Hisun HS 1000UTV Manual
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Hisun HS 1000UTV Manual

Hisun HS 1000UTV Manual

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Introduction HS 1000UTV
INTRODUCTION
Congratulations on your purchase of the HS 1000UTV/HS 900UTV/HS 800UTV-5. This
Owner's / Operator's manual will provide you information regarding safe operation,
operational instructions, maintenance and care. Fully understanding this manual and
following all of the instructions herein will provide the knowledge needed to have safe and
enjoyable UTV operation.
For questions regarding this UTV, please call (972) 446-0760.
IMPORTANT SAFETY MESSAGES
● READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR UTV.
MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS.
● PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE UTV.
● NEVER OPERATE THE UTV WITHOUT PROPER TRAINING OR INSTRUCTION.
● THIS UTV SHOULD NOT BE RIDDEN BY ANYONE UNDER
16 YEARS OF AGE.
1-1

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Summary of Contents for Hisun HS 1000UTV

  • Page 1 Introduction HS 1000UTV INTRODUCTION Congratulations on your purchase of the HS 1000UTV/HS 900UTV/HS 800UTV-5. This Owner’s / Operator’s manual will provide you information regarding safe operation, operational instructions, maintenance and care. Fully understanding this manual and following all of the instructions herein will provide the knowledge needed to have safe and enjoyable UTV operation.

  • Page 2: Important Manual Information

    Introduction HS 1000UTV IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY Particularly important information is distinguished in this manual by the following OR DEATH. notations: The Safety Alert Symbol means ATTENTION!

  • Page 3: Important Notice

    Introduction HS 1000UTV IMPORTANT NOTICE This UTV is designed and manufactured for OFF - ROAD use only. It is illegal and unsafe to operate this UTV on any public street, road or highway. This UTV complies with all applicable OFF - ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture.
  • Page 4 Introduction HS 1000UTV NIVERSAL SYMBOLS As a guide to the operation of your vehicle, various universal symbols have been utilized on the instruments and controls. The symbols are shown below with an indication of their meaning. Safety Alert Symbol Lift Cylinder-Retract...

  • Page 5: Table Of Contents

    Introduction HS 1000UTV Table of Contents Subject Page Subject Page Introduction Starting Important manual information Seat belt Important notice Head light switch Universal symbols Hazard light switch Location of parts Turn signal light switch Illustrated contents Brake pedal Safe operation...
  • Page 6 Introduction HS 1000UTV Every 500 hours 10-18 Checking parking brake 10-8 Replacing fuel filter 10-18 Checking gauges meter and easy 10-8 Every 600 hours 10-18 checker lamps Adjusting engine valve clearance 10-18 Checking head light turn signal light etc 10-8...
  • Page 7 Introduction HS 1000UTV Options 13-1 Emissions warranty 14-1...

  • Page 8: Location Of Parts

    Introduction HS 1000UTV LOCATION OF PARTS Roll-over protective structure. ① Front hood ② Hazard/Turn signal light (if equipped) ③ Headlights ④ Winch mount plate ⑤ ILLUSTRATED CONTENTS...
  • Page 9 Introduction HS 1000UTV ① Steering wheel ② Brake pedal ③ Accelerator Pedal ④ Cup holder ⑤ Gear indicator ⑥ Tachometer ⑦ Speedometer ⑧ DC socket ⑨ Gear shift lever (Range) ⑩ Parking brake lever...
  • Page 10 Introduction HS 1000UTV ① Cargo bed ② Tail lamp ③ Muffler ④ Rear trailer hitch bracket ⑤ Handgrip ⑥ Fuel tank cap 1-10...

  • Page 11: Safe Operation

    Safe Operation All operators, including experienced UTV drivers or You should always wear protective equipment, passengers, should carefully read fully such as helmet, boots, eye protection, ear understand this Users Manual, and operate strictly protection, and glove setc. as the manual states in order to achieve the best Only a qualified driver with driving license performance and avoid accidents.

  • Page 12: Operation

    Safe Operation 2. Operation 11. Always close attention your surroundings, and check for streets, trail Start the engine only in an open ventilated intersections or other obstacles. area. Carbon monoxide is colorless, odorless 12. Always use signals in advance of turns. and is emitted from the engine and can cause 13.

