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Manuals
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Hisun Manuals
Utility Vehicle
HS500UTV
Service manual
Hisun HS500UTV Service Manual
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Also See for HS500UTV
:
Owner's manual
(173 pages)
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Contents
General Information
Description
Identification Code
Safety
Handling Gasoline Safety
Cleaning Parts
Warning Labels
Serial Numbers, Fasteners
Trorque Specifications
Washers
Cotter Pins
Snap Rings and E-Clips
Shop Supplies
Lubricants and Fluids
Engine Oils
Greases
Brake Fluid
Coolant
Cleaners, Degreasers and Solvents
Gasket Sealant
Gasket Remover
Thread Locking Compound
Basic Tools
Screwdrivers
Wrenches, Adjustable Wrenches
Socket Wrenches, Ratchets and Handles
Impact Drivers
Allen Wrenches
Torque Wrenches
Torque Adapters
Pliers, Snap Ring Pliers
Precision Measuring Tools
Hammers
Ignition Grounding Tool
Feeler Gauge
Calipers
Micrometers
Micrometers Adjustment, Care
Metric Micrometer
Standard Inch Micrometer
Telescoping and Small Bore Gauges
Dial Indicator
Compression Gauge
Multimeter
Electrical System Fundamentals
Voltage
Resistance
Amperage
Basic Service Methods
Removing Frozen Fasteners
Removing Broken Fasteners
Repairing Damaged Threads
Stud Removal/Installation
Removing Hoses
Bearings Removal
Bearings Installation
Interface Fit
Seal Replacement
Storage Area Selection
Preparing the Motorcycle for Storage
Returning the UTV to Service
Troubleshooting
Engine Principles and Operating Requirements
Starting the Engine
Engine Is Cold/War
Starting the Engine after a Fall or after the Engine Stalls
Flooded Engine
Engine Cold with Air Temperature between 10-35C/Above 35C/Below 10C
Engine Is Hot
Engine will Not Start
Spark Test
Poor Engine Performance
Starter Does Not Turn over or Turns over Slowly
Engine Starts but Stalls and Is Hard to Restart
Engine Backfires, Cuts out or Misfires During Acceleration
Engine Backfires on Deceleration
Poor Fuel Mileage
Engine will Not Idle or Idles Roughly
Low Engine Power
Poor Idle or Low Speed Performance
Fuel System
Rich Mixture
Poor High Speed Performance
Engine Smoke
Lean Mixture
Engine Overheating (Cooling System)
Low/High Engine Compression
Engine Overheating (Engine)
Preignition, Detonation
Power Loss
Engine Noises
Engine Lubrication
High Oil Consumption or Excessive
Cylinder Leak down Test
High Oil Pressure, no Oil Pressure
Oil Level too Low
Oil Contamination
Electrical Testing
Preliminary Checks and Precautions
Intermittent Problems
Electrical Component Replacement
Test Equipment
Ammeter
Self-Powered Test Light
Ohmmeter
Jumper Wire
Test Procedures
Voltage Test, Voltage Drop Test
Peak Voltage Test
Continuity Test
Testing for a Short with a Self-Powered Test Light of Ohmmeter
Brake System
Testing for a Short with a Test Light or Voltmeter
Soft or Sponge Brake Lever or Pedal
Brake Drag
Hard Brake Lever or Pedal Operation
Brake Grabs
Brake Squeal or Chatter
Leaking Brake Caliper
Specifications
How to Conversion Table of Unit
Definition of Unit
Geberar Specifications
Engine Specifications
Chassis Specifications
Electrical Specifications
Engine Tightening Torques
Chassis Tightening Torques
General Tightening Torque Specifications
Lubrication Points and Lubricant Types: Engine
Hydrographic Chart
Lubrication Oil Way
Maintenance and Adjustment of the UTV
Maintenance Schedule
Engine
Idle Adjustment
Adjusting the Throttle Cable
Adjusting the Starter Cable
Checking the Spark Plug
Checking the Ignition Timing
Measuring the Compression Pressure
Checking the Engine Oil Level
Changing the Engine Oil
Chassis
Cleaning the Air Filter
Checking the Coolant Level
Changing the Coolant
Checking the Coolant Temperature
Warning Light
Coolant Temperature Warning Light Checking Method
Checking the V-Belt
Cleaning the Spark Arrester
Adjusting the Brake Pedal
Adjusting the Parking Brake
Checking the Brake Fluid Level
Checking the Front Brake Pads
Checking the Rear Brake Pads
Checking the Brake Hoses and Brake Pipes
Bleeding the Hydraulic Brake System
Adjusting the Select Lever Shift Rod
Adjusting the Brake Light Switch
Checking the Final Gear Oil Level
Changing the Final Gear Oil
Checking/Changing the Differential Gear Oil
Checking the Constant Velocity Joint Dust Boots
Checking the Steering System
