft universal joint. Install the opposite yoke onto the universal joint. Apply wheel bearing grease to the bearings and install the bearing (1) onto the yoke. Caution: Check each bearing. The needles can easily fall out of their races. Slide the yoke back and forth on the bearings;...

  • Page 115: Output Shaft

    Engine Output Shaft Part Name Remarks Remove the output shaft Remove the parts in the order listed Middle drive gear Left gear case cover Drive shaft coupling Drive shaft spring/bearing Output shaft Y-1 Washer/collar Washer/O-ring Universal joint A Oil seal Collar/O-ring Rear drive bearing seat Dowel pin...
  • Page 116 Engine Inspection Installation Inspect the drive shaft coupling and the Install the bearing retainer (1) by placing a output shat Y-1. Look for pitting, galling or rag (2) in a vise and securing the bearing wear. housing. Attach the bearing retainer wrench (3) and tighten.
  • Page 117 Engine Caution: Check each bearing. The needles can easily fall out of their races. Slide the yoke back and forth on the bearings; the yoke will not go all the way onto a bearing if a needle is out of place. Press each bearing into the universal joint using a suitable socket.

  • Page 118: Gearcase Shift Lever And Oil

    Engine Gearcase Shift Lever and Oil Pump Part Name Remarks Removing the shift lever and Remove the parts in the order listed gearcase Gearcase separation Shift Lever cover/gasket Shift lever 2 assembly Shift lever 1 Oil pump/O-ring Outer rotor Inner rotor Oil pump shaft/pin Connecting pipe 1/2 Gearcase vent nozzle...
  • Page 119 Engine Gearcase Shift lever and Oil pump Part Name Remarks Guide bar Shift fork 1/long spring Shift fork 2/short spring Gearcase cover For installation, reverse the order Bracket clutch cover seat listed. 4-34...

  • Page 120: Gearcase Transmission

    Engine Gearcase Transmission Part Name Remarks Removing the gearcase Remove the parts in the order listed. transmission Gearcase separation Gearcase cover Inner Hex screw 8M X 45 Inner Hex screw 8M X 40 Spring washer Oil seal Bushing O-ring 25 X 2.4 Flange bolt M6 X 45 Flange bolt M6 X 35 Bracket clutch cover seat...
  • Page 121 Engine Gearcase Transmission Part Name Remarks H drive gear Washer L drive gear Bearing 6402 DU Bearing 6403 Washer R driven gear Washer H driven gear L Driven gear Needle bearing 25 X 29 X 9.6 Countershaft Needle bearing AXK 15 X 28 X 2 Washer Needle bearing NBI 19 X 27 x 16 R idle gear...
  • Page 122 Engine Inspection Inspect the shift drum grooves for scratches, wear or damage. Inspect the shift forks, shift fork follower (1) and shift fork pawl (2) for scoring, wear or damage. Inspect the bearings, clean and lubricate, then rotate the inner race with a finger, looking for any roughness.
  • Page 123 Engine Measure the oil pump Measure the tip clearance between the inner rotor (1) and the outer rotor (2). Measure the side clearance (b) between the outer rotor (2) and the pump housing (3). Measure the body clearance (c) between the outer rotor (2) and the pump housing (3).
  • Page 124 CHASSIS Steering assembly Rear Bridge reducer 5-33 Disc Brake components Gear shift assembly 5-36 Front brake caliper 5-11 Front swing arm 5-39 Rear brake caliper 5-15 Front suspension 5-40 Parking brake caliper 5-16 Rear anti-roll bar 5-43 Footrest 5-20 Rear swing arm 5-44 Front Wheel and Tire 5-23...
  • Page 125 CHASSIS...

  • Page 126: Steering Assembly

    CHASSIS Steering Assembly Part Name Remarks Remove the parts in the order listed Removing the steering assembly Socket hexagon screw M6×16 Steering wheel body Hexagon flange nut M12×1.25 Nylon bush Φ11×Φ16×Φ23×11 Steering column Hex flange step bolt M8×13-Φ12×12 Hexagon flange self-lock nuts M8 Steering rod Hexagon flange bolt M6×25 Cap nut M6×12...
  • Page 127 CHASSIS Steering Assembly Part Name Remarks Passenger handle bar assembly Handle bar grip Locking knob, handle bar Steering drive axle Hexagon flange bolt M8×30 Washer Φ8×Φ16×1.6 Driving gear Hexagon flange bolt M10×1.25×35 Cross big plate head screw M5×16 Hexagon flange nut M5 Screw M5×12 Clamp Rubber dust cover...
  • Page 128 CHASSIS Steering Assembly Part Name Remarks Ball joint steering mechanism Hexagon nut M12×1.25 Collar pin 2×25 Steering wheel comp Hexagon flange bolt M6×30 Rubber dust cover Steering column decorative cover Handle sheath Steering mechanism comp Hexagon flange bolt M8×35 Hexagon flange self-lock nuts M8 Bushing Φ6×Φ10×18 Spring washer -8 Dust sleeve...
  • Page 129 CHASSIS Steering Assembly Part Name Remarks Steering wheel decorative cover Steering wheel middle cover Steering wheel upper cover Screw M8×16 Ignition lock upper cover Ignition switch Ignition switch assembly lower cover Light switch assembly Spring washer Φ10 Washer Φ10×Φ20×2 Phillips plate head screw ST3.6×10 For installation, reverse the order Washer Φ15×Φ28×2 listed...
  • Page 130 CHASSIS Removal of the steering assembly Warning: Any abnormalities with the steering Remove the steering wheel upper cover system should be addressed (1), then the Hex socket screw (2) and the immediately for safety reasons. steering wheel (3). Remove the Hood (1), Dash cover (2), Steering wheel cover (3), Display Panel (4) And the steering wheel (5).
  • Page 131 CHASSIS To remove the steering column, remove Inspection of the brake system the two fasteners that attach the column to the frame and lift out. The brake system is critical to the life safety of the operator and passenger; Inspect the rubber dust boots (2), Look for therefore it must be periodically inspected cracks, wear or damage.

