Hisun HS500UTV Manuals

Manuals and User Guides for Hisun HS500UTV. We have 2 Hisun HS500UTV manuals available for free PDF download: Service Manual, Owner's Manual

Hisun HS500UTV Service Manual (391 pages)

Brand: Hisun | Category: Utility Vehicle | Size: 53 MB

Contents
3
General Information
17
Description
17
Identification Code
18
Safety
19
Handling Gasoline Safety
20
Cleaning Parts
20
Warning Labels
21
Serial Numbers, Fasteners
21
Trorque Specifications
21
Washers
22
Cotter Pins
22
Snap Rings and E-Clips
22
Shop Supplies
23
Lubricants and Fluids
23
Engine Oils
23
Greases
24
Brake Fluid
24
Coolant
24
Cleaners, Degreasers and Solvents
24
Gasket Sealant
25
Gasket Remover
25
Thread Locking Compound
25
Basic Tools
26
Screwdrivers
26
Wrenches, Adjustable Wrenches
27
Socket Wrenches, Ratchets and Handles
28
Impact Drivers
29
Allen Wrenches
29
Torque Wrenches
29
Torque Adapters
30
Pliers, Snap Ring Pliers
31
Precision Measuring Tools
32
Hammers
32
Ignition Grounding Tool
32
Feeler Gauge
33
Calipers
33
Micrometers
34
Micrometers Adjustment, Care
35
Metric Micrometer
35
Standard Inch Micrometer
36
Telescoping and Small Bore Gauges
37
Dial Indicator
37
Compression Gauge
38
Multimeter
38
Electrical System Fundamentals
39
Voltage
39
Resistance
39
Amperage
39
Basic Service Methods
40
Removing Frozen Fasteners
41
Removing Broken Fasteners
41
Repairing Damaged Threads
42
Stud Removal/Installation
42
Removing Hoses
42
Bearings Removal
43
Bearings Installation
44
Interface Fit
44
Seal Replacement
46
Storage Area Selection
46
Preparing the Motorcycle for Storage
47
Returning the UTV to Service
47
Troubleshooting
48
Engine Principles and Operating Requirements
48
Starting the Engine
49
Engine Is Cold/War
49
Starting the Engine after a Fall or after the Engine Stalls
49
Flooded Engine
49
Engine Cold with Air Temperature between 10-35C/Above 35C/Below 10C
50
Engine Is Hot
51
Engine will Not Start
52
Spark Test
53
Poor Engine Performance
54
Starter Does Not Turn over or Turns over Slowly
54
Engine Starts but Stalls and Is Hard to Restart
54
Engine Backfires, Cuts out or Misfires During Acceleration
55
Engine Backfires on Deceleration
55
Poor Fuel Mileage
55
Engine will Not Idle or Idles Roughly
56
Low Engine Power
56
Poor Idle or Low Speed Performance
57
Fuel System
58
Rich Mixture
58
Poor High Speed Performance
58
Engine Smoke
59
Lean Mixture
59
Engine Overheating (Cooling System)
60
Low/High Engine Compression
60
Engine Overheating (Engine)
61
Preignition, Detonation
61
Power Loss
61
Engine Noises
61
Engine Lubrication
62
High Oil Consumption or Excessive
62
Cylinder Leak down Test
63
High Oil Pressure, no Oil Pressure
63
Oil Level too Low
63
Oil Contamination
63
Electrical Testing
66
Preliminary Checks and Precautions
66
Intermittent Problems
67
Electrical Component Replacement
68
Test Equipment
68
Ammeter
68
Self-Powered Test Light
68
Ohmmeter
69
Jumper Wire
69
Test Procedures
70
Voltage Test, Voltage Drop Test
70
Peak Voltage Test
71
Continuity Test
71
Testing for a Short with a Self-Powered Test Light of Ohmmeter
71
Brake System
72
Testing for a Short with a Test Light or Voltmeter
72
Soft or Sponge Brake Lever or Pedal
72
Brake Drag
73
Hard Brake Lever or Pedal Operation
74
Brake Grabs
74
Brake Squeal or Chatter
74
Leaking Brake Caliper
75
Specifications
76
How to Conversion Table of Unit
76
Definition of Unit
76
Geberar Specifications
77
Engine Specifications
80
Chassis Specifications
86
Electrical Specifications
88
Engine Tightening Torques
90
Chassis Tightening Torques
93
General Tightening Torque Specifications
96
