Hisun AXIS 110 Owner's Manual
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Hisun AXIS 110 Owner's Manual

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AXIS 110 &
FORGE 110
OWNER'S MANUAL
TM
h i su nm oto r s.com

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  • Page 1 AXIS 110 & FORGE 110 OWNER’S MANUAL h i su nm oto r s.com...
  • Page 2 Owner's Manual...
  • Page 3 Owner's Manual INTRODUCTION Congratulations on your purchase of the Axis 110 or Forge 110 ATV. 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 a safe and enjoyable ATV operation.
  • Page 4 Owner's Manual THIS ATV IS NOT A TOY AND COULD BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning, driving on hills and over obstacles. TRAINING COURSE Adults and children should take an ATV training course before operating an ATV for the first time.
  • Page 5 Owner's Manual This Owner’s/ Operator’s manual should be a permanent part of the ATV and should remain with the vehicle at all times. The manual should also remain with the vehicle if sold. FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS Particularly important information is distinguished in this manual using the INJURY OR DEATH.
  • Page 6 For this reason, owners should recycle, trade in, or dispose as appropriate, batteries, oil and tires. This manual is based on the latest product information available at the time of publication. Hisun Motors Corp USA has a policy of continually improving its products. Due to improvements, or other changes, there may be some discrepancies.

  • Page 7: Table Of Contents

    Owner's Manual Location of the Warning and Shifting Specification Labels Fuel Cap and Shock Adj Chain adjustment 4-11 Safety Information Seat removal 4-12 Description and Vehicle Pre Operation Checks List Identification Before using this ATV, check Identification number records the following points Vehicle identification number Brake system Engine identification number...
  • Page 8 Owner's Manual Periodic Maintenance and Jump Starting Adjustment Warming Up the Engine Periodic maintenance chart for Gear shift : neutral to reverse the emission control system Engine Break-in General maintenance 0-10 hours lubrication chart 10-20 hours EFI System Throttle Valve Parking Idle control step motor Parking on a slope...
  • Page 9 Owner's Manual Cleaning and Storage Spark Plug Check 8-11 Cleaning Air Filter 8-11 Inspection 8-12 10-1 Installation 8-12 Specifications 10-1 Spark Arrestor 8-13 10-2 Cleaning the Spark Arrestor 8-13 Fault Codes for EFI System 11-1 Adjust the throttle 8-14 Idle-speed adjustment 8-14 12-1 Valve clearance...

  • Page 10: Location Of The Warning And Specification Labels

    Location of the Warning and Safety Labels LOCATION OF THE WARNING AND SPECIFICATION LABELS FOR Utility model...
  • Page 11 Location of the Warning and Safety Labels Read and understand all of the labels on your ATV. They contain important information for safe and proper operation of your ATV. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, a replacement label is available from 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 FOR Sport model...
  • Page 15 Location of the Warning and Safety Labels Read and understand all of the labels on your ATV. They contain important information for safe and proper operation of your ATV. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, a replacement label is available from your dealer.
  • Page 16 Location of the Warning and Safety Labels...
  • Page 17 Location of the Warning and Safety Labels...

  • Page 18: Safety Information

    Safety Information SAFETY INFORMATION AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning, riding on hills or over obstacles. Always take the proper precautions while operating this ATV.
  • Page 19 Safety Information  Never consume alcohol or drugs before or while operating this ATV.  Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is proper for the terrain, visibility and operating conditions, and your experience. ...
  • Page 20 Safety Information smaller hills before attempting larger hills.  Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly. Never go over the top of a hill at high speed.
  • Page 21 Safety Information stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in this manual. ...
  • Page 22 Safety Information  Always use the size and type tires specified in this manual.  Always maintain proper tire pressure as described in this manual.  Never modify an ATV through improper installation or use of accessories.  Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached.

