Table of Contents
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Brief introduction to maintenance handbook of
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 HS450UTV.
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.
First version ,April 2016
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
HS450UTV
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Table of Contents
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Related Manuals for Hisun Motors SECTOR 450
Summary of Contents for Hisun Motors SECTOR 450
- Page 1 FOREWORD Brief introduction to maintenance handbook of HS450UTV 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.
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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 ………………………………………………………………………… 26 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 ……………………………………………………………………………… 40 Blue smoke………………………………………………………………………………… 40 White smoke or steam…………………………………………………………………… 41 Low engine compression ………………………………………………………………… 41 High engine compression ……………………………………………………………… 41 Engine overheating (cooling system) ………………………………………………… 41 Engine overheating (engine)…………………………………………………………… 42 The ignition advance angle is too large………………………………………………… 42 Detonation…………………………………………………………………………………...
- Page 6 Testing for a short with a self-powered test light or ohmmeter……………………… 52 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…………………………………………………… 54 Brake Grabs………………………………………………………………………………...
- Page 7 CHAPTER 3 MAINTENCE AND ADJUSTMENT OF THE UTV MAINTENANCE SCHEDULE……………………………………………………………… 81 ENGINE Adjusting the valve clearance…………………………………………………………… 83 Checking the spark plug………………………………………………………………… 85 Checking the ignition timing……………………………………………………………… 86 Measuring the compression pressure………………………………………………… 87 Checking the engine oil level……………………………………………………………... 89 Changing the engine oil……………………………………………………………… 90 CHASSIS Cleaning the air filter…………………………………………………………………...
- Page 8 Checking the tires ……………………………………………………………………… 112 Checking the wheels…………………………………………………………………… 114 Checking and lubricating the cables ………………………………………………… 114 ELECTRICAL Checking and charging the battery…………………………………………………… 115 Checking the fuses …………………………………………………………………… 120 Adjusting the headlight beam………………………………………………………… 122 Changing the headlight bulbⅠ……………………………………………………… 122 Changing the tail/brake light bulb …………………………………………………… 123 CHAPTER 4 ENGINE ENGINE NOTE………………………………………………………………………………...
- Page 9 Oil pump…………………………………………………………………………………171 TRANSMISSION………………………………………………………………………………174 Transmission……………………………………………………………………………174 Drive axle assembly……………………………………………………………………175 MIDDLE GEAR………………………………………………………………………………179 Middle drive shaft…………………………………………………………………………179 CHAPTER 5 CHASSIS MALFUNCTION INSPECTION…………………………………………………………… 186 PANEL AND CARGO BED Front panel…………………………………………………………………………………189 Side cover, Footrest part ………………………………………………………………193 Cargo rack………………………………………………………………………………197 Cargo bed……………………………………………………………………………… 200 Head shed frame………………………………………………………………………… 204 DIRECTION SYSTEM Steering wheel part………………………………………………………………………...
- Page 10 Front swing arm……………………………………………………………………… 260 Front suspension……………………………………………………………………… 261 Rear suspension……………………………………………………………………… 266 COOLING SYSTEM………………………………………………………………………… 272 Water and oil radiator…………………………………………………………………… 272 SEAT ………………………………………………………………………………………… 277 FUEL TANK………………………………………………………………………………… 279 CHAPTER 6 ELECTRICAL COMPONENTS ELECTRICAL SYSTEM MALFUNCTION INSPECTION ……………………………… 282 ELECTRICAL………………………………………………………………………………… 283 ELECTRICAL COMPONENTS…………………………………………………………… 283 Checking the switch…………………………………………………………………… 285 Checking the switch continuity…………………………………………………………...
- Page 11 Troubleshooting……………………………………………………………………… 301 Checking the signal system……………………………………………………… 302 COOLING SYSTEM………………………………………………………………………… 308 Circuit diagram………………………………………………………………………… 308 Troubleshooting……………………………………………………………………… 309 2WD/4WDSELECTINGSYSTEM………………………………………………………… 311 Circuit diagram………………………………………………………………………… 311 Troubleshooting……………………………………………………………………… 312 CHAPTER 7 ENGINE MANAGEMENT SYSTEM INTRODUCTION Ems (engine management system) …………………………………………………… 313 Typical components of EMS………………………………………………………………313 Layout of EMS components………………………………………………………………314 COMPONENTS OF EMS Electronic control unit ……………………………………………………………………...
