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Hisun Motors HS100ATV Owner's Manual

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Summary of Contents for Hisun Motors HS100ATV

  • Page 1 Owner's Manual...
  • Page 2 Owner's Manual INTRODUCTION Congratulations on your purchase of the HS100ATV/HS110ATV. 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 3 Owner's Manual IMPORTANT MANUAL INFORMATION Please read this manual carefully before operating ATV.Until you have mastered enough driving and operation method, to operate, driving the vehicle.Regular inspection and maintenance, as well as the correct operation, driving skills will ensure that your use of the vehicle safety and reliability.
  • Page 4 Owner's Manual IMPORTANT MANUAL INFORMATION 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. following 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, a bystander or a person inspecting or repairing the machine.
  • Page 5 Owner's Manual IMPORTANT NOTICE This ATV only according to the technical requirements for design and production of road transport.In any public streets, roads or high-speed road is illegal. This ATV conforms to the ATV motor vehicle regulations and spark plug radio interference noise regulations.

  • Page 6: Table Of Contents

    Owner's Manual Location of the Warning and Adjustment of front and rear Specification Labels vibration damper Use specified spanner Safety Information Chain adjustment 4-10 Seat removal 4-11 Description and Vehicle Identification Pre Operation Checks List Identification number records Before using this ATV, check Vehicle identification number the following points Engine identification number...
  • Page 7 Owner's Manual Riding downhill Warm up When approaching roadblocks Ensure the gear shift bar is in the position. Periodic Maintenance and Gear shift : neutral to reverse Adjustment Periodic Maintenance and Adjustment Engine manual reverse Periodic maintenance chart for 0-10 hours the emission control system 10-20 hours General...
  • Page 8 Owner's Manual Oil checking Lubricate steering 8-22 Oil changing (need or do not Wheel hub removal 8-22 need to change the oil filter) Wheel Hub Installation 8-22 Battery 8-23 Disassembling 8-10 Checking 8-11 Maintenance Battery 8-24 Assembling 8-11 Displace fuses 8-25 Inspection 8-12...
  • Page 9 Owner's Manual Fault codes for the 12-1 Electronic Injection System 13-1 YOUR WARRANTY RIGHTS AND OBLIGATIONS...

  • 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 This ATV is different from other vehicles,please carefully read the following safety precautions and strictly abide by,otherwise,will cause deaths and injuries. ● Read the instructions carefully and paste on the vehicle all the warning labels. safety safety warning: Improper operation may cause collision of ATV, out of control and excessive turning, and cause personal injury or death.
  • Page 19 Safety Information Ignore the ATV's inspection before operation, will increase the probability of safety accidents.The examination before operation, to ensure the safety of the operating conditions.Please follow the user manual inspection and maintenance program and schedule.
  • Page 20 Safety Information ●In the process of driving ATV, to remo ●Pick up passengers ve from the hand or feet away from the Pick up passengers will make of ATV d foot pedal may reduce the ability to co rivers' balance and adverse effect on dr ntrol ATV, or out of balance fell off fro iving ability of ATV, which will lead to a m the ATV.If the driver's foot is not fir...
  • Page 21 Safety Information ● Driving on the sidewalk ●Driving on public roads Upon the pavement laying floor tile is In a public street, public road or highwa driving is strictly prohibited, such as y driving ATV may cause collisions with pavement, driveway, parking lot and the other vehicles.In a public street, public pedestrian street.If...
  • Page 22 Safety Information ● Taking drugs or drunk driving ●Safety clothing ATV driving after drinking alcohol or taking When driving ATV, not wearing formal helmet and eye protection will increase the drugs may lead to undesirable operation decision and reaction time, balance and head and eye injury in the accident perception.it is forbidden to drink and take probability.Please wear formal helmet,...
  • Page 23 Safety Information ●Jumping and special effects ● Every time before driving, in accordance Try to balance the front wheel off the gro with the requirements of the specification for und, leap, and other stunts can increase t inspection, maintenance and adjustment, he risk of accidents and vehicles overturn ensure the vehicle in good condition.
  • Page 24 Safety Information ● Operation is prohibited on excessively ● Never turn at high speeds. Practice turning rough, slippery or loose terrain , unless you at slow speeds before attempting to turn at have the ability to operate on the terrain. faster speeds.
  • Page 25 Safety Information Operating on excessively steep hills could ● When climbing, always follow proper pr cause an overturn. Never operate on hills ocedures for climbing as described in the too steep for the ATV or for your abilities. owner's manual. Never operate the ATV on hills steeper than 15 degrees.
  • Page 26 Safety Information ● Check obstacles before operating on unfamiliar terrain. ● Never operate through deep or fast-flowing water. Wet brakes may have reduced stopping ability. After leaving water, test the brakes. Apply them lightly several times while driving. The friction will help dry out the pads.
  • Page 27 Safety Information 2-10 Ensure no obstacles behind operator, when in reverse. If it’s clear, drive slowly. ● Always use the size and type of tires specified for your ATV. ● Always maintain proper tire pressure as described in the owner's manual and on safety labels.

