Hisun HS500UTV Owner's Manual
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Hisun HS500UTV Owner's Manual

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Summary of Contents for Hisun HS500UTV

  • Page 2 Owner Manual...
  • Page 3 Owner Manual INTRODUCTION Congratulations on your purchase of the HS500UTV. This Owner’s / Operator’s manual will provide you information regarding safe operation, operational instructions, maintenance and care. Fully understanding this manual and following all of the instructions herein will provide the knowledge needed to have safe and enjoyable UTV operation.

  • Page 4: Important Manual Information

    Owner Manual IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY Particularly important information is distinguished in this manual by the following OR DEATH. notations: The Safety Alert Symbol means ATTENTION! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the machine operator, bystander or a person inspecting or repairing the machine.

  • Page 5: Important Notice

    Owner Manual IMPORTANT NOTICE This UTV is designed and manufactured for OFF - ROAD use only. It is illegal and unsafe to operate this UTV on any public street, road or highway. This UTV complies with all applicable OFF - ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture.

  • Page 6: Table Of Contents

    Owner Manual Location of the Warning and Fuel meter Specification Labels Switches Accelerator Pedal 4-13 Safety Information Brake Pedal 4-14 Parking Brake Lever 4-14 Description and Vehicle Drive Select Lever 4-15 Identification Fuel Tank Cap 4-15 Identification Number Records Vehicle Identification Number Seats 4-16 Seat Belts...
  • Page 7 Owner Manual Brakes Tires 5-11 Brake Fluid Level How to Measure Tire Pressure 5-12 Brake Fluid Leakage Tire Wear Limit 5-13 Brake Operation Operation Fuel Starting the Engine in Low Gasohol Temperatures Engine Oil Starting the Engine Coolant Warming Up Final Gear Oil Drive Select Lever Operation and Differential Gear Oil...
  • Page 8 Owner Manual Getting to Know Your Vehicle Engine Oil and Oil Filter Cartridge Learning to Operate Your Vehicle To Check the Engine Oil Level Turning your Vehicle To Change the Engine Oil 8-10 Braking Final Gear Oil 8-13 Going Uphill Changing the Final Gear Oil 8-15 Going Downhill...
  • Page 9 Owner Manual Checking the Brake Fluid Level 8-31 Tail/brake Light Bulb Replacement 8-47 Brake Fluid Replacement 8-32 Troubleshooting 8-49 Checking the Brake Pedal 8-32 Solution to Common Problems in Parking Brake Lever Free Play the Vehicle 8-50 Adjustment 8-33 Cleaning and Storage Brake Light Switch Adjustment 8-35 Cleaning...

  • Page 10: Location Of The Warning And

    Location of the Warning and Safety Labels...
  • Page 11 Location of the Warning and Safety Labels Read and understand all of the labels on your vehicle. They contain important information for safe and proper operation of your vehicle. Never remove any labels from your vehicle. If a label becomes difficult to read or comes off, a replacement label is available by contacting your dealer.
  • Page 12 Location of the Warning and Safety Labels...
  • Page 13 Location of the Warning and Safety Labels...
  • Page 14 Location of the Warning and Safety Labels...
  • Page 15 Location of the Warning and Safety Labels...
  • Page 16 Location of the Warning and Safety Labels...
  • Page 17 Safety Information SAFETY INFORMATION This off-highway utility vehicle handles differently from other vehicles including cars and UTVs. SEVERE INJURY OR DEATH can result if you do not follow these instructions: Read this manual and all labels carefully and follow the operating procedures described. ●...

  • Page 18: Safety Information

    Safety Information 2-2 Never attempt jumps or other stunts. ● Always inspect your vehicle each time you use it to be sure it is in safe operating condition, Always ● follow the inspection and maintenance procedures and schedules described in this manual. Always keep hands, arms, feet, and legs inside the vehicle at all times during operation.
  • Page 19 Safety Information Never operate on hills that are slippery or ones where you will not be able to see far enough ahead of ● you. Never go over the top of a hill at speed if you cannot see what is on other side. Always follow proper procedures for going uphill.
  • Page 20 Safety Information 2-4 WARNING POTENTIAL HAZARD Improper handling of gasoline. WHAT CAN HAPPEN Gasoline can catch fire and you could be burned. HOW TO AVOID THE HAZARD Always turn off the engine when refueling. Do not refuel right after the engine has been running and is still very hot.
  • Page 21 Safety Information WARNING POTENTIAL HAZARD Starting or running the engine in a closed area. WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. HOW TO AVOID THE HAZARD Always operate your vehicle in an area with adequate ventilation.
  • Page 22 Description and Vehicle Identification Headlights Spark arrester Front shock absorber assembly adjusting ring Passenger seat belt Brake fluid reservoir Passenger seat Air filter element(engine and air intake duct) Oil filter cartridge V-belt case Engine oil dipstick Driver seat Battery Driver seat belt Fuses Spark plug Coolant reservoir...
  • Page 23 Description and Vehicle Identification Light switch Steering wheel Starter (choke) Main switch On-Command four-wheel-drive and differential lock switches Multi-function meter unit Auxiliary DC jack Drive select lever Parking brake lever Accelerator pedal Brake pedal NOTE: The vehicle you have purchased may differ slightly from those in the figures of this manual.

  • Page 24: Description And Vehicle Identification

    Description and Vehicle Identification Identification Number Records Record the Vehicle Identification Number and Vehicle Identification Number model label information in spaces provided for The Vehicle Identification Number (VIN) is assistance when ordering spare parts from a stamped into the frame. service center or for reference in case the vehicle is stolen.

  • Page 25: Control Functions

    Control Functions Functions of the respective switch positions CONTROL FUNCTIONS are as follows: All electrical circuits are supplied with power, Main switch and the headlights and taillights illuminate when the light switch is on. OFF: All electrical circuits are switched off. The key can be removed in this position.

  • Page 26: Indicator And Warning Lights

    Control Functions Indicator and warning lights CAUTION: Do not operate the electric starter ● continuously for more than 5 seconds at a time or starter damage could occur. Wait at least 5 seconds between each start attempt. Do not turn the key to the “START” ●...
  • Page 27 Control Functions 12. Far light indicator select lever is in the “L” position. On-Command Differential Gear Lock Indicator Light High-range indicator light “H” This indicator light comes on when the drive This indicator light and the On-Command differential gear lock indicator in the display select lever is in the “H”...
  • Page 28 Control Functions NOTE: On-Command differential gear lock switch is If the indicator light flashes under any other set to the “LOCK” position. circumstances or the speedometer does not NOTE: show the speed while riding, have a service Due to the synchronizing mechanism in the center check the speed sensor circuit.