  • Page 132: Disc Brake Components

    CHASSIS Disc Brake Components Part Name Remarks Removing brake components Remove the parts in the order listed. Master cylinder (auxiliary bumper) Rear brake line Clamp Pipe clamp Hex Flange bolt M6 X 16 Hex Flange bolt M6 X 30 Hex Flange bolt M6 X 16 Brake line clip Hex Flange bolt M6 X 12 Front disc brake line clip...
  • Page 133 CHASSIS Disc Brake Components Part Name Remarks Brake line sheath Brake line sheath Right rear Brake hose Left rear brake hose For installation, reverse the order Rear T-junction listed 5-10...

  • Page 134: Front Brake Caliper

    CHASSIS Front Brake Caliper Part Name Remarks Removing the front brake caliper Front brake disc Hex step bolt M8×15-Φ15×5 Front brake disc Front brake caliper Brake caliper piston assembly Brake caliper piston Dust seal Caliper piston seal Bleed screw Brake pad Pad spring Brake pad holding bolt Hexagon flange bolt M10×1.25×22...
  • Page 135 CHASSIS Inspection Measure the thickness of the brake pad (a). Inspect the brake disc for galling or damage. Measure the Brake disc deflection. Brake disc maximum deflection 0.10 mm (0.004 in) Measure the brake disc thickness (1). Brake pad wear limit Brake disc minimum thickness 1.5 mm (0.06 in) 3.0 mm (0.12 in)
  • Page 136 CHASSIS Check the brake fluid level in the reservoir. Fill the brake reservoir. The level must be between the minimum and the maximum level marks. Must use DOT4 Brake Fluid Must use DOT4 Brake Fluid Note: Brake fluid may damage painted surfaces or plastic parts.
  • Page 137 CHASSIS Remove the dust seals (1) and the caliper Fill the brake master cylinder reservoir with piston seals (2). new brake fluid. Must use DOT4 Brake Fluid Note: Brake fluid may damage painted surfaces or plastic parts. Always clean up spilled brake fluid immediately. Bleed the brake system.

  • Page 138: Rear Brake Caliper

    CHASSIS Rear Brake Caliper Part Name Remarks Removing the rear brake caliper The service method for the rear Rear brake disc calipers is the same as the front Rear brake disc calipers. Hexagon step bolt M8×15-Φ15×5 Rear brake caliper Brake caliper piston assembly Brake caliper piston Dust seal Caliper piston seal...

  • Page 139: Parking Brake Caliper

    CHASSIS Parking Brake Caliper Part Name Remarks Removing the parking brake caliper Parking caliper assembly Bolt Parking disc Bolt, flange Brake pad holding bolt Brake caliper assembly Brake, pad Brake pad (piston side) Insulator/pad shim Pad spring Parking brake arm nut Set bolt 5-16...
  • Page 140 CHASSIS Parking Brake Caliper Part Name Remarks Parking brake arm Parking brake arm shaft Spring Parking brake case bolt Parking brake case Gasket Bleed screw Brake caliper bracket Caliper piston seal Dust seal Brake caliper piston 5-17...
  • Page 141 CHASSIS Disassembling the parking brake Install the brake caliper piston (1) by turning it clockwise until section (a) of the caliper caliper piston is level with the surface of Remove the caliper from the utv. the brake caliper body. Remove the brake caliper piston (1). Turn the brake caliper piston counterclockwise to remove it.
  • Page 142 CHASSIS Note: Install the brake pad holding bolts. The hole for the parking brake arm shaft has multiple threads. If the punch 17Nm (1.7 m · kg,12 ft · lb) mark (a) on the parking brake arm shaft Install the brake caliper assembly with the is not between the alignment marks (b) when the parking brake arm shaft is mounting bolts.

  • Page 143: Footrest

    CHASSIS Footrest Part Name Remarks Removing the footrest Left front mud-guard board Cross big plate head screw M6×12 Screw thread clip M6×2 Right front mud-guard board Cross large plate head screw M6×16 Screw thread clip M6×2 Left footrest protector Cross large plate head screw M6×16 Screw thread clip M6×2 Right footrest protector Cross big plate head screw M6×12...
  • Page 144 CHASSIS Footrest Part Name Remarks Cross large plate head screw M6×16 Dustproof plate brake pedal Welding, parking pedal Spring D Spring Φ3×Φ30×46° Rear brake pump bracket assy Hexagon flange bolt M8×20 Washer Φ12×1 Link fork, mandril Connecting axle Accelerator pedal welding assy Throttle cable Washer Φ15×Φ22×1.5 Spring Φ2×Φ14×62...
  • Page 145 CHASSIS Footrest Part Name Remarks Cross large plate head screw M6×16 Cross large plate head screw M6×16 Cross big plate head screw M6×12 Collar pin 2×32 Lamp switch, rear break 5-22...