  • Page 23: Safety Information

    Safety Information 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 24 Description and Vehicle Identification DESCRIPTION AND VEHICLE IDENTIFICATION Meter Gear shift lever Ignition switch Foot brake Tail light comp Rear turning light...
  • Page 25 Description and Vehicle Identification 3-2 Fuel tank cap Right hand grip Rear Rack (Forge 110 only) Front Rack (Forge 110 only) Seat Left hand grip Head light...

  • Page 26: Identification Number Records

    Description and Vehicle Identification NOTE: The ATV you have purchased may differ Vehicle identification number slightly from the figures shown in this vehicle identification number manual. stamped into the frame. Identification number records Record the vehicle identification number (VIN) and the engine identification number in the spaces provided.

  • Page 27: Engine Identification Number

    Description and Vehicle Identification 3-4 Engine identification number Engine identification number 1 NOTE: The engine identification number also is used to identify your machine.

  • Page 28: Control Functions

    4-1 Control Functions Indicator and warning lights Gear position “F” & “R” Moving the shift lever to gear “F” (forward), indicator “F” will illuminate; Moving the shift lever to gear “R” (reverse), indicator “R” will illuminate. Park “P” When placing the ATV in neutral with the Park brake set, the “P”...

  • Page 29: Multi-Function Meter

    Control Functions 4-2 Speed temperature light is on could cause damage ② Speedometer to the ATV ③ Odometer button CAUTION: ④ Trip Odometer Overloading the ATV may cause the engine to ⑤ Left turn overheat which will illuminate the coolant ⑥...
  • Page 30 4-3 Control Functions 1 Toggle Clock button to clock settings 2 hold button in for 3~5 seconds 3 Press “KM/MILE” button to set the hour 4 Press “TRIP/000” button to set the minute 5 Press time button for 3~5 seconds then release to finish setting Fuel level gauge Fuel meter reflects the remaining volume of...

  • Page 31: Master Key Switch

    Control Functions 4-4 Master Key Switch is “ON” the lights can also be turned on. OFF： Turn Master key counterclockwise to the “OFF” position. In this position the ATV will shut off and cannot be started. All electrical functions will be turned off. Always turn the master key switch to the off position when the ATV is not in use.

  • Page 32: Control Functions

    4-5 Control Functions Left Hand Controls Emergency shut off button Horn Hazard Lights Left hand brake lever and parking brake Light Switch Turn lights on and off with the light switch. There are 3 positions: High beam, Off, Parking Electric start button To start the engine the Electric start button needs to be depressed until engine starts.
  • Page 33 Control Functions 4-6 position. The Emergency Shut Off CAUTION: button needs to be in the ON position for Never allow the starter motor to run over 5 the engine to start. seconds at a time. If the engine does not start within 5 seconds, wait 5 seconds then try Horn again.
  • Page 34 4-7 Control Functions Right Hand Controls WARNING POTENTIAL DANGERS Throttle cable not operating properly WHAT COULD HAPPEN Throttle could stick open or closed resulting in an accident ① Throttle control HOW TO AVOID ② Right brake lever Check condition of the throttle control before each ride.
  • Page 35 Control Functions 4-8 Foot brake lever Shift lever Once the ATV has stopped and the Reduce the speed or stop the ATV by brake is set, you can shift the ATV, by pressing the foot brake lever. using the shift lever, into forward, neutral or reverse.
  • Page 36 4-9 Control Functions Fuel cap Adjustment of front and rear shocks Increase load capacity by turning adjustment Fuel cap can be removed by turning counter ring (1) toward A. Reduce load capacity by clockwise. Fuel cap can be installed by turning adjustment ring toward B.
  • Page 37 Control Functions 4-10 CAUTION: Use specified spanner wrench to adjust WARNING shocks POTENTIAL DANGERS Front shocks adjusted to different settings Note: Always adjust both front shocks WHAT COULD HAPPEN to same settings. Loss of stability which could result in an accident HOW TO AVOID Make sure both, left and right, front shocks...