  • Page 29: Use Of Eps System

    Control Functions minutes. and fault indicator of EPS system, so the driver can acknowledge fault of EPS in time CAUTION: take some measures keep The engine may overheat if the vehicle is himself/herself safe. overloaded. If this happens, reduce the When fault occurs on EPS system, fault load to recommended specification.

  • Page 30: Multi-Function Display Gauge

    Control Functions 2. Clock/Hour/ fault code meter If fault indicator light of EPS system is lit, 3. Tachometer 4. Metric/mile button that means EPS system find out some 5. “TRIP/ODO” button fault during ECU self-checking process, 6. Right turn indicator 7.

  • Page 31: Clock Mode

    Control Functions Clock Mode Fault Codes Display of the Electronic Injection System Pushing the button switches the display between the clock mode “CLOCK” When faults occur, the meter will display the and the hour meter mode “HOUR” in the fault codes to guide the repair. following order: CLOCK→HOUR→CLOCK See attachment for faults code（page 11-1）...

  • Page 32: Switches

    Control Functions Switches 1. Fuel level warning indicator 2. Fuel meter 1. Light switch “OFF/ ” Light switch “OFF/ ” Set the switch to “ ”to turn on the low beam and the taillights. Set the switch to “ ”to turn on the high beam and the taillights.
  • Page 33 Control Functions On-Command Four-Wheel–Drive and CAUTION: Differential Gear Lock Switches Do not use the headlights with the engine turned off for an extended period of time. The battery may discharge to the point that the starter motor will not operate properly. If this happens, remove the battery and recharge it.
  • Page 34 Control Functions 4-10 conditions. Two-wheel drive (”2WD”): Power is sup- WARNING plied to the rear wheels only. POTENTIAL HAZARD Changing from 2WD to 4WD or from 2WD Four-wheel drive (“4WD’): Power is to 2WD-Differential UNLOCK, or supplied to the rear and front wheels. vice-versa while the vehicle is moving.
  • Page 35 4-11 Control Functions the select lever is set to position , and On-Command four-wheel-drive switch then set the switch to “2WD”. “2WD/4WD” On-Command Differential Gear Lock Switch “4WD”/”LOCK” Select lever On-Command four –wheel-drive switch “2WD/4WD” To change from 2WD to 4WD ,stop the vehicle, and then set the switch to On-Command differential gear lock switch “4WD”/ “LOCK”...
  • Page 36 Control Functions 4-12 set the switch to “LOCK”. When the differential gear is locked, the differential HOW TO AVOID THE HAZARD gear lock indicator light will come on along Always ride at a slow speed when the with the differential gear lock indicatorin the vehicle is in 4WD-LOCK, and allow extra multifunction meter unit display .To release time and distance for maneuvers.

  • Page 37: Accelerator Pedal

    4-13 Control Functions will cause the engine speed to be limited until engagement is complete. Accelerator pedal Press the accelerator pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check that the accelerator pedal returns normally before staring the engine.

  • Page 38: Brake Pedal

    Control Functions 4-14 Brake pedal Press the brake pedal to slow or stop the vehicle. WARNING POTENTIAL HAZARD Malfunction of the accelerator pedal. WHAT CAN HAPPEN A faulty pedal that makes it difficult to speed up or slow down could cause loss of control.

  • Page 39: Drive Select Lever

    4-15 Control Functions lever, press the release button, and then Drive select lever push the lever all the way down. Spring The drive select lever is used to shift you pressure helps return the lever to the vehicle into the low, high, neutral and reverse released position.

  • Page 40: Fuel Tank Cap

    Control Functions 4-16 Fuel tank cap Seats Remove the fuel tank cap by turning it To remove a seat, pull its seat lock lever counterclockwise. upward, lift the front of the seat, and then slide the seat forward and up. 1.

  • Page 41: Seat Belts

    4-17 Control Functions To install a seat, insert the projection on the rear of the seat into the seat holders and push down on the seat at the front. WARNING POTENTIAL HAZARD A loose seat. WHAT CAN HAPPEN The operator could lose control or the operator or passenger could fall if the seat is loose during operation.
  • Page 42 Control Functions 4-18 2. Push the latch plate into the buckle until it clicks. Pull up on the latch plate to make sure it is secure. 1. Seat belt (×2) 2. Latch plate (×2) 3. Buckle (×2) To wear the seat belt properly, do the 1.
  • Page 43 4-19 Control Functions shoulder belt should fit against your chest. If it is loose, pull the belt out all the WARNING way and then let it retract. POTENTIAL HAZARD 5. To release the buckle, firmly press the Not wearing the seat belt or wearing the release button.

  • Page 44: Glove Compartment

    Control Functions 4-20 Glove compartment Cargo bed CAUTION: To protect from damage, do not put metal products, like tools or sharply edged products directly in the glove compartment. If they must be stored, wrap them in appropriate cushion material. 1. Cargo bed 2.

  • Page 45: Opening And Closing The Tailgate

    4-21 Control Functions Opening and closing the tailgate Lifting and lowering the cargo bed 1. Tailgate 2. Latch (×2) 1. Cargo bed release lever To lift To open Push down cargo bed release lever on left or Unhook the latches, and then lower the right side of the vehicle;...
  • Page 46 Control Functions 4-22 WARNING WARNING POTENTIAL HAZARD POTENTIAL HAZARD Overloading the cargo bed Pinch points. WHAT CAN HAPPEN WHAT CAN HAPPEN Could cause changes in vehicle handling You or someone else could be pinched which could lead to an accident. between the cargo bed and the frame HOW TO AVOID THE HAZARD when the bed is being lowered.

  • Page 47: Front And Rear Shock Absorber Adjustment

    4-23 Control Functions Front and rear shock absorber adjustment The spring preload can be adjusted to suit WARNING the operating conditions. POTENTIAL HAZARD You can reduce preload for a softer ride, or Carrying a passenger in the cargo bed increase preload if frequent bottoming out of WHAT CAN HAPPEN the UTV occurs.
  • Page 48 Control Functions 4-24 Standard position: B A-Minimum(soft) E-Maximum(hard) 1. Spring preload adjusting ring 2. Position indicator NOTE: A special wrench can be obtained at a service center to make this adjustment. 1. Special wrench...

  • Page 49: Trailer Hitch Bracket

    4-25 Control Functions Trailer hitch bracket This vehicle is equipped with a 1 ¼ in WARNING receiver bracket for a standard trailer hitch. POTENTIAL HAZARD Trailer towing equipment can be obtained at Improper shock absorber adjustment. a service center. (See pages 6-12 - 6-14 for WHAT CAN HAPPEN precaution information.) Uneven adjustment can cause poor...