  • Page 146: Front Wheel And Tire

    CHASSIS Front Wheel and Tire Parts Part Name Remarks Removing the Front wheel Warning: Securely support the vehicle so Front wheel rim there is no danger of it falling Front tire over. Valve stem Nut M10 Wheel decoration cover Ⅳ Cotter 3.2×50 Nut M22×1.5 Front hub...

  • Page 147: Rear Wheel And Tire

    CHASSIS Rear Wheel and Tire parts Part Name Remarks Removing the rear wheel Warning: Securely support the vehicle so Rear wheel rim there is no danger of it falling Rear tire over. Valve stem Rear hub Bolt M10×30 Nut M10 Wheel decoration cover Ⅳ...
  • Page 148 CHASSIS Inspection Inspect the wheel hubs (1) for cracks, wear or damage. Inspect the splines (2) for Measure the wheel wear or damage. • Radial runout Wheel runout limit Installing the wheel Radial (2) : 2.0 mm (0.08 in) Install the tire with the directional arrow (1) •...
  • Page 149 CHASSIS Insufficient tire pressure can result in not only intensified wearing of the tire but also instability during the course of operating the vehicle. Excessive tire pressure can also reduce the friction force between the tire and ground, causing spinning or loss of control. Therefore, please ensure the tire pressure strictly complies with figures shown in the chart above.

  • Page 150: Cv Axle, Front Axle

    CHASSIS CV Axle, Front axle Part Name Remarks Removing the Cv axle front (L +R) Circlip Double off-set assembly Circlip Ball bearing Circlip Hoop A, dust P shed Outer rubber dust-P cover (C-1610) Adjustable clamp C.V shaft assembly Inner rubber dust-P cover (C-1605) C.V axle, front axle 5-27...

  • Page 151: Front Bridge

    CHASSIS Front Bridge Part Name Remarks Removing the front bridge Front differential caseⅣ Front differential case Ⅳ Oil drain screw plug O-ring gasket, fuel injection Φ2.2×Φ16.4 Drive & driven gears Differential Breather pipe Clip Φ11 Rubber dust coverΦ19×Φ38×50 Front transmission shaft comp Front differential assy Universal jointⅣ...
  • Page 152 CHASSIS Front Bridge Part Name Remarks O-ring gasket, fuel injectionΦ2.2×Φ16.4 Front transmission shaft Speed sensor comp. Joint cross shaft Connection fork Ⅳ Connection fork Ⅳ Transfer case assembly Seal ring Φ3.1×Φ78 ,transfer Bearing 6306 P5 Bearing Rna4910 Bearing 32008×2 P5 Differntial adjustment gasket Hexagon flange bolt M8×25 Outer raceway...
  • Page 153 CHASSIS Disassembling the universal joint Inspect the movement of the inner and outer ball cages on the left and right Remove the circlips (1) by placing the transmission shafts. Movement should be universal joint into a press. With a suitable smooth.
  • Page 154 CHASSIS Install the circlips (2) into the groove of each bearing. 5-31...

  • Page 155: Cv Axle, Rear Axle

    CHASSIS CV Axle, Rear Axle Part Name Remarks Removing the rear bridge (L+R) Circlip Adjustable Clamp Hoop A,dust p shed Inner rubber dust-proof(c-1513), front axle Circlip Double off-set joint assembly Double off-set joint assembly Circlip Ball bearing Joint shaft assembly Outer rubber dust-proof(C-1605), front axle C.V Axle, rear axle Rear Bridge Reducer...
  • Page 156 CHASSIS Part Name Remarks Removing the rear bridge Rear differential case I Rear differential case II Oil seal Φ52×Φ35×7 Bearing 32008E Rear differential Vent pipe, rear differential Steel wire clamp Φ11 Rear differential assy Hexagon flange locked nut M14×1.5 Magnetic valve Bearing 32010E Bearing seat Metal Bushing...
  • Page 157 CHASSIS Part Name Remarks Oil drain screw Welding combination of shift fork U Type spring Fix bracket Returning spring Sleeve of shift fork Column pin of shift fork Washer Φ12×Φ30×4 Oil fill plug O-ring gasket, fill plug O-ring gasket Hexagon flange nut M10×1.25 Bearing 32206E Adjust bushing II Gasket of adjust bushing...
  • Page 158 CHASSIS Part Name Remarks Driving and driven gears Rear adjustment gasket I Hexagon Flange Self-Lock Nuts M6 Parking Plate Hexagon step cheese head M6×14-Φ7×15 Middle brake assembly Hexagon flange bolt M10×1.25×30 Mount bracket, rear disk brake plate Differential adjustment gasket Adjustment gasket O-ring Φ2.5×Φ192 Hexagon flange bolt M8×25...

