Hisun Motors HS800UTV 2014 Maintenance Handbook

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Brief introduction to maintenance handbook of HS800UTV

The handbook is edited by Technical Center of Chongqing Huansong Science And

Technology Industrial Co.,Ltd, and is supplied to dealers and technicians as document of

technique.Mainly, the handbook gives methods to check, maintain and repair utility terrain

vehicles （UTV）, and supplies some relevant technique and performance data. Some

techniques and method inside may be used to check, maintain and repair other models of

UTV, although it is mainly for HS800UTV.

Please read the handbook through and fully understand it; otherwise, any improper

repairing and amounting would bring you problems, and accident may occur in your use.

Proper use and maintenance can guarantee UTV being driven safely, reduce its

malfunction, and help the vehicle remain its best performance.

The standards, performances and specifications mentioned in interpretation are

based on the sample in design, and they are subject to changes according to the

product's improvement without prior notice.

Second version ,January, 2014

Published by Chongqing Huansong Science And Technology Industrial Co.,Ltd

Chongqing Huansong Science And Technology Industrial Co.,Ltd holds the copy right.

No publishing and reprinting without permission.

FOREWORD

Table of Contents

Troubleshooting

Need help?

Do you have a question about the HS800UTV 2014 and is the answer not in the manual?

Questions and answers

Juan Manuel Reyes p.

January 18, 2025

Quiero saber donde va el filtro de aceite

1 comments:

Mr. Anderson

February 3, 2025

The oil filter on the Hisun Motors HS800UTV 2014 is located under the engine. To access it, you need to remove the driver seat, passenger seat, console, and oil filter cover. The filter is secured with an M6 x 20 bolt and includes a sealing ring and a paper core oil filter.