  • Page 50: Auxiliary Dc Jack

    Control Functions 4-26 jack. Auxiliary DC jack The auxiliary DC jack is located at the right side of the front panel. The auxiliary DC jack can be used for suitable work lights, radios, etc. The auxiliary DC jack should only be used when the engine is running.
  • Page 51 4-27 Control Functions 4. When the auxiliary DC jack is not being used, cover it with the cap. CAUTION: Do not use accessories requiring more than the above maximum capacity. This may overload the circuit and cause the fuse to blow. If accessories are used without the engine running or with the headlights turned on, the battery will lose its charge...
  • Page 52 Pre Operation Checks Before using this vehicle, check the following items: ITEM ROUTINE PAGE Check operation, free play, fluid level and fluid leakage ● Brakes 5-2 - 5-3， 8-32 Fill with DOT 4 brake fluid if necessary ● Check for proper operation, condition and free play Parking brake ●...

  • Page 53: Pre Operation Checks

    Pre Operation Checks WARNING Brakes Check for correct brake pedal free play. If the POTENTIAL HAZARD brake pedal free play is incorrect, have a Failure to inspect the vehicle before service center adjust it. (See pages 8-34 - operating. Failure to properly maintain the 8-35.) vehicle.

  • Page 54: Brake Fluid Leakage

    Pre Operation Checks Brake fluid leakage Check to see if any brake fluid is leaking out of WARNING the pipe joints or the brake fluid reservoir. Apply POTENTIAL HAZARD the brakes firmly for one minute. If there is any Driving with improperly operating brakes. leakage, have the vehicle inspected by a WHAT CAN HAPPEN service center.

  • Page 55: Fuel

    Pre Operation Checks Fuel Your engine has been designed to use regular Make sure there is sufficient gasoline in the unleaded gasoline with a pump octane number tank. ([R+M] /2) of 91 or higher, or research octane number of 91 or higher. If knocking or pinging Recommended fuel: occurs, use a different brand of gasoline or Unleaded gasoline only...

  • Page 56: Engine Oil

    Pre Operation Checks Engine oil Make sure the engine oil is at the specified level. WARNING Add oil as necessary. (See pages 8-10) POTENTIAL HAZARD Improper care when refueling. CAUTION: WHAT CAN HAPPEN In order to prevent clutch slippage Fuel can spill, which can cause a fire and (since the engine oil also lubricates the severe injury.

  • Page 57: Coolant

    Pre Operation Checks CAUTION: Recommended engine oil type and Hard water or salt water is harmful to the engine. quantity: You may use soft water if you cannot get See page 10-2 distilled water. Coolant Coolant reservoir capacity Check the coolant level in the coolant reservoir (up to the maximum level mark): when the engine is cold.

  • Page 58: Final Gear Oil

    Pre Operation Checks Final gear oil Make sure the final gear oil is at the specified WARNING level. Add oil as necessary. (See pages 8-14 - POTENTIAL HAZARD 8-15 for details) Removing the radiator cap when the engine and radiator are still hot. Recommended oil: WHAT CAN HAPPEN SAE 80 API GL-4 Hypoid gear oil...

  • Page 59: Throttle Pedal

    Pre Operation Checks WARNING Recommended oil: Failure to check or maintain proper SAE 80 API GL-5 Hypoid gear oil operation of the throttle system can result in an accident and lead to serious injury or Throttle Pedal death if the throttle pedal sticks during Check to see that the accelerator pedal operation.

  • Page 60: Throttle Freeplay

    Pre Operation Checks Throttle Freeplay Throttle Freeplay Adjustment 1. Remove both seats. Remove the middle If the throttle pedal has excessive play due to cover of the engine. (see PAGE 8-9 ) cable stretch or mis-adjustment, it will cause a 2.

  • Page 61: Steering Wheel Inspection

    5-10 Pre Operation Checks 4. Resume the center cover and seat to their when pulled out and retract on its own when position released. The latch plate should click securely into the buckle and release when the release Steering Wheel Inspection button is pushed firmly.

  • Page 62: Switches

    Pre Operation Checks 5-11 as necessary for proper operation. Tires WARNING POTENTIAL HAZARD Switches Operating this vehicle with improper tires, Check the operation of all switches. Have a or with improper or uneven tire pressure. service center repair as necessary for proper WHAT CAN HAPPEN operation.

  • Page 63: How To Measure Tire Pressure

    5-12 Pre Operation Checks 3. The tires should be set to the 5. Use no more than the following pressures recommended pressure: when seating the tire beads. Front 10psi (70kpa, 0.7 kgf/cm Front 36psi (250kpa, 2.5kgf/cm Rear 10psi (70kpa, 0.7 kgf/cm Rear 36psi (250kpa, 2.5kgf/cm Check and adjust tire pressures when the Higher pressures may cause the tire to burst.

  • Page 64: Tire Wear Limit

    Pre Operation Checks 5-13 Set pressure with tires cold. Set tire pressures Tire wear limit to the following specifications: When the tire groove decreases to 0.12 in (3 Recommended mm) due to wear, replace the tire. Minimum Maximum Pressure 10psi (70kpa 9 psi (63kpa, 11 psi, (77kpa, Front...

  • Page 65: Operation

    Operation WARNING WARNING POTENTIAL HAZARD POTENTIAL HAZARD Operating vehicle without being familiar Freezing control cables due to cold with all controls. weather conditions. WHAT CAN HAPPEN WHAT CAN HAPPEN Loss of control, which could cause an Loss of vehicle control, which could accident or injury.

  • Page 66: Starting The Engine

    Operation service center to inspect the electric Starting the Engine circuit. The engine can be started in any gear if CAUTION: ● the brake is applied. However, it is See the “Engine Break-In”section prior to operating the engine for the first time. recommended to shift into neutral ”N”...

  • Page 67: Warming Up

    Operation Continue warming up the engine until it idles smoothly before riding. 2500RPM to charge the battery for 5-10 minutes; when the voltage of battery is over 12V, the idle speed will be normal. If the WARNING idle speed is still high, please contact your POTENTIAL HAZARD service center.

  • Page 68: Drive Select Lever Operation And Driving In Reverse

    Operation Otherwise, go on with the third step. 1. Stop the vehicle. Keep your foot off the 3. Continue warming up the engine until it accelerator pedal. idles smoothly. 2. Apply the brakes, and then shift by CAUTION: moving the drive select lever along the See the “Engine break-in”...
  • Page 69 Operation the shift guide. NOTE: Please kick the brake pedal first, before place ● gearshifts lever to“reverse”position. In the brake pedal, there is a cable, which is ● connected to a position pin located on the gearshift assembly. Only when the brake pedal is depressed, the position pin will be retracked, and gearshifts can be removed to “reverse”...
  • Page 70 Operation until the vehicle starts moving. 4. Check behind for people or obstacles, and then release the brake pedal. 5. Press the accelerator pedal gradually and continue to watch to the rear while backing up. 1. Drive select lever NOTE: When in reverse, the reverse indicator ●...
  • Page 71 Operation WARNING WARNING POTENTIAL HAZARD POTENTIAL HAZARD Parking on a hill or other incline. Improperly operating in reverse. WHAT CAN HAPPEN WHAT CAN HAPPEN The vehicle could roll out of control, You could hit an obstacle or person increasing the chance of an accident. behind you, resulting in serious injury.