  • Page 13: Driving In Harsh Conditions

    Safe Operation Driving at high speed Be cautious when riding on a slope, as this is the main reason for loss of control, and overturn, Check the condition of the front and rear leading to severe injury or even death. wheels.

  • Page 14: Transportation

    Safe Operation Set the gear shift to the “N” position and pull kept away from sparks. The battery produces the braking brake to the top position to park the hydrogen and oxygen during charging and this vehicle. could accelerate the risk of explosion. Avoid stopping the vehicle on a slope.

  • Page 15: Warning And Caution Labels

    Warning Labels Warning and caution labels （1） （2） （3） （4） （5） （6） （7） （8） （9）...
  • Page 16 Warning Labels （10） （11） (12） (13) (14) (15) (16)
  • Page 17 Warning Labels (17)

  • Page 18: Servicing Of Vehicle

    Vehicle Identification Number SERVICING OF VEHICLE Your dealer is interested in your new vehicle and has the desire to help you get the most value from it. After reading this manual thoroughly, you will find you can do some of the regular maintenance by yourself.

  • Page 19: Specifications Table

    Specifications SPECIFICATION TABLE Model Specification HS2V91MY-1 for HS1000UTV HS2V91MX-1 for HS9000UTV Make HS2V91MW for HS800UTV-5 2 cylinders, 4-cycle, gasoline, SOHC, water Type 976CC for HS1000UTV Displacement(s) 924CC for HS9000UTV 800CC for HS800UTV-5 Engine 48.85（65.51）for HS1000UTV Horsepower Kw(HP) 45（60.34）for HS9000UTV 41（54.98）for HS800UTV-5 7500 for HS1000UTV 6000 for HS9000UTV Rated revolution...
  • Page 20 Specifications Model Specification Max. rolling weight (Towing Capacity) kg (lbs.) 800（1764） Payload capacity kg (lbs.) 159（350） Weight kg (lbs.) 690(50.8) Width mm (in.) 1290（27.16） Length mm (in.) 690（27.2） Depth mm (in.) 190（7.5） Volume (1 row/2 row) (cu.ft.) 0.24（8.47） Cargo bed Bed height mm (in.) 927（36.5）...

  • Page 21: Vehicle Limitations

    Specifications VEHICLE LIMITATIONS The Vehicle has been thoroughly tested for proper performance with implements sold or approved by manufacturer. Use with implements which are not sold or approved and which exceed the maximum specifications listed below, or which are otherwise unfit for use, vehicle may result in vehicle malfunction or failures with a possibility of the vehicle damage, property damage and injury to the operator or others.

  • Page 22: Pre-Operation

    Pre-Operation DAILY CHECK To better prevent troubles,it is important to know condition vehicle, before operating.Check it before starting. CAUTION： To avoid personal injury： Be sure to check and service the vehicle on a level surface with the engineoff, the parking brake “ON”, andimplements lowered to the ground if equipped.

  • Page 23: Operating The Engine

    Operating the Engine STARTING THE ENGINE CAUTION： To avoid personal injury： 1.Make sure the parking brake is set. Read "SAFE OPERATION" in front of  this manual. Read the danger,warning and caution  labels located on the vehicle. To avoid the danger of exhaust fume ...
  • Page 24 Operating the Engine 2.Set gear shift lever to the “NEUTRAL”position. 1. Insert the key into the key switch and turn it to START.(Starts the engine.) (Stops the engine) (Engine runs or headlights on) ◆ Display and Warning Lights When the key is turned to “START”, lamps(1 engine oil pressure) should come on.

  • Page 25: Cold Starting

    Operating the Engine ■Cold Starting When the ambient temperature is below - 15℃( 5℉), and the engine is very cold. If the engine fails to start after 5 seconds, turn off the key for 30 seconds and start again. STOPPING THE ENGINE 1.

  • Page 26: Operating The Vehicle

    Operating the Vehicle OPERATING NEW VEHICLE and are not mated to each other. Small pieces of How a new vehicle is handled and maintained metal grit may develop during the operation of determines the life of vehicle. the vehicle; and this may wear out or damage A new vehicle just off the factory production line the parts.

  • Page 27: Head Light Switch

    Operating the Vehicle Tail lights (lamps at the rear of the vehicle) The instrument panel illuminates. ■Hazard Light Switch [If equipped] Press the top half of the hazard light switch, the hazard lights flash along with the indicator on the instrument panel.

