Hisun Motors HS800UTV 2014 Manuals

Manuals and User Guides for Hisun Motors HS800UTV 2014. We have 1 Hisun Motors HS800UTV 2014 manual available for free PDF download: Maintenance Handbook

Hisun Motors HS800UTV 2014 Maintenance Handbook (361 pages)

Brand: Hisun Motors | Category: Utility Vehicle | Size: 41 MB

Table of Contents
2
Chapter 1 General Information

13
Watnings , Cautions and Notes

13
Description

14
Identification Code

15
- Frame no
  15
- Engine no
  15
Safety

16
- Handing Gasoline Safely
  16
- Cleaning Parts
  17
- Warning Labels
  17
Serial Numbers

18
Fasteners

18
- Torque Specifications
  18
- Self-Locking Fasteners
  18
- Washers
  18
- Cotter Pins
  19
- Snap Rings and E-Clips
  19
Shop Supplies

20
- Lubricants and Fluids
  20
- Engine Oils
  20
- Greases
  20
- Brake Fluid
  21
- Coolant
  21
- Cleaners, Degreasers and Solvents
  21
- Gasket Sealant
  21
- Gasket Remover
  22
- Thread Locking Compound
  22
Basic Tools

22
- Screwdrivers
  23
  - Wrenches
    23
  - Adjustable Wrenches
    24
  - Socket Wrenches, Ratchets and Handles
    24
  - Impact Drivers
    25
  - Allen Wrenches
    25
  - Torque Wrenches
    25
  - Torque Adapters
    26
  - Pliers
    27
  - Snap Ring Pliers
    27
  - Hammers
    28
  - Ignition Grounding Tool
    28
Precision Measuring Tools

28
- Feeler Gauge
  29
- Calipers
  29
- Micrometers
  30
- Adjustment
  30
- Care
  31
- Metric Micrometer
  31
- Standard Inch Micrometer
  32
- Telescoping and Small Bore Gauges
  33
- Dial Indicator
  33
- Compression Gauge
  34
- Multimeter
  34
- Cltp-On Ammeter
  34
- Magneto Puller
  35
Electrical System Fundamentals

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

36
- Removing Frozen Fasteners
  37
- Removing Broken Fasteners
  37
- Repairing Damaged Threads
  38
- Stud Removal/Installation
  38
- Removing Hoses
  39
- Bearings
  39
- Removal
  39
- Installation
  40
- 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
  46
- Flooded Engine
  46
Engine will Not Start

46
Poor Engine Performance

48
Fuel System

52
- Rich Mixture
  52
- Lean Mixture
  52
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 (Cooling System)
  54
- Engine Overheating (Engine)
  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
  56
- Oil Level too Low
  57
- Oil Contamination
  57
Cylinder Leak down Test

57
Electrical Testing

59
- Preliminary Checks and Precautions
  59
- Intermittent Problems
  60
- Electrical Component Replacement
  61
- Test Equipment
  61
- Ammeter
  61
- Self-Powered Test Light
  62
- Ohmmeter
  62
- Jumper Wire
  62
Test Procedures

63
- Voltage Test
  63
Brake System

65
- Soft or Spongy Brake Lever or Pedal
  65
- Brake Drag
  66
- Hard Brake Lever or Pedal Operation
  67
- Brake Grabs
  67
- Brake Squeal or Chatter
  67
- Leaking Brake Caliper
  68
- Leaking Master Cylinder
  68
Chapter 2 Specifications

69
How to Use Conversion Table of Unit

69
- How to Use Conversion Table
  69
- Definition of Unit
  69
Geberar Specifications

70
Engine Specifications

73
Chassis Specifications

79
Electrical Specifications

81
Tightening Torques

83
- Engine Tightening Torques
  83
- Chassis Tightening Torques
  86
General Tightening Torque Specifications

88
Lubrication Pionts and Lubricant Types

89
- Engine
  89
- Chassis
  90
Hydrographic Chart

91
Engine Gearbox Lubrication Oil Parth Circuit

93
Maintenance Schedule

94
Chapter 3

96
- Adjusting the Valve Clearance
  96
- Checking the Spark Plug
  99
- Checking the Ignition Timing
  100
- Measuring the Compression Pressure
  101
- Checking the Engine Oil Level
  102
- Changing the Engine Oil
  103
Engine