  • Page 72: Parking

    Operation Parking Parking on a Slope a) When parking, stop the engine and shift the drive select lever into the neutral position. b) Push the brake pedal down, and pull the parking brake to top position to park the vehicle 1.

  • Page 73: Vehicle Break-In Period

    Operation Vehicle Break-in Period The break-in period for your new UTV vehicle is the first 25 hours of operation, or the time it takes to use the first three tanks full of gasoline. No single action on your part is as important as a proper break-in period. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these...

  • Page 74: Engine Break-In

    Operation 6-10 momentary (2-3 seconds maximum) full of use. Use of any engine oil not mentioned in throttle operation under load does not harm ● this manual will cause severe damage to the engine. the engine. Each full throttle acceleration sequence should be followed with a substantial rest period for the engine by cruising at lower Engine Break-In...

  • Page 75: Accessories

    6-11 Operation 10-25 Hours: performance. Break in the clutches and belt Avoid prolonged operation above 3/4 throttle. by operating at slower speeds during the Rev the vehicle freely but do not use full break-in period as recommended. Pull only throttle at any time. light loads.

  • Page 76: Loading

    Operation 6-12 test all nonstandard accessories, nor with accessories. The vehicle may have any control over the quality or handle differently than it does without suitability of them. Choose a genuine accessories. accessory, or one that is equivalent in design and quality. Loading Accessories should be rigidly and Cargo or a trailer can change the stability...
  • Page 77 6-13 Operation with a bathroom scale. Put the tongue of the loaded trailer on the scale with the MAXIMUM LOADING LIMIT tongue at hitch height. Adjust the load in Vehicle loading limit (total weight of ● cargo, operator, passenger and the trailer, if necessary, to reduce the accessories, and tongue weight): weight on hitch.
  • Page 78 Operation 6-14 Make sure cargo in the trailer cannot Avoid hills and rough terrain. Choose ● move around. A shifting load can cause terrain carefully. Added weight affects the an accident. stability and handling of the vehicle. Make sure the load does not interfere ●...
  • Page 79 6-15 Operation WARNING POTENTIAL HAZARD Overloading this vehicle or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this vehicle.

  • Page 80: Driving Your Vehicle

    Your Vehicle DRIVING YOUR VEHICLE WARNING GETTING TO KNOW YOUR VEHICLE POTENTIAL HAZARD This off-highway utility vehicle will handle Not wearing the seat belt. and maneuver differently form an ordinary Wearing the seat belt improperly. passenger car or other vehicle. WHAT CAN HAPPEN Before you begin to use your vehicle, be sure There is increased risk of being killed or...
  • Page 81 Your Vehicle WARNING The total weight of operator, passenger, accessories, cargo, trailer tongue weight, POTENTIAL HAZARD and the vehicle itself must not exceed 1,880 Carrying a passenger in the cargo bed. lbs (853Kg). WHAT CAN HAPPEN The passenger could fall or be struck by objects in the cargo bed.
  • Page 82 Your Vehicle The driver and passenger must always wear WARNING a seat belt, an approved motorcycle helmet, POTENTIAL HAZARD eye protection and protective clothing, Overloading this vehicle or carrying or including over-the-ankle boots, gloves, a towing cargo improperly. long-sleeved shirt or jacket, and long pants. WHAT CAN HAPPEN Keep hands and feet inside the vehicle at all Could cause changes in vehicle...
  • Page 83 Your Vehicle WARNING HOW TO AVOID THE HAZARD POTENTIAL HAZARD Always wear an approved motorcycle Operating this vehicle without wearing an helmet that fits properly. You should also approved motorcycle helmet, eye wear: protection, and protective clothing. WHAT CAN eye protection HAPPEN (goggles or face shield) Operating without...

  • Page 84: Learning To Operate Your Vehicle

    Your Vehicle Perform the Pre-Operation Checks on pages LEARNING TO OPERATE YOUR VEHICLE 5-1 - 5-11. Set the parking brake, shift to You should become familiar with the neutral, and follow the instructions on page performance characteristics of the vehicle in 6-1 to start the engine.

  • Page 85: Turning Your Vehicle

    Your Vehicle maneuvers on slope. Position your hands on the steering wheel so CAUTION: that your thumbs and fingers do not wrap Do not shift from low to high or vice versa around the wheel. This is particularly important without coming to a complete stop and when driving in rough terrain.
  • Page 86 Your Vehicle Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Apply the throttle lightly. Never open the throttle suddenly. 3. Back up slowly. 4. Apply the brakes lightly for stopping. 5.

  • Page 87: Braking

    Your Vehicle BRAKING Braking ability is affected by the type of terrain. In most cases, gradual application of the brakes is more effective than abrupt braking, particularly on loose surfaces like gravel. Always allow for greater braking distance on rough, loose, or slippery surfaces.
  • Page 88 Your Vehicle some hills are too steep for you to climb. WARNING Maximum slope angle:15° POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle can over turn more easily on extremely steep hills than on level surfaces or small hills. HOW TO AVOID THE HAZARD Never operate your vehicle on hills too steep for it or your abilities.

  • Page 89: Going Downhill

    7-10 Your Vehicle Before climbing the hill, first be sure you are around. With your foot on the brake, look operating in low range 4WD or, if necessary, behind you and plan your descent. Shift the with 4WD. To climb a hill, you need traction, drive select lever in reverse so you can use momentum, and steady throttle.
  • Page 90 Your Vehicle 7-11 Before starting downhill, make sure the you will be able to react to obstacles that may vehicle is in low-range 4WD. On most slopes, appear. this will let you use engine braking to help you go downhill slowly. Go as slowly as WARNING possible.

  • Page 91: Crossing Through Shallow Water

    7-12 Your Vehicle CROSSING THROUGH SHALLOW WATER WARNING If you must cross shallow, slow moving water POTENTIAL HAZARD up to the depth of the vehicle’s floorboards, Operating this vehicle through deep or choose your path carefully to avoid sharp fast-flowing water. drop-offs, large rocks, or slippery surfaces WHAT CAN HAPPEN Loss of control, which could result in an...
  • Page 92 Your Vehicle 7-13 CAUTION: Vehicle Immersion CAUTION: After riding your vehicle in water, be sure to If your vehicle becomes immersed, major drain the trapped water by removing the engine damage can result if the machine is check hose at the bottom of the air filter case, the V-belt cooling duct check hose, the drive not thoroughly inspected.
  • Page 93 7-14 Your Vehicle 5. Dry the spark plugs and reinstall them, or CAUTION: install new plugs. Make sure all components that are washed 6. Attempt to start the engine. If necessary, and assembled are coated lightly with repeat the drying procedure. grease.