  • Page 159: Gear Shift Assembly

    CHASSIS Part Name Remarks Removing the gear shift assembly Gear shifter assembly Gear Shifting Support Hexagon Flange bolt M8×12 Gearshift Rod I Hexagon flange bolt M6×16 Hexagon flange self-lock nuts M6 Gearshift rod II Gearshift boot Gearshift knob Gear shifting support Hexagon flange self-lock nuts M6 Hexagon flange bolt M6×16 Gearshift arm assembly II...
  • Page 160 CHASSIS Part Name Remarks Hexagon flange nut M8 Gearshift arm assembly I Gearshift assembly Rubber cover clamp Plastic screw Hexagon flange bolt M8×20 5-37...
  • Page 161 CHASSIS Adjusting the gear shift mechanism (1) Neutral (2) High (3) Low (4) Reverse (5) Select lever shift rod (6) Shift control cable Note: Before shifting, you must stop the vehicle and take your foot off the accelerator pedal. Otherwise, the transmission may be damaged.

  • Page 162: Front Swing Arm

    CHASSIS Front Swing Arm Part Name Remarks Removing the front swing arm Front shock absorber Hexagon flange nut M10×1.25 Hexagon flange bolt M10×1.25×55 Hexagon flange nut M10×1.25 Front anti-roll bar "U" type rubber bush Φ21-40 Press block, rear anti-roll bar Hexagon flange bolt M8×22 Tie-Rod, front anti-roll bar Hexagon flange bolt M10×1.25×45...

  • Page 163: Front Suspension

    CHASSIS Front Suspension Part Name Remarks Removing the front suspension Right front upper swing arm Left front upper swing arm Right Front Lower Swing Arm Left front lower swing arm Hexagon flange bolt M10×1.25×70 Dust cover B Hexagon flange nut M10×1.25 Middle rubber tube, swing arm Elasticity block ring D=30 Universal joint A...
  • Page 164 CHASSIS Front Suspension Part Name Remarks Collar pin 2.5×30 Protective board, swing arm Spring washer -12 Cross large plate head screw M6×16 5-41...
  • Page 165 CHASSIS Inspection Installation Inspect the stabilizer bar for bends, cracks Install the front upper arm (1) and front or damage. lower arm (2). Apply lithium soap based grease to the bolts (3) and position the bolts so that the bolt head faces inward. Temporarily tighten the nuts (4).

  • Page 166: Rear Anti-Roll Bar

    CHASSIS Rear Anti-Roll Bar Part Name Remarks Removing the rear anti-roll bar Rear shock absorber Hexagon flange bolt M12×1.25×70 Hexagon flange nut M12×1.25 Hexagon flange bolt M12×1.25×60 Rear anti-roll bar "U" type rubber bush Φ21-40 Press block, rear anti-roll bar Hexagon flange bolt M8×22 Rear Anti-roller lever assy Hexagon flange bolt M10×1.25×45...

  • Page 167: Rear Swing Arm

    CHASSIS Rear Swing Arm Part Name Remarks Removing the rear swing arm Rear right upper swing arm Rear left upper swing arm Rear right lower swing arm Rear left lower swing arm Cross big plate head screw M6×12 Protective board, rear right lower swing arm Hexagon flange bolt M10×1.25×195 Nylon bush Ⅳ...
  • Page 168 CHASSIS Rear Swing Arm Part Name Remarks Hexagon flange Nut M10×1.25 Protective board, rear left lower swing arm Iron nipple Hexagon flange bolt M10×1.25×70 Dust cover B 5-45...
  • Page 169 CHASSIS Inspection Inspect he stabilizer bar for bends, cracks or damage. Inspect the steering knuckles for pitting, wear or damage. Install the rear shock absorbers (5). Inspect the rear arms for bends, cracks or Nut (6) damage. 45 Nm (4.5 m · kg, 32 ft · lb) Inspect the middle bushing fro wear or Install the ball joints.

  • Page 170: Radiator And Oil Cooler

    CHASSIS Radiator and Oil Cooler Part Name Remarks Removing the radiator Screw hoop Φ12×20 Pressureproof rubber oil pipe A-860 Pressureproof rubber oil pipe A-1100 Oil cooler H-shaped rubber washer M type clip , oil pipe Front metal oil pipe Pressureproof rubber oil pipe C-1280 Screw clip Φ14-27 Rear water pipe (R) Rear water pipe (L)
  • Page 171 CHASSIS Radiator and Oil Cooler Part Name Remarks Metal water pipe (R) Clip , metal water pipe Hexagon flange bolt M6×16 Front water pipe (L) Front water pipe (R) Reservoir rubber pipe II Clip Φ10 Coolant reservoir cap Coolant Reservoir Bushing Φ6×Φ9×Φ22×6.5 Hexagon flange Bolt M6×16 Reservoir rubber pipe Φ5×Φ9×540-30...
  • Page 172 CHASSIS Radiator and Oil Cooler Part Name Remarks Water inlet assembly Hexagon flange bolt M6×12 Radiator assembly Radiator Radiator fan assembly Water pipe G Pressure-proof rubber oil pipe A-540 Front metal oil pipe II Water temperature sensor Hexagon flange bolt M6×16 5-49...
  • Page 173 CHASSIS Inspection Installing the radiator Inspect the radiator fins for obstruction or Fill the radiator with the correct antifreeze. damage. Green Ethylene Glycol at 50/50 dilution Use compressed air to clean from the rear side. Straighten any flattened fins with a Start the engine and add coolant to the thin flathead screwdriver.