  • Page 38: Chain Adjustment

    4-11 Control Functions Chain adjustment Chain should have ¼” to ½” slack when pushed up in the center. To adjust chain, loosen Nuts(1). To tighten chain, turn nuts (2) clockwise. To loosen chain, turn nuts (2) counter clockwise.

  • Page 39: Seat Removal

    Control Functions 4-12 Seat removal WARNING POTENTIAL DANGERS Inspecting or adjusting chain while the engine is running. WHAT COULD HAPPEN Finger or hand could get caught between chain and sprocket which could result in severe injury. HOW TO AVOID Turn off engine before attempting to As shown in figure, seat is removed by inspect or adjust chain.

  • Page 40: Pre Operation Checks List

    5-1 Pre Operation Check List Before operating this ATV, check the following points: ITEM ROUTINE MARKER Check the operation, free play, fluid levels and look for any fluid leaks. ● Brakes Add DOT 4 brake fluid if necessary. ● Check to see if the disc brake rotor and the brake pads are worn beyond limits. ●...
  • Page 41 Pre Operation Check List 5-2 WARNING Failing to inspect and maintain your ATV could be hazardous. Not following the pre-ride inspection procedures could result in loosing control of the ATV resulting in an accident or damage to the ATV Always perform a Pre-ride inspection before each ride.

  • Page 42: Brake System

    Inspect brake fluid hoses, fittings and master WHAT COULD HAPPEN cylinder for leaks. If a leak is found, contact Can cause an accident which could result your Hisun Authorized service center for in severe injury or death. repair. HOW TO AVOID...

  • Page 43: Mixed Fuel(Alcohol-Gasoline)

    Pre Operation Check List 5-4 FUEL ethyl alcohol. Over 10% ethyl alcohol will Fill fuel tank with gasoline damage engine components. WARNING Fuel recommended: unleaded gasoline POTENTIAL DANGERS with an octane rating of 91 or above Gas spilling on a hot engine. Fuel Tank Capacity: 1.85 gal.

  • Page 44: Engine Oil

    5-5 Pre Operation Check List Engine oil be used. Check engine oil level before each ride. The Tires engine oil should be between the “Full” and WARNING “Add Oil” line. Add oil if necessary. POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure.

  • Page 45: Tire Wear Limit

    Pre Operation Check List 5-6 Tire Pressure Tire wear limit Inspect tread wear The tires should be inflated to the recommended As shown in the figure below, replace tires pressures before each ride: Front tires: 4psi（0.28kgf/cm , 28kpa） before tread thickness (a) becomes less Rear tires: 7psi（0.49kgf/cm , 49kpa）...

  • Page 46: Starting A Cold Engine

    6-1 Operation Starting a cold engine WARNING WARNING POTENTIAL HAZARD POTENTIAL HAZARD Operating an ATV without being familiar with Freezing control cables in cold weather. all controls. WHAT CAN HAPPEN WHAT CAN HAPPEN You could be unable to control the ATV, which Loss of control, which could result in a severe could lead to an accident or collision.

  • Page 47: Starting Engine

    Operation 6-2 start button more than 5 seconds at a time, STARTING ENGINE doing so, could damage the starter motor. To start the engine 1. Make sure the hand brake lever is pulled in and the parking brake is set before attempting to start the engine.
  • Page 48 6-3 Operation Jump Starting the ATV pole on the drained battery. Avoid using an auxiliary booster located on Place the negative (black) jumper cable on a battery charger to jump the ATV. It is the good battery then place the other end best to use another 12V battery such as a of the negative cable on a paint-less car or ATV battery.

  • Page 49: Shifting

    Operation 6-4 Warming up engine Start the engine. (Refer to Starting Engine in the manual) To prolong engine life, always warm up the When engine starts, disconnect the engine before starting off. This allows the jumper cables and install battery cover. oil to warm up and circulate through the engine components.
  • Page 50 6-5 Operation 2. Activate brake lever, then shift into the 3. Release brake and accelerate gradually. desired position. NOTE: Gear shift lever: Shifting to reverse Make sure the gear shift lever is fully engaged in the correct position before Stop vehicle and remove hand from applying the throttle.