- Page 12 Electrical system ………………………………………………………………………… 334 Compression system …………………………………………………………………… 335 POOR IDLE SPEED PERFORMANCE ………………………………………………… 335 Poor idle speed performance…………………………………………………………… 335 POOR MEDIUM AND HIGH-SPEED PERFORMANCE ……………………………… 336 Poor medium and high-speed performance………………………………………… 336 FAULTY GEAR SHIFTING………………………………………………………………… 336 Shift lever does not move ……………………………………………………………… 336 Jumps out of gear………………………………………………………………………...
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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. Headlight Assy 2. Front Shock Absorber Assembly Unit Qa(Gasbag Shock Absorber) 3. Second Water Tank 4. Steering Wheel Comp 5. Driver Seat 6. Driver Safety Belt 7. Rear Cargo 8. Rear Shock Absorber Assembly Unit Q(Gasbag Shock Absorber) 9. -
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 Never use gasoline to clean parts. Refer to Cleaning Parts in this section. 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 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 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 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 the scope of this manual. -
Page 36: Basic Service Methods
GENERAL INFORMATION Warning If the current insulation damage, may cause short circuit fault which lead to short circuit or large current in components. It may cause a fire. Thus, if the current of circuit or components measured by amperage exceeds the standard level, must check and repair electrical system at once. -
Page 37: Removing Frozen Fasteners
GENERAL INFORMATION 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. If special tools are required, have them available before starting the procedure. When special tools are required, they are described at the beginning of the procedure. -
Page 38: Repairing Damaged Threads
GENERAL INFORMATION remaining portion of the screw or bolt. Drill a small hole in the screw and tap the extractor into the hole. Back the screw out with a wrench on the extractor (Figure 38) Repairing Damaged Threads Occasionally, threads are stripped through carelessness or impact damage. -
Page 39: Bearings
GENERAL INFORMATION 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. Clean the fitting of any corrosion or rubber hose material with a wire brush Clean the inside of the hose thoroughly. -
Page 40: Installation
GENERAL INFORMATION and/or the inner race will damage them. Always make sure the press arm (Figure 44) aligns with the center of the shaft. If the arm is not centered, it may damage the bearing and/or shaft. The moment the shaft is free of the bearing. It drops to the floor. - Page 41 GENERAL INFORMATION Turn the heat on and monitor the thermometer. When the oil temperature rises to approximately 120℃(248°F), remove the bearing from the pot and quickly install it. If necessary, place a socket on the inner bearing race and tap the bearing into place. As the bearing chills, it will tighten on the shaft, so install it quickly.
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Page 42: Seal Replacement
GENERAL INFORMATION 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. Improperly installing the seal can damage the seat. Note the following: 1. -
Page 43: Returning The Utv To Service
GENERAL INFORMATION 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. 7. Cover the exhaust and intake opening. 8. Apply a protective substance to the plastic and rubber components. Make sure to follow the manufacturer’s instructions for each type of product being used. -
Page 44: Engine Principles And Operating Requirements
GENERAL INFORMATION 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. Even with the best of care, however, the motorcycle may develop problems that require trouble shooting. -
Page 45: Engine Is Cold
GENERAL INFORMATION 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. The wrong signal transmits to the ECU which result the increasing of oil supply. -
Page 46: Engine Will Not Start
GENERAL INFORMATION when the engine is flooded. Troubleshoot a flooded engine as follows: 1. Open the throttle fully and hold in this position. Then start the engine firmly through its entire stoke ten times to clear the engine. Close the throttle. Check and repair ignition system. -
Page 47: Spark Test
GENERAL INFORMATION 6. Perform the Spark Test in this section. If there is a strong spark, perform Step 7. If there is no spark or if the spark is very weak, refer to Ignition System Testing in Chapter Ten. 7. If the fuel and ignition systems are working correctly, perform a leak down test (this chapter) and cylinder compression test. -
Page 48: The Starter Cannot Work Repeatedly Or Can Only Work Slowly
GENERAL INFORMATION c. engine damage(low compression). 7. If the spark was weak (white or yellow) or if there was no spark, perform the peak voltage checks described under Ignition System Testing. 8. Reinstall the fuel tank. The Starter Cannot Work Repeatedly Or Can Only Work Slowly Refer to Starting System Testing POOR ENGINE PERFORMANCE If the engine runs, but performance is unsatisfactory, refer to the following section that best... -
Page 49: The Engine Is Not Idling Or Cannot Idle Stably
GENERAL INFORMATION 5. Incorrect ignition timing or a damaged ignition system can cause these conditions. Perform the Peak Voltage Tests to isolate the damaged ignition system component. Check the ignition timing as described. NOTE The ignition timing is controlled by the ICM and cannot be adjusted. - Page 50 GENERAL INFORMATION not spin freely. Check for the following conditions: a. Dragging brakes. Check for this condition immediately after riding the UTV NOTE After riding the UTV. Come to a stop on a level surface. Turn engine shift transmission into neutral. Walk or push the UTV forward.