  • Page 174: Water Pump

    CHASSIS Water Pump Part Name Remarks Removing the water pump Clip Water pipe O-ring Φ27×2.5 Water outlet connector, cylinder Save temperature Bolt M6×50 Bolt M6×12 Washer Φ6×Φ10×1 Bolt M6×25 Thermostat cover Washer Φ20.5×Φ30×1 Gasket Water pipe 5-51...
  • Page 175 CHASSIS Part Name Remarks Removing the water pump Water pump housing cover Water pump assembly Bolt M6×40 Washer Φ6×Φ10×1 Bolt M6×65 Secondary gear, water pump Transmission shaft, water pump Pin Φ4×21 Circlip Φ10 Bearing Oil seal Φ15×Φ10×5 Gasket, water pump cover O-ring Φ34×2.5 Water pump housing 5-52...
  • Page 176 CHASSIS Part Name Remarks Boot band Overflow pipe Gasket,water pump cover Water pump seal assembly Impeller Cover, water pump Clip Water pipe 5-53...
  • Page 177 CHASSIS Disassembling the water pump Inspection Remove the rubber damper (2) from the Inspect the water pump housing cover (1) damper holder (1). and the housing (2) for cracks, wear or damage. Inspect the impeller (3) for pitting, wear or damage.
  • Page 178 CHASSIS Use a straightedge (1) to measure the Apply tap water or coolant to the outer impeller (2) for squareness. surface and Install the rubber damper (1) onto the holder (2). Press down until the damper is flush with the impeller. Max.

  • Page 179: Seat

    CHASSIS Seat Part Name Remarks Removing the seat Safety belt assembly Back rest Seat cushion Seat connection assembly Socket hexagon screw M8×25 Washer Φ8×Φ16×1.6 Washer Φ8×Φ28×3 Slide rail (R) Slide rail (L) Socket hexagon screw M8×25 Seat mounting board Hexagon flange bolt M6×16 Hexagon flange self-lock nuts M8 Seat belt buckle (L) 5-56...
  • Page 180 CHASSIS Part Name Remarks Hexagon flange bolt M10×1.25×22 Combined connecting rod guide Shock absorbtion rubber II Rubber insulation (R) Hexagon flange step bolt M10×1.25×20-Φ14×5 Gasket Φ10.5×Φ19×5 Hexagon flange nut M10×1.25 Hexagon flange nut M10×1.25 Hexagon flange bolt M10×1.25×22 Hexagon flange nut M10×1.25 Hexagon flange step bolt Seat Belt buckle (R) Rubber insulation (L)
  • Page 181 CHASSIS Disassembling the seat Remove the seat assembly (1) and (2) from the UTV. Remove the M8 bolts from the back top of the seat base and lift out. Moving the seat forward and backward. The seat can be moved forward and backward to fit the height of different drivers.

  • Page 182: Fuel Tank

    CHASSIS Fuel Tank Part Name Remarks Removing the fuel tank Fuel tank Hexagon flange bolt M8×25 Flanging collar Φ8×Φ10×Φ20×7 T Style rubber ring IV Fuel filler cap Rubber pipe Φ7×Φ11×1400 Plug for fuel outlet Binder plate for fuel tank Hook, fuel tank Hexagon flange self-lock nuts M8 Fuel tank support Hexagon flange bolt M8×45...
  • Page 183 CHASSIS Part Name Remarks Triplet joint fuel pipe Clamp High voltage fuel filter Fuel pump plate Hexagon flange nut M6 Seal gasket for fuel pump Shock absorbtion rubber Φ15-6 Plug, fuel inlet Foam sleeve IIΦ10×250 Clip Φ16 Hexagon flange bolt M8×25 Hexagon flange bolt M8×45 Fuel pipe Φ8×Φ14×500 Clip Φ11...

  • Page 184: Charging A Maintenance Free

    Electrical Electrical Basics Component Locations 6-11 Charging a Lead Acid Battery Troubleshoot No Spark 6-12 Charging a Maintenance Free Troubleshoot Starter Motor 6-15 Battery Failure Checking the Fuses Starter Motor Removal 6-16 Electrical Components Troubleshoot the charging 6-17 system, Battery is not Inspection of the Main Switch 6-10 charging...
  • Page 185 Electrical...
  • Page 186 Electrical Whenever performing any type of electrical test it is very important to start off with a known good Battery! Check the charge State of the Battery. It needs to be fully charged. There are 2 types of Batteries commonly used on UTV’s. •...
  • Page 187 Electrical Warnings: Batteries generate explosive gas and contain electrolyte, which is made of sulfuric acid, a highly poisonous and caustic chemical. Whenever working with batteries always follow these preventative measures: • Wear eye protection, Eye shield or safety glasses with side shields. •...
  • Page 188 Electrical...
  • Page 189 Electrical...
  • Page 190 Electrical...