This answer is automatically generated

Summary of Contents for Hisun Motors HS800UTV 2014

Page 1 FOREWORD Brief introduction to maintenance handbook of HS800UTV The handbook is edited by Technical Center of Chongqing Huansong Science And Technology Industrial Co.,Ltd, and is supplied to dealers and technicians as document of technique.Mainly, the handbook gives methods to check, maintain and repair utility terrain vehicles （UTV）, and supplies some relevant technique and performance data.
Page 2: Table Of Contents
CONTENT CHAPTER 1 GENERAL INFORMATION GENERAL INFORMATION……………………………………………………………………1 WATNINGS CAUTIONS AND NOTES……………………………………………………1 DESCRIPTION……………………………………………………………………………………2 IDENTIFICATION CODE……………………………………………………………………… 3 Frame No. ………………………………………………………………………………… 3 Engine No. ………………………………………………………………………………… 3 SAFETY ………………………………………………………………………………………… 4 Handing gasoline safely…………………………………………………………………… 4 Cleaning parts……………………………………………………………………………… 5 Warning labels……………………………………………………………………………… 5 SERIAL NUMBERS…………………………………………………………………………… 6 FASTENERS…………………………………………………………………………………… 6 Torque specifications ………………………………………………………………………...
Page 3 Wrenches ………………………………………………………………………………… 11 Adjustable wrenches …………………………………………………………………… 12 Socket wrenches, ratchets and handles ……………………………………………… 12 Impact drivers …………………………………………………………………………… 13 Allen wrenches…………………………………………………………………………… 13 Torque wrenches………………………………………………………………………… 13 Torque adapters ………………………………………………………………………… 14 Pliers……………………………………………………………………………………… 15 Snap ring pliers…………………………………………………………………………… 15 Hammers ………………………………………………………………………………… 16 Ignition grounding tool…………………………………………………………………… 16 PRECISION MEASURING TOOLS …………………………………………………………...
Page 4 Removing hoses ………………………………………………………………………… 27 Bearings…………………………………………………………………………………… 27 Removal…………………………………………………………………………………… 27 Installation………………………………………………………………………………… 28 Interference fit …………………………………………………………………………… 28 Seal replacement………………………………………………………………………… 30 STORAGE……………………………………………………………………………………… 30 Storage area selection…………………………………………………………………… 30 Preparing the motorcycle for storage …………………………………………………… 30 Returning the UTV to service…………………………………………………… 31 TROVBLESHOOTING……………………………………………………………………… 31 ENGINE PRINCIPLES AND OPERATING REQUIREMENTS………………………… 32 STARTING THE ENGINE …………………………………………………………………...
Page 5 Black smoke ……………………………………………………………………………… 41 Blue smoke………………………………………………………………………………… 41 White smoke or steam…………………………………………………………………… 41 Low engine compression ………………………………………………………………… 41 High engine compression ……………………………………………………………… 42 Engine overheating (cooling system) ………………………………………………… 42 Engine overheating (engine)…………………………………………………………… 42 The ignition advance angle is too large………………………………………………… 43 Detonation…………………………………………………………………………………...
Page 6 Testing for a short with a self-powered test light or ohmmeter……………………… 53 Testing for a short with a test light or voltmeter………………………………………… 53 BRAKE SYSTEM……………………………………………………………………………… 53 Soft or spongy brake lever or pedal…………………………………………………… 53 Brake drag………………………………………………………………………………… 54 Hard brake lever or pedal operation…………………………………………………… 55 Brake Grabs………………………………………………………………………………...
Page 7 CHAPTER 3 MAINTENCE AND ADJUSTMENT OF THE UTV MAINTENANCE SCHEDULE……………………………………………………………… 82 ENGINE Adjusting the valve clearance…………………………………………………………… 84 Checking the spark plug ………………………………………………………………… 87 Checking the ignition timing……………………………………………………………… 88 Measuring the compression pressure………………………………………………… 89 Checking the engine oil level …………………………………………………………… 90 Changing the engine oil …………………………………………………………………...
Page 8 Checking the tires ……………………………………………………………………… 115 Checking the wheels…………………………………………………………………… 117 Checking and lubricating the cables ………………………………………………… 117 ELECTRICAL Checking and charging the battery…………………………………………………… 118 Checking the fuses …………………………………………………………………… 124 Adjusting the headlight beam ………………………………………………………… 126 Changing the headlight bulb ………………………………………………………… 126 Changing the tail/brake light bulb ……………………………………………………...
Page 9 CHAPTER 5 CHASSIS MALFUNCTION INSPECTION…………………………………………………………… 180 DIRECTION SYSTEM The steering wheel part…………………………………………………………… 183 BRAKE SYSTEM…………………………………………………………………………… 192 Disk brake components ……………………………………………………………… 193 Front brake caliper ……………………………………………………………………… 195 Rear brake calipers……………………………………………………………………… 203 Parking brake caliper…………………………………………………………… 206 FOOTREST ASSEMBLY ………………………………………………………………… 217 WHEEL AND TYRE PARTS ……………………………………………………………… 220 Front wheels………………………………………………………………………………...
Page 10 CHAPTER 6 ELECTRICAL COMPONENTS ELECTRICAL SYSTEM MALFUNCTION INSPECTION ……………………………… 278 ELECTRICAL………………………………………………………………………………… 279 ELECTRICALCOMPONENTS……………………………………………………………… 279 Checking the switch…………………………………………………………………… 281 Checking the switch continuity………………………………………………………… 282 Checking the bulbs and bulb sockets ……………………………………… 283 IGNITION SYSTEM………………………………………………………………………… 283 Circuit diagram…………………………………………………………………………… 283 Troubleshooting……………………………………………………………………… 284 ELECTRIC STARTING SYSTEM………………………………………………………… 287 Circuit diagram…………………………………………………………………………...
Page 11 Troubleshooting……………………………………………………………………… 313 CHAPTER 7 ENGINE MANAGEMENT SYSTEM INTRODUCTION Ems (engine management system) …………………………………………………… 314 Typical components of EMS………………………………………………………………314 Layout of EMS components………………………………………………………………315 COMPONENTS OF EMS Electronic control unit …………………………………………………………………… 315 Multec 3.5 injectors ……………………………………………………………………… 316 Throttle body assembly(with stepper motor) …………………………………………320 Engine coolant temperature sensor ……………………………………………………...
Page 12 FAULTY GEAR SHIFTING………………………………………………………………… 337 Shift lever does not move ……………………………………………………………… 337 Jumps out of gear……………………………………………………………………… 337 ENGING OVERHEATING…………………………………………………………………… 338 Overheating……………………………………………………………………………… 338 FAULTY BRAKE…………………………………………………………………………… 338 Poor braking effect……………………………………………………………………… 338 SHOCK ABSORBER MALFUNCTION………………………………………………… 339 Loss of damping function……………………………………………………………… 339 UNSTABLE HANDLING…………………………………………………………………… 339 Unstable handling………………………………………………………………………...
Page 13: General Information
GENERAL INFORMATION GENERAL INFORMATION The text provides complete information on maintenance， tune-up repair and overhaul， Hundreds of photographs and illustrations created during the complete disassembly of four wheel utility terrain venires (UTV) guide the reader through every job，All procedures are in step-by-step format and designed for the reader who may be working on the UTV for the first time.
Page 14: Description
GENERAL INFORMATION DESCRIPTION 1. Headlights/Front turning lights/ Position lights 2. Front shock absorber spring preload Adjusting ring 3. Rear brake fluid reservoir 4. Parking brake lever 5. Driver seat 6. Battery 7. Fuses 8. Left shoulder protection plate 9. Driver seat belt 10.
Page 15: Identification Code
GENERAL INFORMATION IDENTIFICATION CODE Frame No. Frame No. is carved on the right side of front main frame Engine No. Engine NO. Is carved on the right side of the engine, Figure.
Page 16: Safety
GENERAL INFORMATION SAFETY Professional mechanics can work for years and never sustain a serous injury or mishap. Follow these guidelines and practice common sense to safely service the utility terrain venires Do not operate the utility terrain venires in an enclosed area venires The exhaust gasses contain carbon monoxide.
Page 17: Cleaning Parts
GENERAL INFORMATION When working of the fuel system, work outside or in a well-ventilated area. Do not add fuel to the fuel tank or service the fuel system while the UTV is near open flames, sparks or where someone is smoking .Gasoline vapor is heavier than air, it collects in low areas and is more easily ignited than liquid gasoline.
Page 18: Serial Numbers
GENERAL INFORMATION SERIAL NUMBERS Serial and identification numbers are stamped on various locations on the frame engine throttle body. Record these numbers in the Quick Reference Data section in the front of the manual. Have these numbers available when ordering parts. FASTENERS Proper fastener selection and installation is important to ensure the motorcycle operates as designed and can be serviced efficiently.
Page 19: Cotter Pins
GENERAL INFORMATION Cotter Pins A cotter pin is a split metal pin inserted into a hole or slot to prevent a fastener from loosening. In certain applications, such as the rear axle on an UTV or motorcycle, the fastener must be secured in this way.
Page 20: Shop Supplies
GENERAL INFORMATION SHOP SIPPLIES Lubricants and Fluids Periodic lubrication help ensure a long service life for any type of equipment. Using the correct type of lubricant is as important as performing the lubrication service. Although in an emergency the wrong type is better than not using one, The following section describes the types of lubricants most often required.
Page 21: Brake Fluid
GENERAL INFORMATION Brake fluid Brake fluid is the hydraulic fluid used to transmit hydraulic pressure (force) to the wheel brakes. Brake fluid is classified by the Department of Transportation (DOT). Current designations for brake fluid are DOT 3, DOT 4 and DOT 5, this classification appears on the fluid container. Each type of brake fluid has its own definite characteristics.
Page 22: Gasket Remover
GENERAL INFORMATION Gasket Remover Aerosol gaskets remover can help remove stubborn gasket. This product can speed up the removal process and prevent damage to the mating surface that may be caused by using a scraping tool. Most of these types of products are very caustic. Follow the gasket remover manufacturer’s instructions for use.
Page 23: Screwdrivers
GENERAL INFORMATION Screwdrivers Screwdrivers of various lengths and types are mandatory for the simplest tool kit. The two basic types are the slotted tip (flat blade) and the Phillips tip. These are available in sets that often include an assortment of tip size and shaft lengths. As with all tools, use a screwdriver designed for the job.
Page 24: Adjustable Wrenches
GENERAL INFORMATION An open-end wrench is fast and works best in areas with limited overhead access. It contacts the fastener at only two points and is subject to slipping if under heavy force, or if the tool or fastener is worn. A box-end wrench is preferred in most instances, especially when braking loose and applying the final tightness to a fastener.
Page 25: Impact Drivers
GENERAL INFORMATION WARNING Do not use hand sockets with air or impact tools because they may shatter and cause injury. Always wear eye protection when using impact or air tools Various handles are available for sockets. Use the speed handle for fast operation. Flexible ratchet heads in varying length allow the socket to be turned with varying force and at odd angles.
Page 26: Torque Adapters
GENERAL INFORMATION accepts the socket, adapter or extension. Common methods of reading the torque value are the deflecting beam, the dial indicator and the audible click (Figure 12). When choosing a torque wrench, consider the torque range, drive size and accuracy. The torque specifications in this manual provide an indication of the range required.
Page 27: Pliers
GENERAL INFORMATION The effective length is the sum of L and A. Example: TA=20 ft.-lb. A=3in. L=14in. TW=20×14=280=16.5 ft. - lb. 14+3 = 17 In this example, the torque wrench would be set to the recalculated torque value (TW = 16.5 ft. –lb.). When using a beam-type wrench, tighten the fastener until the pointer aligns with 16.5 ft.
Page 28: Hammers
GENERAL INFORMATION Always wear eye protection when using snap ring pliers. Hammers Various types of hammers are available to fit a number of applications. Use a ball-peen hammer to strike another tool, such as a punch or chisel. Use soft-faced hammers when a metal object must be struck without damaging it.
Page 29: Feeler Gauge
GENERAL INFORMATION Feeler Gauge Use feeler or thickness gauges (Figure19) for measuring the distance between two surfaces. A feeler gauge set consists of an assortment of steel strips of graduated thickness. Each blade is marked with its thickness. Blades can be of various lengths and angles for different procedures.
Page 30: Micrometers
GENERAL INFORMATION Micrometers A micrometer is an instrument designed for linear measurement using the decimal divisions of the inch or meter (Figure 22). While there are many types and styles of micrometers, most of the DECIMAL PLACE VALUES* Indicates 1/10 (one tenth of an inch or millimeter) 0.01 Indicates 1/100 (one one-hundredth of...
Page 31: Care
GENERAL INFORMATION b. If the adjustment is correct, the 0 mark on the thimble will align exactly with the 0 mark on the sleeve line. If the marks do not align, the micrometer is out of adjustment. c. Follow the manufacturer’s instructions to adjust the micrometer. 2B.
Page 32: Standard Inch Micrometer
GENERAL INFORMATION while referring to Figure 25. 1. Read the upper half of the sleeve line and count the number of lines visible. Each upper line equals 1mm. 2. See if the half –millimeter line is visible on the lower sleeve line. If so, add 0.50mm to the reading in Step 1.
Page 33: Telescoping And Small Bore Gauges
GENERAL INFORMATION 4. Add the readings from Steps 1-3. Telescoping and Small Bore Gauges Use telescoping gauges (Figure 28) and small bore gauges (Figure 29) to measure bores. Neither gauge has a scale for direct readings. Use an outside micrometer to determine the reading. To use a telescoping gauge, select the correct size gauge for the bore.
Page 34: Compression Gauge
GENERAL INFORMATION instructions. Compression Gauge A compression gauge (Figure 33) measures combustion chamber (cylinder) pressure, usually in PSI or kg/ cm . The gauge adapter is either inserted or screwed into the spark plug hole to obtain the reading. Disable the engine so it does not start and hold the throttle in the wide-open position when performing a compression test An engine that does not have adequate compression cannot be properly tuned.
Page 35: Magneto Puller
GENERAL INFORMATION negative pole mistakenly, wrong result will appear. Magneto puller Magneto drawing (figure 36) is special tool to dismantle magneto rotor . firstly put the mandril into th e inside of shaft hole ,Turn the magneto rotor accordingly, screw magneto drawing and push-out ma gneto rotor ELECTRICAL SYSTEM FUNDAMENTALS A thorough study of the many types of electrical systems used in today’s motorcycles is beyond...
Page 36: Basic Service Methods
GENERAL INFORMATION actual flow of electricity. The higher the current, the more work can be performed up to a given point. If the current flow exceeds the circuit or component capacity, it will damage the system. Warning If the current insulation damage, may cause short circuit fault which lead to short circuit or large current in components.
Page 37: Removing Frozen Fasteners
GENERAL INFORMATION Clean all parts with cleaning solvent when removing them. CAUTION Do not direct high-pressure water at steering bearings, fuel hoses, wheel bearings, suspension electrical components. Water may force grease out of the bearings and possibly damage the seals 14.
Page 38: Repairing Damaged Threads
GENERAL INFORMATION portion. If a large portion of the remainder projects out, try gripping it with locking pliers. If the projecting portion is too small, file it to fit a wrench of cut a slot in it to fit a screwdriver (Figure 37) If the head breaks off flush, use a screw extractor.
Page 39: Removing Hoses
GENERAL INFORMATION Removing Hoses When removing stubborn hoses, do not exert excessive force on the hose or fitting. Remove the hose, do not exert excessive force on the hose or fitting. Remove the hose clamp and carefully insert a small screwdriver or pick tool between the fitting and hose. Apply a spray lubricant under the hose and carefully twist the hose off the fitting.
Page 40: Installation
GENERAL INFORMATION press: Always support the inner and outer bearing races with a suitable size wooden or aluminum spacer (Figure 44). If only the outer race is supported, pressure applie against the balls and/or the inner race will damage them. Always make sure the press arm (Figure 44) aligns with the center of the shaft.
Page 41 GENERAL INFORMATION of the pot. Remove the bearing from its wrapper and secure it with a piece of heavy wire bent to hold it in the pot. Hang the bearing in the pot so it does not touch the bottom or sides of the pot. Turn the heat on and monitor the thermometer.
Page 42: Seal Replacement
GENERAL INFORMATION the outer bearing race (Figure 43). Do not install new bearings by driving on the inner-bearing race. Install the bearing(s) until it seats completely. Seal Replacement Seals (Figure 49) contain oil, water, grease or combustion gasses in a housing or shaft. Improperly removing a seal can damage the housing or shaft.
Page 43: Returning The Utv To Service
GENERAL INFORMATION chapter. Then pour a teaspoon (15-20ml) of engine oil into the cylinder. Place a rag over the opening and Start the engine over to distribute the oil. Remove the grounding tool and reinstall the spark plug. 6. When the engine has cooled to room temperature, drain the cooling system drain the coolant in the coolant reserve tank and all tank lines.
Page 44: Engine Principles And Operating Requirements
GENERAL INFORMATION By following a systematic approach, the possibility of unnecessary parts replacement can be avoid, always start with the simple and most obvious checks when troubleshooting, This would include the engine stop switch, fuel quantity and condition, fuel vale position and spark plug cap tightness Proper maintenance as described in Chapter Three reduces the necessity for troubleshooting.
Page 45: Engine Is Cold
GENERAL INFORMATION Result: Ensure the engine can work with steady idle speed and conducive to complete the engine warm-up process quickly after start engine in low temperature. 2.Special fault： Idle instability, CH and CO of off-gas out of limits Reason：Oxygen sensor loosing cause slight leakage or pipe slight leakage and makes the oxygen sensor collect too much oxygen ion signal.
Page 46: Engine Is Warm
GENERAL INFORMATION Engine is warm 1. Shift the transmission into neutral. 2. Confirm if the fuel is in upper or below retied in the tank. 3. Start the engine. If the engine can run in idle speed steady and the engine speed is lower than 1600RPM, the UTV can shift driving forward.