Lubrication Points and Lubricant Types: Engine
97
Hydrographic Chart
98
Lubrication Oil Way
99
Maintenance and Adjustment of the UTV
100
Maintenance Schedule
100
Engine
102
Idle Adjustment
105
Adjusting the Throttle Cable
105
Adjusting the Starter Cable
106
Checking the Spark Plug
107
Checking the Ignition Timing
108
Measuring the Compression Pressure
109
Checking the Engine Oil Level
111
Changing the Engine Oil
112
Chassis
115
Cleaning the Air Filter
115
Checking the Coolant Level
116
Changing the Coolant
117
Checking the Coolant Temperature
120
Warning Light
120
Coolant Temperature Warning Light Checking Method
121
Checking the V-Belt
121
Cleaning the Spark Arrester
122
Adjusting the Brake Pedal
123
Adjusting the Parking Brake
124
Checking the Brake Fluid Level
125
Checking the Front Brake Pads
125
Checking the Rear Brake Pads
126
Checking the Brake Hoses and Brake Pipes
126
Bleeding the Hydraulic Brake System
127
Adjusting the Select Lever Shift Rod
129
Adjusting the Brake Light Switch
129
Checking the Final Gear Oil Level
130
Changing the Final Gear Oil
130
Checking/Changing the Differential Gear Oil
131
Checking the Constant Velocity Joint Dust Boots
132
Checking the Steering System
133
Adjusting the Toe-In
134
Adjusting the Front/Rear Shock Absorbers
135
Checking the Tires
136
Checking the Wheels
138
Checking and Lubricating the Cables
138
Checking and Charging the Battery
139
Charging Method Using a Constant Voltage Charger
143
Checking the Fuses
144
Adjusting the Headlight Beam
145
Changing the Headlight Bulb
146
Changing the Tail/Brake Light Bulb
147
Engine Note
148
Engine Removal
149
Cylinder Head and Cylinder Head Cover
151
Engine Check
153
Rocker Arms and Camshaft
156
Checking the Rocker Arms
158
Installing the Rocker Arms
159
Valves and Valve Springs
162
Valves and Valve Springs Check, Measure
163
Valves and Valve Springs Install
166
Cylinder and Piston
168
Cylinder and Piston Check, Measure
169
Cylinder and Piston - Install
171
Engine Cooling Fan and A.C. Magneto
172
Engine Cooling Fan and A.C. Magneto Check
174
Engine Cooling Fan and A.C. Magneto Install
175
Balancer Gears and Oil Pump Gears
177
Balancer Gears and Oil Pump Check
178
Balancer Gears and Oil Pump Install
178
Primary and Secondary Sheaves
180
Primary Sheave
181
Secondary Sheave
182
Primary/Secondary Sheave Check
183
Primary/Secondary Sheave Measure, Install
184
Clutch
187
Clutch Check, Measure
189
Clutch Install
190
Crankcase
191
Starter Motor and Oil Filter
191
Crankcase Overview
193
Crankcase Bearings
194
Crankcase Check
195
Crankcase Install
196
Crankshaft and Oil Pump
198
Oil Pump
199
Crankshaft and Oil Pump Check, Measure
200
Crankshaft Install
201
Transmission
202
Drive Axle Assembly
203
Drive Axle Check
204
Drive Axle Install
206
Middle Gear
207
Middle Drive Shaft
207
Middle Driven Shaft
208
Middle Drive Shaft Check, Measure
210
Middle Drive Shaft Install
211
Carburetor
214
Carburetor Check
216
Carburetor Measure
217
Carburetor Install
218
Malfunction Inspection
219
Direction System
222
The Structure of the Steering
222
The Structure of Steering Wheel Part
224
Disassembling the Parts of the Steering Wheel
225
Checking the Parts of the Steering Wheel
225
Disassembling the Steering Column Parts
226
Checking and Service the Steering Column Parts
227
Steering Drive Axle
228
Checking and Service the Steering Drive Axle
228
Steering Machine Parts
229
Disassembling the Steering Machine Part
229
Reinstalls the Steering System Parts
230
Preparation for Checking before the Maintenance of the Brake System
232
Front Disk Brake Components
233
Front Brake Discs
234