  • Page 51: Engine Break-In

    Operation 6-6 There is never a more important period in While operating in reverse, keep the life of your vehicle than the period looking behind for obstacles or people between zero and 20 hours. For this reason, we ask that you carefully read the following material.

  • Page 52: Hours

    6-7 Operation period for the engine by cruising at lower Stop ATV, move the gear select lever to r/min so the engine can rid itself of the park Neutral (N). Set the parking brake. Parking on a slope temporary buildup of heat. If any WARNING abnormality is noticed during this period,...
  • Page 53 Operation 6-8 Brake lever ① Parking brake 1. Stop the vehicle with brakes applied. 3.Park the vehicle with parking brake applied. 2. Shut down the engine.

  • Page 54: Accessories And Load

    6-9 Operation Accessories and loading difficult, an accessory that limits your ability to move around on the seat, or one that Accessories limits your view. Accessories can affect the handling and Use extra caution when riding an ATV with control of your ATV. Keep the following in accessories.

  • Page 55: Your Vehicle

    Your Vehicle RIDING YOUR ATV Safety Gear Always wear a DOT or SNELL certified motorcycle/ATV helmet . A helmet helps protect against serious head injuries in the event of an accident. A helmet is the most important safety gear item you can wear. Consult with a motorcycle/ATV dealer for the correct size and type of helmet that is right for you.

  • Page 56: Driving Your Vehicle

    Your Vehicle however, are appropriate for all types of riding. Riding your ATV requires special skills could increase your chances of a head acquired through practice over a period of and/or eye injury, and the possibility of time. Take the time to learn the basic death in the event of a severe accident.

  • Page 57: Turning

    Your Vehicle RIDE WITH CARE AND GOOD engine and transmission chain. JUDGEMENT Turning Get training if you are inexperienced. Turning improperly could cause loss of Beginners should get training from a certified traction, loss of control, accident or overturn. instructor. Always follow proper procedures for turning Become familiar with this ATV at slow speeds as described in the owner's manual.

  • Page 58: Climbing Uphill

    Your Vehicle Brake operate the ATV on hills steeper than 15 Climbing uphill degrees. Improper hill climbing could cause loss of control or overturn. Always follow proper The maximum gradient：15° procedures for climbing hills as described in the owner's manual. Use proper riding skills to keep your ATV from overturning on hills.
  • Page 59 Your Vehicle WARNING POTENTIAL HAZARD Drive on steep slop terrain. WHAT CAN HAPPEN It may cause turn over to drive on steep uphill. HOW TO AVOID HARZARD Never operate on hills too steep for the ATV or for your abilities. Never operate the ATV on hills steeper than 15 In all cases avoid inclines with slippery or degrees.

  • Page 60: Riding Downhill

    Your Vehicle you should turn around the ATV early while When approaching obstacles you still have the operation space. If you failed to avoid the roadblock you may stop the vehicle and check the road Riding downhill conditions then choose the safest path to Improperly descending a hill could cause avoid turnover.
  • Page 61 Your Vehicle Regular examining and adjusting. WARNING Regular examining, adjusting and lubricating will keep the vehicle in the best condition. POTENTIAL HAZARD Safe driving is the first responsibility for Check the engine when functioning. driver. HAZARDS MIGHT OCCUR The key points you should pay attention to Your body parts or clothes might get stuck when examining,...
  • Page 62 Your Vehicle WARNING POTENTIAL HAZARD Driving nonstandard modified vehicle: HAZARDS MIGHT OCCUR If you assemble and modify the vehicle incorrectly, it might cause hazards under some circumstances. HOW TO AVOID Any inappropriate vehicle modifying is strictly prohibited.
  • Page 63 Periodic Maintenance and Adjustment 8-1 Periodic Maintenance And Adjustment WARNING POTENTIAL HAZARD Following the proper maintenance procedures Operating this with improper and time table for maintenance listed in this modifications. manual is important for the safety of the rider WHAT CAN HAPPEN and the life span of the ATV.