  • Page 191: Electrical Components

    Electrical Electrical Components 1. Thermo switch 2 2. Radiator fan 3. Brake light switch 4. Thermo switch 1 5. Ignition coil 1 6. Gear position switch 7. Reverse switch 8. Speed sensor 9. Ignition coil 2 10. Stator assembly 11. Winch 12.
  • Page 192 Electrical Electrical Components 1. Relay assy. 2. ECU unit 3. Battery 4. Starter relay 5. DC socket 6. Display 7. On-Command four-wheel drive switch and differential gear lock switch 8. Light switch 9. Main switch 10. Rectifier/regulator...

  • Page 193: Inspection Of The Main Switch

    Electrical Inspection of the main switch The terminal connections for switches (main switch, light switch, etc.) are shown Use a pocket tester to check the terminals in a chart similar to the one below. This for continuity. If the continuity is faulty at chart shows the switch positions in the any point, replace the switch.

  • Page 194: Component Locations

    Electrical Component Locations 1. Fuse 2. Brake light switch 3. Main switch 4. On-Command four-wheel drive switch and differential gear lock switch 5. Light switch 6. Parking brake switch 7. Reverse switch 6-11...
  • Page 195 Electrical 6-12...
  • Page 196 Electrical 6-13...
  • Page 197 Electrical 6-14...
  • Page 198 Electrical 6-15...
  • Page 199 Electrical Starter Motor 6-16...
  • Page 200 Electrical Troubleshooting the charging system Condition: Battery is not charging. Check connections and wires from the stator to the regulator to the battery. Connect a multimeter to the leads coming from the stator. (3 White wires). Test for an external short. test in ohms # 1 white wire to ground #2 white wire to ground #3 white wire to ground...

  • Page 201: Ems Introduction, Components

    Engine Management System EMS Introduction, Throttle Body assembly Components Engine coolant temperature Layout sensor, Oxygen sensor Fuel Pump Module Fault Codes 7-12 Multec 3.5 Injectors...
  • Page 202 Engine Management System...
  • Page 203 Engine Management System Introduction EMS (Engine Management System) EMS is a self contained set of components including a custom built computer, sensors, and actuators which control the operation of an engine by monitoring the engine speed, load and temperature. While doing that it also provides the ignition spark at the right time for the prevailing conditions and metering the fuel to the engine in the exact quantity required.

  • Page 204: Layout

    Engine Management System Layout of EMS Components Components of EMS Electronic Control Unit The ECU continuously monitors the operating conditions of the engine through the system sensors. It also provides the necessary computation, adaptability, and output control in order to minimize the tailpipe emissions and fuel consumption, while optimizing vehicle drivability for all operating conditions.

  • Page 205: Multec 3.5 Injectors

    Engine Management System Maintenance service and Repair Multec 3.5 Injectors ECU is a non-serviceable part. Once there The Multec 3.5 Fuel Injector is an are problems, it’s important to first electromechanical device. A magnetic field determine if the problem is caused by is generated as voltage is applied to the software/calibration.
  • Page 206 Engine Management System Installation Relieve fuel pressure. Follow these guidelines to prevent damage Remove the retaining clip from the fuel to the injector and its electrical interface injector. during the replacement or re-installation process. Remove the fuel line connection from the injector.

  • Page 207: Throttle Body Assembly

    Engine Management System Plugging Disconnect the injector-cleaning tank from the system and install the fuel pump Fuel deposits cause plugging. connections. Connect the fuel feed line to injector. Plugging can cause flow restrictions, frictional changes and the collection of Start and idle the vehicle for an additional other particles attracted by the tacky 2 minutes to ensure the residual injector surface.
  • Page 208 Engine Management System Throttle Body Installation Intake Air Pressure and Temperature Sensor Reverse the procedure for installation noting the following: This sensor has two functions. The first is the intake manifold air temperature, it Adjust accelerator cable play. provides a resistance that varies as a function of temperature within prescribed Check to ensure that all removed parts are tolerance limits.
  • Page 209 Engine Management System Keep a Min distance of 150 mm (around Disconnect negative cable at battery. 6”) between coil and any VR sensor DO NOT smoke, and place ‘No device. SMOKING” sign near work area. Never route the coil C- wire with the same Make sure to have fire extinguisher handy.
  • Page 210 Engine Management System Fuel System Diagnosis Step Action Switch on Ignition If fuel pump running If fuel pump running key. Fuel Pump noise can be heard, noise can not be primes for 3 go to step 4. heard, go to step 2. seconds when the ignition key is ON.
  • Page 211 Engine Management System Fuel Module Removal: Fuel Leakage Check Procedure: Relieve fuel pressure in fuel lines referring After performing any service on fuel to the ‘Fuel Pressure Relief Procedure’ system, check to make sure that there are provided in this section. no fuel leaks as below.

  • Page 212: Fault Codes

    Engine Management System EMS FAULT DIAGNOSIS When fault codes are triggered, the odometer's clock will turn into a number， which is a fault code, find out the cause with this number, press clock button then it will turn back to clock mode, and five seconds later, the fault code will show again. Fault Code List 7-12...
  • Page 213 Engine Management System Fault Code List (Con’t) 7-13...

