Huansong UTV 700 2009 Manuals

Manuals and User Guides for Huansong UTV 700 2009. We have 1 Huansong UTV 700 2009 manual available for free PDF download: Service Manual

Huansong UTV 700 2009 Service Manual (361 pages)

Brand: Huansong | Category: Utility Vehicle | Size: 56 MB

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
- General Specifications
  75
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
  - Changing the Headlight Bulb
    140
  - Changing the Tail/Brake Light Bulb
    141
Chapter 4 Engine

142
Engine Note

142
Engine Removal

143
Cylinder Head and Cylinder Head Cover

145
- Cylinder Head
  147
Rocker Arms and Camshaft

151
Valves and Valve Springs

157
Cylinder and Piston

163
Engine Cooling Fan and A.C. Magneto

167
Balancer Gears and Oil Pump Gears

172
Primary and Secondary Sheaves

175
- Primary Sheave
  176
- Secondary Sheave
  177
Clutch

182
- Starter Motorand Oil Filter
  186
- Crankcase Bearings
  189
CRANKSHAFT and OIL PUMP Crankshaft and Oil Pump

193
- Oil Pump
  194
TRANSMISSION Transmission

197
Drive Axle Assembly

197
MIDDLE GEAR Middle Drive Shaft

203
Middle Driven Shaft

204
Carburetor

211
Chapter 5

216
Malfunction Inspection

216
- The Structure of Steering Wheel Part
  221
- Diassembling the Parts of the Steering Wheel
  222
The Structure of Steering Wheel Part

222
Diassembling the Steering Column Parts

224
Checking and Service the Steering Column Parts

225
- Steering Drive Axle
  226
- Steering Machine Parts
  227
Brake System

231
- Front Disk Brake Components
  232
- Front Brake Discs
  233
- Checking the Front Brake Disc
  234
- Front Brake Pads
  235
- Replacing the Front Brake Pads
  236
- Front Brake Caliper
  237
- Disassembling the Front Brake Calipers
  238
- Assembling the Front Brake Calipers
  240
- Installing the Front Brake Calipers
  241
- Rear Brake Disc
  242
- Checking the Rear Brake Disc
  243
- Rear Brake Caliper and Brake Pads
  244
- Replacing the Rear Brake Pads
  247
- Disassembling the Rear Brake Caliper
  248
- Assembling the Rear Brake Caliper
  249
- Installing the Rear Brake Caliper
  252
- Brake Master Cylinder
  253
- Checking the Master Cylinder
  254
- Installing the Brake Master Cylinder
  255
Footrest Assembly

256
Wheel and Tyre Parts

260
- Rear Wheels
  260
- Specification of Wheel and Tyre
  263
Transmission System

264
- Front Bridge
  264
- Disassembling the Front Bridge
  269
- Checking the Joints
  270
- Checking the Differential Gear
  271
- Installing the Front Bridge Parts
  272
- Rear Bridge
  273
Reverse Mechanism Parts

279
- Adjusting Reverse Mechanism Parts
  281
- Checking and Service of Reverse Mechanism
  282
Suspension

283
Cooling System

294
- Radiator
  294
- Checking the Radiator
  297
- Installing the Radiator
  298
- Checking the Oil Cooler
  299
- Water Pump
  300
- Disassembling the Water Pump
  302
- Checking the Water Pump
  303
- Assembling the Water Pump
  304
Seat

305
Fuel Tank

307
- Checking the Fuel Pump Operation
  310
- Installing Oil Cooling System
  312
Chapter 6 Electricalcomponents

313
Electrical System Malfunction Inspection

313
Electrical

314
- Electricalcomponents
  314
Checking the Switch

316
- Checking the Switch Continuity
  317
Checking the Bulbs and Bulb Sockets

318
Ignition System

319
Troubleshooting

319
Electric Starting System

323
Circuit Diagram

323
Troubleshooting

324
Starter Motor

324
- Checking the Starter Motor
  328
- Assembling the Starter Motor
  329
Charging System

330
Circuit Diagram

330
Troubleshooting

331
Lighting System

333
Circuit Diagram

333
Troubleshooting

334
Checking the Lighting System

335
- If the Headlights Fail to Come on
  335
Signaling System

337
Circuit Diagram

337
Troubleshooting

338
Checking the Signal System

339
If the Brake Lights Fail to Come on

339
If the Neutral Lights Fail to Come on

340
If the Parking Brake Indicator Light Fails to Come on

341
If the Reverse Indicator Light Fails to Come on

342
If the Coolant Temperature Warning

343
If the Differential Gear Lock Indicator Light Fails to Come on

345
If the Four-Wheel Drive Indicator Light Fails to Come on

347
Cooling System

348
Circuit Diagram

348
Troubleshooting

349
2Wd/4Wd Selecting System

352
Circuit Diagram

352
Troubleshooting

353
Chapter 7 Troubleshooting

356
Starting Failure/Hard Starting

356
- Fuel System
  356
- Electrical System
  356
- Compression System
  357
Poor Idle Speed Performance

358
Poor Medium and High-Speed Performance

358
Faulty Gear Shifting

358
Shift Lever Does Not Move

358
Jumps out of Gear

359
Overheating

359
Faulty Brake

359
Poor Braking Effect

359
Shock Absorber Malfunction

360
Malfunction

360
Unstable Handling

360
Lighting System

361
- Head Light Is out of Work
  361
- Bulb Burnt out
  361

Huansong Categories

Utility Vehicle

More Huansong Manuals

Huansong UTV 700 2009 Manuals

Huansong UTV 700 2009 Service Manual (361 pages)

Table of Contents

Description and Machine Identification

Chapter 1 General Information

Identification Code

Manual Organization

Watnings ,Cautions and Notes

Safety

Serial Numbers

Fasteners

Shop Supplies

Basic Tools

Precision Measuring Tools

Electrical System Fundamentals

Badic Service Methods

Storage

Chapter Two Trovbleshooting

Engine Principles and Operating Requirements

Starting the Engine

Engine will Not Start

Poor Engine Performance

Fuel System

Engine

Englne Lubrication

Cylinder Leakdown Test

Electrical Testing

Brake System

Chapter 2 Specifications

How to Use Conversion Table of Unit

Engine Specifications

Chassis Specifications

Electrical Specifications

Tightening Torques

Engine Tightening Torques

Chassis 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

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 Cooling Fan and A.C. Magneto

Balancer Gears and Oil Pump Gears

Primary and Secondary Sheaves

Clutch

CRANKSHAFT and OIL PUMP Crankshaft and Oil Pump

TRANSMISSION Transmission

Drive Axle Assembly

MIDDLE GEAR Middle Drive Shaft

Middle Driven Shaft

Carburetor

Chapter 5

Malfunction Inspection

The Structure of Steering Wheel Part

Diassembling the Steering Column Parts

Checking and Service the Steering Column Parts

Brake System

Footrest Assembly

Wheel and Tyre Parts

Transmission System

Reverse Mechanism Parts

Suspension

Cooling System

Seat

Fuel Tank

Chapter 6 Electricalcomponents

Electrical System Malfunction Inspection

Electrical

Checking the Switch

Checking the Bulbs and Bulb Sockets