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Page 51: Poor Idle Or Low Speed Performance
GENERAL INFORMATION Lean fuel mixture Advanced ignition timing NOTE Other signs of advanced ignition timing are engine overheating and hard or uneven engine starting Excessive carbon buildup in combustion chamber Worn pistons and/or cylinder bores Poor Idle or Low Speed Performance Check for an incorrect pilot screw adjustment Check for damaged or loose intake pipe and air filter housing hose clamps. -
Page 52: Rich Mixture
GENERAL INFORMATION end of it. Note the following: a. If there is no visible fuel on the end of the spark plug, go to check whether the fuel valve, oil injector or fuel hose is clogged. If the spark plug at the bottom of a fuel. And the engine has spark. Check for an excessive intake air leak or the possibility of contaminated or stale fuel. -
Page 53: White Smoke Or Steam
GENERAL INFORMATION Blue smoke indicates that the engine is burning oil in the combustion chamber as it leaks past worn valve stem seals and piston rings. Excessive oil consumption is another indicator of an engine that is burning oil. Perform a compression test to isolate the problem. White smoke or steam It is normal to see white smoke or steam from the exhaust after first starting the engine in cold weather. -
Page 54: Engine Overheating (Engine)
GENERAL INFORMATION WARNING Do not remove the radiator cap, coolant drain plug or disconnect any coolant hose immediately after or during engine operation. Scalding fluid and steam may be blown out under pressure and cause serious injury. When the engine has been operated, the coolant is very hot and under pressure. -
Page 55: Engine Noises
GENERAL INFORMATION Engine Noises Unusual noises are often the first indication of a developing problem. Investigate any new noises as soon as possible. Something that may be a minor problem, if corrected, could prevent the possibility of more extensive damage. Use a mechanic’s stethoscope or a small section of hose held near your ear (not directly on your ear) with the other end close to the source of the noise to isolate the location. -
Page 56: High Oil Consumption Or Excessive
GENERAL INFORMATION High Oil Consumption or Excessive Exhaust Smoke 1. Worn valve guides. 2. Worn valve guide seals. 3. Worn or damaged piston rings. 4. Incorrect piston ring installation. Low Oil Pressure 1. Low oil level. 2. Worn or damaged oil pump. 3. -
Page 57: Oil Contamination
GENERAL INFORMATION Oil Contamination 1. Blown head gasket allowing coolant to leak into the engine. 2. Coolant leak. 3. Oil and filter not changed at specified intervals or when operating conditions demand more frequent changes. CYLINDER LEAK DOWN TEST A cylinder leak down test can accurately pinpoint engine leakage problems from the head gasket, water jackets in the cylinder head and cylinder, valves and valve seats, and piston rings. - Page 58 GENERAL INFORMATION cause the gauge needle to move slightly. If the crankshaft is 360°off, these indicators will not be present. NOTE The decompress or mechanism will click loudly once during each crankshaft revolution. This is normal. 7. Use hex socket on the primary drive gear mounting bolt and turn the crankshaft clockwise and align the TDC mark on the flywheel with the index mark on the left crankcase cover Remove the hex socket from the primary drive gear.
