Huansong HS500UTV Manuals

Manuals and User Guides for Huansong HS500UTV. We have 1 Huansong HS500UTV manual available for free PDF download: Brief

Huansong HS500UTV Brief (411 pages)

Brand: Huansong | Category: Utility Vehicle | Size: 14 MB

Table of Contents
2
General Information
16
Watnings , Cautions and Notes
16
Description
17
Identification Code
18
Frame no
18
Engine no
18
Safety
19
Handing Gasoline Safely
20
Cleaning Parts
20
Warning Labels
21
Serial Numbers
21
Fasteners
21
Torque Specifications
21
Self-Locking Fasteners
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
27
Adjustable Wrenches
27
Socket Wrenches, Ratchets and Handles
28
Impact Drivers
29
Allen Wrenches
29
Torque Wrenches
29
Torque Adapters
30
Pliers
31
Snap Ring Pliers
31
Hammers
32
Ignition Grounding Tool
32
Precision Measuring Tools
32
Feeler Gauge
33
Calipers
33
Micrometers
34
Adjustment
35
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
43
Removal
43
Installation
44
Interference Fit
44
Seal Replacement
46
Storage
46
Storage Area Selection
46
Preparing the Motorcycle for Storage
47
Returning the UTV to Service
47
Trovbleshooting
48
Engine Principles and Operating Requirements
48
Starting the Engine
49
Engine Is Cold
49
Engine Is Warm
49
Starting the Engine after a Fall or after the Engine Stalls
49
Flooded Engine
49
Engine Cold with Air Temperature
50
Engine Cold with Air Temperature above 35℃（95°F
50
Cold Engine with Air Temperature below 10℃(50°F)
50
Engine Is Hot
51
Starting the Engine after a Fall or after the Engine Stalls
51
Flooded Engine
51
Engine will Not Start
52
Identifying the Problem
52
Spark Test
53
Starter Does Not Turn over or Turns over Slowly
54
Poor Engine Performance
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
Poor High Speed Performance
58
Fuel System
58
Rich Mixture
58
Lean Mixture
59
Engine
59
Engine Smoke
59
Black Smoke
59
Blue Smoke
59
White Smoke or Steam
59
Low Engine Compression
60
High Engine Compression
60
Engine Overheating (Cooling System)
60
Engine Overheating (Engine)
61
Preignition
61
Detonation
61
Power Loss
61
Engine Noises
61
Englne Lubrication
62
High Oil Consumption or Excessive
62
Exhaust Smoke
62
Low Oil Pressure
62
High Oil Pressure
63
No Oil Pressure
63
Oil Level too Low
63
Oil Contamination
63
Cylinder Leak down Test
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
70
Voltage Drop Test
70
Peak Voltage Test
71
Continuity Test
71
Testing for a Short with a Self-Powered Test Light or Ohmmeter
71
Testing for a Short with a Test Light or Voltmeter
72
Brake System
72
Soft or Spongy 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
Leaking Master Cylinder
75
Specifications
76
How to Use Conversion Table of Unit
76
How to Use Conversion Table
76
Definition of Unit
76
Geberar Specifications
77
Engine Specifications
80
Chassis Specifications
86
Electrical Specifications
88
Tightening Torques
90
Engine Tightening Torques
90
Chassis Tightening Torques
93
General Tightening Torque Specifications
96
Lubrication Pionts and Lubricant Types
97
Engine
97
Chassis
98
Hydrographic Chart
99
Lubrication Oil Way
100
Maintenance Schedule
101
Engine
103
Adjusting the Valve Clearance
103
Idle Adjustment
106
Adjusting the Throttle Cable
106
Adjusting the Starter Cable
107
Checking the Spark Plug
108
Checking the Ignition Timing
109
Measuring the Compression Pressure
110
Checking the Engine Oil Level
112
Changing the Engine Oil
113
Chassis
116
Cleaning the Air Filter
116
Checking the Coolant Level
117
Changing the Coolant
118