  • Page 214: Principles And Requirements

    Troubleshooting ? ? ? Troubleshooting basics Electrical testing 8-20 Principles and requirements Test equipment 8-22 Special faults Brake system 8-27 Flooded engine Headlight /Taillight 8-30 Engine will not start Lighting system 8-31 Spark test Brake light 8-32 Poor engine performance Reverse indicator 8-36 Fuel system...
  • Page 215 Troubleshooting...
  • Page 216 Troubleshooting Diagnose electrical and Mechanical problems by using a systematic approach and remembering basic operating requirements. Define the Problem Symptoms Determine Which areas could exhibit these symptoms? Test and Analyze The Suspect Areas Verify Data The Problem By following a systematic approach, the possibility of unnecessary parts replacement can be avoided, always start with the simple and most obvious checks when troubleshooting, This would include the engine stop switch, fuel quantity and condition, fuel vale position and spark plug cap tightness.

  • Page 217: Special Faults

    Troubleshooting ENGINE PRINCIPLES AND OPERATING REQUIREMENTS An engine needs three basics to run properly: If any one of the basic requirement is missing the engine will not run. STARTING THE ENGINE When experiencing engine-starting troubles, it is easy to work out of sequence and forget basic starting procedures.
  • Page 218 Troubleshooting Special fault: Idle instability, CH and CO of exhaust gas is out of limits. Reason: Oxygen sensor loosening which causes a slight leakage or slight pipe leakage and makes the oxygen sensor collect too much oxygen ion signal. The wrong signal transmits to the ECU which results in the increasing of the fuel supply.

  • Page 219: Flooded Engine

    Troubleshooting Flooded engine If the engine fails to start after several attempts, it is probably flooded. This occurs when too much fuel is drawn into the engine and the spark plug fails to ignite it. The smell of gasoline is often evident when the engine is flooded. Troubleshoot a flooded engine as follows: 1.

  • Page 220: Spark Test

    Troubleshooting 6. Perform the Spark Test in this section. If there is a strong spark, perform Step 7. If there is no spark or if the spark is very weak, refer to Ignition System Testing in Chapter Ten. 7. If the fuel and ignition systems are working correctly, perform a leak down test and cylinder compression test.

  • Page 221: Poor Engine Performance

    Troubleshooting 6. If there is a strong, blue spark, the ignition system is functioning properly, Check for one or more of the following possible malfunctions: • Faulty fuel system component. • Flooded engine. • engine damage(low compression). 7. If the spark was weak (white or yellow) or if there was no spark, perform the peak voltage checks described under Ignition System Testing.
  • Page 222 Troubleshooting 2. Faulty accelerator pump. 3. Loose exhaust pipe-to-cylinder head connection. 4. Intake air leak. 5. Incorrect ignition timing or a damaged ignition system can cause these conditions. • Perform the Peak Voltage Tests to isolate the damaged ignition system component.
  • Page 223 Troubleshooting Engine Will Not Idle or Idles Roughly 1. Clogged air filter element. 2. Poor fuel filter or fuel hose. 3. Faulty accelerator pump assembly. 4. Contaminated or stale fuel. 5. ECU is not working properly 6. Leaking head gasket. 7.
  • Page 224 Troubleshooting 4. Check for retarded ignition timing. A decrease in power results when the plugs fire later than normal. 5. Check for one or more of the following problems • Low engine compression • Worn spark plug • Fouled spark plug •...

  • Page 225: Fuel System

    Troubleshooting Poor High Speed Performance 1. Check ignition timing. If the ignition timing is correct. Perform Step 2. If the timing is incorrect. Perform the Peak Voltage test. 2. Check the fuel system as described in this chapter. 3. Check the valve clearance as described. Note the following: •...

  • Page 226: Engine Smoke

    Troubleshooting Lean Mixture The following conditions can cause a lean air/fuel mixture: 1. The injector is clogged 2. The pump pressure is not enough 3. ECU program is corrupted 4. ECU damage 5. The pressure sensor, oxygen sensor Engine Smoke The color of engine smoke can help diagnose engine problems or operating conditions.

  • Page 227: Compression

    Troubleshooting Low Engine Compression Problems with the engine top end will affect engine performance. When the engine is suspect, perform the leak down procedure and do a compression test. Interpret the results as described in each procedure to troubleshoot the suspect area. An engine can lose compression through the following areas: 1.
  • Page 228 Troubleshooting Engine Overheating 1. Improper spark plug heat range. 2. Low oil level. 3. Oil not circulating properly. 4. Valves leaking. 5. Heavy carbon deposits in the combustion chamber. 6. Dragging brake(s). 7. Slipping clutch. Preignition Preignition is the premature burning of fuel and is caused by hot spots in the combustion chamber.

  • Page 229: Engine Lubrication

    Troubleshooting • Rapid on-off squeal—Compression leak around cylinder head gasket or spark plug(s). • Valve train noise—Check for the following: 1. Excessive valve clearance. 2. Worn or damaged camshaft. 3. Damaged camshaft. 4. Worn or damaged valve train components. 5. The valve hose hole is damaged 6.