Page 47: Spark Test
GENERAL INFORMATION that are difficult to diagnose. If the engine occasionally misfires or cuts out, use a spray bottle to wet the direct ignition coil or plug cap and plug cable while the engine is running. Water that enters one of theses areas causes an arc through the insulating material, causing an engine misfire.
Page 48: The Starter Cannot Work Repeatedly Or Can Only Work Slowly
GENERAL INFORMATION flooded, do not perform this test. The spark tester can ignite fuel ejected through the spark plug hole. 4. Shift the transmission into neutral. WARNING Do not hold the spark tester, spark plug or connector or a serious electrical shock may result. 5.
Page 49: Engine Backfires, Cuts Out Or Misfires During Acceleration
GENERAL INFORMATION 7. Clogged air filter. 8. Intake pipe air leak. 9. Plugged exhaust system. Check the silencer or muffler, especially if the utility terrain vehicle was just returned from storage. 10. Faulty ignition system component. Engine Backfires, Cuts Out or Misfires During Acceleration A backfire occurs when fuel is burned or ignited in the exhaust system.
Page 50: Engine Will Not Idle Or Idles Roughly
GENERAL INFORMATION 3. Incorrect ignition timing. Engine Will Not Idle or Idles Roughly 1. Clogged air filter element. 2. Poor fuel filter or fuel hose. 3. Faulty accelerator pump assembly. 4. Contaminated or stale fuel. ECU is not working properly, according to the 33 page "5 special treatment failure" 6.
Page 51: Poor Idle Or Low Speed Performance
GENERAL INFORMATION 4. Check for retarded ignition timing. A decrease in power results when the plugs fire later than normal 5. Check for one or more of the following problems Low engine compression Worn spark plug Fouled spark plug Incorrect spark plug heat range Weak ignition coil Incorrect ignition timing Plugged throttle passages...
Page 52: Fuel System
GENERAL INFORMATION Incorrect valve timing and worn or damaged valve springs can cause poor high-speed performance. If the camshaft was timed just before the UTV experiencing this type of problem. The cam timing may be incorrect. If the cam timing was not set or changed. And all the other inspection procedures in this section failed to locate the problem.
Page 53: Engine
GENERAL INFORMATION 1. The injector is clogged 2. The pump pressure is not enough ECU program chaos ECU damage The pressure sensor, oxygen sensor, solar term door position sensor fault ENGINE Engine Smoke The color of engine smoke can help diagnose engine problems or operating conditions Black smoke Black smoke is an indication of a rich air/fuel mixture Blue smoke...
Page 54: High Engine Compression
GENERAL INFORMATION Weak or broken valve springs. 2. Cylinder head: a. Loose spark plug or damaged spark plug hole. b. Damaged cylinder head gasket. c. Warped or cracked cylinder head. 3. The pressure relief system is damaged. High Engine Compression 1.
Page 55: The Ignition Advance Angle Is Too Large
GENERAL INFORMATION The Ignition Advance Angle Is Too Large Preignition is the premature burning of fuel and is caused by hot spots in the combustion chamber. Glowing deposits in the combustion chamber, inadequate Cooling or an overheated spark plug can all cause preignition.
Page 56: Englne Lubrication
GENERAL INFORMATION Excessive valve clearance. Worn or damaged camshaft. Damaged camshaft. Worn or damaged valve train components. The valve hose hole is damaged The valve sticks on the hose Broken valve spring. Low oil pressure. Clogged cylinder oil hole or oil passage. ENGLNE LUBRICATION Mis-operation of the engine lubrication system will cause the engine scrap.Check the lubrication oil level and pressure of the engine.
Page 57: Oil Level Too Low
GENERAL INFORMATION 4. Incorrect oil pump installation. 5. Internal oil leak. Oil Level Too Low 1. The lubrication oil does not keep at the normal level. 2. Worn piston rings. 3. Worn cylinder. 4. Worn valve guides. 5. Worn valve guide seals. 6.
Page 58 GENERAL INFORMATION NOTE Because the following test is performed with the cylinder head cover installed on the engine, the camshaft lobes cannot be viewed to ensure that the engine is positioned at TDC on its compression stroke. To determine when the engine is approaching TDC on its compression stroke, or whether it is 360°off.
Page 59: Electrical Testing
GENERAL INFORMATION NOTE Because of play in the transmission gears, it is unlikely the engine will stay at TDC on the first try If the crankshaft turns, reposition the countershaft slightly and then relock it in position with the holding tool. After several attempts, you will get a feel of the transmission play and know what direction the countershaft should be turned and locked.
Page 60: Intermittent Problems
GENERAL INFORMATION 1. Check the fuse if the fuse is blown, replace it. 2. Inspect the battery. Make sure it is fully charged, and the battery leads are clean and securely attached to the battery terminals. Disconnect each electrical connector in the suspect circuit and make sure there are no bent terminals in the electrical connector Make sure the terminals on the end of each wire are pushed all the way into the connector.
Page 61: Electrical Component Replacement
GENERAL INFORMATION c. To check a component, wait until the engine is clod, then start and run the engine. Note operational differences when the engine is cold and hot. d. If the engine does not start, isolate and remove the component. First test it at room temperature, and then after heating it with a hair dryer.
Page 62: Self-Powered Test Light
GENERAL INFORMATION Self-powered test light A self-powered test light can be constructed from a 12-volt light bulb, a pair of test leads and a 12-volt battery. When the test leads are touched together, the light bulb should go on. Use a self-powered test light as follows: 1.
Page 63: Test Procedures
GENERAL INFORMATION is good so the problem is between the lamp and the power source. To isolate the problem. Connect the jumper between the battery and the lamp. If it comes on. The problem is between these two points. Next. Connect the jumper between the battery and the fuse side of the switch.
Page 64: Peak Voltage Test
GENERAL INFORMATION loss of voltage. Voltage drop indicates where there is resistance in a circuit. A higher than normal amount of resistance in a circuit decreases the flow of current and cause the voltage to drop between the source and destination in the circuit. Because resistance causes voltage to drop.
Page 65: Testing For A Short With A Self-Powered Test Light Or Ohmmeter
GENERAL INFORMATION 4. The self-powered test lead comes on if there is continuity. An ohmmeter reads 0 or very low resistance if there is continuity. A reading of infinite resistance if there is continuity. A reading of infinite resistance indicates no continuity, the circuit is open. Testing for a short with a self-powered test light or ohmmeter 1.
Page 66: Brake Drag
GENERAL INFORMATION 1. Air in system. WARNING If the fluid level drops too low, air can enter the hydraulic system through the master cylinder. Air can also enter the system from loose or damaged hose fittings. Air in the hydraulic system causes a soft or spongy brake lever action.
Page 67: Hard Brake Lever Or Pedal Operation
GENERAL INFORMATION 1. Warped or damaged brake disc. 2. Brake caliper not sliding correctly on slide pins. 3. Sticking or damaged brake caliper pistons. 4. Contaminated brake pads and disc. 5. Plugged master cylinder port. 6. Contaminated brake fluid and hydraulic passages. 7.
Page 68: Leaking Brake Caliper
GENERAL INFORMATION 6. Incorrectly installed brake pads. 7. Damaged or missing brake pad spring or pad retainer. Leaking Brake Caliper 1. Damaged dust and piston seals. 2. Damaged cylinder bore. 3. Loose caliper body bolts. 4. Loose banjo bolt. 5. Damaged banjo bolt washers. 6.
Page 69: Specifications
SPECIFICATIONS SPECIFICATIONS HOW TO CONVERSION TABLE OF UNIT （1）How to use conversion table All the specified documents in this manual are taken SI and Metric as unit. With the following conversion table, metric unit could be conversed into imperial unit. Sample: METRIC MULTIPLY...
Page 70: Geberar Specifications
SPECIFICATIONS GEBERAR SPECIFICATIONS Item Standard Dimensions : Overall length 2,700mm (106.3in) Overall width 1,360mm（53.5 in） Overall height 1,840mm（72.4in） Seat height 800mm（31.50in） Wheelbase 1,940mm（76.4in） Minimum ground clearance 260 mm（10.2 in） Minimum turning radius 6,730mm（265.0 in） Basic weight : With oil and full fuel tank 547kg (1,206 lb) Engine : Engine type...
Page 71 SPECIFICATIONS Item Standard Ignition system Type/quantity 28198992 / 1 Spark plug DCPR7E / 1 (NGK) Type/manufacturer 0.8-0.9 mm（0.031-0.035 in） Spark plug gap Dry ,centrifugal automatic Clutch type Transmission Primary reduction system V-belt Secondary reduction system Shaft drive Transmission type V-belt automatic Operation Right hand operation Single speed automatic...
Page 72 SPECIFICATIONS Item Standard Suspension Front suspension Double wishbone Rear suspension Double wishbone Shock absorber Front shock absorber Coil spring/oil damper Rear shock absorber Coil spring/oil damper Wheel travel Front wheel travel 130mm (5.12 in) Rear wheel travel 150mm (5.91 in) Electrical Ignition system Generator system...
Page 73: Engine Specifications
SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Cylinder head Warp limit ---- 0.03 mm (0.0012 in) Cylinder Bore size 91.016 ~ 91.030mm ---- Measuring point (3.544~ 3.584 in) 50 mm (1.97 in) Camshaft Drive method ---- Cam dimensions Intake 31.95 ~ 32.11mm “A”...
Page 74 SPECIFICATIONS Item Standard Limit Cam chain No. of links Cam chain adjustment method Automatic Rocker arm/rocker arm shaft Rocker arm inside diameter 12.011~ 12.018 mm (0.4729 ~ 0.4731 in) Shaft outside diameter 11.982~ 11.989 mm ---- (0.4717 ~ 0.4720 in) Arm-to-shaft clearance 0.022 ~ 0.036 mm ----...
Page 75 SPECIFICATIONS Item Standard Limit Stem-to-guide clearance 0.010 ~ 0.037 mm 0.08 mm (0.0004 ~ 0.0015 in) (0.0031 in) 0.025 ~ 0.052 mm 0.10 mm (0.0010 ~ 0.0020 in) (0.0039 in) Stem runout limit ---- 0.01 mm (0.0004 in) Valve seat width 0.9 ~ 1.1 mm ---- (0.0354 ~ 0.0433 in)
Page 76 SPECIFICATIONS Item Standard Limit Piston Piston to cylinder clearance 0.050 ~ 0.070 mm 0.15 mm (0.0020 ~ 0.0028 in) (0.0059 in) Piston size “D” 90.940 ~ 90.955mm ---- (3.5803 ~ 3.5809 in) ---- Measuring point “H” 4.0 mm (0.15 in) ---- Piston off-set 0.5mm(0.0394 in)
Page 77 SPECIFICATIONS Item Standard Limit Oil ring ---- 4.0×3.40mm (0.1575× 0 .1339in) Dimensions (B×T) ---- 0.20 ~ 0.70 mm (0.0079 ~ 0.0276 in) End gap (installed) ---- 0.06 ~ 0.15 mm (0.0024 ~ 0.0059 in) Side clearance Crankshaft 90.523~ 90.577mm ---- Crank width “A”...
Page 78 SPECIFICATIONS Item Standard Limit Shifter Shifter type Shift drum and guide bar ---- Engine oil ---- Air filter oil grade Oil pump Oil filter type Chartaceous ---- Oil pump type Trochoid Tip clearance 0.15 mm ---- (0.0059 in) ---- Side clearance 0.03 ~ 0.10 mm ---- (0.0012 ~ 0.0039 in)
Page 79: Chassis Specifications
SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Steering system Type Rack and pinion ---- Front suspension Shock absorber travel 64 mm (2.52 in) ---- Spring free length 320 mm (12.60 in) ---- Spring fitting length 245 mm (9.65in) ---- Spring rate 28 N/mm(2.8kg/mm, 156.80lb/in) ---- Stroke...
Page 80 SPECIFICATIONS Item Standard Limit Front disc brake Type Dual ---- Disc outside diameter × thickness 200 × 3.5 mm (7.87 × 0.14 in) ---- Pad thickness inner 9.0 mm (0.35 in) ---- Pad thickness outer 9.0 mm (0.35 in) ---- Master cylinder inside diameter 19.0mm (0.75in) ----...
Page 81: Electrical Specifications
SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit 12 V ---- Voltage Ignition system Ignition timing (BTDC) 15°±1°before TDC ---- Advancer type ECU Digital type ---- Ignition coil Minimum spark gap 6 mm (0.24 in) ---- Primary winding resistance 0.18 ~ 0.28 Ωat 20 °C (68 °F) ---- Secondary winding resistance 6.32 ~ 9.48 kΩat 20 °C (68 °F)
Page 82 SPECIFICATIONS Item Standard Limit Electric starter system Type Constant mesh type ---- Starter motor ---- Output 0.8 kW ---- Armature coil resistance 0.025 ~ 0.035 Ωat 20 °C (68 °F) ---- Brush overall length 12.5 mm (0.49 in) 5 mm(0.20 in) Spring force 7.65 ~ 10.01 N ----...
Page 83: Tightening Torques
SPECIFICATIONS TIGHTENING TORQUES Engine tightening torques Thread Tightening torque Part to be tightened Part name Q’ty Remarks size m · kg ft · lb Cylinder head Bolt Bolt Spark plug — Cylinder head (exhaust pipe) Stud bolt Cylinder head cover Bolt —...
Page 84 SPECIFICATIONS Thread Tightening torque Part to be tightened Part name Q’ty Remarks size m · kg ft · lb Bolt Bolt Crankcase Bolt Bearing housing (clutch housing Bolt assembly) Bolt Air duct assembly 1 bracket Oil seal (engine cooling fan pulley) Bolt Retainer Drive belt case...
Page 85 SPECIFICATIONS Tightening torque Thread Remarks Part to be tightened Part name Q’ty ft · lb m.kg size Left-hand Shift rod locknut (select lever unit) — threads Shift rod locknut (shift arm side) — Select lever unit Bolt Plug (right crankcase) —...
Page 86: Chassis Tightening Torques
SPECIFICATIONS Chassis tightening torques Thread Tightening torque Part to be tightened Remarks size m · kg ft · lb Rubber connecting bracket 1(or 2) and frame Engine and Rubber connecting bracket 2 (front) Engine and Rubber connecting bracket 1 (rear) Rear upper arm and frame Rear lower arm and frame Rear knuckle and rear upper arm...
Page 87 SPECIFICATIONS Thread Tightening torque Part to be tightened Remarks size m · kg ft · lb Seat belt and ceiling (enclosure) 7/16 Front wheel and front wheel hub Front wheel hub and constant velocity joint of half 26.0 Stake shaft Steering knuckle and brake disc guard Front brake caliper and front wheel steering knuckle Front brake hose union bolt...
Page 88: General Tightening Torque Specifications
SPECIFICATIONS GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached.
Page 89: Lubrication Pionts And Lubricant Types
SPECIFICATIONS LUBRICATION PIONTS AND LUBRICANT TYPES Engine Lubrication points Lubricant Oil seal lips Apply lithium-soap-based grease Bearings Apply engine oil O-rings Apply lithium-soap-based grease Piston, piston ring Apply engine oil Piston pin Apply engine oil Buffer boss and balancer drive gear Apply engine oil Crankshaft seal and spacer Apply engine oil...
Page 90: Chassis
SPECIFICATIONS CHASSIS Lubrication points Lubricant Lip of oil seal (full) Light lithium-base grease o-ring(full) Light lithium-base grease Steering shaft (upper end ,lower end) Light lithium-base grease Ball connection of steering pushing rod Light lithium-base grease Front wheel fork(ball-shaped joint) Light lithium-base grease Front wheel bearing Grease used for bearing Front &...
Page 91: Hydrographic Chart
SPECIFICATIONS HYDROGRAPHIC CHART Hydrographic chart ：Pressure - 79-...
Page 92 SPECIFICATIONS LUBRICATION OIL WAY LUBRICATION OIL WAY ：Pressure ：splashing oil - 80-...
Page 93: Engine Gearbox Lubrication Oil Parth Circuit
SPECIFICATIONS Engine gearbox lubrication oil path circuit Gearbox lubrication oil path circuit ：Pressure ：splashing oil - 81-...
Page 94: Maintenance Schedule
MAINTENCE AND ADJUSTMENT OF THE UTV MAINTENCE AND ADJUSTMENT OF THE UTV NOTE: The correct maintenance and adjustment are necessary to ensure vehicle and normal driving The repair personnel should be familiar with the contents of this article. MAINTENANCE SCHEDULE EVERY INITAL Whichever...
Page 95 MAINTENCE AND ADJUSTMENT OF THE UTV · Check condition. · Spark plug Adjust gap and clean. ○ ○ ○ ○ ○ · Rep; ace if necessary. · Check operation. V-belt* ○ ○ ○ ○ · Check for cracks or damage. ·...
Page 96: Engine
MAINTENANCE AND ADJUSTMENT OF THE UTV ENGINE Adjusting the valve clearance NOTE: ·The valve clearance must be adjusted when the engine is cool to the touch. · Adjust the valve clearance when the piston is at the Top Dead Center TDC) on the compression stroke.
Page 97 MAINTENANCE AND ADJUSTMENT OF THE UTV 3. Check: ·valve clearance ·Beyond the standard Adjust. Valve clearance (cold) Intake 0.08 ~ 0.12 mm (0.0031 ~ 0.0047 in) Exhaust 0.12 ~ 0.16 mm (0.0047 ~ 0.0063 in) 4. calibration adjusting tools ○ Spin the crank, when the rotoflex’s scale shows 1, it is cylinder 1’s timing;...
Page 98 MAINTENANCE AND ADJUSTMENT OF THE UTV Adjust the valve clearance of cylinder 1, and cylinder 2 the same way valve clearance Pin lock nut ① Valve thickness gauge（gap Regulation） ② ③ Regulator Adjust tools ④ · Loosen the locknut ① ·...
Page 99: Checking The Spark Plug
MAINTENANCE AND ADJUSTMENT OF THE UTV CHECKING THE SPARK PLUG 1. lift up cargo box and dismount the seat 2. Remove: pull out the spark plug cap ① 3. Check: ·spark plug type Incorrect Replace. Standard spark plug DCPR7E/NGK 4. Check: ·electrode ①...
Page 100: Checking The Ignition Timing
MAINTENANCE AND ADJUSTMENT OF THE UTV CHECKING THE IGNITION TIMING NOTE: before checking the ignition timing, adjust the engine’s racing speed and throttle cable. 1. Remove: ·driver seat ·passenger seat ·console Refer to “SEATS” in chapter 5. 2. Lift the cargo bed up. 3.
Page 101: Measuring The Compression Pressure
MAINTENANCE AND ADJUSTMENT OF THE UTV ·console ·passenger seat ·driver seat Refer to “SEATS” in chapter 5. MEASURING THE COMPRESSION PRESSURE NOTE: Insufficient compression pressure will result in a loss of performance. 1. Start the engine and let it warm up for several minutes.
Page 102: Checking The Engine Oil Level
MAINTENANCE AND ADJUSTMENT OF THE UTV (11.5 kg/cm2, 163.57Psi) Maximum: 1,480Kpa (14.8 kg/cm2, 210.50Psi) ·Crank over the engine with the electric starter (be sure the battery is fully charged) with the throttle wide-open until the compression reading on the gauge stabilizes. NOTE: When cranking the engine, ground the spark plug lead to prevent sparking.
Page 103: Changing The Engine Oil
MAINTENANCE AND ADJUSTMENT OF THE UTV 4. Stop the engine and check the oil level again NOTE: Wait a few minutes until the oil settles before checking the oil level. NOTE: Never remove the dipsti]ck just after high speed operation because the heated oil could spurt out. Wait until the oil cools down before removing the dipstick.
Page 104 MAINTENANCE AND ADJUSTMENT OF THE UTV disassembly sequence reverse operation. 6. Install： ·engine oil drain bolt ② ·Final gear oil drain bolt ③ 7. conditions ·Change for new oil filter before impouring oil to crankcase, and make sure it is in good working condition before assembling.