  • Page 28: Identification Description And Vehicle

    Description and Vehicle Identification DESCRIPTION AND VEHICLE IDENTIFICATION Meter Range gear shift lever Ignition switch Tail light comp Rear turning light...
  • Page 29 Description and Vehicle Identification Fuel tank cap Steering bar part Hood Front seat Left handle bar Head light...

  • Page 30: Identification Number Records

    Description and Vehicle Identification NOTE: The ATV you have purchased may differ slightly from those shown in the figures of 3. MODEL LABEL INFORMATION: this manual. ○ ● Identification number records Vehicle identification number Record the vehicle identification number, vehicle identification number engine identification number and model...

  • Page 31: Engine Identification Number

    Description and Vehicle Identification NOTE: used to identify your machine. The vehicle identification number is used to identify your machine. Model label The model label is affixed at the location Engine identification number shown in the illustration. Record the information on this label in the space provided.

  • Page 32: Control Functions

    Control Functions and rear light would be on after turning on CONTROL FUNCTIONS the light switch. OFF： All circles are switched off. Key would be moved out. START: Turn the key clockwise to the ON position before starting the engine. Release the bottom when the engine runs.

  • Page 33: Gear Position "F" & "R"

    Control Functions It’s strictly prohibited to run electric starter ① Gear position “F” & “R” ② Parking Brake “P” continuously over minutes, otherwise ③ Coolant temp warning light damage would be caused. Start again after ④ Clearance lamp minimum 5 minutes. ⑤...

  • Page 34: Multi-Function Meter

    Control Functions Multi-function meter CAUTION: Overloading the ATV may cause overheat of engine, reduce weight loaded if case of overloading. Ensure the coolant temp warning light is off when restart. Never run the ATV when the light is still on, otherwise result in damage to the engine.

  • Page 35: Odometer Patterns

    Control Functions ③ Odometer button “TRIP/ODO” , then squeeze again for more ④ Odometer than 3 seconds. Cruising distance would be ⑤ Left turn shown in this pattern so that you would ⑥ Right turn schedule for next fuel filling. ⑦...

  • Page 36: Fuel Level Meter

    Control Functions Fuel level meter ① Low fuel level warning Fuel meter reflects the remaining volume of ② Fuel meter gasoline. It will change from RED to GREEN as running and from GREEN to RED as filling. CAUTION: It’s strictly prohibited to turn on high-bean light when the ATV hasn’t been used for a long term.
  • Page 37 Control Functions WARNING POTENTIAL DANGERS Failure of throttle control RISKS WILL HAPPEN Fail to well operate the throttle control, fail to well accelerate or decelerate, result in accident ① Throttle control HOW TO AVOID Check the conditions of the throttle control before starting the engine, fix it as Always make sure the throttle control does needed...

  • Page 38: Brake Pedal

    Control Functions Brake pedal Shift lever Reduce the speed or stop the ATV by pressing the brake pedal. ① Brake pedal ① Shift lever...

  • Page 39: Fuel Cap

    Control Functions Fuel cap Adjustment front rear vibration damper Open the gas cap by Counterclockwise Adjust the loading capacity of the spring rotating the way of adjustment Increase the loading capacity by turning toward A Reduce the loading capacity by turning toward B ①...

  • Page 40: Use Specified Spanner

    Control Functions CAUTION: WARNING Use specified spanner POTENTIAL DANGERS Failure of adjustment of vibration damper Standard position : B RISKS WILL HAPPEN A-Minimum Loss of stability due to poor function, E-Maximum resulting in accident HOW TO AVOID Ensure both right and left vibration damper are on the same position ①...