  • Page 94: Riding Over Rough Terrain

    Your Vehicle 7-15 1. Drive select lever box check hose 1．V-belt cooling duct check hose 1．V-belt case drain plug Riding Over Rough Terrain Operating over rough terrain should be done with caution. Look for obstacles that could cause damage to the vehicle or could lead to a rollover accident.
  • Page 95 7-16 Your Vehicle vehicle could occur. WARNING POTENTIAL HAZARD Failure to use extra care when operating this vehicle on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the vehicle overturning or going out of control.

  • Page 96: Riding In Brush Or Wooded Areas

    Your Vehicle 7-17 thoroughly. Look from both your approach Riding in Brush or Wooded Areas side and the exit side. If you believe you can When operating in areas with brush or trees, continue safely, decide the path that will watch carefully on both sides and above the allow you to get over the obstacle at as close vehicle for obstacles such as branches that...
  • Page 97 7-18 Your Vehicle WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the vehicle to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles.

  • Page 98: Periodic Maintenance And Adjustment

    Periodic Maintenance and Adjustment NOTE: Periodic Maintenance and Adjustment If you do not have a torque wrench available Periodic inspection, adjustment and during a service operation requirin lubrication will keep your vehicle in the safest g one, take your vehicle to service center to and most efficient condition possible.
  • Page 99 Periodic Maintenance and Adjustment WARNING WARNING POTENTIAL HAZARD POTENTIAL HAZARD Operating this vehicle with improper Servicing an engine while it is running. modifications. WHAT CAN HAPPEN Moving parts can catch clothing or parts WHAT CAN HAPPEN of the body, causing injury. Improper installation of accessories or Electrical components can cause shocks modification of this vehicle may cause...

  • Page 100: Periodic Maintenance Chart For The Emission Control System

    Periodic Maintenance and Adjustment Periodic Maintenance Chart for the Emission Control System ● For vehicles not equipped with an odometer or hour meter, follow the month maintenance intervals. ● For vehicles equipped with an odometer or an hour meter, follow the mile (km) or hours maintenance intervals. However, keep in mind that if the vehicle is not used for a long period, the month maintenance intervals should be followed.

  • Page 101: General Maintenance And Lubrication Chart

    Periodic Maintenance and Adjustment General maintenance and lubrication chart INITIAL EVERY Month Whichever ITEM ROUTINE Miles 1,500 1,500 3,000 Comes first (Km) (320) (2,400) (2,400) (4,800) (1,200) hours Check coolant leakage. ● Cooling system Repair if necessary. ○ ○ ○ ○...
  • Page 102 Periodic Maintenance and Adjustment INITIAL EVERY Month Whichever ITEM ROUTINE Miles 1,500 1,500 3,000 Comes first (Km) (320) (2,400) (2,400) (4,800) (1,200) hours Check bearing assemblies for looseness/damaged. ● Wheel bearings* ○ ○ ○ ○ Repair if damaged. ● Stabilizer bushings* Check for cracks or damage.
  • Page 103 Periodic Maintenance and Adjustment NOTE: Recommended brake fluld:DOT4 ● Brake fluid replacement. ● When disassembling the master cylinder or caliper, replace the brake fluid. Check the brake fluid level ● and add fluid as required. On the inner parts of the master cylinder and caliper, replace the oil seals every two years. ●...

  • Page 104: Hood

    Periodic Maintenance and Adjustment Hood To open Unhook the hood latches, and then slowly tilt the hood up until it stops. Hood To close Lower the hood slowly to its original position, 1. Latch (×2) and then hook the hood latches. Secure projections on the underside of the ①...

  • Page 105: Console

    Periodic Maintenance and Adjustment Console To remove 1. Remove the seats. (See pages 4-16─ 4-17 for seat removal and installation procedures.) 2. Remove the parking brake lever boot. 3. Pull the console upward (the drive select lever boot will come loose.) 1.

  • Page 106: Engine Oil And Oil Filter Cartridge

    Periodic Maintenance and Adjustment procedures.) 2. Install the parking brake lever boot. 3. Install the seats. 3. Check the engine oil level on a cold engine. CAUTION: NOTE: When installing the console, be sure not If the engine was started before checking the to pinch the cables or wires.

  • Page 107: To Change The Engine Oil

    8-10 Periodic Maintenance and Adjustment 8. Install the console. To change the engine oil (with or without oil filter cartridge replacement) 1. Remove the console. (See page 8-9 for console removal and installation procedures.) 2. Place an oil pan under the engine to collect the used oil, and then remove the engine oil filler cap.
  • Page 108 Periodic Maintenance and Adjustment 8-11 1. Engine oil drain bolt 1. Oil filter cartridge 2. Oil filter wrench NOTE: NOTE: Skip steps 4-6 if the oil filter cartridge is not An oil filter wrench is available at a nearby being replaced. service center.
  • Page 109 8-12 Periodic Maintenance and Adjustment 1. Oil filler cartridge 2. Torque wrench 1. O-ring 7. Install the engine oil drain bolt, and then 6. Install the new oil filter cartridge with an tighten it to the specified torque. oil filter wrench, and then tighten it to the specified torque with a torque wrench.

  • Page 110: Final Gear Oil

    Periodic Maintenance and Adjustment 8-13 several minutes while checking it for oil Recommended engine oil: leakage. If oil is leaking, immediately turn See page 10-2. the engine off and check for the cause. Oil quantity: 10. Turn the engine off, wait at least ten Without oil filter cartridge replacement minutes, and then check the oil level and 2.01 qt (1.9L)
  • Page 111 8-14 Periodic Maintenance and Adjustment CAUTION: 1. Be sure no foreign material enters the final gear case. 2. Please clean the sensor every 320 mile period. 3. Install the oil filler bolt, and then tighten it to the specified torque. Tightening torque: 1.

  • Page 112: Changing The Final Gear Oil

    Periodic Maintenance and Adjustment 8-15 Changing the final gear oil Tightening torque: 1. Place the vehicle on a level surface. Final gear oil drain bolt: 2. Place a container under the final gear 14 ft·lbf (20 Nm, 2.0 m·kgf ) case to collect the used oil.