Page 105: Chassis
MAINTENCE AND ADJUSTMENT OF THE UTV CHASSIS CLEANING THE AIR FILTER NOTE: There is a check hose ② at the bottom of the air filter case. If dust and/or water collect in this hose, clean the air filter element and air filter case.
Page 106: Checking The Coolant Level
MAINTENCE AND ADJUSTMENT OF THE UTV WARNING Use a cleaning solvent which is designed to clean parts only. Never use gasoline or low flash point solvents as they may cause a fire or explosion. b. squeeze the excess solvent out of the element and let it dry.
Page 107: Changing The Coolant
MAINTENCE AND ADJUSTMENT OF THE UTV ·coolant level The coolant level should be between the minimum level mark ○ and maximum level mark ○ .Below the minimum level mark Add the recommended coolant to the proper level. CHANGING THE COOLANT 1.Remove: Front faceplate ·coolant reservoir cap ①...
Page 108 MAINTENCE AND ADJUSTMENT OF THE UTV 5. Remove: ·radiator cap ① WARNING A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause serious injury. When the engine has cooled, open the radiator cap as follows: Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap...
Page 109 MAINTENCE AND ADJUSTMENT OF THE UTV 12. Remove: ·air bleed bolt ① 13. Fill cooling (with the specified amount of the recommended coolant) Recommended antifreeze High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1 : 1 (antifreeze : water) Quantity total amount 1.32 L Coolant reservoir capacity...
Page 110: Checking The Coolant Temperature Warning Light
MAINTENCE AND ADJUSTMENT OF THE UTV NOTE: Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead coolant, check, necessary, correct the antifreeze concentration of the coolant. Use only distilled water. However, soft water may be used if distilled water is not available.
Page 111: Checking The V-Belt
MAINTENCE AND ADJUSTMENT OF THE UTV Coolant temperature warning light checking method Turn the main switch “ON”. Coolant temperature warning light Coolant temperature warning light does not come on. come on. Turn the main switch to “START” with the transmission in neutral position.
Page 112: Cleaning The Spark Arrester
MAINTENCE AND ADJUSTMENT OF THE UTV V-belt width: 31.2 mm <Limit:> 26 mm ·Replace V-belt: Install the bolts ① into the secondary fixed sheave hold. NOTE: Tightening the bolts ①will push the secondary sliding sheave away, causing the gap between the secondary fixed and sliding sheaves to widen.
Page 113: Adjusting The Brake Pedal
MAINTENCE AND ADJUSTMENT OF THE UTV WARNING: · Select well-ventilated area free combustible materials. · Always let the exhaust system cool before performing this operation. · Do not start the engine when removing the tailpipe from the muffler. 3. Remove: ·Remove the bolts .
Page 114: Checking The Brake Fluid Level
MAINTENCE AND ADJUSTMENT OF THE UTV b. Turn brake rod ② in or out until the correct free play is obtained. Turning in Free play is increased. Turning out Free play is decreased. c. Tighten the locknut to specification. Locknut 17 Nm (1.7 m ·...
Page 115: Checking The Front Brake Pads
MAINTENCE AND ADJUSTMENT OF THE UTV cylinder when refilling. Water will significantly lower the boiling point of the fluid and may result in a vapor lock. 4. Close the hood. CHECKING THE FRONT BRAKE PADS 1. Remove: ·front wheels 2. Check: ·brake pads Wear indicator groove ○...
Page 116: Checking The Brake Hoses And Brake Pipes
MAINTENCE AND ADJUSTMENT OF THE UTV CHECKING THE BRAKE HOSES AND BRAKE PIPES 1. Remove: ·driver seat Refer to “SEATS” in chapter 5. 2. Lift the hood up. 3. Check: ·front brake hoses ① ·rear brake hoses ② Cracks/wear/damage Replace. Fluid leakage Replace all damaged parts.
Page 117 MAINTENCE AND ADJUSTMENT OF THE UTV d. Place the other end of the hose into a container. e. Slowly apply the brake pedal several times. f. Push down on the pedal and hold it. g. Loosen the bleed screw and allow the pedal to travel towards its limit.
Page 118: Adjusting The Select Lever Shift Rod
MAINTENCE AND ADJUSTMENT OF THE UTV ADJUSTING THE SELECT LEVER SHIFT ROD ① Neutral ② High ③ Low ④ Reverse ⑤ Parking ⑥ Select lever shift rod WARNING Before shifting, you must stop the vehicle and take your foot off the accelerator pedal. Otherwise, the transmission may be damaged.
Page 119: Checking The Final Gear Oil Level
MAINTENCE AND ADJUSTMENT OF THE UTV a. Hold the main body of the brake light switch so ① that it does not rotate and turn the adjusting nut ② ○ ○ in direction until the brake light comes on at the proper time. ○...
Page 120: Checking The Differential Gear Oil
MAINTENCE AND ADJUSTMENT OF THE UTV Periodic oil change : 0.25 L (0.22 Imp qt) Total amount : 0.4 L (0.35 lmp qt, 0.42 US qt) WARNING Take care not to allow foreign material to enter the final gear case. ·Install: oil filler plug 23 Nm (2.3 m ·...
Page 121: Checking The Constant Velocity Joint Dust Boots
MAINTENCE AND ADJUSTMENT OF THE UTV 5. Install: ·drain plug 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Check the gasket (drain plug). If it is damaged, replace it with new one. 6. Fill: ·differential gear case Periodic oil change 0.32 L (0.28 Imp qt, 0.34 US qt) Total amount...
Page 122: Checking The Steering System
MAINTENCE AND ADJUSTMENT OF THE UTV □ Rear CHECKING THE STEERING SYSTEM 1. place the vehicle on the flat ground . Check: ● Clamp seat of steeing vertical column and sliding bearing on the lower end of steering vertical column, upper ＆...
Page 123: Adjusting The Toe-In
MAINTENCE AND ADJUSTMENT OF THE UTV ADJUSTING THE TOE-IN 1. Place the vehicle on a level surface. 2. Measure: • toe-in Adjust. Out of specification Toe-in 8~ 18 mm (0.00 ~ 0.39 in) (with tires touching the ground) NOTE: Before measuring the toe-in, make sure that the tire pressure is correct.
Page 124: Adjusting The Front And Rear Shock Absorbers
MAINTENCE AND ADJUSTMENT OF THE UTV make , sure if the Steering bar is pormal , if not , adjust the tension rod left or right within the specification . a. Mark both tie-rods ends. This reference point will be needed during adjustment. b.
Page 125 MAINTENCE AND ADJUSTMENT OF THE UTV ADJUSTING THE FRONT AND REAR SHOCK ABSORBERS (Option 2) WARNING These shock absorber assemblies contain highly pressurized nitrogen gas, read and understand the following information before handling the shock absorber assemblies. · Do not tamper with or attempt to open the cylinder assemblies.
Page 126 MAINTENCE AND ADJUSTMENT OF THE UTV · A special wrench can be obtained at a HSUN dealer to make this adjustment. · The spring preload setting is determined by measuring ①, shown in the illustration. The shorter ① is, the lower the spring preload; the longer distance A is, the higher the spring preload.
Page 127: Checking The Tires
MAINTENCE AND ADJUSTMENT OF THE UTV damping force adjusting screw, the rebound damping force adjusting screw or the oil reservoir with your bare hand or skin until suspension components have cooled. ·Always adjust shock absorber assemblies on the left and right side to the same setting.
Page 128 MAINTENCE AND ADJUSTMENT OF THE UTV • MAXIMUM LOADING LIMIT a. Vehicle loading limit (total weight of cargo, operator, passenger and accessories):797kg b. Cargo bed: 100kg c. Trailer hitch: Pulling load (total weight of trailer and cargo): 100 kg Be extra careful of the vehicle balance and stability when towing a trailer.
Page 129: Checking The Wheels
MAINTENCE AND ADJUSTMENT OF THE UTV the tire immediately. CHECKING THE WHEELS 1. Check: • Wheels Damage/bends Replace. ① NOTE: Always balance the wheel when a tire or wheel has been changed or replaced. WARNING • Never attempt even small repairs to the wheel. •...
Page 130: Electrical
MAINTENCE AND ADJUSTMENT OF THE UTV ELECTRICAL CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries;...
Page 131 MAINTENCE AND ADJUSTMENT OF THE UTV different from those of conventional batteries. The MF battery should be charged as explained in the charging method illustrations. If the battery is overcharged, the electrolyte level will drop considerably; • Therefore, take special care when charging the battery.
Page 132 MAINTENCE AND ADJUSTMENT OF THE UTV NOTE: • The charge state of an MF battery can be checked by measuring its open-circuit voltage (i.e., the voltage when the positive terminal is disconnected). • charging necessary when open-circuit voltage equals or exceeds 12.8 V. b.
Page 133 MAINTENCE AND ADJUSTMENT OF THE UTV they are not shorted. A corroded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks. • If the battery becomes hot to the touch at any time during the charging process, disconnect the battery charger and let the battery cool before reconnecting it.
Page 134 MAINTENCE AND ADJUSTMENT OF THE UTV Measure the open-circuit voltage prior to charging. Connect a charger and ammeter to the battery and start charging. Is the amperage higher than the standard charging amperage written on the battery? Adjust the charging voltage to 14.0 ~ 14.2 V Monitor the amperage for 3 ~ 5 Adjust the voltage to obtain the...
Page 135 MAINTENCE AND ADJUSTMENT OF THE UTV Charging method using a constant voltage charger NOTE: Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage. Measure the open-circuit voltage prior to charging. Connect a charger and ammeter to the battery and start charging.
Page 136: Checking The Fuses
MAINTENCE AND ADJUSTMENT OF THE UTV NOTE: Constant amperage chargers are not suitable for charging MF batteries. 3. Install: • battery • Connect: battery leads NOTE: First, connect the positive battery lead ①, and then the negative battery lead ②. •...
Page 137 MAINTENCE AND ADJUSTMENT OF THE UTV b. If the tester indicates“∞”, replace the fuse. 3. Replace: a. Turn off the ignition. b. Install a new fuse of the proper amperage. c. Turn on switches to verify operation of the related electrical devices. d.
Page 138: Adjusting The Headlight Beam
MAINTENCE AND ADJUSTMENT OF THE UTV ADJUSTING THE HEADLIGHT BEAM 1. Adjust: • headlight beam (vertically) • turn the adjuster in or out ① Turning in Headlight beam raised. Turning out Headlight beam lowered. CHANGING THE HEADLIGHT BULB Remove: • Lift the hood up. •...
Page 139: Changing The Tail/Brake Light Bulb
MAINTENCE AND ADJUSTMENT OF THE UTV 2. Install: • bulb new Secure the new bulb with the headlight bulb holder. NOTE: Avoid touching the glass part of the bulb. Keep it free from oil; otherwise, the transparency of the glass, life of the bulb, and luminous flux will be adversely affected.
Page 140 MAINTENCE AND ADJUSTMENT OF THE UTV 2. Install: • bulb new Secure the new bulb with the tail/brake light bulb holder. NOTE: Avoid touching the glass part of the bulb. Keep it free from oil; otherwise, the transparency of the glass, life of the bulb, and luminous flux will be adversely affected.
Page 141: Engine
ENGINE ENGINE ENGINE NOTE 1．Make sure the components, oil, adhesive, sealant are from the company or recommended. 2．Original removal oil seal，gasket, O-ring, piston ring can not be re-assemblied again, make sure all these parts are new. 3．Pay attention to keep dismantled parts orderly, make sure their original positions for reassembling. 4．Prevent dismantled parts damaged, clean before measure and assembly, remove the oil with compressed air.
Page 142: Engine Removal
ENGINE ENGINE REMOVAL Part Name Remarks Removing throttle and intake Remove the parts in the order listed. manifold. Dampers Dampers joint (intake manifold) Intake manifold Temperature sensor Cylinder head Timing chain tensioner cap bolt Pressure plate TMAP Fuel Injector Fuel Injector seat Drain blind nut Drain plug For installation, reverse the removal...
Page 143: Cylinder Head And Cylinder Head Cover
ENGINE CYLINDER HEAD AND CYLINDER HEAD COVER Part Name Remarks Removing the cylinder head and Remove the parts in the order listed. cylinder head Thermostat cover Thermostat Cylinder water outlet connector Washer O-ring Cylinder head cover Cylinder cover pad Spark plug Stud Bolt M8×45 (stainless steel ) Temperature sensor Cylinder head...
Page 144 ENGINE Part Name Remarks Timing chain tensioner/gasket Dowel pin Timing chain guide (exhaust side) For installation, reverse the removal procedure. - 132 -...
Page 145 ENGINE 1、CHECK 1). Checking the valve clearance • Valve clearance Refer to “ADJUSTING THE VALVE CLEARANCE” in chapter 3. 2). Checking the cylinder head cover • cylinder head cover Cracks/damage Replace the cylinder head cover and cylinder head as a set. 3).
Page 146 ENGINE 5). Checking the cylinder head (1). Eliminate: • carbon deposits (from combustion chamber) Use a rounded scraper. NOTE: Do not use a sharp instrument to avoid damaging or scratching: • spark plug threads • valve seats (2). Check: • cylinder head Scratches/damage Replace the cylinder head cover and cylinder head as a set.
Page 147 ENGINE WARNING Always use a new gasket. NOTE: The “UP” mark on the timing chain tensioner should face up. Timing chain tensioner bolt (10 Nm) d. Remove the screwdriver, make sure that the timing chain tensioner rod releases, and tighten the cap bolt to the specified torque. Timing chain tensioner cap bolt (7 Nm) - 135 -...
Page 148: Rocker Arms And Camshaft
ENGINE ROCKER ARMS AND CAMSHAFT Part Name Remarks Removing the rocker arms and Remove the parts in the order listed. camshaft Cylinder head cover Rocker arm shaft Wave washer Rocker arm (exhaust) Rocker arm (intake) Valve adjuster Locknut Camshaft sprocket Camshaft station plate Camshaft Ⅱ...
Page 149 ENGINE 1、CHECK 1). Checking the rocker arms • rocker arm lobes • valve adjusters Blue discoloration/pitting/scratches Replace. • rocker arms • rocker arm shafts Damage/wear Replace. a. Check whether the rocker arm is worn out, or damaged and whether the oil hole is blocked. b.
Page 150 ENGINE 2). Checking the camshaft • cam lobes Pitting/scratches/blue discoloration Replace • camshaft journal Wear/damage Replace • Measure the external diameter of camshaft journal with micrometer. Out of specification Replace. • small holes on camshaft sprocket • rotor “I” mark Out of alignment 3).
Page 151: Valves And Valve Springs
ENGINE VALVES AND VALVE SPRINGS Part Name Remarks moving the valves and valve springs Remove the parts in the order listed. Cylinder head cover Valve lock clip Valve spring retainer Intake valve spring Exhaust valve spring Intake valve Exhaust valve Valve stem seal Valve spring seat For installation, reverse the removal...
Page 152 ENGINE 1、CHECK • valve sealing Leakage at the valve seat Check the valve face, valve seat and valve seat width. a. Pour a clean solvent ① into the intake and exhaust ports. b. Check that the valve seals properly. There should be no leakage at the valve seat ②.
Page 153 ENGINE • valve stem runout Out of specification Replace. Runout limit 0.01 mm NOTE: • When installing a new valve always replace the guide. • If the valve is removed or replaced always replace the oil seal. • The valve seat surface width Out of specification Reface the valve seat.
Page 154 ENGINE NOTE: To ease guide removal, installation and to maintain correct fit, heat the cylinder head to 100 °C (212 °F) in an oven. a. Install the new valve guide using a valve guide remover ① and valve guide installer ②. b.
Page 155 ENGINE d. Apply a fine lapping compound to the valve face and repeat the above steps. NOTE: After every lapping operation be sure to clean off all of the compound from the valve face and valve seat. e. Install the valve into the cylinder head. g.
Page 156: Cylinder And Piston
ENGINE CYLINDER AND PISTON Part Name Remarks Removing the cylinder and piston Remove the parts in the order listed. Water pump outlet hose Cylinder head Dowel pin Cylinder head gasket Cylinder Cylinder gasket Piston pin clip Piston pin Piston Piston ring set For installation, reverse the removal procedure.
Page 157 ENGINE 1、CHECK 1).Checking the cylinder and piston • cylinder and piston walls Vertical scratches Rebore or replace the cylinder and the piston. 2).Checking the piston rings • piston ring (Insert in cylinder piston ring will be ① ,and measure the end gap.) NOTE: Check whether the piston and the piston groove is cracked and abraded.
Page 158 ENGINE • ring end gap Out of specification Replace. Repairing limit value Top ring/2nd ring:0.5mm • ring side clearance Use a thickness gauge. Out of specification Replace the piston and rings as a set. NOTE: Clean carbon from the piston ring grooves rings before measuring...
Page 159 ENGINE 3、INSTALL: 1). Installing the piston • piston rings (onto the piston) NOTE: • Be sure to install the piston rings so that the manufacturer’s marks or numbers are located on the upper side of the rings. • Lubricate the piston and piston rings liberally with engine oil.
Page 160: Engine Left Crankcase Cover A.c. Magneto
ENGINE ENGINE LEFT CRANKCASE COVER AND A.C. MAGNETO Part Name Remarks Removing the engine left crankcase Remove the parts in the order listed. cover and A.C. magneto Engine oil Water pump assembly Left crankcase cover Inspection port cover /O-ring Crankcase location sensor/ O-ring Plug oil level gauge/O-ring A.C.
Page 161 ENGINE Part Name Remarks Starter idle gear Starter idle gear shaft For installation, reverse the removal procedure. - 149 -...
Page 162 ENGINE 1、CHECK 1). Checking the A.C. magneto • stator coil • pickup coil Damage Replace. 2). Checking the starter clutch • starter clutch ① Cracks/damage Replace. • starter clutch bolts ② Loose Replace with new ones, and clinch the end of the bolts. NOTE: •...
Page 163 ENGINE 2、INSTALL • woodruff key • dowel pins • A.C. magneto rotor NOTE: • Before installing the rotor, clean the outside of the crankshaft and the inside of the rotor. • After installing the rotor, check that the rotor rotates smoothly. If not, reinstall the key and rotor.
Page 164: Starter Motor And Oil Filter
ENGINE STARTER MOTOR AND OIL FILTER Part Name Remarks Removing the starter motor and oil Remove the parts in the order listed. filter A.C. magneto rotor Starter idle gear Starter idle gear shaft Relief valve spring/steel ball Chain plate Timing chain guide(first cylinder) Timing chain Pump Oil filter cover...
Page 165 ENGINE Part Name Remarks Oil pressure sensor For installation, reverse the removal procedure. - 153 -...
Page 166 ENGINE 1、CHECK 1) Checking the starter idle gear • starter idle gear Cracks/wear/damage Replace 2) Checking the timing chain and guides • timing chain Cracks/stiff Replace the timing chain and Camshaft sprocket as a set. • Timing chain guides Wear/damage Replace.