  • Page 230: Cylinder Leak Down Test

    Troubleshooting No Oil Pressure 1. Low oil level. 2. The lubrication oil pressure valve is stuck and closed. 3. Damaged oil pump. 4. Incorrect oil pump installation. 5. Internal oil leak. Oil Level Too Low 1. The lubrication oil does not keep at the normal level. 2.
  • Page 231 Troubleshooting 1. Support the UTV on a work stand with the rear wheels off the ground. 2. Remove the air filter assembly Open and secure the throttle so it is at its in the wide-open position. 3. Remove the spark plug. 4.
  • Page 232 Troubleshooting c. Check that the TDC marks are still aligned as described in Step7, If not, turn the crankshaft as required, then relock the holding tool in position. 9. Perform a cylinder leak down test by applying air pressure to the combustion chamber.

  • Page 233: Electrical Testing

    Troubleshooting ELECTRICAL TESTING This section describes basic electrical testing and test equipment use. Preliminary Checks and Precautions Refer to the color wiring diagrams at the end of the manual for component and connector identification; Use the wiring diagrams to determine how the circuit should work by tracing the current paths from the power source through the circuit components to ground.
  • Page 234 Troubleshooting 1. Vibration---This is a common problem with loose or damaged electrical connectors a. Perform a continuity test as described in the appropriate service procedure. Or under Continuity Test in this section b. Lightly pull or wiggle the connectors while repeating the test. Do the same when checking the wiring harness and individual components.

  • Page 235: Test Equipment

    Troubleshooting Electrical component replacement Most UTV dealerships and parts suppliers will not accept the return of any electrical part, if you cannot determine the exact cause of any electrical system malfunction. If you purchase a new electrical component(s), install it, and then find that the system still does not work properly, you will probably be unable to return the unit for a refund.
  • Page 236 Troubleshooting crossed, the needle should move to the other end of the scale indicating infinite resistance. During a continuity test, a reading of infinity indicates that there is an open in the circuit or component. A reading of zero indicates continuity, that is, there is no measurable resistance.
  • Page 237 Troubleshooting Test Procedures Unless otherwise specified. Make all voltage tests with the electrical connectors still connected. Insert the test leads into the backside of the connector and make sure the test lead touches the electrical wire or metal terminal within the connector housing. If the test lead only touches the wire insulation, there will be a false reading.
  • Page 238 Troubleshooting Note the following: • The voltmeter should indicate 0 volts. If there is a drop of 0.5 volts or more. There is a problem within the circuit. A voltage drop reading of 12 volts indicates an open in the circuit. •...
  • Page 239 Troubleshooting Testing for a short with a self-powered test light or ohmmeter 1. Disconnect the negative battery cable. 2. Remove the blown fuse. 3. Connect one test lead of the test light or ohmmeter to the load side (battery side) of the fuse terminal in the starter relay.

  • Page 240: Brake System

    Troubleshooting BRAKE SYSTEM The front and rear brake units are critical to the performance and safety of the UTV and passengers. Inspect the front and rear brakes frequently and repair any problem immediately. When replacing or refilling the brake fluid, use only DOT 4 brake fluid from a closed container.
  • Page 241 Troubleshooting Brake Drag When the brakes drag, the brake pads are not capable of moving away from the brake disc when the brake lever or pedal is released. Any of the following causes, if they occur, would prevent correct brake pad movement and cause brake drag. 1.
  • Page 242 Troubleshooting Brake Squeal or Chatter 1. Contaminated brake pads and disc. 2. Incorrectly installed brake caliper. 3. Warped brake disc. 4. Incorrect wheel alignment. 5. Mismatched brake pads. 6. Incorrectly installed brake pads. 7. Damaged or missing brake pad spring or pad retainer. Leaking Brake Caliper 1.
  • Page 243 Troubleshooting 8-30...
  • Page 244 Troubleshooting 8-31...

  • Page 245: Brake Light

    Troubleshooting If the Brake light, indicator light, or the warning light fails to come on: 8-32...
  • Page 246 Troubleshooting 8-33...
  • Page 247 Troubleshooting 8-34...
  • Page 248 Troubleshooting 8-35...
  • Page 249 Troubleshooting 8-36...
  • Page 250 Troubleshooting 8-37...
  • Page 251 Troubleshooting 8-38...
  • Page 252 Troubleshooting 8-39...
  • Page 253 Troubleshooting 8-40...
  • Page 254 Troubleshooting 8-41...
  • Page 255 Troubleshooting 8-42...
  • Page 256 Troubleshooting 8-43...
  • Page 257 Troubleshooting TROUBLESHOOTING 1. Check if the 2/4WD switch is working. • Turn on the switch, put the gear to position N; keep front and rear wheel off the ground , and then roll the front wheel to see if the rear wheel is moving together with it or if it is rotatable.
  • Page 258 Troubleshooting Note: This section is not all inclusive, it is meant as a troubleshooting guide. Please refer to the relevant sections of this manual for inspection, adjustment or replacement of components. Fuel System Fuel tank 1. No Fuel 2. Fuel filter is clogged 3.
  • Page 259 Troubleshooting Starter Motor 1. Faulty Starter motor 2. Faulty Starter relay 3. Faulty overrunning clutch in engine 4. Broken main switch 5. Broken main fuse Battery 1. Low Battery voltage 2. Bad Battery (Dead cell) Faulty gear shifting Shift Drum, Shift Forks 1.
  • Page 263 HISUN MOTORS 1434 Patton Place Suite 106 Carrollton, Texas 75007 (972) 446-0760 (877) 838-6188 www.hisunmotors.com...

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