Hisun Motors HS750UTV-2 Manuals

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Hisun Motors HS750UTV-2 Manual (358 pages)

Brand: Hisun Motors | Category: Utility Vehicle | Size: 51 MB

Table of Contents
2
Chapter 1 General Information

11
Description

12
Identification Code

13
- Frame no
  13
- Engine no
  13
Safety

14
- Handling Gasoline Safely
  15
- Cleaning Parts
  15
- Warning Labels
  16
Serial Numbers

16
Fasteners

16
- Torque Specifications
  16
- Self-Locking Fasteners
  16
- Washers
  17
- Cotter Pins
  17
- Snap Rings and E-Clips
  17
Shop Sipplies

18
- Lubricants and Fluids
  18
- Engine Oils
  18
- Greases
  19
- Brake Fluid
  19
- Coolant
  19
- Cleaners, Degreasers and Solvents
  19
- Gasket Sealant
  20
- Gasket Remover
  20
- Thread Locking Compound
  20
Basic Tools

21
- Screwdrivers
  21
- Wrenches
  22
- Adjustable Wrenches
  22
- Socket Wrenches, Ratchets and Handles
  23
- Impact Drivers
  24
- Allen Wrenches
  24
- Torque Wrenches
  24
- Torque Adapters
  25
- Pliers
  26
- Snap Ring Pliers
  26
- Hammers
  27
- Ignition Grounding Tool
  27
Precision Measuring Tools

27
- Feeler Gauge
  28
- Calipers
  28
- Micrometers
  29
- Adjustment
  30
- Care
  30
- Metric Micrometer
  30
- Standard Inch Micrometer
  31
- Telescoping and Small Bore Gauges
  32
- Dial Indicator
  32
- Compression Gauge
  33
- Multimeter
  33
- Clip-On Ammeter
  34
- Magneto Puller
  34
Electrical System Fundamentals

34
- Voltage
  34
- Resistance
  34
- Amperage
  35
Basic Service Methods

35
- Removing Frozen Fasteners
  36
- Removing Broken Fasteners
  37
- Repairing Damaged Threads
  37
- Stud Removal/Installation
  37
- Removing Hoses
  38
- Bearings
  38
- Removal
  39
- Installation
  39
- Interference Fit
  40
- Seal Replacement
  42
Storage

42
Trovbleshooting

43
Engine Principles and Operating Requirements

44
Starting the Engine

44
- Engine Is Cold
  45
- Engine Is Warm
  45
- Flooded Engine
  46
Engine will Not Start

46
Poor Engine Performance

48
Fuel System

52
- Rich Mixture
  52
- Lean Mixture
  53
Engine

53
- Engine Smoke
  53
- Black Smoke
  53
- Blue Smoke
  53
- White Smoke or Steam
  53
- Low Engine Compression
  53
- High Engine Compression
  54
- Engine Overheating
  54
- The Ignition Advance Angle Is too Large
  55
- Detonation
  55
- Power Loss
  55
- Engine Noises
  55
Englne Lubrication

56
High Oil Consumption or Excessive

56
- Exhaust Smoke
  56
- Low Oil Pressure
  56
- High Oil Pressure
  56
- No Oil Pressure
  57
- Oil Level too Low
  57
- Oil Contamination
  57
Cylinder Leak down Test

57
Electrical Testing

60
- Preliminary Checks and Precautions
  60
- Intermittent Problems
  60
- Electrical Component Replacement
  61
- Test Equipment
  62
- Ammeter
  62
- Self-Powered Test Light
  62
  - Ohmmeter
    62
  - Jumper Wire
    63
Test Procedures

64
Brake System

66
- Soft or Spongy Brake Lever or Pedal
  66
- Brake Drag
  67
- Hard Brake Lever or Pedal Operation
  68
- Brake Grabs
  68
- Brake Squeal or Chatter
  68
- Leaking Brake Caliper
  68
- Leaking Master Cylinder
  69
Chapter 2 Specifications

70
How to Use Conversion Table of Unit

70
- How to Use Conversion Table
  70
- Definition of Unit
  70
Geberar Specifications

71
Engine Specifications

74
Chassis Specifications

80
Electrical Specifications

82
Tightening Torques

84
- Engine Tightening Torques
  84
- Chassis Tightening Torques
  87
General Tightening Torque Specifications

89
Lubrication Pionts and Lubricant Types

90
- Engine
  90
- Chassis
  91
Hydrographic Chart

92
Lubrication Oil Way

93
Chapter 3 Maintence and Adjustment of the Utv

94
Maintenance Schedule

94
Engine

96
- Adjusting the Valve Clearance
  96
- Checking the Spark Plug
  99
- Checking the Ignition Timing
  99
- Measuring the Compression Pressure
  101
- Checking the Engine Oil Level
  102
- Changing the Engine Oil
  103
Chassis

106
- Cleaning the Air Filter
  106
- Checking the Coolant Level
  107
- Changing the Coolant
  108
- Checking the Coolant Temperature Warning Light
  111
- Checking the V-Belt
  112
- Cleaning the Spark Arrester
  113
- Adjusting the Brake Pedal
  114
- Adjusting the Parking Brake
  114
- Checking the Brake Fluid Level
  115
- Checking the Front Brake Pads
  116
- Checking the Rear Brake Pads
  116
- Checking the Brake Hoses and Brake Pipes
  117
- Bleeding the Hydraulic Brake System
  117
- Adjusting the Select Lever Shift Rod
  118
- Checking the Final Gear Oil Level
  119
- Changing the Final Gear Oil
  120
- Checking the Differential Gear Oil
  120
- Changing the Differential Gear Oil
  121
- Checking the Constant Velocity Joint Dust Boots
  121
- Checking the Steering System
  122
- Adjusting the Toe-In
  123
- Adjusting the Front Shock Absorbers
  124
- Checking the Tires
  125
- Checking the Wheels
  126
Electrical