96
Chassis

105
- Cleaning the Air Filter
  105
- Checking the Coolant Level
  106
- Changing the Coolant
  107
- Checking the Coolant Temperature Warning Light
  110
- Checking the V-Belt
  111
- Cleaning the Spark Arrester
  112
- Adjusting the Brake Pedal
  113
- Checking the Brake Fluid Level
  114
- Checking the Front Brake Pads
  115
- Checking the Rear Brake Pads
  115
- Checking the Brake Hoses and Brake Pipes
  116
- Bleeding the Hydraulic Brake System
  116
- Adjusting the Select Lever Shift Rod
  118
- Adjusting the Brake Light Switch
  118
- Checking the Final Gear Oil Level
  119
- Changing the Final Gear Oil
  119
- Checking the Differential Gear Oil
  120
- Changing the Differential Gear Oil
  120
- Checking the Constant Velocity Joint Dust Boots
  121
- Checking the Steering System
  122
- Adjusting the Toe-In
  123
- Adjusting the Front and Rear Shock Absorbers
  124
- Checking the Tires
  127
- Checking the Wheels
  129
- Checking and Lubricating the Cables
  129
Electrical

130
- Checking and Charging the Battery
  130
- Checking the Fuses
  136
- Adjusting the Headlight Beam
  138
- Changing the Headlight Bulb
  138
- Changing the Tail/Brake Light Bulb
  139
Chapter 4 Engine

141
Engine Note

141
Engine Removal

142
Cylinder Head and Cylinder Head Cover

143
Rocker Arms and Camshaft

148
Valves and Valve Springs

151
Cylinder and Piston

156
Engine Left Crankcase Cover A.C. Magneto

160
Starter Motor and Oil Filter

164
Primary and Secondary Sheaves

167
Crankcase Cover and Oil Pump

171
Crankcase and Middle Driven Shaft

175
Output Shaft

180
Gearcase

181
- Gearcase
  182
- Shift Lever and Oil Pump
  184
- Gearcase Transmission
  186
Chapter 5

192
Malfunction Inspection

192
Direction System

195
- The Steering Wheel Part
  195
Brake System

204
- Disk Brake Components
  205
  - Front Brake Caliper
    207
  - Rear Brake Calipers
    215
  - Parking Brake Caliper
    218
Footrest Assembly

229
Wheel and Tyre Parts

232
- Front Wheels
  232
- Rear Wheels
  233
Transmission System

237
- C.V Axle, Front Axle
  237
- Front Bridge
  238
- C.V Axle, Rear Axle
  244
- Rear Bridge Reducer
  245
  - Rear Bridge
    249
Shift Operating System

250
Suspension

254
- Front Swing Arm
  254
- Front Suspension
  256
- Rear Anti-Roll Bar
  262
  - Rear Swing Arm
    263
Cooling System

268
- Water and Oil Radiator
  268
- Water Pump
  275
Seat

282
Fuel Tank

286
Chapter 6 Electrical Components

290
Electrical System Malfunction Inspection

290
Electrical

291
Electricalcomponents

291
- Checking the Switch
  293
- Checking the Switch Continuity
  294
- Checking the Bulbs and Bulb Sockets
  295
Ignition System

295
- Circuit Diagram
  295
- Troubleshooting
  296
Electric Starting System

299
- Circuit Diagram
  299
- Troubleshooting
  300
Starter Motor

303
- Checking the Starter Motor
  304
- Assembling the Starter Motor
  305
Charging System

305
- Circuit Diagram
  305
- Troubleshooting
  306
Lighting System

307
- Circuit Diagram
  307
- Troubleshooting
  308
- Checking the Lighting System
  309
Signaling System

310
- Circuit Diagram
  310
- Troubleshooting
  311
- Checking the Signal System
  312
Cooling System

321
- Circuit Diagram
  321
- Troubleshooting
  322
2Wd/4Wd Selecting System

324
- Circuit Diagram
  324
- Troubleshooting
  325
Chapter 7 Engine Management System

326
Introduction

326
- Ems (Engine Management System)
  326
- Typical Components of EMS
  326
- Layout of EMS Components
  327
Components of Ems

327
- Electronic Control Unit
  327
- Multec 3.5 Injectors
  328
- Throttle Body Assembly(with Stepper Motor)
  332
- Engine Coolant Temperature Sensor
  334
- Intake Air Pressure and Temperature Sensor
  335
- Oxygen Sensor
  335
- Ignition Coil
  335
- Fuel Pump Module
  339
Ems Fault Diagnosis

345
- EME Fault Diagnosis
  345
- Fault Code List
  345
Chapter 8 Troubleshooting

347
Starting Failure/Hard Starting

347
- Fuel System
  347
- Electrical System
  347
- Compression System
  348
Poor Idle Speed Performance

348
Faulty Gear Shifting

349
- Shift Lever Does Not Move
  349
- Jumps out of Gear
  349
Poor Medium and High-Speed Performance

349
Enging Overheating

350
- Overheating
  350
Faulty Brake

350
- Poor Braking Effect
  350
Shock Absorber Malfunction

351
- Loss of Damping Function
  351
Unstable Handling

351
Lighting System

351
- Head Light Is out of Work
  351
- Bulb Burnt out
  352
- Error Display of Meter
  352

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Hisun Motors HS800UTV 2014 Manuals

Hisun Motors HS800UTV 2014 Maintenance Handbook (361 pages)

Table of Contents

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