  • Page 113: Differential Gear Oil

    8-16 Periodic Maintenance and Adjustment Tightening torque: Final gear oil filler bolt: 17 ft·lbf (23 Nm, 2.3 m·kgf) 7. Check for oil leakage. If oil leakage is found, check for the cause. Differential gear oil Checking the differential gear oil level 1.

  • Page 114: Changing The Differential Gear Oil

    Periodic Maintenance and Adjustment 8-17 Changing the differential gear oil 1. Place the vehicle on a level surface. Tightening torque: 2. Place a container under the differential Differential gear oil drain bolt: gear case to collect the used oil. 7.1 ft·lbf (9.8Nm, 0.98 m·kgf) 3.

  • Page 115: Coolant

    8-18 Periodic Maintenance and Adjustment temperature. Tightening torque: NOTE: Differential gear oil filler bolt: The coolant should be between the minimum 17 ft·lbf (23Nm, 2.3m·kgf) and maximum level marks. 7. Check for oil leakage. If oil leakage is found, check for the cause. Coolant The coolant level should be checked before each ride.

  • Page 116: Axle Boots

    Periodic Maintenance and Adjustment 8-19 the hood. content of the coolant as soon as possible. Coolant reservoir capacity The radiator fan is automatically ● (up to the maximum level mark): switched on or off according to the 0.37 qt (0.35L) coolant temperature in the radiator.

  • Page 117: Spark Plug Inspection

    8-20 Periodic Maintenance and Adjustment Spark plug inspection Removal 1. Lift the cargo bed up. (See pages 4-20 - 4-21 for cargo bed lifting and lowering procedures.) 2. Remove the spark plug cap. 1.Front axle boot (×2 each side) 1. Spark plug cap 3.

  • Page 118: Inspection

    Periodic Maintenance and Adjustment 8-21 Do not attempt to diagnose such problems yourself. Instead, take the vehicle to a service center. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. If electrode erosion becomes excessive, or if carbon and other deposits are excessive, you should replace the spark plug with the specified...
  • Page 119 8-22 Periodic Maintenance and Adjustment Tightening torque: Spark plug: 12.7 ft·lbf (17.5 Nm, 1.75 m·kgf) NOTE: If a torque wrench is not available when you are installing the spark plug, a good estimate of the correct torque is 1/4 to 1/2 turn past finger tight.
  • Page 120 Periodic Maintenance and Adjustment 8-23 1. Holder (×4) 2. Air filter case cover 1. Air filter check hose 1. Remove the seats. (See pages 4-16 - 4. Remove the air filter element. 4-17 for seat removal and installation 5. Remove the sponge material from its procedures.) frame.
  • Page 121 8-24 Periodic Maintenance and Adjustment 1. Air filter frame 2. Sponge material 3. Element retaining plate 6. Wash the sponge material gently but thoroughly in solvent. WARNING POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the sponge material. WHAT CAN HAPPEN 1.
  • Page 122 Periodic Maintenance and Adjustment 8-25 CAUTION: Do not twist the sponge material when squeezing it. 8. Inspect the sponge material and replace it if damaged. 9. Thoroughly apply foam air filter oil or other quality liquid foam air filter oil (not spray type) to the sponge material.

  • Page 123: V-Belt Cooling Duct Check Hose

    8-26 Periodic Maintenance and Adjustment V-belt cooling duct check hose element rubber joint to the fuel system and The V-belt cooling duct check hose is located manifold fittings securely to avoid the under the driver seat. (See pages 4-17 - 4-18 possibility of unfiltered air entering the for seat removal and installation procedures.) engine.

  • Page 124: V-Belt Case Drain Plug

    Periodic Maintenance and Adjustment 8-27 V-belt case drain plug The V-belt case drain plug is located under the driver seat. (See pages 4-17 - 4-18 for seat removal and installation procedures.) After riding in water deep enough to allow water to enter the V-belt case, remove the drain plug to drain any water from the case.
  • Page 125 8-28 Periodic Maintenance and Adjustment Bolt(×3) 1. Tailpipe 2. Spark arrester 2. Remove the tailpipe by pulling it out of 4. Insert the tailpipe into the muffler and the muffler. align the bolt holes. 3. Tap the tailpipe lightly, and then use a 5.

  • Page 126: Valve Clearance

    Periodic Maintenance and Adjustment 8-29 WARNING Valve clearance POTENTIAL HAZARD The correct valve clearance changes with Improper cleaning of the spark arrester. use, resulting in improper fuel-air supply or Hot exhaust system engine noise. To prevent this, the valve WHAT CAN HAPPEN Could injure the eyes.

  • Page 127: Rear Brake Pad Check

    8-30 Periodic Maintenance and Adjustment Rear brake pad check Each brake pad is provided with wear indicator grooves, which allow you to check the brake pad wear without having to disassemble the brake. To check the brake pad wear, check the wear indicator grooves. If a brake pad has worn to the point that the wear indicator grooves have almost disappeared, have a service center replace...

  • Page 128: Checking The Brake Fluid Level

    Periodic Maintenance and Adjustment 8-31 The brake fluid reservoir is located under the Checking the brake fluid level hood. (See pages 8-8- 8-9 for hood opening Insufficient brake fluid may let air enter the and closing procedures.) brake system, possibly causing the brakes to become ineffective.

  • Page 129: Brake Fluid Replacement

    8-32 Periodic Maintenance and Adjustment the fluid and may result in vapor lock. should be no free play in the brake pedal. Brake fluid may deteriorate painted The brakes should operate smoothly and there should be no brake drag. If the brakes surfaces or plastic parts.

  • Page 130: Parking Brake Lever Free Play Adjustment

    Periodic Maintenance and Adjustment 8-33 WARNING Parking brake lever free play adjustment Periodically check the parking brake lever POTENTIAL HAZARD Operating with improperly serviced or free play and adjust it if necessary. adjusted brakes. 1. Shift the drive select lever into low gear WHAT CAN HAPPEN “L”.
  • Page 131 8-34 Periodic Maintenance and Adjustment 1.Parking brake lever free play 1. Locknut 2. Adjusting nut NOTE: 6. Turn the adjusting nut in direction The parking brake lever must be released increase the free play or in direction when checking and adjusting the parking to decrease the free play.

  • Page 132: Brake Light Switch Adjustment

    Periodic Maintenance and Adjustment 8-35 Brake light switch adjustment The brake light switch, which is activated by the brake pedal, is properly adjusted when the brake light comes on just before braking takes effect. If necessary, adjust the brake light switch as follows. 1.

  • Page 133: Brake Pedal And Accelerator Pedal Lubrication

    8-36 Periodic Maintenance and Adjustment Brake pedal and accelerator pedal WARNING lubrication POTENTIAL HAZARD Lubricate the pivoting parts. Damaged control cables. Recommended lubricant: WHAT CAN HAPPEN Lithium-soap-based grease Corrosion can result when the outer (all-purpose grease) covering of control cables becomes damaged.