  • Page 41: Chain Adjustment

    Control Functions 4-10 Chain adjustment If the chain was found too loose against inspection, as shown in figure, you can tighten the chain by adjusting the two Nuts, rotating counterclockwise Nut(1) rotating clockwise Nut (2).

  • Page 42: Seat Removal

    4-11 Control Functions Seat removal As shown in figure, seat could be removed by softly pressing②located on the back of car body① by your hand and pushing the seat at the same time.

  • Page 43: Pre Operation Checks List

    Pre Operation Check List Before using this ATV, check the following points: ITEM ROUTINE REMARK 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 44 Pre Operation Check List WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN This increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this Owner’s Manual.

  • Page 45: Brake System

    Pre Operation Check List Brake System WARNING Braking pedal POTENTIAL DANGERS It would be a little bit hard to start pressing Non-proper Braking System the braking pedal, otherwise it is abnormal RISK WILL HAPPEN and need checking up. Causing accidents HOW TO AVOID Fluid level Check parking brake before driving.

  • Page 46: Ensure Full Tank Of Fuel

    Pre Operation Check List FUEL ethyl alcohol over purity Ensure full tank of fuel acceptable. Fuel recommended: unleaded gasoline WARNING Fuel Tank Capacity: 7L POTENTIAL DANGERS Careless when fill the fuel tank CAUTION: RISKS WILL HAPPEN Must be filled with unleaded gasoline, for Spilling of gasoline which results in fire leaded gasoline would cause severe damage Spilling of gasoline when the temperature...

  • Page 47: Engine Oil

    Pre Operation Check List Engine oil “ENERGY CONSERVING 11” or of higher Ensure engine oil level stays in the safe standard is prohibited, ensuring purity. range as shown in figure. Tire WARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure.

  • Page 48: Tire Wear Limit

    Pre Operation Check List 1. The tires listed below have been approved. down. Type Size Front 21×7-8/19×7-8 Rear 20×9.5-8/18×9.5-8 tires should inflated recommended pressure: Pressures applied to the edges of tires should not exceed: Front tires:28kpa（0.28kgf/cm ，4psi） Rear tires: 49kpa（0.49kgf/cm ，7 psi）...
  • Page 49 Pre Operation Check List WARNING POTENTIAL DANGERS Failure to operate the ATV properly RISKS MAY HAPPEN Loss of control which may cause accident and injury HOW TO AVOID Read over the instructions and warnings ○ a tire change rules contained in this owner’s manual. Refer to seller or dealer of HSUN if any queries.

  • Page 50: Start A Cold Engine

    Pre Operation Check List START A COLD ENGINE would be on. Please refer to your dealer of WARNING HSUN for circuit inspection in case Neutral indicator can’t be turned on. POTENTIAL DANGERS Squeeze brake, shift to any gear, start engine Controlling wires were frozen in cold successfully.

  • Page 51: Starting A Cold Engine

    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 cause an could lead to an accident or collision.
  • Page 52 Operation Please avoid using the auxiliary booster. Remove the battery and replace. If must, please follow the below instruction. 1.Shut down the engine. 2.Open the engine hood. 3.Remove the battery cover. 4.Prepare a replaced 12v battery, connect the jumper cable positive pole to the original battery positive pole, connect ①...
  • Page 53 Operation Warm up 7.When the engine started, disconnect the jumper cable and the replaced battery To prolong the engine life, Please warm up negative pole, disconnect the replaced the engine before starting often. Never battery and the original battery negative start the cold engine sharply.

  • Page 54: The Position

    Operation 3. Release the brake, accelerate slightly. NOTE: Gear shift : neutral to reverse Ensure the gear shift bar is in the position. 1. Stop the vehicle, remove hand from the accelerator. 2. Hold the brake. 3. Move the gear shift from neutral to reverse.

  • Page 55: Engine Manual Reverse

    Operation 5.Accelerate slightly and keep looking information carefully. When the engine is behind. new, there’s no need to load too much at WARNING the first few hours drive. POTENTIAL HAZARD In this period, please avoid any operation that may cause the engine over-heating Improper reverse operation and reduce the engine life.However, fully WHAT CAN HAPPEN...