Page 167: Primary And Secondary Sheaves
ENGINE PRIMARY AND SECONDARY SHEAVES Part Name Remarks Removing the primary and secondary Remove the parts in the order listed. sheaves Engine assembly Drive belt cover Rubber gasket Clutch cove of plug keeper V-belt Secondary fixed sheave Secondary sliding sheave Compression spring Guide Base, Driven Gear Driving Flyweight...
Page 168 ENGINE Part Name Remarks Primary fixed sheave Compression spring/Spring seat Spacer Fixing Base One-Way Bearing Guide pin/spring Primary sliding sheave Flange Bolt M6×25 Flange Bolt M6×22 Spring Washer φ6 Drive belt case O-ring For assembly, reverse the disassembly procedure. - 156 -...
Page 169 ENGINE 1、Check 1). Checking the primary sheave • primary pulley slider • primary sliding sheave splines Wear/cracks/damage Replace. • spacer • primary pulley cam Cracks/damage Replace. • primary sliding sheave • primary fixed sheave Cracks/damage Replace. 2、Measure • secondary sheave spring free length (a) Out of specification Replace the secondary sheave spring.
Page 170 ENGINE 2). Assembling the secondary sheave (1)Apply: • assembly lube (to the secondary sliding sheave ① inner surface and oil seals)。 • assembly lube (to the bearings, oil seals and inner surface of the secondary fixed sheave ②) 3). Installing the primary and secondary sheaves (1) Install: •...
Page 171: Crankcase Cover And Oil Pump
ENGINE CRANKCASE COVER AND OIL PUMP Part Name Remarks Removing the crankcase cover and oil Remove the parts in the order listed. pump Crankcase separation Crankshaft cover Gasket Dowel pin Crankcase exhaust pipe Crankcase block Oil seal Oil pump gasket Oil pump Outer rotor Innter rotor...
Page 172 ENGINE Part Name Remarks Shaft/pin Oil pump housing Oil pump gear Water pump Ⅱ gear/circlip Shaft/pin Water pump Ⅰ gear/washer Oil pump middle gear Shaft Bearing Fuel and air separator assy V-ring Shaft Valve piece plate - 160 -...
Page 173 ENGINE Part Name Remarks Valve piece Chain plate Timing chain guide(secondly cylinder) Timing chain Right crankcase For assembly, reverse the disassembly procedure. - 161 -...
Page 174 ENGINE 1、CHECK 1). Checking the oil pump • rotor housing • rotor cover Cracks/wear/damage Replace. • oil pump operation Unsmooth Repeat steps #1 and #2 or replace the defective parts. 2) Checking the timing chain and guides • timing chain Cracks/stiff Replace the timing chain and camshaft sprocket as a set.
Page 175: Crankcase And Middle Driven Shaft
ENGINE CRANKCASE AND MIDDLE DRIVEN SHAFT Part Name Remarks Remove the crankcase and middle Remove the parts in the order listed. drive shaft Crankcase separation Right crankcase Crankcase gasket Dowel pin Crankshaft Shaft Connection rod cover/rod bushing Universal joint Oil seal Bearing retainer Bearing seat dowel pin - 163 -...
Page 176 ENGINE Part Name Remarks Bearing Middle driven shaft Bearing O-ring/bearing Left crankcase For installation, reverse the removal procedure. - 164 -...
Page 177 ENGINE 1、CHECK 1). Checking the middle drive • O-ring Damage Replace. • bearings Clean and lubricate, then rotate the inner race with a finger. Pitting/damage Replace. • universal joint movement Roughness Replace universal joint. 2). Checking the crankcase (1) Thoroughly wash the case halves in a mild solvent.
Page 178 ENGINE a tolerance of less than 1 mm (0.04 in). CAUTION: The buffer boss and woodruff key should be replaced when removed from the crankshaft. 2). Assembling the crankcase (1) Apply: • sealant (Quick Gasket) (to the mating surfaces of both case halves) (2) Install: •...
Page 179 ENGINE 2). Installing the middle driven shaft • universal joint. a. Install the opposite yoke into the universal joint. b. Apply wheel bearing grease to the bearings. c. Install the bearing ① onto the yoke. CAUTION: Check each bearing. The needles can easily fall out of their races.
Page 180: Output Shaft
ENGINE OUTPUT SHAFT Part Name Remarks Remove the output shaft Remove the parts in the order listed. Middle drive gear Left gear case cover Drive shaft coupling Drive shaft spring/bearing Output shaft Y-1 Washer/collar Washer/o-ring Universal Joint A φ22 Fuel seal Collar/o-ring Rear drive bearing seat - 168 -...
Page 181: Gearcase
ENGINE Part Name Remarks Dowel pin Gearcase Washer φ10×φ32×5 Cross Joint φ22 Universal Joint B φ22 For installation, reverse the removal procedure. - 169 -...
Page 182: Gearcase
ENGINE 1、CHECK 1). Checking the output shaft Y-1 • Drive shaft coupling • Output shaft Y-1 Pitting/galling/wear Replace. • O-ring Damage Replace. • bearings Pitting/damage Replace. 2、MEASURE • Output shaft Y-1 swing a. Temporary install the gearcase . b. Wrap a rag ① around a screwdriver ②, and then insert it into the installation hole ③...
Page 183 ENGINE • shims ① • universal joint yoke • washer • nut ① NOTE: Use the universal joint holder ② to hold the yoke. • universal joint. a. Install the opposite yoke into the universal joint. b. Apply wheel bearing grease to the bearings. c.
Page 184: Shift Lever And Oil Pump
ENGINE GEARCASE SHIFT LEVER AND OIL PUMP Part Name Remarks Removing the shift lever and gearcase Remove the parts in the order listed. Gear case separation Shift lever cover/gasket Shift lever 2 assembly Shift lever 1 Oil pump/o-ring Outer rotor Inner rotor Oil pump shaft/pin Connecting pipe1/2...
Page 185 ENGINE Part Name Remarks Oil filler cap/o-ring Gear case gasket/dowel pin Shift drum stopper/spring/steel ball Reverse switch/washer Gearshift indicator/o-ring Spring seat/ circlip Guide bar Shift fork 1/long spring Shift fork 2/short spring Gea r case cover Bracket clutch cover seat For assembly, reverse the disassembly procedure.
Page 186: Gearcase Transmission
ENGINE GEARCASE TRANSMISSION Part Name Remarks Removing the gear case transmission Remove the parts in the order listed. Gear case separation Gear case cover Inner hexangular screw M8×45 Inner hexangular screw M8×40 Spring washerφ8 Oil seal 32×47×7 Bush φ25×φ32×18 O-ring 25×2.4 Flange bolt M6×45 Flange bolt M6×35 Bracket clutch cover seat...
Page 187 ENGINE Part Name Remarks Bearing 6305 Bearing plate Cross recessed countersunk head Screw Main shaft Pin φ2×18 Needle bearing 25×29×12.6 H Drive gear Washer φ27×3φ2×2 L Drive gear Bearing 6204 DU Bearing 6403 Washer φ17.3×φ34×2 R Driven gear - 175 -...
Page 188 ENGINE Part Name Remarks Washer φ25.4×φ33×1 H driven gear L Driven gear Needle bearing 25×29×9.6 Counter shaft Needle bearing AXK15×28×2 Washer φ15.3×φ32×1.5 Needle bearing NBI19×27×16 R Idle gear R Idle gear shaft Reverse gear-shaft φ12×56 For assembly, reverse the disassembly procedure.
Page 189 ENGINE 1、CHECK 1). Checking the shift forks • shift fork follower ① • shift fork pawl ② Scoring/bends/wear/damage Replace. • guide bar Roll the guide bar on a flat surface. Bends Replace. ： WARNING Do not attempt to straighten a bent guide bar.
Page 190 ENGINE 3). Checking the bearings (1) Check: • bearings Clean and lubricate, then rotate the inner race with a finger. Roughness Replace 4). Checking the oil pump • rotor housing • rotor cover Cracks/wear/damage Replace. • oil pump operation Unsmooth Repeat steps #1 and #2 or replace the defective parts.
Page 191 ENGINE 3、INSTALL 1). Assembling the shift fork • guide bar ① • shift fork 2 ② • long spring ③ • shift fork 1 ④ • short spring ⑤ 2). Installing the shift levers • shift lever 2 assembly ① (14Nm) •...
Page 192: Malfunction Inspection
CHASSIS MALFUNCTION INSPECTION Appearance malfunction inspection Phenomenon Measure 1. Replace new plastic cover. 2. Check whether installation supporter deformed, repairing Plastic cover damaged or re-painting is needed before replacing new plastic cover. 3. Re-paste decals and re-rivet warning labels. 1. Replace new bumper. 2.
Page 193 CHASSIS 4. Check whether front wheel and front wheel axle nut loosen or damaged. Off tracking by braking at 5. Check whether front wheel hub inner spline and front high-speed wheel axle outer spline worn or loosen. 6. Check whether rubber cushion connected to front suspension rocker and frame damaged.
Page 194 CHASSIS Phenomenon Measure 1. Check whether front and rear axles splines damaged. 2. Check whether gears of front gearbox and differential over Front and rear axles arise worn. abnormal sound during drive 3. Check whether rear gearbox gears over worn. 4.
Page 195: Direction System
CHASSIS DIRECTION SYSTEM Steering Wheel part Part Name Remarks Removing the steering wheel Socket hexagon screw M6×16 Steering wheel body Hexagon flange nut M12×1.25 Nylon bush Φ11×Φ16×Φ23×11 Steering column Hex flange step bolt M8×13-Φ12×12 Hexagon flange self-lock nuts M8 Steering rod Hexagon flange bolt M6×25 - 183-...
Page 196 CHASSIS Part Name Remarks Cap nut M6×12 Decoration cover, steering column Cross large plate head screw M6×16 Passenger handle bar assy Handle bar grip Locking knob, handle bar Steering drive axle Hexagon flange bolt M8×30 Washer Φ8×Φ16×1.6 Driving gear Hexagon flange bolt M10×1.25×35 - 184-...
Page 197 CHASSIS Part Name Remarks Cross big plate head screw M5×16 Hexagon flange nut M5 Screw M5×12 Clamp Rubber dust cover Clip Φ15 Ball joint steering mechanism Hexagon nut M12×1.25 Collar pin 2×25 Steering wheel comp Hexagon flange bolt M6×30 - 185-...
Page 198 CHASSIS Part Name Remarks Rubber dust cover Decoration cover for steering column Handle sheath Steering mechanism comp Hexagon flange bolt M8×35 Hexagon flange self-lock nuts M8 Bushing Φ6×Φ10×18 Spring washer -8 Dust sleeve Down cover for steering wheel Decoration cover for steering wheel - 186-...
Page 199 CHASSIS Part Name Remarks Middle cover for steering wheel Up cover for steering wheel Screw M8×16 Upper cover ignition lock Ignition switch Lower cover for ignition switch assy Light switch assy Spring washer Φ10 Washer Φ10×Φ20×2 Cross recessed plate head screw ST3.6×10 Washer Φ15×Φ28×2 - 187-...
Page 200 CHASSIS THE STRUCTURE OF STEERING WHEEL PART DIASSEMBLING THE PARTS OF THE STEERING WHEEL Remove: • up cover for steering wheel ① • socket Hexagon Screw ② • steering wheel ③ a. Takes down the Up cover for steering wheel ① b.
Page 201 CHASSIS • Flange nut ③ Inspect fastens nut of the steering wheel whether does have flaw and fissure , if it is, must replace. Check the internal spline between the steering wheel and steering column whether have damaged, if the attrition is serious, must replace the steering wheel.
Page 202 CHASSIS CHECKING AND SERVICE THE STEERING COLUMN PARTS 1. Check: • steering column tube ① • bearing ② • central axis of the steering shaft ③ • spline ④ • loosening ⑤ The central axis of the steering shaft whether flexible and moves.
Page 203 CHASSIS STEERING MACHINE PARTS THE STRUCTURE OF THE STEERING 1. Check: • pressure pad ① • Rubber dust cover ② Replace. Wear/damage Damage/degradation Replace NOTE: When replace the dust boots of the ball , must enter 1/2 volume in lithium grease in to the dust boots.
Page 204: Brake System
CHASSIS BRAKE SYSTEM PREPARATION FOR CHECKING BEFORE THE MAINTENANCE OF THE BRAKE SYSTEM. Brake system is crucial to the life safety of the operator and therefore must be periodically inspected and maintained. This vehicle uses the single return route hydraulic pressure disc brake system. Please follow the tips of inspection as below.
Page 205: Disk Brake Components
CHASSIS DISK BRAKE COMPONENTS Part Name Remarks Removing brake components Auxiliary bumper Rear brake oil pipe Clamp Ⅱ （L=250） Rubber water pipe clip Hexagon flange bolt M6×16 Hexagon flange bolt M6×30 Hexagon flange bolt M6×16 Oil pipe clip Hexagon flange bolt M6×12 Oil pipe clip front disc brake - 193-...
Page 206 CHASSIS DISK BRAKE COMPONENTS Part Name Remarks Disc brake parts Front brake hose Oil pipe clip Corrugated pipe Φ10×Φ13×450 Corrugated pipe Φ10×Φ13×250 Corrugated pipe Φ10×Φ13×300 Rear right brake hose Rear left brake hose Rear T-junction - 194-...
Page 207: Front Brake Caliper
CHASSIS FRONT BRAKE CALIPER Remarks Part Name Removing front brake caliper Front brake disc Hexagon step bolt M8×15-Φ15×5 Front brake disc Front brake caliper Brake caliper piston assembly Brake caliper piston Dust seal Caliper piston seal Bleed screw Brake pad - 195-...
Page 208 CHASSIS Part Name Remarks Pad spring Brake pad holding bolt Hexagon flange bolt M10×1.25×22 - 196-...
Page 209 CHASSIS CHECKING THE FRONT BRAKE DISC 1. Check: • brake disc Galling/damage Replace. 2. Measure: • brake disc deflection Out of specification Check the wheel runout. If wheel runout is within the limits, replace the brake disc. Brake disc maximum deflection 0.10 mm (0.004 in) •...
Page 210 CHASSIS REPLACING THE FRONT BRAKE PADS NOTE: It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads. 1.Check: • brake pad ① Damage/wear Replace 2.Measure: • brake pad thickness ⓐ Out of specification Replace the brake pads as a set.
Page 211 CHASSIS 4. Check: • brake fluid level • minimum level mark ① Must use DOT4 Brake Fluid 5. Check: •brake pedal operation Soft or spongy feeling Bleed the brake system. DISASSEMBLING THE FRONT BRAKE CALIPERS WARNING: • Brake caliper is one of the most important security components.
Page 212 CHASSIS b. Remove the dust seals and caliper piston seals. WARNING: All internal brake components should be cleaned in new brake fluid only. Do not use solvents as they will cause seals to swell and distort. 2. Check: • brake caliper pistons ① Scratches/rust/wear Replace the brake caliper assembly.
Page 213 CHASSIS ASSEMBLING THE FRONT BRAKE CALIPERS WARNING: • All internal brake components should be cleaned and lubricated with new brake fluid only before installation. Must use DOT4 Brake Fluid • Replace the caliper piston seals and dust seal whenever a brake caliper is disassembled. 1.
Page 214 CHASSIS NOTE: When installing the brake hose on the brake caliper, make sure that the brake pipe touches the projection a on the brake caliper. WARNING: Proper brake hose routing is essential to insure safe vehicle operation. 2. Fill: • brake reservoir Must use DOT4 Brake Fluid NOTE: Brake fluid may damage painted surfaces...
Page 215: Rear Brake Calipers
CHASSIS REAR BRAKE CALIPER Remarks Part Name Removing rear brake caliper Rear brake disc Rear brake disc Hexagon step bolt M8×15-Φ15×5 Rear brake caliper Brake caliper piston assembly Brake caliper piston Dust seal Caliper piston seal Bleed screw Brake pad - 203-...
Page 216 CHASSIS Remarks Part Name Pad spring Brake pad holding bolt Hexagon flange bolt M10×1.25×22 - 204-...
Page 217 CHASSIS The service method of the rear brake caliper is as the same as the front brake caliper, please refer to the before-mentioned to operate.) - 205-...
Page 218: Parking Brake Caliper
CHASSIS PARKING BRAKE CALIPER Remarks Part Name Removing parking brake caliper Parking caliper assembly Bolt Parking disc Bolt, flange Brake pad holding bolt Brake caliper assembly Brake, pad - 206-...
Page 219 CHASSIS Remarks Part Name Brake pad (piston side) Insulator/pad shim Pad spring Parking brake arm nut Set bolt Parking brake arm Parking brake arm shaft Spring Parking brake case bolt - 207-...
Page 220 CHASSIS Remarks Part Name Parking brake case Gasket Bleed screw Brake caliper bracket Caliper piston seal Dust seal Brake caliper piston - 208-...
Page 221 CHASSIS CHECKING THE PARKING BRAKE DISC 1. Check: • parking disc ① Galling/damage Replace. 2. Measure: • parking disc deflection Out of specification Replace. Parking disc maximum deflection 0.10 mm (0.004 in) • parking disc thickness ② Out of specification Replace.
Page 222 CHASSIS REPLACING THE PARKING BRAKE PADS 1. Check: • brake pad • brake pad plate Damage/wear Replace 2. Measure: • brake pad thickness Out of specification Replace the brake pads as a set. Brake pad wear limit 1.0 mm (0.04 in) 3.
Page 223 CHASSIS DISASSEMBLING THE PARKING BRAKE CALIPER WARNING: • Brake caliper is one of the most important security components. Disassembly and maintenance must have a rich experience in technology and complete tool. •Wrong disassembly and reassembly may cause serious injury and even death. Replace damaged brake caliper.
Page 224 CHASSIS • brake caliper body ③ • brake fluid delivery passage (brake caliper body) Blockage Blow out with compressed air. WARNING: Replace the caliper piston seals and dust seals whenever the brake caliper is disassembled. ASSEMBLING THE REAR BRAKE CALIPER WARNING: •...
Page 225 CHASSIS 3. Install: • gasket ① • parking brake case ② • parking brake case bolts ③ 22Nm (2.2 m · kg,16 ft · lb) • O-ring ④ 4. Install: • parking brake arm shaft ① • parking brake arm ② •...
Page 226 CHASSIS 5. Install: • brake pad (piston side) ① (with insulator and pad shim) NOTE: Align the projection a on the piston side of the brake pad with the groove in the brake caliper piston. 6. Install: • brake pad holding bolts 17Nm (1.7 m ·...
Page 227 CHASSIS 3. Air bleed: • brake system 4. Check: • brake fluid level Brake fluid level is below the “MIN” level line  A dd the recommended brake fluid to the proper level. 5. Adjust: • parking brake cable free play CHECKING THE MASTER CYLINDER 1.
Page 228 CHASSIS INSTALLING THE BRAKE MASTER CYLINDER 1. Install: • brake master cylinder 16Nm (1.6 m · kg,11 ft · lb) 2. Install: • brake pipe 19Nm (1.9 m · kg,13 ft · lb) • washer plate • brake hose • union bolt 27Nm (2.7 m ·...
Page 229: Footrest Assembly
CHASSIS FOOTREST PART Part Name Remarks Removing the footrest part Left front mud-guard board Cross big plate head screw M6×12 Screw thread clip M6×2 Right front mud-guard board Cross large plate head screw M6×16 Screw thread clip M6×2 Left footrest protector Cross large plate head screw M6×16 Screw thread clip M6×2 - 217-...
Page 230 CHASSIS Part Name Remarks Right footrest protector Cross big plate head screw M6×12 Screw thread clip M6×2 Axle cover Cross large plate head screw M6×16 Dustproof plate brake pedal Welding, parking pedal Spring D Spring Φ3×Φ30×46° Rear brake pump bracket assy Hexagon flange bolt M8×20 Washer Φ12×1 - 218-...
Page 231 CHASSIS Part Name Remarks Link fork, mandril Connecting axle Accelerator pedal welding assy Throttle cable Washer Φ15×Φ22×1.5 Spring Φ2×Φ14×62 Expansion bolt(plastic) Cross large plate head screw M6×16 Cross large plate head screw M6×16 Cross big plate head screw M6×12 Collar pin 2×32 Lamp switch, rear break - 219-...
Page 232: Wheel And Tyre Parts
CHASSIS WHEEL AND TYRE PARTS FRONT WHEELS Part Name Remarks Removing the front wheel Front wheel rim Front tyre Cycle valve Nut M10 Wheel decoration cover Ⅳ Cotter 3.2×50 WARNING: Nut M22×1.5 Securely support the vehicle so Front hub There is no danger of it falling over. Bolt M10×30 - 220-...
Page 233: Rear Wheels