  • Page 64: Periodic Maintenance Chart For The Emission Control System

    8-2 Periodic Maintenance and Adjustment Periodic maintenance chart for the emission control system ● For an ATV, which is not equipped with an odometer or an hour meter, follow the monthly maintenance intervals. ● For an ATV, which is equipped with an odometer or an hour meter, follow the km (miles) or hours maintenance intervals. ●...

  • Page 65: General Maintenance And Lubrication Chart

    Periodic Maintenance and Adjustment 8-3 General maintenance and lubrication chart INITIAL EVERY Month Whichever ITEM ROUTINE Comes first 1,200 2,400 2,400 4,800 (Mi) (200) (750) (1,500) (1,500) (3,000) Hours ● Replace (Warm engine before draining.) ○ ○ ○ ○ Engine oil ●...
  • Page 66 8-4 Periodic Maintenance and Adjustment INITIAL EVERY Month Whichever ITEM ROUTINE Comes first 1,200 2,400 2,400 4,800 (Mi) (200) (750) (1,500) (1,500) (3,000) Hours ● Check operation. Front rear ○ ○ ● Correct if necessary. suspension* ● Lubricate every 6 months with lithium-soap-based grease. ○...

  • Page 67: Efi System

    Periodic Maintenance and Adjustment 8-5 EFI System An EFI system is different from a carbureted engine. An EFI engine is composed of advanced parts such as an ECU, EFI wires, and sensors. Parts are shown below: ① High voltage wire ② Ignition signal plug ③...

  • Page 68: Throttle Valve

    8-6 Periodic Maintenance and Adjustment ③ Intake air temperature sensor/ pressure sensor Inlet temperature sensor ④Duct, dampers Monitors the air intake temperature to the engine, the ECU automatically adjusts the fuel injection according to the temperature. Inlet pressure sensor Monitors the inner pressure of the inlet line, the operation of the engine is determined both by the throttle valve’s angle and the inlet line pressure.

  • Page 69: Efi System Examination

    Periodic Maintenance and Adjustment 8-7 gathered by the sensors. This enables the engine operate with better fuel consumption and less emissions. EFI system examination If the EFI system fails, the associated fault code is shown on the display panel. You can diagnose the system using an EFI scanner (purchased from your dealer).

  • Page 70: Oil And Oil Filter

    8-8 Periodic Maintenance and Adjustment Oil and oil filter Always check the oil level before starting the ATV. Change the oil at intervals listed in the Maintenance chart. Checking oil level 1. Place ATV on a flat surface 2. Remove oil cap (4) 3.
  • Page 71 Periodic Maintenance and Adjustment 8-9 Torque spec – Oil drain bolt Changing engine oil 1. Start the engine and allow to warm up 22ft-lbf（3.0m-kgf, 30Nm） approximately 2 – 3 minutes then shut off. Place an oil reclaim container under the ATV. 3.

  • Page 72: Spark Plug

    8-10 Periodic Maintenance and Adjustment Checking the spark plug 1. Locate the spark plug 2. Remove the plug cap (1) from the spark plug. ① Spark plug Inspection Inspect the plug for carbon deposits and clean if necessary. If plug shows excessive ①...