  • Page 56: Hours

    Operation vehicle cool down 5-10minutes after each WARNING hour driving change speed accordingly. POTENTIAL HAZARD Park the vehicle on a slope or uneven 10-20 hours terrain. Do not prolong the operation time in 3/4 WHAT CAN HAPPEN accelerate position. The vehicle may loose control and result in an accident.
  • Page 57 Operation ① Parking brake 3.Park the vehicle with brakes applied. 1. Stop the vehicle with brake applied. NOTE: 2. Shut down the engine. The parking system is equipped on the rear wheels. Since the braking system works on four wheels, please switch the vehicle to four wheel drive before stop.

  • Page 58: Accessories And Load

    Operation ACCESSORIES AND LOAD accident . Accessories Accessories could effect vehicle ● Accessories should be mounted performance and the controls. Please properly. Any move or loose will reduce the follow the below instruction when you control of the vehicle. carried other accessories. ●...

  • Page 59: Your Vehicle

    Your Vehicle DRIVING YOUR VEHICLE Driving could increase your chances of head and/or eye injury, and the possibility of For your safety, we strongly recommend that death in the event of a severe accident. you always wear motorcycle helmet, eye HOW TO AVOID THE HAZARD protection, boots, gloves, long pants, and Always wear an approved motorcycle...
  • Page 60 Your Vehicle when the vehicle get in stable condition. the tire lose traction, and result in an Please also practice the brake operation. accident. Practice basic handles in safe area until you NOTE: build your skills and play stunner stunt when Never shift the gear into reverse until the you become a experienced and skillful driver.

  • Page 61: Brake

    Your Vehicle to lose control. at high speeds. Practice turning at slow Operating on excessively steep hills could speeds before attempting to turn at faster speeds. cause an overturn. Never operate on hills too steep for the ATV or for your abilities. Never operate the ATV on hills steeper than 15 Brake degrees.
  • Page 62 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 63: Riding Downhill

    Your Vehicle you should turn around the ATV early while When approaching roadblocks 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 64 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 65 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 66: Adjustment

    8-1 Periodic Maintenance and Adjustment Periodic Maintenance And Adjustment WARNING Paying attention to periodic inspection, POTENTIAL HAZARD adjustment and lubrication will keep your Operating this with improper ATV always in a safe and good condition. modifications. WHAT CAN HAPPEN WARNING Improper installation accessories...

  • Page 67: Periodic Maintenance Chart For The Emission Control System

    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 68: Lubrication Chart

    8-3 Periodic Maintenance and Adjustment 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 Engine oil ● Replace (Warm engine before draining.) ○ ○ ○ ○...

  • Page 69: Brake Fluid Replacement

    Periodic Maintenance and Adjustment INITIAL EVERY Whichever Month ITEM ROUTINE Comes first 1,200 2,400 2,400 4,800 (200) (750) (1,500) (1,500) (3,000) (Mi) Hours Front and rear ● Check operation. ○ ○ suspension* ● Correct if necessary. Rear arm pivot* ● Lubricate every 6 months with lithium-soap-based grease. ○...

  • Page 70: Efi System

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

  • Page 71: Throttle Valve

    Periodic Maintenance and Adjustment ③ Intake air temperature sensor/ pressure sensor Fuel Injection Tap ④Duct, dampers To inject the fuel into the cylinder. Inlet temperature sensor To monitor the air intake temperature to the engine, the ECU automatically adjusts the fuel injection according to the temperature.

  • Page 72: Efi System Examination

    8-7 Periodic Maintenance and Adjustment The generator provides the ECU with the proper ignition timing signal. At the center of the EFI system, this model adopts a specially designed microcomputer chip controller, which controls the injection quantity by calculating the information gathered by the sensors.

  • Page 73: Oil Changing (Need Or Do Not Need To Change The Oil Filter)

    Periodic Maintenance and Adjustment scale. 5.Put the cleaned oil scale back into the oil Oil changing (need or do not need to filter, then recheck the oil level. change the oil filter) 1.Disassemble the controller cover. You can see the assemble and disassemble process on page 8-9.
  • Page 74 8-9 Periodic Maintenance and Adjustment proper torque. tighten the torque： Oil drain bolt Oil capacity Without changing the oil filter tubular: 1.90L（1.67 lmp qt,2.01 US qt） Changing the oil filter tubular: 2.00L（1.76lmp qt,2.11 US qt） ① Oil drainage bolt NOTE: 4.Assemble the oil drainage bolt back with In order to avoid clutch slipping (because proper torque.