Checking the Coolant Temperature Warning Light
121
Checking the V-Belt
122
Cleaning the Spark Arrester
123
Adjusting the Brake Pedal
124
Adjusting the Parking Brake
125
Checking the Brake Fluid Level
126
Checking the Front Brake Pads
126
Checking the Rear Brake Pads
127
Checking the Brake Hoses and Brake Pipes
127
Bleeding the Hydraulic Brake System
128
Adjusting the Select Lever Shift Rod
130
Adjusting the Brake Light Switch
130
Checking the Final Gear Oil Level
131
Changing the Final Gear Oil
131
Checking the Differential Gear Oil
132
Changing the Differential Gear Oil
132
Checking the Constant Velocity Joint Dust Boots
133
Checking the Steering System
134
Adjusting the Toe-In
135
Adjusting the Front Shock Absorbers
136
Adjusting the Rear Shock Absorbers
136
Checking the Tires
137
Checking the Wheels
139
Checking and Lubricating the Cables
139
Electrical
140
Checking and Charging the Battery
140
Checking the Fuses
145
Adjusting the Headlight Beam
146
Changing the Headlight Bulb
147
Changing the Tail/Brake Light Bulb
148
Engine
149
Engine Note
149
Engine Removal
150
Cylinder Head and Cylinder Head Cover
152
Rocker Arms and Camshaft
157
Valves and Valve Springs
163
Cylinder and Piston
169
Engine Cooling Fan and A.C. Magneto
173
Balancer Gears and Oil Pump Gears
178
PRIMARY and SECONDARY SHEAVES Primary and Secondary Sheaves
181
Primary Sheave
182
Secondary Sheave
183
Clutch
188
Starter Motorand Oil Filter
192
Crankcase
194
Crankcase Bearings
195
CRANKSHAFT and OIL PUMP Crankshaft and Oil Pump
199
Oil Pump
200
TRANSMISSION Transmission
203
Drive Axle Assembly
204
MIDDLE GEAR Middle Drive Shaft
208
Middle Driven Shaft
209
Carburetor
215
Malfunction Inspection
220
DIRECTION SYSTEM the Structure of the Steering
223
The Structure of Steering Wheel Part
225
Diassembling the Parts of the Steering Wheel
226
Checking the Parts of the Steering Wheel
226
Diassembling the Steering Column Parts
227
Checking and Service the Steering Column Parts
228
Diassembling the Steering Drive Axle
228
Checking and Service the Steering Drive Axle
229
Diassembling the Steering Machine Part
230
The Structure of the Steering
230
Reinstalls the Steering System Parts
231
Brake System
233
Front Disk Brake Components
234
Front Brake Discs
235
Checking the Front Brake Disc
236
Front Brake Pads
237
Replacing the Front Brake Pads
238
Front Brake Caliper
239
Disassembling the Front Brake Calipers
241
Assembling the Front Brake Calipers
242
Installing the Front Brake Calipers
242
Rear Brake Disc
244
Checking the Rear Brake Disc
245
Rear Brake Caliper and Brake Pads
246
Replacing the Rear Brake Pads
249
Disassembling the Rear Brake Caliper
249
Assembling the Rear Brake Caliper
250
Installing the Rear Brake Caliper
252
Brake Master Cylinder
254
Checking the Master Cylinder
255
Assembling the Brake Master Cylinder
255
Installing the Brake Master Cylinder
255
Footrest Assembly
257
Wheel and Tyre Parts
260
Front Wheels
260
Rear Wheels
261
Checking the Wheel Tyre
262
Checking the Wheel Hub
262
Installing the Wheel Hub
262
Installing the Wheel Tyre
263
Specification of Wheel and Tyre
263
Transmission System
264
Front Bridge
264
Disassembling the Front Bridge
269
Disassembling the Universal Joint
269
Removing the Differential Gear Assembly
269
Checking the Joints
270
Checking the Differential Gear
270
Checking the Gear Motor
271
Assembling the Universal Joint
272
Adjusting the Differential Gear Lash
272
Assembling the Differential Gear
273
Installing the Front Bridge Parts
274
Rear Bridge
275
Reverse Mechanism Parts
281