  • Page 28: Brake Pedal

    Operating the Vehicle and other will stay on.  Be sure to return switch to center position after turning. ① Brake pedal 4.Selecting the Correct Gear. ① Head light ②Front turn signal lamp; ■Gear ShiftLever 3.Checking the brake pedal. ■Brake Pedal CAUTION: CAUTION: To avoid personal injury:...

  • Page 29: 4Wd Lever

    Operating the Vehicle  to avoid skidding and loss of steering control. Reduce the speed and engage the 4-wheel drive.  An accident may occur if the brakes are applied suddenly while towing heavy loads. The load can shift forward causing loss of control.

  • Page 30: Accelerator Pedal

    Operating the Vehicle ① Parking brake lever ② “RELEASE” ■Accelerator Pedal The Accelerator pedal is used to increase the engine and vehicle speed. Push down on it for higher speed. ① Coolant temperature gauge ② Fuel gauge ■Fuel Gauge Park the vehicle on a flat place. Turn the key switch to “On”, the fuel gauge will indicate the fuel level.
  • Page 31 Operating the Vehicle With the key switch “ON” the temperature gauge indicates the temperature of the coolant. White Zone for “cold” and Red zone for “hot”. If the indicator reaches the Red zone, the engine coolant is overheated. Check the vehicle by referring to the “TROUBLESHOOTING”...

  • Page 32: Winch Mount Plate

    Maintenance and Adjustment WINCH MOUNT PLATE Always read and follow the instructions in the winch owner’s manual before attempting to install or use a winch. ① Winch mount plate ■Transporting The Vehicle Pay attention to the following points when transporting the vehicle. Use a suitable truck or trailer.

  • Page 33: Service Intervals

    Maintenance and Adjustment CAUTION: To avoid personal injury and vehicle damage:  Be sure you have sufficient knowledge, experience, the proper replacement parts and tools before you attempt any vehicle maintenance task.  If you don’t have the knowledge and equipment which are necessary to perform the maintenance task, consult your local dealer.
  • Page 34 Maintenance and Adjustment Indication of After Items 700 hrs 50 100 150 200 250 300 350 400 450 500 550 600 650 700 Every Check ○ ○ ○ ○ ○ ○ ○ Fuel filter 100 hrs element Every Replace ○ 100 hrs Every Check...
  • Page 35 Maintenance and Adjustment Indication of After Items 700 hrs 50 100 150 200 250 300 350 400 450 500 550 600 650 700 Every 2 Coolant Change years Fuel system Bleed Service as Fuse Replace required Light bulb Replace NOTE: ◆...

  • Page 36: Periodic Service

    Periodic Service CAUTION: To avoid personal injury: HOW TO OPEN THE HOOD AND TILT THE SEAT CAUTION To avoid personal injury from contact with moving parts: ① seat  Never open operator’s seat while the engine is running. ■Hood Seats To remove a seat, Remove bolts M6 with a To open the hood, turn the latch to release and socket wrench, and then remove the seat.

  • Page 37: Moving The Seat Forward And Backward

    Periodic Service CAUTION: “vertical or upper” direction and hold. 2. Adjust the steering wheel up or down to To install the seat, Adjust the four bolts M8evenly The proper position. to ensure the seat moves forward and backward 3. Tighten the adjustment lever to secure the normally.

  • Page 38: Front And Rear Shock Adjustment

    · A special wrench can be obtained at a to an open flame or other high heat source. This may cause the unit to explode due to excessive HiSUN dealer to make this adjustment. gas pressure. · The spring preload setting is determined by ·Do not deform or damage the cylinders in any...

  • Page 39: Rebound Damping Force

    Periodic Service Spring Preload Setting(Front) Minimum(soft): 332mm(13.07 in) Maximum(hard): 442mm(17.40in) Spring travel setting(Rear) Minimum(soft): 402mm(15.83in) Maximum(hard): 502mm(19.76 in) 1.Compression damping force adjusting screw NOTE: Always tighten the locknut against the adjusting WARNING nut, and then tighten it to the specified torque. components become ·Suspension...