  • Page 75: Disassembling

    Periodic Maintenance and Adjustment 8-10 Make sure none extraneous impurities get into the crank box. 6.Turn on the engine, keep it in idling condition for few minutes, check is there any oil leaking, if so, turn off the engine immediately and detect what causes the leaking.

  • Page 76: Checking

    8-11 Periodic Maintenance and Adjustment be the normal color for a normally operating vehicle. Please don’t do the checking just by yourself, check the spark plug regularly, The heat and the precipitate will gradually damage and erode the spark plug. If the electrode has been eroded so seriously or carbon other...

  • Page 77: Inspection

    Periodic Maintenance and Adjustment 8-12 Inspection Installation Spark plug important engine 1.Use the thickness gauge measuring component.The spark plug can illuminate electrode gap, if necessary ,adjust the gap the whole situation of the engine to a specified distance The Ceramic thermal insulator on the edge clearance of spark plug of center electrode should show the light 0.6-0.7mm （0.024-0.028in）...

  • Page 78: Install The Spark Plug

    8-13 Periodic Maintenance and Adjustment of the spark plug gasket, and then clean up hose, if there is a grey layer and water in the ash layer in the thread the hose, empty tube and cleaning 3.Install the spark plug and tighten it to the 1.Loosen the bolt first, and then remove specified torque the air filter cover...
  • Page 79 Periodic Maintenance and Adjustment 8-14 change in time WARNING 6.Fully soaked the air filter liquid with liquid POTENTIAL HAZARD bubble provided by Hsun or other material Using low flash point solvent or liquid bubble applied to the sponge gasoline clean sponge POSSIBLE HAZARDS NOTE: Low flash point solvent easily caused...

  • Page 80: Clean The Spark Plug Brake

    8-15 Periodic Maintenance and Adjustment CAUTION: Under the condition of its filter element is not installed, all is not allowed to drive a motorcycle.It can lead to no filtering air inflow, cause rapid wear and damage to engine.In addition, this kind circumstance also can affect the carburetor, resulted in poor performance and engine...
  • Page 81 Periodic Maintenance and Adjustment 8-16 WARNING POTENTIAL HAZARD Clean the spark plug brake wrongly Hot exhaust system POSSIBLE HAZARDS Hurt the eyes Cause burn Caused carbon monoxide ①exhaust pipe ②spark plug brake poisoning, and even lead to death 4.Inserted the exhaust muffler and the bolt Cause fire hole in parallel HOW TO AVOID THE HAZARDS...

  • Page 82: Adjust The Throttle

    8-17 Periodic Maintenance and Adjustment Adjust the throttle and up to 4000R/MIN to 5000R/MIN The choke is necessary part of the engine, occasionally.When the engine can quickly and it need to be adjusted intricately react to the accelerator, the engine has CAUTION: heating The throttle is set by ring loose after many...

  • Page 83: Valve Clearance

    Periodic Maintenance and Adjustment 8-18 valve clearance should be often Check the front brake pads Wear degree according to the brake pads are fitted with groove, so that you can not remove the brake to check the brake pads wear degree.Check brake gasket wear degree, check wear display tank.If wear degree show tank have the degree of wear ①...

  • Page 84: Check For The Rear Brake Pads

    8-19 Periodic Maintenance and Adjustment ① wear display tank of brake pad CAUTION: Remove the wheel hubs before checking the brake pads. Check for the rear brake pads Every brake pad has a scale to show the degree of wear, so you don’t need to Brake pad wear indicator disassemble the brake to check it.

  • Page 85: Check Brake Fluid

    Periodic Maintenance and Adjustment 8-20 Check brake fluid oil leakage. Routine Checking ●Make sure the top of the storage container is flat when checking the brake fluid lever. ● Using recommended brake fluid to avoid corroding rubber seals, then causing leakage and braking function decline.
  • Page 86 8-21 Periodic Maintenance and Adjustment ●Brake fluid may corrode the surface of WARNING paint pray or some component made of plastic. Always immediately clean up Potential Danger spilled brake fluid. Damaged cables Dangers may occur Replace Brake Fluid When the circuit is destroyed, it may Brake fluid must be replaced by Hisun Corrode.