128
- Checking and Charging the Battery
  128
- Checking the Fuses
  134
- Adjusting the Headlight Beam
  135
- Changing the Headlight Bulb
  136
- Changing the Tail/Brake Light Bulb
  137
Chapter 4

138
Engine Note

138
Engine Removal

139
Cylinder Head and Cylinder Head Cover

142
Rocker Arms and Camshaft

147
Valves and Valve Springs

152
Cylinder and Piston

157
Engine Cooling Fan and A.C. Magneto

161
Balancer Gears and Oil Pump Gears

166
Primary and Secondary Sheaves

169
Primary Sheave

170
Secondary Sheave

171
Clutch

176
Clutch Housing

177
Crankcase Starter Motorand Oil Filter

180
Crankcase

182
Crankcase Bearings

183
Crankshaft and Oil Pump

187
Oil Pump

188
Transmission

191
Drive Axle Assembly

192
Middle Gear

196
Middle Drive Shaft

197
Chapter 5 Chassis

203
Direction System

206
- The Steering Wheel Parts (Epa Type)
  206
- The Steering Wheel Parts (E-Mark Type)
  209
Brake System

219
- Disk Brake Components
  220
- Front and Rear Brake Discs
  222
- Front and Rear Brake Pads
  224
- Front and Rear Brake Caliper
  226
- Parking Brake Disc
  231
- Parking Brake Caliper and Brake Pads
  233
- Brake Master Cylinder
  241
Footrest Assembly

244
Wheel and Tyre Parts

247
- Front Wheels
  247
- Rear Wheels
  248
Transmission System

251
- Front Axle
  251
- Front Bridge
  252
- Rear Axle
  262
- Rear Bridge
  263
- Reverse Mechanism Parts
  267
Suspension

271
- Front Suspension and Arm
  271
- Rear Suspension
  277
- Rear Arm Shaft
  279
Cooling System

283
- Radiator 1
  283
- Radiator 2
  285
- Water Pump
  289
Seat

294
Oil System

296
Fuel Tank

296
Chapter 6 Electrical Components

299
Electrical System Malfunction Inspection

299
Electrical

300
Electricalcomponents(Bucket Seat)

300
Ignition System

305
Electric Starting System

308
- Circuit Diagram（See348
  308
- Troubleshooting
  309
Starter Motor

312
Charging System

313
- Circuit Diagram
  313
- Troubleshooting
  314
Lighting System

315
- Circuit Diagram（See348
  315
- Troubleshooting
  316
- Checking the Lighting System
  317
Signaling System

318
- Circuit Diagram（See348
  318
- Troubleshooting
  319
- Checking the Signal System
  320
Cooling System

326
- Circuit Diagram
  326
- Troubleshooting
  327
2Wd/4Wd Selecting System

329
- CIRCUIT Diagram（See348
  329
Troubleshooting

330
- Check if the 2/4WD Switch Is Working
  330
- Check if the Rear Differential Is Working
  330
Chapter 7 Engine Management System

331
EMS (Engine Management System)

331
Typical Components of Ems

331
Layout of Ems Components

332
Components of Ems

332
- Electronic Control Unit
  332
- Multec 3.5 Injectors
  333
- Throttle Body Assembly(with Stepper Motor)
  337
- Engine Coolant Temperature Sensor
  339
- Intake Air Pressure and Temperature Sensor
  339
- Oxygen Sensor
  340
- Ignition Coil
  340
- Fuel Pump Module
  344
Ems Fault Diagnosis

350
- EME Fault Diagnosis
  350
- Fault Code List
  350
Chapter 8 Troubleshooting

352
Starting Failure/Hard Starting

352
- Fuel System
  352
- Electrical System
  352
- Compression System
  353
Poor Idle Speed Performance

353
Faulty Gear Shifting

354
- Shift Lever Does Not Move
  354
- Jumps out of Gear
  354
Poor Medium and High-Speed Performance

354
Engine Overheating

355
- Overheating
  355
Faulty Brake

355
- Poor Braking Effect
  355
Shock Absorber Malfunction

356
Unstable Handling

356
Lighting System

356
- Head Light Is out of Work
  356
- Bulb Burnt out
  357
- Error Display of Meter
  357

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Hisun Motors HS750UTV-2 Manuals

Hisun Motors HS750UTV-2 Manual (358 pages)

Table of Contents

Chapter 1 General Information

Description

Identification Code

Safety

Serial Numbers

Fasteners

Shop Sipplies

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

Lubrication Oil Way

Chapter 3 Maintence and Adjustment of the Utv

Maintenance Schedule

Engine

Chassis

Electrical

Chapter 4

Engine Note

Engine Removal

Cylinder Head and Cylinder Head Cover

Rocker Arms and Camshaft

Valves and Valve Springs

Cylinder and Piston

Engine Cooling Fan and A.C. Magneto

Balancer Gears and Oil Pump Gears

Primary and Secondary Sheaves

Primary Sheave

Secondary Sheave

Clutch

Clutch Housing

Crankcase Starter Motorand Oil Filter

Crankcase

Crankcase Bearings

Crankshaft and Oil Pump

Oil Pump

Transmission

Drive Axle Assembly

Middle Gear

Middle Drive Shaft

Chapter 5 Chassis

Direction System

Brake System

Footrest Assembly

Wheel and Tyre Parts

Transmission System

Suspension

Cooling System

Seat

Oil System

Fuel Tank

Chapter 6 Electrical Components

Electrical System Malfunction Inspection