Hsun HS700UTV Utility Vehicle Manuals

Manuals and User Guides for Hsun HS700UTV Utility Vehicle. We have 1 Hsun HS700UTV Utility Vehicle manual available for free PDF download: Maintenance Handbook

Hsun HS700UTV Maintenance Handbook

Hsun HS700UTV Maintenance Handbook (150 pages)

Brand: Hsun | Category: Utility Vehicle | Size: 4.03 MB

Table of Contents

Table of Contents
2
Description and Machine Identification

13
Chapter 1 General Information

14
Identification Code

14
- Frame no
  14
- Engine no
  14
Manual Organization

15
Watnings ,Cautions and Notes

15
Safety

15
- Handing Gasoline Safely
  16
- Cleaning Parts
  17
- Warning Labels
  17
Serial Numbers

18
Fasteners

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

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

23
- Screwdrivers
  23
- Wrenches
  24
- Adjustable Wrenches
  25
- Socket Wrenches, Ratchets and Handles
  25
- Impact Drivers
  26
- Allen Wrenches
  26
- Torque Wrenches
  26
- Torque Adapters
  27
- Pliers
  28
- Snap Ring Pliers
  28
- Hammers
  28
- Ignition Grounding Tool
  29
Precision Measuring Tools

29
- Feeler Gauge
  30
- Calipers
  30
- Micrometers
  31
- Adjustment
  31
- Care
  32
- Metric Micrometer
  32
- Standard Inch Micrometer
  33
- Telescoping and Small Bore Gauges
  34
- Dial Indicator
  34
- Cylinder Bore Gauge
  34
- Compression Gauge
  35
- Multimeter
  35
- Ohmmeter(Analog)Calibration
  35
Electrical System Fundamentals

35
- Voltage
  36
- Resistance
  36
Badic Service Methods

36
- Removing Frozen Fasteners
  38
- Removing Broken Fasteners
  38
- Repairing Damaged Threads
  38
- Stud Removal/Installation
  39
- Removing Hoses
  39
- Bearings
  39
- Removal
  40
- Installation
  40
- Interference Fit
  41
- Seal Replacement
  43
Storage

43
- Storage Area Selection
  43
- Preparing the Motorcycle for Storage
  43
Chapter Two Trovbleshooting

45
Engine Principles and Operating Requirements

46
Starting the Engine

46
Engine will Not Start

49
Poor Engine Performance

51
Fuel System

55
- Rich Mixture
  56
- Lean Mixture
  56
Engine

56
- Engine Smoke
  56
- Black Smoke
  56
- Blue Smoke
  57
- White Smoke or Steam
  57
- Low Engine Compression
  57
- High Engine Compression
  57
- Engine Overheating (Cooling System)
  58
- Engine Overheating (Engine)
  58
- Preignition
  58
- Detonation
  59
Englne Lubrication

60
- High Oil Consumption or Excessive
  60
  - Exhaust Smoke
    60
  - Low Oil Pressure
    60
  - High Oil Pressure
    60
  - No Oil Pressure
    61
  - Oil Level too Low
    61
  - Oil Contamination
    61
Cylinder Leakdown Test

61
Electrical Testing

64
- Preliminary Checks and Precautions
  64
- Intermittent Problems
  64
- Electrical Component Replacement
  65
- Test Equipment
  66
- Ammeter
  66
- Self-Powered Test Light
  66
- Ohmmeter
  67
- Jumper Wire
  67
- Test Procedures
  68
- Voltage Drop Test
  68
- Peak Voltage Test
  69
- Continuity Test
  69
- Testing for a Short with a Self-Powered Test Light or Ohmmeter
  69
- Testing for a Short with a Test Light or Voltmeter
  70
Brake System

70
- Soft or Spongy Brake Lever or Pedal
  70
- Brake Drag
  71
- Hard Brake Lever or Pedal Operation
  72
- Brake Squeal or Chatter
  72
- Leaking Brake Caliper
  72
- Leaking Master Cylinder
  73
Chapter 2 Specifications

74
How to Use Conversion Table of Unit

74
- How to Use Conversion Table
  74
Engine Specifications

78
Chassis Specifications

85
Electrical Specifications

87
Tightening Torques

89
Engine Tightening Torques

89
Chassis Tightening Torques

92
General Tightening Torque Specifications

94
Lubrication Pionts and Lubricant Types

95
- Engine
  95
Hydrographic Chart

96
Lubrication Oil Way

97
Chapter 3 Maintence and Adjustment of the Utv

98
Maintenance Schedule

98
Engine

100
- Adjusting the Valve Clearance
  100
- Idle Adjustment
  102
- Adjusting the Throttle Cable
  103
- Adjusting the Starter Cable
  104
- Checking the Spark Plug
  105
- Checking the Ignition Timing
  106
- Measuring the Compression Pressure
  107
- Checking the Engine Oil Level
  108
- Changing the Engine Oil
  109
- Cleaning the Air Filter
  112
- Checking the Coolant Level
  113
- Changing the Coolant
  113
- Checking the Coolant Temperature Warning Light
  116
- Checking the V-Belt
  117
- Cleaning the Spark Arrester
  118
- Adjusting the Brake Pedal
  119
- Adjusting the Parking Brake
  120
- Checking the Brake Fluid Level
  120
- Checking the Front Brake Pads
  121
- Checking the Rear Brake Pads
  121
- Checking the Brake Hoses and Brake Pipes
  122
- Bleeding the Hydraulic Brake System
  122
- Adjusting the Select Lever Shift Rod
  123
- Adjusting the Brake Light Switch
  124
- Checking the Final Gear Oil Level
  124
- Changing the Final Gear Oil
  125
- Checking the Differential Gear Oil
  125
- Changing the Differential Gear Oil
  126
- Checking the Constant Velocity Joint Dust Boots
  127
- Checking the Steering System
  127
- Adjusting the Toe-In
  128
- Adjusting the Front Shock Absorbers
  129
- Adjusting the Rear Shock Absorbers
  129
- Checking the Tires
  130
- Checking the Wheels
  131
- Checking and Lubricating the Cables
  132
Electrical

133
- Checking and Charging the Battery
  133
- Checking the Fuses
  138
- Adjusting the Headlight Beam
  140
- Cylinder Head
  142

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