  • Page 134: Rear Knuckle Upper And Lower Pivot Lubrication

    Periodic Maintenance and Adjustment 8-37 Rear knuckle upper and lower pivot Steering shaft lubrication lubrication Lubricate the pivot points. Lubricate the knuckle upper and lower pivots Recommended lubricant: with a grease gun. Lithium-soap-based grease (all-purpose grease) Recommended lubricant: Lithium-soap-based grease...

  • Page 135: Wheel Removal

    8-38 Periodic Maintenance and Adjustment Wheel installation Wheel removal 1. Install the wheel and the nuts. Loosen the wheel nuts . NOTE: Elevate the vehicle and place a suitable The arrow mark on the tire must stand under the frame. ●...

  • Page 136: Battery

    Periodic Maintenance and Adjustment 8-39 Battery This vehicle is equipped with a sealed-type battery. Therefore it is not necessary to check the electrolyte or add distilled water in the battery. If the battery seems to have discharged, consult a service center. 1.
  • Page 137 8-40 Periodic Maintenance and Adjustment WARNING POTENTIAL HAZARD Failure to handle batteries or battery electrolyte carefully. WHAT CAN HAPPEN You could be poisoned. You could be severely burned by the sulfuric acid in battery electrolyte. Batteries produce explosive gases. HOW TO AVOID THE HAZARD Avoid contact with skin, eyes or clothing.

  • Page 138: Battery Maintenance

    Periodic Maintenance and Adjustment 8-41 Battery maintenance 1. When the vehicle is not used for a month or longer, remove the battery and store it in a cool, dark place. Completely recharge the battery before reinstallation. CAUTION: A special battery charger (constant voltage/ampere or constant voltage) is required for recharging a sealed-type battery.
  • Page 139 8-42 Periodic Maintenance and Adjustment by lifting it up and pulling it out. 1. Battery compartment cover 1. Main fuse 2. Spare main fuse 2. Turn the key to “OFF” and turn off the 3. Headlight fuse 4. Ignition fuse 5.

  • Page 140: Replacing Headlight Bulb

    Periodic Maintenance and Adjustment 8-43 Specified fuse: WARNING Main fuse: 30.0A POTENTIAL HAZARD Headlight fuse: 15.0A Using an improper fuse Ignition fuse: 10.0A WHAT CAN HAPPEN Auxiliary DC jack fuse: 10.0A An improper fuse can cause damage to Signaling system fuse: 10.0A the electrical system, which could lead to Fuel system warmer fuse:...
  • Page 141 8-44 Periodic Maintenance and Adjustment 1. Cover at the rear of the headlight 1. Headlight bulb holder cover 4. Remove the headlight bulb holder by 3. Remove the headlight bulb holder cover pushing it in and turning it by pulling it off. counterclockwise.
  • Page 142 Periodic Maintenance and Adjustment 8-45 WARNING POTENTIAL HAZARD A headlight bulb is hot when it is on and immediately after it is turned off. WHAT CAN HAPPEN You can be burned, or a fire could start if the bulb touches something flammable. HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it.

  • Page 143: Headlight Beam Adjustment

    8-46 Periodic Maintenance and Adjustment turning it clockwise. 8. Install the bulb holder cover and the cover at the rear of the headlight. CAUTION: Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly. 9.

  • Page 144: Tail/Brake Light Bulb Replacement

    Periodic Maintenance and Adjustment 8-47 1. Panel A 1. Headlight beam adjusting screw Tail/brake light bulb replacement If a tail/brake light bulb burns out, replace it as follows: 1. Remove panel A (if replacing the left tail/brake bulb) or panel B (if replacing the right tail/brake bulb) by removing the quick fasteners and bolts.
  • Page 145 8-48 Periodic Maintenance and Adjustment 1. Quick fastener（×8） 2. Bolt（×2） 1. Tail/brake light bulb holder 3. Panel A 3. Push the defective bulb in and turn it counterclockwise to remove it from the 2. Remove the bulb holder（together with bulb holder. the bulb）by turning it counterclockwise.

  • Page 146: Troubleshooting

    Periodic Maintenance and Adjustment 8-49 Imitation parts may look like genuine parts, Tightening torque: but they are often inferior. Panel bolt: Consequently, they have a shorter service 4.7 ft·lbf (6.5N·m, 0.65 m·kgf） life and can lead to expensive repair bills. WARNING Troubleshooting Although vehicles receive a rigid inspection...

  • Page 147: Solution To Common Problems In The Vehicle

    8-50 Periodic Maintenance and Adjustment Solution to Common Problems in Vehicle The below tables show some common problems that may come up when you are driving a UTV, which will help to solve these problems. To repair a UTV requires technical skills, if you cannot repair the UTV yourself, please contact your service center.
  • Page 148 Periodic Maintenance and Adjustment 8-51 Table 2：Solution of Common Problems in Brake System. Problems Solutions 1. Check if the handle of parking brake return to its position. Brake system is locked 2. Check if the brake discs are bent or deformed. 3.
  • Page 149 8-52 Periodic Maintenance and Adjustment fasteners of calipers are deformed. 1. Check if left and right brake force deviation of front brake is with specified limit. 2. Check if the brake force of front brake goes down, which Vehicle makes odd turn causes the rear wheels to lock up before the front wheels.
  • Page 150 Periodic Maintenance and Adjustment 8-53 Table 3: Solution of Common Problems in Electrical System Problems Solutions 1. Check if the headlight switch functions properly. Lights do not work. 2. Check if the wires are broken. 3. Check if the lamps or bulbs are broken. 1.
  • Page 151 8-54 Periodic Maintenance and Adjustment Table 4: Solution of Common Problems in Running System Problems Solutions 1. Check the fasteners connecting steering rod to steering stem and knuckle to find out if they are loose or broken. Swing clearance of 2.
  • Page 152 Periodic Maintenance and Adjustment 8-55 3. Check the inner splines of rear wheel hubs and outer splines of rear wheel axles to find out if they are worn or broken. Rear wheels shake during 4. Check the lock screws of rear wheels and axles to find out use.
  • Page 153 8-56 Periodic Maintenance and Adjustment Table 5: Solution of Common Problems in Engine System Problems Solutions Check the battery voltage for Within specified value Check the rectifier output voltage for within specified Idle speed is not stable value Check MEUI for failure Check and clean air filter.
  • Page 154 Periodic Maintenance and Adjustment 8-57 Check the coolant drain tube for with air. Check the battery charge. Check the battery connection. Check the starter for damage. Check if the ignition loop is in good condition. Engine cannot start. Check if the spark plug creating sparks. Check if the ignition signal is in good condition.
  • Page 155 8-58 Periodic Maintenance and Adjustment WARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot. WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure. HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap.