Adjusting Reverse Mechanism Parts
283
Checking and Service of Reverse Mechanism
283
Suspension
285
Front Suspension and Arm
285
Disassembling, Service and Assembly the Supporting Rocker Parts
287
Checking the Front Arms
288
Checking the Front Shock Absorber
288
Installing the Front Arms and Front Shock Absorber
289
Rear Suspension
290
Rear Arm Shaft
291
Checking and Service of Rear Suspension
292
Checking the Stabilizer
292
Checking the Rear Arms
292
Checking the Stabilizer and Shock Absorber
292
Installing the Rear Arms and Rear Shock Absorber
293
Cooling System
294
Radiator
294
Checking the Radiator
297
Installing the Radiator
297
Checking the Oil Cooler
298
Water Pump
299
Disassembling the Water Pump
301
Checking the Water Pump
301
Assembling the Water Pump
302
Seat
304
Fuel Tank
306
Checking the Fuel Pump Operation
309
Disassembling and Checking ,Service Oil Cooling System
309
Installing Oil Cooling System
310
Electrical Components
311
Electrical System Malfunction Inspection
311
Electrical
312
Electricalcomponents
312
Checking the Switch
314
Checking the Switch Continuity
315
Checking the Bulbs and Bulb Sockets
316
Ignition System
317
Circuit Diagram
317
Troubleshooting
318
Electric Starting System
322
Circuit Diagram
322
Troubleshooting
323
Starter Motor
326
Checking the Starter Motor
327
Assembling the Starter Motor
328
Charging System
329
Circuit Diagram
329
Troubleshooting
330
Lighting System
332
Circuit Diagram
332
Troubleshooting
333
Checking the Lighting System
334
If the Headlights Fail to Come on
334
If the Taillights Fail to Come on
335
Signaling System
336
Circuit Diagram
336
Troubleshooting
337
Checking the Signal System
338
If the Brake Lights Fail to Come on
338
If the Neutral Lights Fail to Come on
339
If the Parking Brake Indicator Light Fails to Come on
340
If the Reverse Indicator Light Fails to Come on
341
If the Coolant Temperature Warning
342
If the Differential Gear Lock Indicator Light Fails to Come on
344
If the Four-Wheel Drive Indicator Light Fails to Come on
346
Cooling System
348
Circuit Diagram
348
Troubleshooting
349
2Wd/4Wd Selecting System
352
Circuit Diagram
352
Troubleshooting
353
Engine Management System
357
Ems (Engine Management System)
357
Typical Components of EMS
357
Layout of EMS Components
358
Components of Ems
358
Electronic Control Unit
358
Multec 3.5 Injectors
359
Throttle Body Assembly(with Stepper Motor)
363
Engine Coolant Temperature Sensor
365
Intake Air Pressure and Temperature Sensor
365
Oxygen Sensor
366
Ignition Coil
366
Fuel Pump Module
370
Ems Fault Diagnosis
376
EME Fault Diagnosis
376
Fault Code List
376
Troubleshooting
378
Starting Failure/Hard Starting
378
Fuel System
378
Electrical System
378
Compression System
379
Poor Idle Speed Performance
380
Poor Medium and High-Speed Performance
380
Faulty Gear Shifting
380
Shift Lever Does Not Move
380
Jumps out of Gear
381
Overheating
381
Faulty Brake
382
Poor Braking Effect
382
Shock Absorber Malfunction
382
Malfunction
382
Unstable Handling
382
Lighting System
383
Head Light Is out of Work
383
Bulb Burnt out
383
Hs600Utv Supplementary
384
Hs600Utv Service Manual
385
Specifications
385
Geberar Specifications
385
Engine Specifications
385
Hs500Utv Service Manual
387
Hs500Utv Supplementary
387
Specifications
388
Geberar Specifications
388
Engine Specifications
388
Engine Removal
394
Cylinder Head and Cylinder Head Cover
396
Rocker Arms and Camshaft
399
Valves and Valve Springs
403
Cylinder and Piston
408

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