  • Page 40: Front End

    Periodic Service PRE-OPERATION CHECK JACK STAND POINT For your own safety and maximum service life WARNING the vehicle, make a thorough daily To avoid personal injury, death or vehicle damage: inspection before starting the engine or  Do not work under the vehicle unless it is operating the vehicle.

  • Page 41: Checking Coolant Level

    ■Checking Coolant Level fill the recovery tank.  If water should leak, consult your local CAUTION HISUN Dealer. TO avoid personal injury ■Cleaning radiator screen  Do not remove radiator cap while coolant is hot. When cool, slowly rotate to the first...

  • Page 42: Checking Brake Pedal

    Periodic Service materials, Park the vehicle on a level ground and open the hood. Check to see that the brake fluid level is up to the LOWER mark. If it is below the “LOWER” mark add brake fluid . ① Radiator screen ②...

  • Page 43: Checking Parking Brake

    Periodic Service ■Checking seat belt and ROPS ① Brake pedal ② FREE TRAVEL ■Checking parking brake Always check condition of seat belt and Pull the parking brake lever to apply the brakes ROPS attaching hardware before with the key switch in the"ON" position and the operating vehicle.

  • Page 44: Every 50 Hours

    Periodic Service tire sizes inflation pressure Front : 27x9-14 140kPa (1.4kgf/cm , 20psi) Rear:27x11-14 140kPa (1.4kgf/cm , 20psi) EVERY 50 HOURS ■Greasing Apply a small amount of multi-purpose grease to the following points every 50 hours. If you ① Gear shift lever pivot (spray type grease ) operated the vehicle in extremely wet and muddy conditions lubricate grease fittings more often.

  • Page 45: Checking Wheel Bolt Torque

    Periodic Service ① Range gear shift lever Torque Lug Nuts to 75to 90 N.m ■Cleaning air cleaner primary element Remove the air cleaner cover and primary element. Clean the primary elements. When dry dust adheres to the element blow compressed air from the inside turning the element.

  • Page 46: Evacuator Valve

    Periodic Service ① First air cleaner ② Secondary air cleaner ③ Primary element ④ Cover The fuel line is made of rubber and ages IMPORTANT regardless of service period.  The air cleaner uses a dry element never If the fuel line and clamps are found to be apply oil.

  • Page 47: Battery Charging

    Periodic Service To slowly charge the battery, connect the  Keep electrolyte away from eyes, hands battery positive terminal to the chargers and clothes. If spattered with it, wash it positive terminal and the negative to the away completely with water immediately negative terminal.

  • Page 48: Cleaning Muffler

    Periodic Service Return the spark arrester to the muffler body and refasten the bolts. IMPORTANT:  Visually check the muffler for cracks or holes in the body, welds or pipes at regular intervals.  USDA approval requires clearance ■Cleaning Muffler between spark arrester...

  • Page 49: Replacing Engine Oil Filter

    ③ “O” seal ring; ④ Engine oil filter IMPORANT:  To prevent serious damage to the engine, ① ② Oil level is acceptable within this range use only a genuine Hisun filter. ③ Dipstick④ Oil inlet ■Replacing Engine Oil ■Replacing Engine Oil Filter CAUTION...

  • Page 50: Checking Brake Pedal

    Periodic Service Reinstall the drain plug. If brake pedal free travel is outside of the Add the prescribed amount of oil to the engine specifications, contact your local dealer for After running the engine for a few minutes, adjusting the brake. stop the engine and check the oil level again.

  • Page 51: Checking Radiator Hose And Clamp

    Periodic Service Turn the key switch to the “ON” position. after about 5 minutes after unloaded Step on the brake pedal to check if the brake idling. light comes on. Keep yourself well away from the vehicle If it does not, check the bulb or brake light for at least 10 minutes or while the steam switch.

  • Page 52: Every 400 Hours

    Periodic Service ◆ Tire Tread Depth Always replace the tires when the tread depth is worn to minimum allowable. ① Drain plug ① 3mm(0.12in) IMPORTANT:  Do not operate the vehicle immediately EVERY 400 HOURS after changing the transmission fluid. ■Changing Transmission Fluid ...

  • Page 53: Every 500 Hours

    Periodic Service CAUTION To avoid personal injury:  Do not remove the radiator cap while coolant is hot. When cool, slowly rotate cap to the first stop and allow sufficient time for excess pressure to escape before removing the cap completely. Stop the engine and let cool down.