  • Page 156: Cleaning And Storage

    Cleaning and Storage Cleaning CAUTION: Frequent, thorough cleaning of your vehicle Excessive water pressure may cause water will not only enhance its appearance but also seepage and deterioration of wheel bearings, will improve its general performance and brakes, transmission seals and electrical extend the useful life of many components.
  • Page 157 Cleaning and Storage chamois, clean towel or soft absorbent cloth. WARNING 6. Clean the seats with vinyl upholstery POTENTIAL HAZARD cleaner to keep the cover pliable and Operation with wet brakes after washing. glossy. WHAT CAN HAPPEN 7. Automotive type wax may be applied to Wet brakes may have reduced stopping all painted and chrome plated surfaces.

  • Page 158: Storage

    Cleaning and Storage Storage Specified amount: Long-term storage (60 days or more) of your 1 oz of stabilizer to each gallon of fuel (or vehicle will require some preventive 7.5 ml of stabilizer to each liter of fuel) procedures to guard against deterioration. After thoroughly cleaning the vehicle, NOTE: prepare for storage as follows:...
  • Page 159 Cleaning and Storage 6. Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering. 7. If storing in a humid or salty atmosphere, coat all exposed metal surfaces with a light film of oil. Do not apply oil to any rubber parts or the seat covers.

  • Page 160: Specifications

    Specifications 10-1 Model HS500UTV Dimensions: Overall length 3010mm (118.5 in) Overall width 1460m m (57.5 in) Overall height 1940mm (76.4 in) Seat height 818mm (32.2 in) Wheelbase 1890mm (74.4 in) Ground clearance 280mm (11.0 in) Minimum turning radius 3900mm (154 in)
  • Page 161 10-2 Specifications Model HS500UTV Engine oil: Type API service SG type or higher, JASO standard MA Recommended engine oil classification CAUTION: In order to prevent clutch slippage（since the engine oil also lubricates the clutch ） , do not mix any chemical additives.
  • Page 162 Specifications 10-3 Model HS500UTV Final gear case oil: Type SAE80 API GL-4 Hypoid gear oil Quantity: 0.25L (0.26 qt ) Differential gear case oil: Type SAE80 API GL-5 Hypoid gear oil Quantity: 0.32L (0.34 qt ) Radiator capacity（including all routes）: 2.50L (2.64 qt )
  • Page 163 10-4 Specifications Model HS500UTV Spark plug: Type DR8EA Spark plug gap 0.6-0.7 mm (0.023-0.027 in) Clutch type: Wet, centrifugal automatic Transmission: Primary reduction system V-belt Secondary reduction system Shaft drive Secondary reduction ratio Transmission type V-belt automatic Operation Right hand operation Reverse gear 1.471...
  • Page 164 Specifications 10-5 Model HS500UTV Tire: Type Tubeless Size front 25×8-12 rear 25×10-12 Brakes: Front brake Type Dual disc brake Ⅰ: Operation Foot operation Rear brake Type Single disc brake Operation Foot operation Front brake Type Dual disc brake Ⅱ: Operation...
  • Page 165 10-6 Specifications Model HS500UTV Wheel travel: Front wheel travel 130mm (5.12in) Rear wheel travel 150mm (5.91in) Electrical: Ignition system Generator system AC magneto Battery type U1L-11 Battery capacity 12V3.2.0Ah Bulb voltage, wattage × quantity: Headlight 12V30.3W/30.0W × 2 Tail/brake light 12V5.0W/21.0W ×...
  • Page 166 Specifications 10-7 Model HS500UTV High-range/ Low-range indicator light Specified fuses: Main fuse 30.0A Headlight fuse 15.0A Ignition fuse 10.0A Auxiliary DC jack fuse 10.0A Four-wheel-drive motor fuse 3.0A Signaling system fuse 10.0A Backup fuse 10.0A...
  • Page 167 11-1 Fault Code of Electronic Injection System Fault Code of Electronic Injection System DTC Description Related Calibration Number P0107 MAP Circuit Low Voltage or Open KsDGDM_MAP_ShortLow P0108 MAP Circuit High Voltage KsDGDM_MAP_ShortHigh P0112 IAT Circuit Low Voltage KsDGDM_IAT_ShortLow P0113 IAT Circuit High Voltage or Open KsDGDM_IAT_ShortHigh Coolant/Oil Temperature Sensor Circuit P0117...
  • Page 168 Fault Code of Electronic Injection System 11-2 P0132 O2S 1 Circuit High Voltage KsDGDM_O2_1_ShortHigh P0031 O2S Heater Circuit High Voltage KsDGDM_O2_HeaterShortHigh P0032 O2S Heater Circuit Low Voltage KsDGDM_O2_HeaterShortLow P0201 Injector 1 Circuit Malfunction KsDGDM_INJ_CYL_A_Fault P0202 Injector 2 Circuit Malfunction KsDGDM_INJ_CYL_B_Fault P0230 FPR Coil Circuit Low Voltage or Open KsDGDM_FPP_CircuitShortLow...
  • Page 169 11-3 Fault Code of Electronic Injection System P0563 System Voltage High KsDGDM_SysVoltHigh 1379 P0650 MIL Circuit Malfunction KsDGDM_MIL_Circuit 1616 P1693 Tachometer Circuit Low Voltage KsDGDM_TAC_Circuit_Low 1693 5779 P1694 Tachometer Circuit High Voltage KsDGDM_TAC_Circuit_High 1694 5780 P0137 O2S 2 Circuit Low Voltage KsDGDM_O2_2_ShortLow P0138 O2S 2 Circuit High Voltage...
  • Page 170 Where a warrantable condition exists, HISUN will repair your vehicle at no cost to you, including diagnosis, parts and labor. If an emission-related part on your vehicle is defective, the part will be repaired or replaced by HISUN. This is your EMISSION CONTROL SYSTEM WARRANTY.
  • Page 171 Emission Control System Warranty Statement 12-2 As the vehicle owner, you should be aware that HISUN may deny your warranty coverage if your vehicle or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications. If you use your vehicle in any type of competitive event, this warranty is immediately and completely void.
  • Page 172 HISUN brand vehicle for any purpose. Some states do not allow the exclusion or limitation of any incidental or consequential damages, so the above limitations may not apply to you.
  • Page 173 VI. ADDITIONAL INFORMATION. Any replacement part that is equivalent in performance and durability may be used in the performance of any maintenance or repairs by the owner. However, HISUN is not liable for these parts. The owner is responsible for the performance of all required maintenance.

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