Checking the Front Brake Disc
235
Front Brake Pads
236
Replacing the Front Brake Pads
237
Front Brake Caliper
238
Disassembling the Front Brake Calipers
240
Assembling/Installing the Front Brake Calipers
241
Rear Brake Disc
243
Checking the Rear Brake Disc
244
Rear Brake Caliper and Brake Pads
245
Replacing the Rear Brake Pads
248
Disassembling the Rear Brake Caliper
248
Assembling the Rear Brake Caliper
249
Installing the Rear Brake Caliper
251
Brake Master Cylinder
253
Checking the Master Cylinder
254
Assembling/Installing the Brake Master Cylinder
254
Footrest Assembly
256
Wheel and Tyre Parts
259
Front Wheels
259
Rear Wheels
260
Checking the Wheel Tyre
261
Checking/Installing the Wheel Hub
261
Installing the Wheel Tyre
262
Specification of Wheel and Tyre
262
Transmission System
263
Front Bridge
263
Disassembling the Front Bridge
268
Disassembling the Universal Joint
268
Removing the Differential Gear Assembly
268
Checking the Joints
269
Checking the Differential Gear
269
Checking the Gear Motor
270
Assembling the Universal Joint
271
Adjusting the Differential Gear Lash
271
Assembling the Differential Gear
272
Installing the Front Bridge Parts
273
Rear Bridge
274
Reverse Mechanism Parts
280
Adjusting Reverse Mechanism Parts
282
Checking and Service of Reverse Mechanism
282
Suspension
284
Front Suspension and Arm
284
Disassembling, Service and Assembly the Supporting Rocker Parts
286
Checking the Front Arms
287
Checking the Front Shock Absorber
287
Installing the Front Arms and Front Shock Absorber
288
Rear Suspension
289
Rear Arm Shaft
290
Rear Suspension and Arm
291
Checking and Service of Rear Suspension
291
Checking the Stabilizer
291
Checking the Rear Arms
291
Checking the Rear Shock Absorber
292
Installing the Rear Arms and Rear Shock Absorber
292
Cooling System
293
Radiator
293
Checking/Installing the Radiator
296
Checking the Oil Cooler
297
Water Pump
298
Disassembling the Water Pump
300
Checking the Water Pump
300
Assembling the Water Pump
301
Seat
303
Oil System
305
Fuel Tank
305
Checking the Fuel Pump Operation
308
Disassembling Oil Cooling System
308
Checking and Service the Oil Cooling System
308
Installing Oil Cooling System
309
Electrical System Malfunction Inspection
310
Electrical Components
311
Checking the Switch
313
Checking the Switch Continuity
314
Checking the Bulbs and Bulb Sockets
315
Ignition System
316
Circuit Diagram
316
Electrical Components Troubleshooting
317
Electric Starting System: Circuit Diagram
321
Electric Starting System: Troubleshooting
322
Starter Motor
325
Checking the Starter Motor
326
Assembling the Starter Motor
327
Charging System: Circuit Diagram
328
Charging System: Troubleshooting
329
Lighting System: Circuit Diagram
331
Lighting System Troubleshooting
332
Checking the Lighting System
333
Signaling System: Circuit Diagram
335
Signaling System: Troubleshooting
336
Checking the Signal System
337
Cooling System: Circuit Diagram
347
Cooling System Troubleshooting
348
2WD/4WD Selecting System: Circuit Diagram
351
2WD/4WD Selecting System: Troubleshooting
352
Troubleshooting the Product
356
Starting Failure/Hard Starting
356
Poor Idle Speed Performance
358
Poor Medium and High Speed Performance
358
Faulty Gear Shifting
358
Overheating
359
Faulty Brake
360
Shock Absorber Malfunction
360
Unstable Handling
360
HS600UTV Specifications
363
HS500UTV Specifications
366
HS500UTV Engine Removal
372
HS500UTV: Cylinder Head and Cylinder Head Cover
374
HS500UTV Rocker Arms and Camshaft
377
HS500UTV Valves and Valve Springs
381
HS500UTV Cylinder and Piston
386
HS700UTV/HS600UTV/HS500UTV Wiring Diagram
390