Adjusting the Toe-In
Adjusting the Front/Rear Shock Absorbers
Checking the Tires
Checking the Wheels
Checking and Lubricating the Cables
Checking and Charging the Battery
Charging Method Using a Constant Voltage Charger
Checking the Fuses
Adjusting the Headlight Beam
Changing the Headlight Bulb
Changing the Tail/Brake Light Bulb
Engine Note
Engine Removal
Cylinder Head and Cylinder Head Cover
Engine Check
Rocker Arms and Camshaft
Checking the Rocker Arms
Installing the Rocker Arms
Valves and Valve Springs
Valves and Valve Springs Check, Measure
Valves and Valve Springs Install
Cylinder and Piston
Cylinder and Piston Check, Measure
Cylinder and Piston - Install
Engine Cooling Fan and A.C. Magneto
Engine Cooling Fan and A.C. Magneto Check
Engine Cooling Fan and A.C. Magneto Install
Balancer Gears and Oil Pump Gears
Balancer Gears and Oil Pump Check
Balancer Gears and Oil Pump Install
Primary and Secondary Sheaves
Primary Sheave
Secondary Sheave
Primary/Secondary Sheave Check
Primary/Secondary Sheave Measure, Install
Clutch
Clutch Check, Measure
Clutch Install
Crankcase
Starter Motor and Oil Filter
Crankcase Overview
Crankcase Bearings
Crankcase Check
Crankcase Install
Crankshaft and Oil Pump
Oil Pump
Crankshaft and Oil Pump Check, Measure
Crankshaft Install
Transmission
Drive Axle Assembly
Drive Axle Check
Drive Axle Install
Middle Gear
Middle Drive Shaft
Middle Driven Shaft
Middle Drive Shaft Check, Measure
Middle Drive Shaft Install
Carburetor
Carburetor Check
Carburetor Measure
Carburetor Install
Malfunction Inspection
Direction System
The Structure of the Steering
The Structure of Steering Wheel Part
Disassembling the Parts of the Steering Wheel
Checking the Parts of the Steering Wheel
Disassembling the Steering Column Parts
Checking and Service the Steering Column Parts
Steering Drive Axle
Checking and Service the Steering Drive Axle
Steering Machine Parts
Disassembling the Steering Machine Part
Reinstalls the Steering System Parts
Preparation for Checking before the Maintenance of the Brake System
Front Disk Brake Components
Front Brake Discs
Checking the Front Brake Disc
Front Brake Pads
Replacing the Front Brake Pads
Front Brake Caliper
Disassembling the Front Brake Calipers
Assembling/Installing the Front Brake Calipers
Rear Brake Disc
Checking the Rear Brake Disc
Rear Brake Caliper and Brake Pads
Replacing the Rear Brake Pads
Disassembling the Rear Brake Caliper
Assembling the Rear Brake Caliper
Installing the Rear Brake Caliper
Brake Master Cylinder
Checking the Master Cylinder
Assembling/Installing the Brake Master Cylinder
Footrest Assembly
Wheel and Tyre Parts
Front Wheels
Rear Wheels
Checking the Wheel Tyre
Checking/Installing the Wheel Hub
Installing the Wheel Tyre
Specification of Wheel and Tyre
Transmission System
Front Bridge
Disassembling the Front Bridge
Disassembling the Universal Joint
Removing the Differential Gear Assembly
Checking the Joints
Checking the Differential Gear
Checking the Gear Motor
Assembling the Universal Joint
Adjusting the Differential Gear Lash
Assembling the Differential Gear
Installing the Front Bridge Parts
Rear Bridge
Reverse Mechanism Parts
Adjusting Reverse Mechanism Parts
Checking and Service of Reverse Mechanism
Suspension
Front Suspension and Arm
Disassembling, Service and Assembly the Supporting Rocker Parts
Checking the Front Arms
Checking the Front Shock Absorber
Installing the Front Arms and Front Shock Absorber
Rear Suspension
Rear Arm Shaft
Rear Suspension and Arm
Checking and Service of Rear Suspension
Checking the Stabilizer
Checking the Rear Arms
Checking the Rear Shock Absorber
Installing the Rear Arms and Rear Shock Absorber
Cooling System
Radiator
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See also:
Owner's Manual
Table of
Contents
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Table of Contents
Troubleshooting
Troubleshooting
48
Electrical Components Troubleshooting
317
Electric Starting System: Troubleshooting
322
Charging System: Troubleshooting
329
Lighting System Troubleshooting
332
Signaling System: Troubleshooting
336
Cooling System Troubleshooting
348
2WD/4WD Selecting System: Troubleshooting
352
Troubleshooting The Product
356
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This manual is also suitable for:
Hs600utv
Hs700utv
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