  • Page 87: Lubricate Steering

    Periodic Maintenance and Adjustment 8-22 Lubricate steering Lubricate the connecting joint of steering column. Using a recommended grease: Lithium soap -based grease lubricants Multipurpose grease Wheel hub removal 1. Loosen the wheel bolts. ① Bolts（4pcs） 2.Elevate the side of the vehicle by placing a suitable stand under the footrest frame.

  • Page 88: Battery

    8-23 Periodic Maintenance and Adjustment Battery The battery is a sealed battery. There is no need to check the electrolyte or add water to the battery. CAUTION: Don’t remove the sealing strip, it may damage the battery. WARNING ① Arrow Potential Danger 2.

  • Page 89: Maintenance Battery

    Periodic Maintenance and Adjustment 8-24 Maintenance Battery and clothes. Protect your eyes when 1. Whenever the vehicle is not used for a you touch the battery. Keep children period of one months or more, remove the away from it. battery from the vehicle, and store it in a Solutions：...

  • Page 90: Displace Fuses

    8-25 Periodic Maintenance and Adjustment 2. Turn the key to the OFF position and cut down the problem electric circuit. CAUTION: To avoid a sudden short circuit, be carefully check or replace the fuses after the main switch is shut off . 3.Replace the broken fuse with a new one.

  • Page 91: Change Headlight Bulb

    Periodic Maintenance and Adjustment 8-26 WARNING Potential Danger Use incorrect fuse DANGERS MAY OCCUR Using incorrect fuse may damage the circuit and catch a fire. HOW TO AVOID DANGEROUS Always use specified power fuses and ① Cap of rear part of headlight never use a replacement with defective 3.Tear up Bulb Holder of Headlight materials.
  • Page 92 8-27 Periodic Maintenance and Adjustment ① Cap of headlight bulb holder 5. pull out the defect bulb First Push forward, then switch WARNING counterclockwise remove HIDDEN DANGER headlight bulb holder When headlight on or just off, can cause danger, the bulb is hot. DANGER TO HAPPEN You may get scald.

  • Page 93: Reconnect The Lights To The

    Periodic Maintenance and Adjustment 8-28 print. 7. Reinstall the lamp retainer. Press the retainer inward and turn it clockwise. 8. Reinstall the bulb cover and the rear cover of the lamp. CAUTION: Ensure headlamps lamp cover is firmly ① Don't touch the glass parts of the bulbs. installed on the bulb holder, and is installed properly.

  • Page 94: Harness

    8-29 Periodic Maintenance and Adjustment Reconnect the lights to the harness Replace the taillight bulb. Like the following picture, put up the If the tail lights burn out, and replace it as harness, the adjustment screw will be follows. rotated in A direction. Like the following picture, down harness,...
  • Page 95 Periodic Maintenance and Adjustment 8-30 there may be problems. Fault inspection and repair table describes a quick and simple check program. To avoid similar to Hisun counterfeit products. WARNING THE UNDERLYING DANGEROUS In the smoking or near a fire place to CHECK THE FUEL SYSTEM May ignite the fuel or explode, causing ①...
  • Page 96 8-31 Periodic Maintenance and Adjustment...
  • Page 97 Periodic Maintenance and Adjustment 8-32...

  • Page 98: Atv Common Fault Inspection And Solution Charts

    8-33 Periodic Maintenance and Adjustment ATV common fault inspection and solution charts This section provides inspection and solution charts for common faults for the ATV, it will help you maintain the ATV more efficiently for safe use. Some ATV maintenance requires special techniques. If you encounter a problem which you cannot solve, please contact a dealer.
  • Page 99 Periodic Maintenance and Adjustment 8-34 Sheet 1: Inspection and solution table for common faults Problems Solutions 1. Check if the frame and support brackets are deformed or broken. Repair and touch-up paint as necessary Panel damaged during 2. Replace any damaged body panels. off-road driving 3.
  • Page 100 8-35 Periodic Maintenance and Adjustment Sheet 2: Inspection methods / solutions for common faults in the Brake system. Solutions Problems 1. Check if the parking brake lever returns to the normal position. 2. Check if the brake discs on the front or rear wheels are deformed. Brake system seizing 3.
  • Page 101 Periodic Maintenance and Adjustment 8-36 Sheet 3: Inspection methods / solutions for common faults in the Electrical system. Problems Solutions 1. Check to be sure the light switch is working. Lights not working 2. Check to see if the wires are damaged. 3.
  • Page 102 8-37 Periodic Maintenance and Adjustment Sheet 4: Inspection methods / solutions for common faults in the operational systems. Problems Solutions 1. Check to see if the nuts on the steering column, steering knuckles and steering stem are damaged or loose. Tighten if necessary. 2.
  • Page 103 Periodic Maintenance and Adjustment 8-38 Sheet 5: Inspection methods / solutions for common problems with the engine. Problems Solutions Engine idle cannot 1. Check to be sure the throttle cable is NOT seized. adjusted using a computer 2. Check to see if the ECU is damaged. 1.