  • Page 54: Anti-Freeze

    Periodic Service  Antifreeze is extremely flammable and explosive under certain conditions. Keep fire and children away from antifreeze.  When draining fluids from the engine, place a container underneath the engine body.  Do not pour used coolant onto the ground, down a drain, or into any water source.

  • Page 55: Replacing Radiator Hose

    ■Replacing Fuel Hose Adding the LLC Consult your local HISUN Dealer for this service. Add only water if the mixture reduces in any ■ Replacing Brake Master Cylinder (Inner amount by evaporation.

  • Page 56: Replacing Procedure

    Periodic Service STORAGE ◆ Replacing procedure Disconnect the negative cable of the battery. CAUTION Open the mini-blade fuse box cover. To avoid personal injury: Pull out the mini-blade fuse.  Do not clean the vehicle when the engine Insert a new mini-blade fuse into the mini- is running.

  • Page 57: Removing The Vehicle From Storage

    Periodic Service Remove the battery from the vehicle. Store REMOVING THE VEHICLE FROM the battery following the battery storage STORAGE procedures. Keep the vehicle in a dry place where the Check the tire air pressure and inflate the vehicle is sheltered from the elements. tires if they are low.

  • Page 58: Electric Power Steering System

     much higher efficiency of up to 90%. Please carefully read this chapter before 2) Hisun’s EPS system starts the motor only operating or driving and understand the when it needs to generate power without correct ways to operate and drive the UTV increasing fuel consumption.
  • Page 59 Electric Power Steering System  EPS system control unit (ECU） 。 and monitors working condition of the EPS  Speed sensor。 system.  Temperature sensor Faults can be displayed by a fault indicator light  Battery voltage sensor and fault indicator of EPS system, so the driver ...

  • Page 60: Troubleshooting

    Troubleshooting ENGINE TROUBLESHOOTING If something is wrong with the engine, refer to the table below for the cause and its corrective countermeasure. Trouble Cause Countermeasure  Check the fuel tank and fuel filter。  Check the electric fuel pump.  Check the injector.

  • Page 61: Check Malf Code Meaning By Reading

    Troubleshooting Check malf code meaning by reading the below table. Mt05 ECU Malf Code Table:23 Malf code in MT05 Description P0107 MAP Circuit Low Voltage or Open P0108 MAP Circuit High Voltage P0112 IAT Circuit Low Voltage P0113 IAT Circuit High Voltage or Open P0117 Coolant/Oil Temperature Sensor Circuit Low Voltage P0118...

  • Page 62: Battery Troubleshooting

    Troubleshooting BATTERY TROUBLESHOOTING Trouble Cause Countermeasure Preventive measure  Battery overused until lights are dim. Charge the battery Charge the battery    Battery sufficiently. properly. been recharged.  Keep the terminal Starter does not function Clean the terminal ...

  • Page 63: Machine Troubleshooting

    Troubleshooting MACHINE TROUBLESHOOTING Trouble Cause Countermeasure  Replace throttle cable;  High idling speed of engine  Replace throttle petal  Replace the throttle  High rotary speed for clutch  Replace he junior clutch spring; connection.  Replace the primary clutch. ...
  • Page 64 OPTIONS Consult your local dealer for further details. Roof； Windshield； Windlass ; Motor Scan KF90121; Rear Trailer Hitch & Pin(2〞)； EPS. 13-1...
  • Page 65 Where a warrantable condition exists, HISUN will repair your vehicle at no cost to you, including diagnosis, parts and labor. If an emission-related part on your vehicle is defective, the part will be repaired or replaced by HISUN. This is your EMISSION CONTROL SYSTEM WARRANTY.
  • Page 66 Warranty defects shall be remedied during customary business hours at any authorized HISUN dealer located within the United States of America in compliance with the Clean Air Act and applicable regulations of the United States Environmental Protection Agency. Any part or parts replaced under this warranty shall become the property of HISUN.
  • Page 67 ADDITIONAL INFORMATION. Any replacement part that is equivalent in performance and durability may be used in the performance of any maintenance or repairs by the owner. However, HISUN is not liable for these parts. The owner is responsible for the performance of all required maintenance.

This manual is also suitable for:

Hs 900utvHs 800utv-5

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