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Page 59: Electrical Testing
GENERAL INFORMATION at TDC but there is still a large amount of air escaping from the engine, the crankshaft is off one revolution. Turn the engine 360°and realign the TDC mark as described in Step 7, then relock it as described in Step8. Air leaking through the exhaust pipe indicates a leaking exhaust valve. -
Page 60: Intermittent Problems
GENERAL INFORMATION Intermittent Problems Intermittent problems are problems that do not occur all the time and can be difficult to locate. For example. When a problem only occurs when the UTV is ridden over rough roads (vibration) or in wet conditions (water penetration). -
Page 61: Electrical Component Replacement
GENERAL INFORMATION Electrical component replacement Most UTV dealerships and parts suppliers will not accept the return of any electrical part. If you cannot determine the exact cause of any electrical system malfunction. If you purchase a new electrical component(s), install it, and then find that the system still does not work properly, you will probably be unable to return the unit for a refund. -
Page 62: Jumper Wire
GENERAL INFORMATION self-powered test light, an ohmmeter contains its own power source and should not be connected to a live circuit. Ohmmeter may be analog type (needle scale) or digital type (LCD or LED readout). Both types of ohmmeter have a switch that allows the user to select different ranges of resistance for accurate readings. -
Page 63: Test Procedures
GENERAL INFORMATION any load (a component that is connected and turned on). This would result in a direct short and will blow the fuse(s) Test Procedures Voltage test Unless otherwise specified. Make all voltage tests with the electrical connectors still connected. Insert the test leads into the backside of the connector and make sure the test lead touches the electrical wire or metal terminal within the connector housing. -
Page 64: Peak Voltage Test
GENERAL INFORMATION a. The voltmeter should indicate 0 volts. If there is a drop of 0.5 volts or more. There is a problem within the circuit. A voltage drop reading of 12 volts indicates an open in the circuit. b. A voltage drop of 1 or more volts indicates that a circuit has excessive resistance. c. -
Page 65: Testing For A Short With A Test Light Or Voltmeter
GENERAL INFORMATION along the harness. 6. If the test light blinks or the needle on the ohmmeter moves, there is a short-to-ground at that point in the harness. Testing for a short with a test light or voltmeter 1. Remove the blown fuse. 2. -
Page 66: Brake Drag
GENERAL INFORMATION the master cylinder reservoir drops. Whenever adding brake fluid to the reservoir, visually check the brake pads for wear. If it does not appear that there is an increase in pad wear, check the brake hoses, lines and banjo bolts for leaks. 3. -
Page 67: Brake Grabs
GENERAL INFORMATION lever feels excessively hard, check for the following possible causes: 1. Clogged brake hydraulic system. 2. Sticking caliper piston. 3. Sticking master cylinder piston. 4. Glazed or worn brake pads. 5. Mismatched brake pads. 6. Damaged front brake lever. 7. - Page 68 GENERAL INFORMATION 4. Loose banjo bolt washers. 5. Damaged banjo bolt washers. 6. Damaged banjo bolt threads in master cylinder body. 7. Loose or damaged reservoir cap. - 56 -...
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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 2,720mm (107.09in) Overall width 1,550mm（61.02 in） Overall height 1,885mm（74.21in） Seat height 875mm（34.45in） Wheelbase 1,850mm（51.18in） Minimum ground clearance 310mm（12.2 in） Minimum turning radius 3,420mm (134.64 in) Basic weight : With oil and full fuel tank 544kg (1,200 lb) Engine : Model... - Page 71 SPECIFICATIONS Item Standard Throttle Type/quantity D46-5 / 1 Spark plug DR8EA / 1 (NGK) Type/manufacturer 0.6-0.7 mm（0.024-0.028in） Spark plug gap Clutch type Wet ,centrifugal automatic Transmission Primary reduction system V-belt Secondary reduction system Shaft drive Transmission type V-belt automatic Operation Right hand operation Single speed automatic 0.75～2.45...
- Page 72 SPECIFICATIONS Item Standard Electrical Ignition system Generator system A.C. magneto Battery type GS U1-9 Battery capacity 12 V, 25.0Ah Headlight type Bulb wattage×quantity 12V，35W/35W × 2 Headlight 12V，0.5W（LED） Front Position Lamp 12V，0.7 W（LED） Front direction indicator 12V，0.75W（LED） Rear direction indicator 12V，0.5W（LED）...
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Page 73: Engine Specifications
SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Cylinder head Warp limit ---- 0.03 mm (0.0012 in) Cylinder 91.000 ~ 91.015mm Bore size ---- (3.582 ~ 3.583 in) Measuring point 50 mm (1.97 in) Camshaft Chain drive (Left) Drive method ---- Cam dimensions Intake 32.30~32.20 mm “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 12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in) Shaft outside diameter 11.976 ~ 11.991 mm ---- (0.4715 ~ 0.4721 in) Arm-to-shaft clearance 0.009 ~ 0.042 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) 0.01 mm ---- Stem runout limit (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 ~ 90.955 mm ---- (3.5803~ 3.5809 in) ---- Measuring point “H” 4.0mm (0.15in) ---- Piston off-set 0.5mm(0.0394in) ---- Off-set direction...