CHASSIS REAR WHEELS Part Name Remarks Removing the rear wheel Rear wheel rim Rear tyre Cycle valve Rear hub Bolt M10×30 WARNING: Nut M10 Securely support the vehicle so There is no danger of it falling over. Wheel decoration cover Ⅳ Nut M22×1.5 Cotter 3.2×50 - 221-...
Page 234 CHASSIS CHECKING THE WHEEL TYRE 1. Check: • wheel tyre 2. Measure: • wheel runout Over the specified limit Replace the wheel or check the wheel bearing play ① 3. Check: • wheel balance Out of balance           Adjust.
Page 235 CHASSIS INSTALLING THE WHEEL HUB 1. Install: • axle nut 260 Nm (26.0 m · kg, 190 ft · lb) INSTALLING THE WHEEL TYRE 1. Install: • wheel NOTE: The arrow mark ① on the tyre must point in the direction of rotation □ of the wheel.
Page 236 CHASSIS SPECIFICATION OF WHEEL AND TYRE Tyre Wheel hub Tyre Pressure Dimension Dimension （Kpa /PSI） Front 12×6.AT 25×8-12 140/20 Wheel Rear 12×8.AT 25×10-12 140/20 Wheel • Since wheels and tyres are crucial to the vehicle operation, inspection for tyre pressure and profile depth is necessary.
Page 237: Transmission System
CHASSIS TRANSMISSION SYSTEM C.V Axle, Front Axle Part Name Remarks Removing the C.V axle, front axle (L.&R.) Circlip Double off-set assembly Circlip Ball bearing Circlip Hoop A, dust P shed Outer rubber dust-P cover (C-1610) Adjustable clamp C.V shaft assembly Inner rubber dust-P cover (C-1605) C.V axle, front axle - 225-...
Page 238: Front Bridge
CHASSIS Front Bridge Part Name Remarks Removing the front bridge Front differential caseⅠ Front differential case Ⅱ Fuel drain screw plug O-ring gasket, fuel injection Φ2.2×Φ16.4 Drive & driven gears Differential Breather pipe Clip Φ11 Dustproof rubber coverΦ19×Φ38×50 Front transmission shaft comp Front differential assy Universal jointⅠ...
Page 239 CHASSIS Part Name Remarks Circlip Φ20×Φ26×1 Oil seal, front box input shaft Seal Ring Spring, transmission shaft, O-ring gasket, fuel injection Φ2.2×Φ16.4 Front transmission shaft Speed sensor comp. Joint cross shaft Connection fork Ⅱ Connection fork Ⅰ Transfer case assembly Seal ring Φ3.1×Φ78 ,transfer Bearing 6306 P5 Bearing Rna4910...
Page 240 CHASSIS Part Name Remarks Differntial adjustment gasket Hexagon flange bolt M8×25 Outer raceway Washer 14.5×30×4 Hexagon flange self-lock nuts M14×1.5 Hexagon flange bolt M8×30 Clip Φ72 - 228-...
Page 241 CHASSIS Front Bridge DISASSEMBLING THE UNIVERSAL JOINT Remove: • universal joint a. Remove the circlips ① b. Place the universal joint in a press. c. With a suitable diameter pipe - eath the ② yoke , press the bearing into the pipe as ③...
Page 242 CHASSIS CHECKING THE AXLE, FRONT AXLE 1.Check: • Rubber dust-P cover Cracks/damage Replace 2.Check: • double off-set assembly • ball joint spline • shaft spline Wear/damage Replace. • balls and ball races • inner surface of double off-set Pitting/wear/damage Replace. ·Check whether the inner and outer ball cage of the left and right transmission shaft movement is Smooth, ceaseless.
Page 243 CHASSIS ASSEMBLING THE UNIVERSAL JOINT Install: • universal joint a. Install the opposite yoke into the universal joint. b. Apply wheel bearing grease to the bearings. c. Install the bearing ① onto the yoke. d. Press each bearing into the universal joint using a suitable socket.
Page 244: C.v Axle, Rear Axle
CHASSIS C.V Axle, Rear Axle Part Name Remarks Removing the rear bridge(L.&R.) Circlip Adjustable Clamp Hoop A,dust p shed Inner rubber dust-proof(c-1513), front axle Circlip Double off-set joint assembly Double off-set joint assembly Circlip Ball bearing Joint shaft assembly Outer rubber dust-proof(C-1605), front axle C.V Axle, rear axle - 232-...
Page 245: Rear Bridge Reducer
CHASSIS Rear Bridge Reducer Part Name Remarks Removing the rear bridge Rear differential caseⅠ Rear differential case Ⅱ Oil seal Φ52×Φ35×7 Bearing 32008E Rear differntial Vent pipe, rear differential Steel wire clamp Φ11 Rear differential assy Hexagon flange locked nut M14×1.5 Magnetic valve - 233-...
Page 246 CHASSIS Part Name Remarks Bearing 32010E Bearing seat Metal Bushing Fuel drain O type seal Fuel drain screw plug Welding combination of shift fork U Type spring Fix bracket Returning spring Sleeve of shift fork Column pin of shift fork Washer Φ12×Φ30×4 - 234-...
Page 247 CHASSIS Part Name Remarks Oil fill plug O-ring gasket, fuel injection O-ring gasket Hexagon flange nut M10×1.25 Bearing 32206E Adjust bushing Ⅱ Gasket of adjust bushing Adjust bushing Ⅰ Oil fill plug O-Ring gasket, fuel injection Driving and driven gears Rear adjustment gasketⅠ...
Page 248 CHASSIS Part Name Remarks Hexagon Flange Self-Lock Nuts M6 Parking Plate Hexagon step zylinderschraube M6×14-Φ7×15 Middle brake assy Hexagon flange bolt M10×1.25×30 Mount bracket,rear disk brake plate Differntial adjustment gasket Adjustment gasket O-ring Φ2.5×Φ192 Hexagon flange bolt M8×25 Parking brake pad assy - 236-...
Page 249: Rear Bridge
CHASSIS Rear Bridge The service method of the rear bridge parts is as the same as the front bridge parts, please refer to the before-mentioned to operate.) NOTE: Apply lithium-soap-based grease to the bearing assembly and o-ring and bearing and driven gear and oil seal and drive shaft coupling and final drive pinion gear bearing housing.
Page 250: Shift Operating System
CHASSIS Shift Operating System Part Name Remarks Removing the shift operating system Gear shifter assembly Gear Shifting Support Hexagon Flange bolt M8×12 Gearshift Rod Ⅰ Hexagon flange bolt M6×16 Hexagon flange self-lock nuts M6 Gearshift rod Ⅱ Gearshift boot Gearshift knob Gear shifting support - 238-...
Page 251 CHASSIS Part Name Remarks Hexagon flange self-lock nuts M6 Hexagon flange bolt M6×16 Gearshift arm assy Ⅱ Hexagon flange nut M8 Gearshift arm assy Ⅰ Gearshift assy Rubber cover clamp Plastic screw Hexagon flange bolt M8×20 - 239-...
Page 252 CHASSIS Reverse mechanism parts ADJUSTING REVERSE MECHANISM PARTS ① Neutral ② High ③ Low ④ Reverse ⑤Select lever shift rod ⑥Shift control cable NOTE: Before shifting, you must stop the vehicle and take your foot off the accelerator pedal. Otherwise, the transmission may be damaged.
Page 253 CHASSIS Reverse mechanism parts CHECKING SERVICE REVERSE MECHANISM 1. Check the mobility of gear shift handle. If it is not working properly, remove the gear shift Mechanism to check if the fork , ball and spring is stuck.,in which case replace defective component and try again.The last way is to turn to...
Page 254: Suspension
CHASSIS SUSPENSION Front Swing Arm Part Name Remarks Removing the front swing arm Front shock absorber Hexagon flange nut M10×1.25 Hexagon flange bolt M10×1.25×55 Hexagon flange nut M10×1.25 Front anti-roll bar "U" type rubber bush Φ21-40 Press block, rear anti-roll bar Hexagon flange bolt M8×22 - 242-...
Page 255 CHASSIS Part Name Remarks Tie-Rod, front anti-roll bar Hexagon flange bolt M10×1.25×45 Hexagon flange nut M10×1.25 Hexagon flange bolt M10×1.25×102 Bush Φ10×Φ16×20 - 243-...
Page 256: Front Suspension
CHASSIS Front Suspension Part Name Remarks Removing the front suspension Right front upper swing arm Left front upper swing arm Right Front Lower Swing Arm Left front lower swing arm Hexagon flange bolt M10×1.25×70 Dust cover B Hexagon flange nut M10×1.25 Middle rubber tube, swing arm Elasticity block ring D=30 Universal joint A...
Page 257 CHASSIS Part Name Remarks Hexagon flange bolt M10×1.25×70 Hexagon flange nut M10×1.25 Hexagon nut M12×1.25 Collar pin 2.5×30 Protective board, swing arm Spring washer -12 Cross large plate head screw M6×16 - 245-...
Page 258 CHASSIS Front Suspension and arm DISASSEMBLING, SERVICE AND ASSEMBLY THE SUPPORTING ROCKER PARTS 1. Disassembling and Service In the suspension, there is easy to appear the problem with bushing, cotter pin and shock absorber. ·If the left and right rocker rocks fiercely, check the few aspect, whether the bushing of the rocker is crushed, the middle rubber separate is aging and chapped.
Page 259 CHASSIS Front Suspension and arm ·Check whether these components are greased with butter and then tighten the up-and-down rocker arm assembly and L/R fore dampers and ther components. Fix the L/R tension rods into hole by way of the trough of open-groove nut with cotter pin (4 pcs), and make these tension rods bisection on feet.
Page 260 CHASSIS CHECKING THE FRONT SHOCK ABSORBER 1. Check: • shock absorber rod Bends/damage Replace the shock absorber assembly. • shock absorber assembly Oil leaks Replace the shock absorber assembly. • spring Fatigue Replace the shock absorber assembly. Move the spring up and down. - 248-...
Page 261 CHASSIS Front Suspension and arm INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER 1. Install: • front arms • front shock absorber a. Install the front upper arm ①and front lower arm ②. NOTE: • Lubricate the bolts ③ with lithium-soap-based grease.
Page 262: Rear Anti-Roll Bar
CHASSIS Rear Anti-Roll Bar Part Name Remarks rear anti-roll bar Removing the Rear shock absorber Hexagon flange bolt M12×1.25×70 Hexagon flange nut M12×1.25 Hexagon flange bolt M12×1.25×60 Rear anti-roll bar "U" type rubber bush Φ21-40 Press block, rear anti-roll bar Hexagon flange bolt M8×22 Rear Anti-roller lever assy Hexagon flange bolt M10×1.25×45...
Page 263: Rear Swing Arm
CHASSIS Rear Swing Arm Part Name Remarks Removing the rear swing arm Rear right upper swing arm Rear left upper swing arm Rear right lower swing arm Rear left lower swing arm Cross big plate head screw M6×12 Protective board, rear right lower swing arm Hexagon flange bolt M10×1.25×195 Nylon bush Ⅲ...
Page 264 CHASSIS Part Name Remarks Hexagon flange nut M10×1.25 Middle rubber tube, swing arm Hexagon flange Nut M10×1.25 Protective board, rear left lower swing arm Iron nipple Hexagon flange bolt M10×1.25×70 Dust cover B - 252-...
Page 265 CHASSIS Rear Suspension and arm CHECKING SERVICE REAR SUSPENSION 1. It is similar to the front suspension ,Check if there exists any distortion or crack on the install axis of the shock absorber in which case it must be replaced. 2.
Page 266 CHASSIS Rear Suspension and arm CHECKING THE STABILIZER 1. Check: • bar, stabilizer Bends/cracks/damage Replace. CHECKING THE STEERING KNUCKLES 1. Check: • steering knuckles Damage/pitting Replace CHECKING THE REAR ARMS 1. Check: • rear arms Bends/damage Replace. 2. Check: • Middle bushing Wear/damage Replace.
Page 267 CHASSIS I NSTALLING THE REAR ARMS AND REAR SHOCK ABSORBER 1. Install: • rear arms • rear shock absorber a. Install the rear upper arm ① and rear lower arm ②. NOTE: • Lubricate the bolts ③with lithium-soap-based grease. • Be sure to position the bolts ③so that the bolt head faces outward.
Page 268: Cooling System
CHASSIS COOLING SYSTEM Water And Oil Radiator Part Name Remarks Removing the radiator Screw hoop Φ12×20 Pressureproof rubber oil pipe A-860 Pressureproof rubber oil pipe A-1100 Oil cooling radiator assy H-shaped rubber washer M type clip , oil pipe Front metal oil pipe Pressureproof rubber oil pipe C-1280 - 256-...
Page 269 CHASSIS Part Name Remarks Screw clip Φ14-27 Reaer water pipe （R） Reaer water pipe （L） Metal water pipe (L) Metal water pipe (R) Clip , metal water pipe Hexagon flange bolt M6×16 Front water pipe （L） Front water pipe （R） Expansion water tank rubber pipeⅡ...
Page 270 CHASSIS Part Name Remarks Standby water bottle Bushing Φ6×Φ9×Φ22×6.5 Hexagon flange Bolt M6×16 Expansion water tank rubber pipe Φ5×Φ9×540-30 Clip Φ9 Water pipe Rear metal water pipe(R) Water inlet assy Hexagon flange bolt M6×12 Cooler, water tank Water tank assy Water-tank fan assy - 258-...
Page 271 CHASSIS Part Name Remarks Water pipe G Pressure-proof rubber oil pipe A-540 Front metal oil pipe Ⅱ Water temperature sensor Hexagon flange bolt M6×16 - 259-...
Page 272 CHASSIS CHECKING THE RADIATOR 1. Check: • radiator fins Obstruction Clean. Apply compressed air to the rear of the radiator Damage Repair or replace. NOTE: Straighten any flattened fins with a thin, flat-head screwdriver. 2. Check: • all rubber hose Cracks/damage Replace.
Page 273 CHASSIS INSTALLING THE RADIATOR 1. Fill: • cooling system Start engine when pour full the refrigerating fluid, loose the exhaust nut on the pipe, the water level will get lower at this time, Supply the refrigerating fluid until the water level stop to change, then screw the exhaust nut, cover the water tank lid.
Page 274 CHASSIS CHECKING THE OIL COOLER 1. Check: • oil cooler Obstruction  C lean. Apply compressed air to the rear of the oil cooler. Damage  R epair or replace the oil cooler. NOTE: Straighten any flattened fins with a thin, flathead screwdriver.
Page 275: Water Pump
CHASSIS WATER PUMP Part Name Remarks Removing the water pump Clip Water pipe O-ring Φ27×2.5 Water outlet connector, cylinder Save temperature Bolt M6×50 Bolt M6×12 Washer Φ6×Φ10×1 Bolt M6×25 Thermostat cover Washer Φ20.5×Φ30×1 Gasket Water pipe - 263-...
Page 276 CHASSIS Part Name Remarks Removing the water pump water pump housing cover Water pump assembly Bolt M6×40 Washer Φ6×Φ10×1 Bolt M6×65 Secondary gear,water pump Transmission shaft,water pump Pin Φ4×21 Circlip Φ10 - 264-...
Page 277 CHASSIS Part Name Remarks Bearing Oil seal Φ15×Φ10×5 Gasket,water pump cover O-ring Φ34×2.5 Water pump housing Boot band Overflow pipe Gasket,water pump cover Water pump seal assembly - 265-...
Page 278 CHASSIS Part Name Remarks Impeller Cover, water pump Clip Water pipe - 266-...
Page 279 CHASSIS DISASSEMBLING THE WATER PUMP 1. Remove: • rubber damper holder ① • rubber damper ② NOTE: Do not scratch the impeller shaft. 2. Remove: • water pump seal ① • Water pump housing② NOTE: Tap out the water pump seal from the inside of the water pump housing.
Page 280 CHASSIS CHECKING THE WATER PUMP 1. Check: • water pump housing cover ① • water pump housing ② • impeller ③ • rubber damper ④ • rubber damper holder ⑤ • o-ring ⑥ Cracks/damage/wear Replace. NOTE: Apply lithium-soap-based grease to the o-ring. 2.
Page 281 CHASSIS ASSEMBLING THE WATER PUMP 1. Install: • oil seal ① (into the water pump housing ②) NOTE: • Before installing the oil seal, apply tap water or coolant onto its outer surface. • Install the oil seal with a socket ③ that matches its outside diameter.
Page 282: Seat
CHASSIS SEAT Part Name Remarks Removing the seat Safety belt assy Back rest Seat cushion Seat connection assy Socket hexagon screw M8×25 Washer Φ8×Φ16×1.6 Washer Φ8×Φ28×3 Slide rail （R） Slide rail （L） Socket hexagon screw M8×25 Seat mounting board - 270-...
Page 283 CHASSIS Part Name Remarks Hexagon flange bolt M6×16 Hexagon flange self-lock nuts M8 Seat belt buckle（L） Hexagon flange bolt M10×1.25×22 Combined connecting rod guide Shock absorbtion rubber Ⅱ Rubber insulation（R） Hexagon flange step bolt M10×1.25×20-Φ14×5 Gasket Φ10.5×Φ19×5 Hexagon flange nut M10×1.25 Hexagon flange nut M10×1.25 Hexagon flange bolt M10×1.25×22 Hexagon flange nut M10×1.25...
Page 284 CHASSIS Part Name Remarks Hexagon flange step bolt Seat Belt buckle（R） Rubber insulation（L） Wire stop plunger for safty belt Rubber plug Φ19×Φ25×10 Hexagon flange nut M10×1.25 - 272-...
Page 285 CHASSIS DISASSEMBLING THE SEAT Remove: • Driver seat ① • Passenger seat ② • Bolt ③ To remove the seat, Remove bolts M6 with socket wrench, and then remove the seat. Installation is the reverse of removal. CAUTION: ·These components should be greased with butter before assembly.
Page 286: Fuel Tank
CHASSIS FUEL TANK Part Name Remarks Removing the fuel tank Fuel tank Hexagon flange bolt M8×25 Flanging collar Φ8×Φ10×Φ20×7 T Style rubber ring Ⅳ Lid for fuel tank Rubber pipe Φ7×Φ11×1400 Plug for fuel outlet Binder plate for fuel tank Hook, fuel tank Hexagon flange self-lock nuts M8 Fuel tank support...
Page 287 CHASSIS Part Name Remarks Shock absorption cushion for fuel tank Fuel pump assy Fuel pipe Φ8×Φ14×250 Fuel tank cap Triplet joint fuel pipe Clamp High voltage fuel filter Fuel pump plate Hexagon flange nut M6 Seal gasket for fuel pump Shock absorbtion rubber Φ15-6 Plug, fuel inlet Foam sleeve ⅡΦ10×250...
Page 288 CHASSIS Part Name Remarks Hexagon flange bolt M8×25 Hexagon flange bolt M8×45 Fuel pipe Φ8×Φ14×500 Clip Φ11 O-seal Ⅰ Fuel fairwater Fuel pump connection wire assy - 276-...
Page 289 CHASSIS • Fuel tank cap Remove the fuel tank cap by turning it counterclockwise. - 277-...
Page 290: Electrical Components
ELECTRICAL COMPONENTS ELECTRICAL SYSTEM MALFUNCTION INSPECTION Phenomenon Measure 1、 Check whether switches normal. 2、 Check whether cables damaged. Abnormal lights 3、 Check whether lights damaged. Fail shift into 1、 Check whether four wheel drive switch normal. four-wheel-drive 2、 Check whether rear bridge reducer differential mechanical conversion lock differential.
Page 291: Electrical
ELECTRICAL COMPONENTS ELECTRICAL ELECTRICALCOMPONENTS 1. Thermo switch 2 2. Radiator fan 3. Brake light switch 4. Thermo switch 1 5. Ignition coil 1 6. Gear position switch 7. Reverse switch 8. Speed sensor 9. Ignition coil 2 10. stator assembly 11.
Page 292 ELECTRICAL COMPONENTS 1. Relay assy. 2. ECU unit 3. Battery 4. Starter relay 5. DC socket 6.Speedmeter 7. On-Command four-wheel drive switch and differential gear lock switch 8. Light switch 9. Main switch 10. Rectifier/regulator - 280 -...
Page 293: Checking The Switch
ELECTRICAL COMPONENTS CHECKING THE SWITCH CHECKING THE SWITCH Use a pocket tester to check the terminals for continuity. If the continuity is faulty at any point, replace the switch. NOTE: • Set the pocket tester to “0” before starting the test. •...
Page 294: Checking The Switch Continuity
ELECTRICAL COMPONENTS Checking the switch continuity Refer to “CHECKING THE SWITCH” and check for continuity between lead terminals. Poor connection, no continuity Correct or replace. * The coupler locations are circled. 1. Fuse 2. Brake light switch 3. Main switch 4.
Page 295: Checking The Bulbs And Bulb Sockets
ELECTRICAL COMPONENTS CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals Damage/wear Repair or replace the bulb, bulb socket or both. Improperly connected Properly connect. Incorrect continuity reading Repair or replace the bulb, bulb socket or both.
Page 296: Troubleshooting
ELECTRICAL COMPONENTS TROUBLESHOOTING IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK): Procedure Check: 1. Fuses (main, ignition) 7. Main switch 2. Battery 8. Pickup coil resistance 3. Spark plug 9. Rotor rotation direction detection coil 4. Ignition spark gap resistance 5.
Page 297 ELECTRICAL COMPONENTS 4. Ignition spark gap INCORRECT • Disconnect the spark plug cap from the spark plug. • Connect the pulse ignition spark checker or ignition checker ① as shown. Repair or replace the spark plug. ② Spark plug cap •...