Hisun HS500UTV Owner's Manual (173 pages)

Brand: Hisun | Category: Utility Vehicle | Size: 5 MB

Important Manual Information
4
Important Notice
5
Table of Contents
6
1 Location of the Warning and

10
2 Safety Information

18
3 Description and Vehicle Identification

24
- Identification Number Records
  24
- Vehicle Identification Number
  24
4 Control Functions

25
- Main Switch
  25
- Indicator and Warning Lights
  26
- Use of EPS System
  29
- Multi-Function Display Gauge
  30
- Clock Mode
  31
- To Set the Clock
  31
- Fault Codes Display of the Electronic
  31
- Fuel Meter
  31
- Switches
  32
- Accelerator Pedal
  37
- Brake Pedal
  38
- Parking Brake Lever
  38
- Drive Select Lever
  39
- Fuel Tank Cap
  40
- Seats
  40
- Seat Belts
  41
- Glove Compartment
  44
- Cargo Bed
  44
- Opening and Closing the Tailgate
  45
- Lifting and Lowering the Cargo Bed
  45
- Front and Rear Shock Absorber Adjustment
  47
- Trailer Hitch Bracket
  49
- Auxiliary DC Jack
  50
Pre Operation Checks

53
- Brakes
  53
- Brake Fluid Level
  53
- Brake Fluid Leakage
  54
- Brake Operation
  54
- Fuel
  55
- Gasohol
  55
- Engine Oil
  56
- Coolant
  57
- Final Gear Oil
  58
- Differential Gear Oil
  58
- Throttle Pedal
  59
- Throttle Freeplay
  60
- Throttle Freeplay Inspection
  60
- Throttle Freeplay Adjustment
  60
- Steering Wheel Inspection
  61
- Seat Belts
  61
- Fittings and Fasteners
  61
- Lights
  61
- Switches
  62
- Tires
  62
- How to Measure Tire Pressure
  63
- Tire Wear Limit
  64
Operation

65
- Starting the Engine in Low Temperatures
  65
- Starting the Engine
  66
- Warming up
  67
- Drive Select Lever Operation and Driving in Reverse
  68
- Parking
  72
- Parking on a Slope
  72
- Vehicle Break-In Period
  73
- Engine Break-In
  74
- Accessories
  75
- Loading
  76
7 Driving Your Vehicle

80
- Getting to Know Your Vehicle
  80
- Learning to Operate Your Vehicle
  84
- Turning Your Vehicle
  85
- Braking
  87
- Going Uphill
  87
- Going Downhill
  89
- Crossing through Shallow Water
  91
- Riding over Rough Terrain
  94
- Riding in Brush or Wooded Areas
  96
- Encountering Obstacles on the Trail
  96
8 Periodic Maintenance and Adjustment

98
- Periodic Maintenance Chart for the Emission Control System
  100
- General Maintenance and Lubrication Chart
  101
- Hood
  104
- Console
  105
- Engine Oil and Oil Filter Cartridge
  106
- To Check the Engine Oil Level
  106
- To Change the Engine Oil
  107
- Final Gear Oil
  110
- Changing the Final Gear Oil
  112
- Differential Gear Oil
  113
- Changing the Differential Gear Oil
  114
- Coolant
  115
- Axle Boots
  116
- Spark Plug Inspection
  117
- Inspection
  118
- Installation
  118
- V-Belt Cooling Duct Check Hose
  123
- V-Belt Case Drain Plug
  124
- Cleaning the Spark Arrester
  124
- Valve Clearance
  126
- Front Brake Pad Check
  126
- Rear Brake Pad Check
  127
- Checking the Brake Fluid Level
  128
- Brake Fluid Replacement
  129
- Checking the Brake Pedal
  129
- Parking Brake Lever Free Play Adjustment
  130
- Brake Light Switch Adjustment
  132
- Cable Inspection and Lubrication
  132
- Brake Pedal and Accelerator Pedal Lubrication
  133
- Rear Knuckle Upper and Lower Pivot Lubrication
  134
- Steering Shaft Lubrication
  134
- Wheel Removal
  135
- Wheel Installation
  135
- Battery
  136
- Battery Maintenance
  138
- Fuse Replacement
  138
- Replacing Headlight Bulb
  140
- Headlight Beam Adjustment
  143
- Tail/Brake Light Bulb Replacement
  144
- Troubleshooting
  146
- Solution to Common Problems in the Vehicle
  147
Cleaning and Storage

156
- Cleaning
  156
- Storage
  158
Specifications

160

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Hisun HS500UTV Manuals

Hisun HS500UTV Service Manual (391 pages)

Table of Contents

Hisun HS500UTV Owner's Manual (173 pages)

Table of Contents

1 Location of the Warning and

2 Safety Information

3 Description and Vehicle Identification

4 Control Functions

Pre Operation Checks

Operation

7 Driving Your Vehicle

8 Periodic Maintenance and Adjustment

Cleaning and Storage

Specifications

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