  • Page 104: Cleaning And Storage

    Cleaning and Storage Cleaning CAUTION: Keeping your ATV clean will not only improve its appearance but it can also If a high pressure water system is used for improve its performance and extend the life cleaning (not recommended), exercise of various components. extreme caution.

  • Page 105: Storage

    Cleaning and Storage STORAGE 7. Polishing the ATV by using selected paraffin. Always use clean paraffin to avoid 1. Fill the tank with fresh gasoline and HSUN scratch to the finish. Then Start the Engine fuel stabilizer or similar add-on. Start the and keep idle running for few minutes.
  • Page 106 Cleaning and Storage apply oil to rubber and seats. CAUTION: 8. Remove the battery from the vehicle, Ignore step 2 if added Fuel Stabilizer or ensure that it's fully charged, and store it out similar add-ons. of the sun in a cool, dry place. Check battery voltage each month during storage and 3.
  • Page 107 Minimum turning radius 3100 mm（122 in） Basic weight: With oil and full fuel tank 170kg（375 lbs） Engine: Engine type 4-stroke, Air cooled, SOHC Cylinder arrangement Single cylinder Displacement 97cm for HS100ATV 108cm for HS110ATV Bore × stroke 50×49.5 mm（1.97×1.95 in）for HS100ATV...

  • Page 108: Specifications

    10-2 Specifications Model HS100ATV/HS110ATV Bore × stroke 52.4×50 mm（2.06×1.97 in）for HS110ATV 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 109 Specification 10-3 Model HS100ATV/HS110ATV oils labeled ENERGY “ Quantity: CONSERVING II” or higher. Without oil filter cartridge replacement 1.9 L (1.67 Imp qt, 2.01 US qt) With oil filter cartridge replacement 2.0 L (1.76 Imp qt, 2.11 US qt) Final gear case oil:...
  • Page 110 10-4 Specifications Model HS100ATV/HS110ATV 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: Tubeless Type Size front 21×7-8 or 19×7-8 rear 20×9.5-8 or 18×9.5-8 Brake: Front brake...
  • Page 111 Specification 10-5 Model HS100ATV/HS110ATV 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 273mm (10.7in) Rear wheel travel 290mm (11.4in) Electrical: Ignition system Generator system A.C. magneto...
  • Page 112 10-6 Specifications Model HS100ATV/HS110ATV 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 Rear turning lights LED 0.85×2W...
  • Page 113 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 114 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 115 Fault Code of Electronic Injection System 11-3 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 116 As the vehicle owner, you should be aware that HISUN may deny your warranty coverage if your vehicle or Hisun Motors Corp., U.S.A. (hereinafter “HISUN”) is pleased to explain the emission control system a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.
  • Page 117 California Air Resources Board at 9528 Telstar Avenue, El Monte, CA 91731. YOUR WARRANTY RIGHTS AND OBLIGATIONS Hisun Motors Corp., U.S.A. warrants that each new HISUN brand off-road vehicle: YOUR WARRANTY RIGHTS AND OBLIGATIONS Hisun Motors Corp., U.S.A. warrants that each new HISUN brand off-road vehicle: A.
  • Page 118 YOUR WARRANTY RIGHTS AND OBLIGATIONS III. Limited Liability Hisun Motors Corp., U.S.A. warrants that each new HISUN brand off-road vehicle: A. The liability of HISUN under this Emission Control System Warranty is limited solely to the remedying of defects in material or workmanship by an authorized HISUN dealer at its A.
  • Page 119 YOUR WARRANTY RIGHTS AND OBLIGATIONS Such maintenance may be performed at a service establishment or by any individual. The warranty period Hisun Motors Corp., U.S.A. warrants that each new HISUN brand off-road vehicle: begins when the vehicle is placed into service.

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