Page 298 ELECTRICAL COMPONENTS . resistance Primary coil resistance 0.18 ~ 0.28 Ω at 20 °C (68 °F) • Connect the pocket tester (Ω × 1k) to the ignition coil. Tester (+) lead Orange lead terminal Tester (–) lead Spark plug lead •...
Page 299: Electric Starting System
ELECTRICAL COMPONENTS 9.Wiring connection POOR CONNECTION • Check the connections of the entire ignition system. Refer to “CIRCUIT DIAGRAM”. CORRECT Properly connect the ignition system. Replace the ECU unit ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM （See 344 page） - 287 -...
Page 300: Troubleshooting
ELECTRICAL COMPONENTS TROUBLESHOOTING IF THE STARTER MOTOR FAILS TO OPERATE: Procedure 6. Gear position switch Check: 7. Brake light switch 1. Fuses (main, ignition, signaling system) 8. Diode 1 2. Battery 9. Wiring connection (the entire starting system) 3. Starter motor NOTE: 4.
Page 301 ELECTRICAL COMPONENTS TURNS NO CONTINUITY 4. Starter relay • Remove the starter relay from the wire Replace the starter relay. harness. • Connect the pocket tester (Ω × 1) and the INCORRECT battery (12 V) to the starter relay terminals. Battery (+) terminal Yellow/Blue terminal ①...
Page 302 ELECTRICAL COMPONENTS Tester (+) lead Yellow/Blue terminal ① Tester(–)lead Continuity Yellow terminal ② Tester(+) lead Yellow/Blue terminal ① Tester (–) lead Blue/White terminal ③ NOTE: Tester (+)lead When you switch the tester’s positive and Yellow terminal ② negative probes, the readings in the left chart Tester (–) lead will be reversed.
Page 303: Starter Motor
ELECTRICAL COMPONENTS STARTER MOTOR Part Name Remarks Removing the starter motor Remove the parts in the order listed. Starter motor lead Starter motor/O-ring For installation, reverse the removal procedure. Disassembling the starter motor Remove the parts in the order listed. Bracket 1 ①...
Page 304: Checking The Starter Motor
ELECTRICAL COMPONENTS CHECKING THE STARTER MOTOR 1. Check: • commutator Dirty Clean it with #600 grit sandpaper. 2. Measure: • commutator diameter Out of specification Replace the starter motor. 3. Measure: • mica undercut ○ Out of specification Scrape the mica using a hacksaw blade.
Page 305: Assembling The Starter Motor
ELECTRICAL COMPONENTS ASSEMBLING THE STARTER MOTOR 1. Install: • brush seat 1 ① NOTE: Align the projection ○ on the brush seat 1 with the slot ○ on the yoke. 2. Install: • yoke • brackets NOTE: Align the match marks ○ a on the yoke with the match marks ○...
Page 306: Troubleshooting
ELECTRICAL COMPONENTS TROUBLESHOOTING Procedure IF THE BATTERY IS NOT CHARGED: Check: 1. Fuse (main) 4. Charging coil resistance 2. Battery 5. Wiring connections(the entire charging system) 3. Charging voltage NOTE: Remove some parts before maintenance 1. Cushion Repair with following special toolings 1.
Page 307: Lighting System
ELECTRICAL COMPONENTS 4. Charging coil resistance • Disconnect the A.C. magneto coupler from the wire harness. • Connect the pocket tester (Ω × 1) to the charging coils. Tester (+) lead White terminal ① Tester (–) lead White terminal ② Tester (+) lead White terminal ①...
Page 308: Troubleshooting
ELECTRICAL COMPONENTS TROUBLESHOOTING IF THE HEADLIGHT AND/OR TAILLIGHT FAIL TO COME ON: Procedure Check 1. Fuses (main, lighting system) 4. Light switch 2. Battery 5. Wiring connections(the entire lighting system) 3. Main switch NOTE: • Remove following part(s) before troubleshooting: 1.
Page 309: Checking The Lighting System
ELECTRICAL COMPONENTS CHECKING THE LIGHTING SYSTEM 1. If the headlights fail to come on: (1). Bulb and bulb socket NO CONTINUITY • Check the bulb and bulb socket for continuity. CONTINUITY Replace the bulb and/or bulb socket. (2). Voltage • Connect the pocket tester (DC 20 V) to the headlight couplers.
Page 310: Signaling System
ELECTRICAL COMPONENTS 2. If the taillights fail to come on: (1). Bulb and bulb socket • Check the bulb and bulb socket for NO CONTINUITY continuity. CONTINUITY Replace the bulb and/or bulb socket. (2) . Voltage • Connect the pocket tester (DC 20 V) to the tail/brake light couplers.
Page 311: Troubleshooting
ELECTRICAL COMPONENTS TROUBLESHOOTING IF A BRAKE LIGHT, AN INDICATOR LIGHT, OR THE WARNING LIGHT FAILS TO COME ON: Procedure 3. Main switch Check: 4. Wiring connections (the entire signal system) 1. Fuses (main, signaling system) NOTE: 2. Battery • Remove the following part(s) before troubleshooting: 1.
Page 312: Checking The Signal System
ELECTRICAL COMPONENTS CHECKING THE SIGNAL SYSTEM 1. If the brake lights fail to come on: (1). Bulb and bulb socket NO CONTINUITY • Check the bulb and bulb socket for continuity. CONTINUITY Replace the bulb and/or bulb socket. (2). Bake light switch NO CONTINUITY Refer to “CHECKING THE SWITCH”.
Page 313 ELECTRICAL COMPONENTS 2. If the neutral lights fail to come on: (1). Bulb and bulb socket NO CONTINUITY • Check the bulb and bulb socket for continuity. CONTINUITY Replace the bulb and/or bulb socket. (2). Gear position switch NO CONTINUITY Refer to “CHECKING THE SWITCH”.
Page 314 ELECTRICAL COMPONENTS 3. If the parking brake indicator light fails to come on: (1). Bulb and bulb socket • Check the bulb and bulb socket for NO CONTINUITY continuity. CONTINUITY Replace the bulb and/or bulb socket. (2). Parking brake switch NO CONTINUITY Refer to “CHECKING THE SWITCH”.
Page 315 ELECTRICAL COMPONENTS 4. If the reverse indicator light fails to come on: (1). Bulb and bulb socket NO CONTINUITY • Check the bulb and bulb socket for continuity. CONTINUITY Replace the bulb and/or bulb socket. (2). Reverse switch NO CONTINUITY Refer to “CHECKING THE SWITCH”.
Page 316 ELECTRICAL COMPONENTS 5. If the coolant temperature warning light does not come on when the main switch to “ON”, or if the coolant temperature warning light does not come on when the temperature is high (more than 117 ~ 123 °C (242.6 ~ 253.4 °F): (1).
Page 317 ELECTRICAL COMPONENTS Test steps 1 & 2: Heating phase Test steps 3 & 4: Cooling phase WARNING： BAD CONDITION Handle the thermo switch 1 with special care. Never subject it to a strong shock or allow Replace the thermo switch 1 it to be dropped.
Page 318 ELECTRICAL COMPONENTS 6. If the differential gear lock indicator light fails to come on: (1). Bulb and bulb socket NO CONTINUITY • Check the bulb and bulb socket for continuity. CONTINUITY Replace the bulb and/or bulb socket. (2). Differential gear lock indicator light relay •...
Page 319 ELECTRICAL COMPONENTS (3). Four-wheel drive switch NO CONTINUITY Refer to “CHECKING THE SWITCH”. CONTINUITY Replace the gear motor. (4).Voltage • Connect the pocket tester (DC 20 V) to the indicator light assembly 1 coupler. Tester (+) lead Brown terminal ① Tester (–) lead White / Black terminal ②...
Page 320 ELECTRICAL COMPONENTS 7. If the four-wheel drive indicator light fails to come on: (1). Bulb and bulb socket NO CONTINUITY • Check the bulb and bulb socket for continuity. CONTINUITY Replace the bulb and/or bulb socket. (2). four-wheel drive indicator light relay •...
Page 321: Cooling System
ELECTRICAL COMPONENTS (3). Four-wheel drive switch NO CONTINUITY Refer to “CHECKING THE SWITCH”. CONTINUITY Replace the gear motor. (4).Voltage 0• Connect the pocket tester (DC 20 V) to the indicator light assembly 1 coupler. Tester (+) lead Brown terminal ① Tester (–) lead Black /Red terminal ②...
Page 322: Troubleshooting
ELECTRICAL COMPONENTS TROUBLESHOOTING IF THE FAN MOTOR DOES NOT MOVE: Procedure 5. Thermo switch 3 Check: 6. Wiring connection(the entire cooling system) 1. Fuse (main) 2. Battery NOTE: 3. Main switch • Remove the following part(s) before 4. Radiator fan motor troubleshooting.
Page 323 ELECTRICAL COMPONENTS 4.Radiator fan motor • Disconnect the radiator fan motor coupler. • Connect the battery (12 V) as shown. Battery (+) lead Blue terminal ① Battery (–) lead Black terminal ② DOES NOT TURN Replace the radiator fan motor. •...
Page 324: 2Wd/4Wd Selecting System
ELECTRICAL COMPONENTS WARNING： Handle the thermo switch 3 with special care. Never subject it to a strong shock or allow it to be dropped. Should it be dropped, it must be replaced. BAD CONDITION Thermo switch 3 28 Nm (2.8 m · kg, 20 ft · lb) Replace the thermo switch 3 GOOD CONDITION 6.
Page 325: Troubleshooting
ELECTRICAL COMPONENTS TROUBLESHOOTING 1. Check if the 2/4WD switch is working. a. Turn on the switch, put the gear to position N; keep front and rear wheel off the ground , and then roll the front wheel to see if the rear wheel is moving together with it or if it is rotatable. b.
Page 326: Engine Management System
ENGINE MANAGEMENT SYSTEM INTRODUCTION EMS (Engine Management System) EMS is a self contained set of components including a custom built computer and sensors and actuators which control the operation of an engine by monitoring the engine speed, load and temperature and providing the ignition spark at the right time for the prevailing conditions and metering the fuel to the engine in the exact quantity required.
Page 327: Layout Of Ems Components
ENGINE MANAGEMENT SYSTEM Layout of EMS Components Legend: Dotted line indicates inputs Solid line indicates outputs COMPONENTS OF EMS Electronic Control Unit 1．Description & Working Principle The ECU continuously monitors the operating conditions of the engine through the system sensors. It also provides the necessary computation, adaptability, and output control in order to minimize the tailpipe emissions and fuel consumption, while optimizing vehicle drivability for all operating conditions.
Page 328: Multec 3.5 Injectors
ENGINE MANAGEMENT SYSTEM 2．Handling – DOs & DONTs ECU Handing ACTION REASON DO NOT: Place the ECU close to the exhaust High temperature might reduce the life of the pipe or Engine when removed ECU and also can damage the ECU DO NOT: Place the ECU close to or pour ECU is susceptible to water and liquids...
Page 329 ENGINE MANAGEMENT SYSTEM 2．Handling - DOs & DONTs 3.5 FUEL INJECTOR HANDLING ACTION REASON DO NOT: Re-use injector seal rings if at all Leakage. possible. If no other choice exists, take extra care in inspecting the seal rings for damage. DO NOT: Dip injector tips into lubricants.
Page 330 ENGINE MANAGEMENT SYSTEM Use proper lubricants on seal ring Avoid damage to seal ring during installation. surfaces to install injector in engine. Avoid contamination at seal. Minimize time between applying lubricant and inserting injector / rail. DO: Pulse (actuate) stuck closed or tip-leak To verify the injector failure suspected injector (Actuate consists of one pulse <5 sec duration at 9 to 15V).
Page 331 ENGINE MANAGEMENT SYSTEM • Remove the fuel line connection from the injector • Carefully clean debris from the interface surfaces. Do not damage seal mating surfaces. • Remove the injector from the manifold • Apply a light coating of a lubricant to both the upper and lower injector seal ring of the replacement injector.
Page 332: Throttle Body Assembly(With Stepper Motor)
ENGINE MANAGEMENT SYSTEM 5．Plugging Fuel deposits cause plugging resulting in flow shifts over the life of the injector. Fuel varnish or gumming, a type of injector deposit, is created when certain types of fuel are heated by high injector tip temperatures at soak (no fuel flow). Deposit build up in the director holes causes the flow shifts •...
Page 333 ENGINE MANAGEMENT SYSTEM 2．Handling – DOs and DONTs THROTTLE BODY ASSEMBLY HANDLING ACTION REASON DO: Use care during assembly of harness to throttle Avoid terminal damage. body. DO: Avoid any liquid contamination in the throttle Ensure proper operation. body area. DO: Unload and install units one at a time from Damage may be done to critical components.
Page 334: Engine Coolant Temperature Sensor
ENGINE MANAGEMENT SYSTEM 4．Cleaning Procedure If there is cover on the bottom, it may be removed and cleaned using carburetor cleaner (3M make recommended). Once the throttle body cover is removed, spray the throttle-body cleaner inside the shipping air passage, and use the brushes to gently dislodge the dirt, gum and varnish that are present.
Page 335: Intake Air Pressure And Temperature Sensor
ENGINE MANAGEMENT SYSTEM Intake Air Pressure and Temperature Sensor 1．Description and Working Principle This sensor has two functions. The first is the intake manifold air temperature, it provides a resistance that varies as a function of temperature within prescribed tolerance limits. The second is the intake manifold air pressure;...
Page 336 ENGINE MANAGEMENT SYSTEM 3．DOs and DONTs Ignition Coil Handing Action Reason DO NOT: Install the low voltage connectors with This might cause an unwanted secondary firing, the power applied possibly leading to personal injury DO NOT: Use a screw driver to asset in removing It is possible to damage a secondary lead in secondary boots from the secondary tower.
Page 337 ENGINE MANAGEMENT SYSTEM DO NOT: Use high impact tools to apply the spark Damage to the coil tower, secondary boot, or plug boot to the ignition secondary towers. mating connection surfaces might occur. Installation of the high voltage secondary leads by hand is preferred.
Page 338 ENGINE MANAGEMENT SYSTEM DO: Ignition secondary leads should not be Voltage spikes can be transmitted from the routed with the ignition primary harness or any secondary cables into other leads which are in other electrical harness. close. This could create a component performance degradation or failure condition DO: Spark plug wires(secondary leads) &...
Page 339: Fuel Pump Module
ENGINE MANAGEMENT SYSTEM deposits, clean with wire brush, taking care to injure the electrode or the insulator tip Regap spark plugs exact -Too wide a gap could cause the plug to measurement specified by the engine misfire(higher required ignition voltage). manufacturer to keep the best fuel economy and -Too narrow of a gap could affect idle stability proper engine performance...
Page 340 ENGINE MANAGEMENT SYSTEM Fuel Pump When power is supplied to fuel pump, motor in pump assembly rotates the impeller. Impeller in turn draws the fuel from strainer and pumps the flow to generate the system pressure. Pressure Regulator Pressure Regulator is a diaphragm type mechanical device. Fuel flow from filter enters in the inlet of pressure regulator.
Page 341 ENGINE MANAGEMENT SYSTEM Connect power supply 1. Check Fuel (battery) to fuel module. 1. Check electrical Pump Harness Make sure that enough fuel available in circuit from fuel integrity fuel tank to avoid fuel pump running module to ECU 2. Check Fuel dry.Is the fuel pump running 2.
Page 342 ENGINE MANAGEMENT SYSTEM • Place the bolts on module cover and tighten the bolts gradually in star pattern sequence to apply equal compression on gasket. It is shown in figure as below. Bolt Tightening Torque: 3~4 Nm. Fuel module is installed with special bolts (step bolts). Use designated bolts only. Follow the tightening torque and tightening sequence instruction.Over torque and miss-sequence can cause unequal compression of gasket and leakage.
Page 343 ENGINE MANAGEMENT SYSTEM After making sure that engine is cold, relieve fuel pressure as follows. • Place vehicle gear in ‘Neutral’. • Disconnect fuel module electrical coupler from vehicle harness. • Start engine and run till it stops due to lack of fuel. Repeat ignition key ON and OFF for 2 ~ 3 times of about 3 seconds each time to relieve fuel pressure in lines.
Page 344 ENGINE MANAGEMENT SYSTEM DO NOT: Use Fuel Module if the strainer Contamination enters fuel pump thru with excessive damage/ cut. damaged strainer damages the Fuel Pump DO NOT: Use Fuel Pump for draining duel Not intended function of fuel module. in fuel tank.
Page 345: Ems Fault Diagnosis
ENGINE MANAGEMENT SYSTEM EMS FAULT DIAGNOSIS EME Fault Diagnosis When fault comes up, the odometer's clock will turn into a number， which is a fault code, find out the cause with this numbe;press clock button,then it will turn back to clock mode, and five second later,the fault code will show again.
Page 346 ENGINE MANAGEMENT SYSTEM 0562 System Voltage Low KsDGDM_SysVoltLow System Voltage 0563 System Voltage High KsDGDM_SysVoltHigh 0650 MIL Circuit Malfunction KsDGDM_MIL_Circuit 1693 Tachometer Circuit Low Voltage KsDGDM_TAC_Circuit_Low Tachometer 1694 Tachometer Circuit High Voltage KsDGDM_TAC_Circuit_High 0137 O2S 2 Circuit Low Voltage KsDGDM_O2_2_ShortLow Oxygen Sensor 2 0138 O2S 2 Circuit High Voltage...
Page 347: Troubleshooting
TROUBLESHOOTING NOTE: The following trouble, not including all possible troubles, is a help for trouble guide. Please refer to relevent contents for the inspection, adjustment and replacement of part. STARTING FAILURE/HARD STARTING FUEL SYSTEM 1、No oil 2、Fuel filter is clogged Fuel tank 3、Fuel pump filter net is clogged 4、Breather tube is clogged...
Page 348: Compression System
TROUBLESHOOTING 1、Faulty starter motor 2、Faulty starter relay Starter motor 3、Faulty overrunning clutch in engine 4、Broken main switch 5、Broken main fuse 1、Low battery voltage Battery 2、Faulty battery COMPRESSION SYSTEM 1、Loose spark plug 2、Loose cylinder head or cylinder 3、Broken cylinder head gasket Cylinder and cylinder head 4、Broken cylinder gasket 5、Worn, damaged or seized cylinder...
Page 349: Poor Medium And High-Speed Performance
TROUBLESHOOTING 1、Faulty ignition plug Electrical system 2、The performace of speed sensor become poor 3、Faulty ignition coil Valve train Improperly adjusted valve clearance Air filter Clogged air filter element POOR MEDIUM AND HIGH-SPEED PERFORMANCE POOR MEDIUM AND HIGH-SPEED PERFORMANCE 1、 Broken ECU 2、...
Page 350: Enging Overheating
TROUBLESHOOTING Transmission Worn gear dog ENGINE OVERHEATING OVERHEATING 1、Improper spark plug gap Ignition system 2、Improper spark plug heat range 1、Improper fuel level Fuel system 2、Clogged air filter element Compression system Heavy carbon deposit 1、Improper oil level Engine oil 2、Improper oil viscosity 3、Inferior oil quality Brake Brake drag...
Page 351: Shock Absorber Malfunction
TROUBLESHOOTING SHOCK ABSORBER MALFUNCTION Loss of damping function 1、Bent or damaged damper rod Shock absorber 2、Damaged oil seal lip 3、Fatigued shock absorber spring UNSTABLE HANDLING UNSTABLE HANDLING Steering wheel Improperly installed or bent 1、Incorrect toe-in 2、Bent steering shaft 3、Improperly installed steering shaft Steering 4、Damaged bearing 5、Bent tie-rods...
Page 352: Bulb Burnt Out
TROUBLESHOOTING BULB BURNT OUT 1、Improper bulb 2、Faulty battery 3、Faulty rectifier/regulator Bulb burnt out 4、Improperly grounded 5、Faulty main and/or lights switch 6、Bulb life expired ERROR DISPLAY OF METER 1、 Then sensor on rear axle is damaged or polluted by iron powder Wrong Speed 2、...