  • Page 73: Air Filter

    Periodic Maintenance and Adjustment 8-11 Spark Plug Gap If plug is an old plug, tighten approximately 1/8 turn more with a wrench. Spark Plug Torque 1. Use a thickness feeler gauge to inspect the spark plug gap. If not within specification, 12.7 ft-lbf（1.75 m-kgf，17.5Nm）...
  • Page 74 8-12 Periodic Maintenance and Adjustment Gently remove the sponge air filter Re-install air filter element in air filter element from the air filter housing. housing 4. Gently clean the sponge air filter element with water. NOTE: Squeeze out excess water from the The air filter element should be cleaned element.
  • Page 75 Periodic Maintenance and Adjustment 8-13 Cleaning Spark Arrestor Locate and remove the 3 bolts (1) holding the spark arrestor in place on back of the muffler. ① Exhaust Outlet ② Spark arrestor 4. Re-install the spark arrestor 5. Re-installl the 3 bolts (1) that hold the spark arrestor in place.
  • Page 76 8-14 Periodic Maintenance and Adjustment NOTE: WARNING A service center can perform this adjustment. POTENTIAL HAZARD A diagnostic tachometer is required for this Cleaning the spark arrestor while the adjustment. engine is hot. POSSIBLE HAZARDS specified idle-speed Attempting to clean the Spark Arrestor 1450-1550 r/min while the engine is hot could result in in severe burn injuries.

  • Page 77: Valve Clearance

    Periodic Maintenance and Adjustment 8-15 Valve clearance Adjusting the valves should be done by an authorized service center or comparable servicing dealer. Proper valve gap will help ATV to run at peak performance. Follow the valve gap adjustment intervals listed in the maintenance chart.
  • Page 78 8-16 Periodic Maintenance and Adjustment Check the front brake pads Check rear brake pads To inspect front brake pad wear, locate the To inspect rear brake pad wear, locate the wear marks located on the brake pad wear marks located on the brake pad assembly scale.
  • Page 79 Changing brake fluid bottle. Add brake fluid if necessary. Low Brake fluid should be replaced by an or no brake fluid could cause air to enter authorized Hisun Authorized service the braking system which could cause a center ● Replace seals every two years.

  • Page 80: Battery Maintenance

    8-18 Periodic Maintenance and Adjustment Battery Always shield eyes when working near batteries. Keep out of reach of children. This ATV is equipped with a sealed-type Antidote: battery. Therefore it is not necessary to EXTERNAL: Flush with water. check the electrolyte or add distilled water INTERNAL: Drink large quantities of water or in the battery.

  • Page 81: Battery

    Periodic Maintenance and Adjustment 8-19 access the fuse box shut off the main CAUTION: switch. Follow the steps below to inspect Sealed battery need a special battery fuses: charger. Using a common type of battery charger will result in a shorter life. 1.

  • Page 82: Headlight Bulbs

    8-20 Periodic Maintenance and Adjustment housing by pushing in bulb holder and turning counter clockwise. WARNING Potential Danger Use incorrect fuse DANGERS MAY OCCUR Using an incorrect fuse can cause severe damage to the ATV and could result in a fire.
  • Page 83 Periodic Maintenance and Adjustment 8-21 3. Remove defective bulb CAUTION: WARNING Do not touch the glass portion of the bulb with your fingers. Touching the glass with HIDDEN DANGER your fingers will allow oil from your skin to Headlight bulb may still be hot if lights affect the transparency of the glass, light were just turned off bulb luminosity and will shorten the life of...
  • Page 84 8-22 Periodic Maintenance and Adjustment 8. Close the front cover. 9. If necessary, reconnect lights to wire harness. Headlight beam adjustment To raise the beam, turn the adjusting screw in direction (a). To lower the beam, turn the adjusting screw in direction (b). CAUTION: 1.
  • Page 85 Periodic Maintenance and Adjustment 8-23 Replacing taillight bulb. Steps for replacing brake and tail light bulb: ① Taillight socket 1. Remove tail light bulb holder socket by turning counter clockwise. 2. Remove bulb from socket assembly by pushing in gently and turning bulb counter clockwise.