- Page 77 SPECIFICATIONS Item Standard Limit Oil ring ---- 4.0×3.4 mm Dimensions (B×T) ---- (0.1575×0.1339in) 0.20 ~ 0.70 mm End gap (installed) ---- (0.0079 ~ 0.0276 in) 0.06 ~ 0.15 mm Side clearance (0.0024 ~ 0.0059 in) Crankshaft 74.95 ~ 75.00 mm ---- Crank width “A”...
- Page 78 SPECIFICATIONS Item Standard Limit Shifter Shifter type Shift drum and guide bar ---- Air filter oil grade Engine oil ---- Oil pump Oil filter type Foam ---- Oil pump type Trochoid Tip clearance 0.15 mm 0.23 mm (0.0059 in) (0.0091 in) Side clearance 0.03 ~ 0.10 mm 0.17 mm...
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Page 79: Chassis Specifications
SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Steering system Type Rack and pinion ---- Front suspension Shock absorber travel 140 mm (5.51 in) ---- Spring free length 294 mm (11.57 in) ---- Spring rate 19.04N/mm(1.94kg/mm) ---- Stroke 30-140 mm (1.18 ~ 5.51in) ---- Rear suspension Shock absorber travel... - 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 6.0 mm (0.24 in) ---- Pad thickness outer 6.0 mm (0.24 in) ---- Master cylinder inside diameter 19.0mm (0.75in) ---- 25.0mm （1.57in）...
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Page 81: Electrical Specifications
SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit Voltage 12 V ---- Ignition system Ignition timing (BTDC) 8°±1°before TDC ---- Advancer type ECU Digital type ---- Ignition coil Minimum spark gap 6 mm (0.24 in) ---- 0.18 ~ 0.28 Ωat 20 °C (68 °F) Primary winding resistance ---- Secondary winding resistance... - Page 82 SPECIFICATIONS Item Standard Limit Electric starter system Type Constant mesh type ---- Starter motor ---- Output 0.8 kW ---- 0.025 ~ 0.035 Ω Armature coil resistance ---- Brush overall length 12.5 mm (0.49 in) ---- Starter relay Amperage rating 180 A ---- ...
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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 Bolt Cylinder head cover Tappet cover (exhaust) —... - Page 84 SPECIFICATIONS Tightening torque Thread 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) —...
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Page 86: Chassis Tightening Torques
SPECIFICATIONS Chassis tightening torques Tightening torque Thread 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 Tightening torque Thread 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...
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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 ：splash - 79-... -
Page 92: Lubrication Oil Way
SPECIFICATIONS LUBRICATION OIL WAY LUBRICATION OIL WAY ：Pressure ：splashing oil - 80-... -
Page 93: Maintence And Adjustment Of The Utv
MAINTENANCE AND ADJUSTMENT OF THE UTV MAINTENANCE 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 94 MAINTENANCE 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. ·...
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Page 95: 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 96 MAINTENANCE AND ADJUSTMENT OF THE UTV 2. Remove the cooling fan： ① Fan cover ② Fan impeller ③ As manhole covers 3. calibration · Wrench to counterclockwise rotation crankshaft · According to the rotor turning counterclockwise, rotor turn to mark the dead spots ⑤ of crank box, namely ④...
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Page 97: Checking The Spark Plug
MAINTENANCE AND ADJUSTMENT OF THE UTV ④ Adjust tools · Loosen the locknut ① · Insert a thickness gauge ② between the adjuster end and the valve end. · Turn ③ adjuster clockwise counterclockwise with the tappet adjusting ④ tool until the proper clearance is obtained. -
Page 98: Checking The Ignition Timing
MAINTENANCE AND ADJUSTMENT OF THE UTV 4. Check: ·electrode ① To check if it is burned blunt or much carbon is there, then check the pole clearance by thickness gauge. It is qualified if the pole clearance between 0.7mm. Otherwise it should be adjusted. Wear/damage Replace. -
Page 99: Measuring The Compression Pressure
MAINTENANCE AND ADJUSTMENT OF THE UTV reference of adjusting valve clearance. 5. Check: ·ignition timing a. Warm up the engine and keep it at the specified speed Engine speed 1,400 ~ 1,500 r/min ○ b. Remove the timing plug c. Visually check the stationary pointer ⑤ to verify it is within the required firing range ④... - Page 100 MAINTENANCE AND ADJUSTMENT OF THE UTV 4. check standard value standard compression pressure data 1200Kpa (12kg/ cm )-1000r/min 5. read the highest data on the compression pressure meter ·Above the maximum pressure: Check the cylinder head, valve surfaces, and piston crown for carbon deposits. ·Below the minimum pressure: Check the accumulation carbon in the firebox...