Hisun Motors HS800UTV 2014 Maintenance Handbook

Chapter 1 General Information

Watnings , Cautions and Notes

Description

Identification Code

Safety

Serial Numbers

Fasteners

Shop Supplies

Basic Tools

Precision Measuring Tools

Electrical System Fundamentals

Basic Service Methods

Storage

Trovbleshooting

Engine Principles and Operating Requirements

Starting the Engine

Engine will Not Start

Poor Engine Performance

Fuel System

Engine

Englne Lubrication

High Oil Consumption or Excessive

Cylinder Leak down Test

Electrical Testing

Test Procedures

Brake System

Chapter 2 Specifications

How to Use Conversion Table of Unit

Geberar Specifications

Engine Specifications

Chassis Specifications

Electrical Specifications

Tightening Torques

General Tightening Torque Specifications

Lubrication Pionts and Lubricant Types

Hydrographic Chart

Engine Gearbox Lubrication Oil Parth Circuit

Maintenance Schedule

Chapter 3

Engine

Chassis

Electrical

Chapter 4 Engine

Engine Note

Engine Removal

Cylinder Head and Cylinder Head Cover

Rocker Arms and Camshaft

Valves and Valve Springs

Cylinder and Piston

Engine Left Crankcase Cover A.C. Magneto

Starter Motor and Oil Filter

Primary and Secondary Sheaves

Crankcase Cover and Oil Pump

Crankcase and Middle Driven Shaft

Output Shaft

Gearcase

Chapter 5

Malfunction Inspection

Direction System

Brake System

Footrest Assembly

Wheel and Tyre Parts

Transmission System

Shift Operating System

Suspension

Cooling System

Seat

Fuel Tank

Chapter 6 Electrical Components

Electrical System Malfunction Inspection

Electrical

Electricalcomponents

Ignition System

Electric Starting System

Starter Motor

Charging System

Lighting System

Signaling System

Cooling System