  • Page 86: Trouble Shooting

    8-24 Periodic Maintenance and Adjustment ATV Troubleshooting This section provides troubleshooting for the ATV. Some ATV maintenance requires special techniques. If you encounter a problem which you cannot solve, please contact a dealer. WARNING POTENTIAL HAZARD： Checking the fuel system while smoking or near an open flame. WHAT CAN HAPPEN：...
  • Page 87 Periodic Maintenance and Adjustment 8-25 Sheet 1: Body Panel troubleshooting Problems Solutions 1. Check if the frame and support brackets are deformed or broken. Repair and touch-up with paint as necessary Panel damaged during 2. Replace any damaged body panels. off-road driving 3.
  • Page 88 8-26 Periodic Maintenance and Adjustment cylinder on calipers for blockage. Inspect calipers for any deformation 1. Check if the brake disc wear limit has been exceeded. Replace disc if necessary 2. Check whether the rotors or the disc brake pads have worn beyond limits or are contaminated by oil or other material which could reduce the braking performance.
  • Page 89 Periodic Maintenance and Adjustment 8-27 needed 1. Check speed sensor for damage. Replace if needed Display is abnormal on 2. Check display panel for damage. Replace if needed the display panel 3. Check surface of speed sensor for oxidation. Replace if needed 1.
  • Page 90 8-28 Periodic Maintenance and Adjustment 4. Check all rubber bushings for damage in front end assembly. Replace if needed. 1. Check bearings in the rear axle assembly for damage. Replace if needed 2. Check swing arm bearing for damage. Replace if needed Rear wheels shake while 3.
  • Page 91 Periodic Maintenance and Adjustment 8-29 value, recharge or replace battery. A service center can perform this diagnosis 2. Check to see if the output voltage of the rectifier when the engine is idling is lower than the specified value. A service center can perform this diagnosis 3.

  • Page 92: Cleaning And Storage

    9-1 Cleaning and Storage Cleaning Keeping your ATV clean will not only CAUTION: improve its appearance but it can also If a pressure washer system is used for improve performance and extend the life of cleaning (not recommended), exercise various components. extreme caution.
  • Page 93 Cleaning and Storage 9-2 STORAGE WARNING POTENTIAL HAZARD 1. Fill the fuel tank with fresh gasoline and fuel stabilizer (fuel stabilizer Diving the ATV with wet brakes purchased at your dealer or any motorcycle, WHAT COULD HAPPEN small engine or car parts store). Start Poor braking performance which could engine and allow to run for 5 minutes so the...
  • Page 94 9-3 Cleaning and Storage the spark plug, turn the engine over a few charge battery and store out of the sun in a times by pressing the starter button. This will cool, dry place. Check battery voltage each lubricate and protect the pistons and piston month during storage and recharge as housing walls from moisture.
  • Page 95 9-1 Cleaning and Storage Cleaning Keeping your ATV clean will not only CAUTION: improve its appearance but it can also If a pressure washer system is used for improve performance and extend the life of cleaning (not recommended), exercise various components. extreme caution.
  • Page 96 Cleaning and Storage 9-2 STORAGE WARNING POTENTIAL HAZARD 1. Fill the fuel tank with fresh gasoline and fuel stabilizer (fuel stabilizer Diving the ATV with wet brakes purchased at your dealer or any motorcycle, WHAT COULD HAPPEN small engine or car parts store). Start Poor braking performance which could engine and allow to run for 5 minutes so the...
  • Page 97 9-3 Cleaning and Storage the spark plug, turn the engine over a few charge battery and store out of the sun in a times by pressing the starter button. This will cool, dry place. Check battery voltage each lubricate and protect the pistons and piston month during storage and recharge as housing walls from moisture.
  • Page 98 Specification 10-1 Model Axis 110 / Forge 110 Dimensions: Overall length 66.3 in (1683 mm) Overall width 40.9 in (1039 mm) Overall height 40.6 in (1033mm) Seat height 25.2 in（640 mm） Wheelbase 44.1 in（1120 mm） Ground clearance 4.7 in（120 mm）...