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Page 101: Checking The Engine Oil Level
MAINTENANCE AND ADJUSTMENT OF THE UTV 18 Nm-20Nm (1.84 kg ·m, 13.3 lb ·ft) 5. Lower the cargo bed. CHECKING THE ENGINE OIL LEVEL 1. Place the vehicle on a level surface 2. Remove: ·driver seat ·console Refer to “SEATS” in chapter 5. 3. -
Page 102: Changing The Engine Oil
MAINTENANCE AND ADJUSTMENT OF THE UTV 6. Install: ·console ·driver seat Refer to “SEATS” in chapter 5. CHANGING THE ENGINE OIL Place the vehicle on a level surface. 1. Start the engine and let it warm up for several minutes. 2. - Page 103 MAINTENANCE AND ADJUSTMENT OF THE UTV · crankcase (with sufficient oil to reach the specified level) Oil quantity Periodic oil change The oil capacity after the engine is disassembled and reassembled. 2.2L The oil should be put into the engine for after all the oil is drawn out 2.0L 8.
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Page 104: Chassis
MAINTENANCE 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 105: Checking The Coolant Level
MAINTENANCE AND ADJUSTMENT OF THE UTV or explosion. b. Squeeze the excess solvent out of the element and let it dry. NOTE: Do not twist or wring out the element. This could damage the foam material. c. Squeeze out the excess oil. NOTE: The element should be wet but not dripping. -
Page 106: Changing The Coolant
MAINTENANCE AND ADJUSTMENT OF THE UTV CHANGING THE COOLANT 1. Remove: Front faceplate ·coolant reservoir cap ④ ·Disconnect coolant reservoir hose ① ·Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant, check and if necessary, correct the antifreeze concentration of the coolant. - Page 107 MAINTENANCE AND ADJUSTMENT OF THE UTV 7. Disconnect: ·coolant outlet hose ② ·water pump inlet hose ③ 8. Drain: ·coolant 9. Check: ·copper washer ① ·coolant drain bolt ② Damage Replace. 10. Install: ·coolant drain bolt (water pump) T R. 10 Nm (1.0 m ·...
- Page 108 MAINTENANCE AND ADJUSTMENT OF THE UTV handled with special care. WARNING : · If coolant splashes in your eyes, thoroughly wash them with water and consult a doctor. · If coolant splashes on your clothes, quickly wash it away with water and then with soap and water.
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Page 109: Checking The Coolant Temperature Warning Light
MAINTENANCE AND ADJUSTMENT OF THE UTV CHECKING THE COOLANT TEMPERATURE WARNING LIGHT Coolant temperature indicator light ① 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. -
Page 110: Checking The V-Belt
MAINTENANCE AND ADJUSTMENT OF THE UTV CHECKING THE V-BELT 1. Remove: · driver seat · console · lift the cargo bed Check: a. V-belt ① Cracks/wear/scaling/chipping Replace. Oil/ grease Check primary sheave and secondary sheave.。 b. V-belt width ② Out of specification Replace. -
Page 111: Cleaning The Spark Arrester
MAINTENANCE AND ADJUSTMENT OF THE UTV CLEANING THE SPARK ARRESTER 1. Clean: Tap the tailpipe lightly with a soft-face hammer or suitable tool, then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and the inner contact surfaces of the muffler.. -
Page 112: Adjusting The Parking Brake
MAINTENANCE AND ADJUSTMENT OF THE UTV 2. Adjust： ·brake pedal free play a. Loosen the locknut ② b. Turn brake rod ① in or out until the correct free play is obtained. Turning in Free play is increased. Turning out Free play is decreased.
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Questions and answers
My HISUN 450 sector won't go into reverse. How do I adjust the transmission to fix