  • Page 99: Specifications

    10-2 Specifications Model Axis 110 / Forge 110 Compression ratio 9.5:1 Starting system Electric starter Lubrication system Wet sump Engine oil: Type API Service SE, SF, SG type or higher 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 100 Specification 10-3 Model Axis 110 / Forge 110 “ ENERGY oils labeled Quantity: CONSERVING II” or higher. Without oil filter cartridge replacement 2.01 US 2 L (1.67 Imp qt. 2 L) With oil filter cartridge replacement 2.11 US qt. (1.76 Imp qt. 2.0 L)
  • Page 101 10-4 Specifications Model Axis 110 / Forge 110 Transmission: Primary ration 3.72(67/18) Secondary ration 1.88(32/17) Reverse gear 2.12(36/17) Final drive ratio 2.62(34/13) Transmission type CVT-belt automatic Operation Right hand operation Tire: Type Tubeless Size front 19×7-8 rear 18×9.5-8 Brake: Front brake...
  • Page 102 Specification 10-5 Model Axis 110 / Forge 110 Vibration Damper Front Vibration Damper Disc Spring/Oil Hydraulic Vibration Damper Rear Vibration Damper Disc Spring/Oil Hydraulic Vibration Damper Wheel travel: Front wheel travel 10.7in (273mm) Rear wheel travel 11.4in (290mm) Electrical: Ignition system Generator system A.C.
  • Page 103 10-6 Specifications Model Axis 110 / Forge 110 Bulb voltage, wattage ×quantity: Head light 12 V, 35 W / 0.5 W×2 Full beam 12 V, /55W×2 Low beam 12 V, /55W×2 Clearance light LED/0.6W×2 Tail/brake light 2V/5.0W/21.0W Front turning lights LED 0.7W×2W...
  • Page 104 Fault Code of Electronic Injection System 11-1 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 105 11-2 Fault Code of Electronic Injection System 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 106 Fault Code of Electronic Injection System 11-3 P0562 System Voltage Low KsDGDM_SysVoltLow 1378 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...
  • Page 107 11-4 Fault Code of Electronic Injection System P0172 BLM Min Adapt(Kohler Special) KsFDIAG_BLM_MinAdapt P0174 PE System Lean(Kohler Special) KsFDIAG_PESystLean...
  • Page 108 10,000 km, or five years, whichever comes first. Your emission control system warranty covers components whose failure would increase an engine’s emissions of any regulated pollutant Where a warrantable condition exists, HISUN will repair your vehicle at no cost to you, including diagnosis, parts and labor.
  • Page 109 You are responsible for presenting your vehicle to the HISUN dealer as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of...
  • Page 110 30 days. As the vehicle owner, you should be aware that HISUN may deny your warranty Hisun Motors Corp., U.S.A. Emission Control System Warranty Statement coverage if your vehicle or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.
  • Page 111 Agency for the periods specified above. I. Coverage. Warranty defects shall be remedied during customary business hours at any authorized HISUN dealer located within the United States of America in compliance with the Clean Air Act and applicable regulations of the United States Environmental Protection Agency.
  • Page 112 Hisun Motors Corp., U.S.A. Limited Warranty on Emission Control System II. Limitations This Emission Control System Warranty shall not cover any of the following: A. Repair or replacement as a result of (1) accident, (2) misuse, (3) repairs improperly performed or replacements improperly...
  • Page 113 HISUN dealer. HISUN shall not be liable for any other expenses, loss or damage, whether direct, indidental, consequential or exemplary arising in connection with the sale or use of or inability to use the vehicle for any purpose.
  • Page 114 Hisun Motors Corp., U.S.A. Limited Warranty on Emission Control System B. No express emission control system warranty is given by HISUN except as specifically set forth herein. Any emission control system warranty implied by law, including any warranty of merchantability or fitness for a particular purpose, is limited to the express emission control system warranty terms stated in this warranty.
  • Page 115 Hisun Motors Corp., U.S.A. Limited Warranty on Emission Control System 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. Such maintenance may be performed at a service establishment or by any individual.
  • Page 116 FORGE 110 OWNER’S MANUAL ATV Safety For your nearest HISUN dealer, call 1-(972) 446-0760 or visit hisunmotors.com. HISUN Motors Corp USA | McKinney, TX 75069 Find out about a free ATV Safety © HISUN 2015. All rights reserved. Rev 07021501...

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