HISUN 500 HS500 4X4 ATV Service Repair Manual

1 HS500ATV Maintenance Manual

2 Catalogue General Information……………………………...5 1 Description…………………………………………………..5 1.1 Identification code………..……………………………..6 1.1.1. Frame No. …………………………………………………6 1.1.2. Engine No.…………………………………………………7 1.2 Special tools, instruments and meters…………………7 1.3 Periodic maintenance chart……………………………….9 Engine………………………………………………………….11 2. Inspection and adjustment of engine…………….11 2.1 Inspection of cylinder head, intake and exhaust valve………………………………………….11 2.2 Inspection of spark Plug………………………………….12 2.3 Inspection of cylinder, piston and piston ring…….14 2.4 Inspection of crankshaft………………………………….17 2.5 Inspection of clutch……………………………………….18 2.6 Inspection of carburetor………………………………….18 2.7 Inspection of air filter………………………………….19 2.8 Inspection of oil filter………………………………….20 2.9 Inspection of lubrication system……………………….20

3 2.10 Lubrication of engine…………………………………….21 2.11 Inspection of cylinder head…………………………….21 3.Disassembly of engine……………………………………27 3.1 Cylinder head and block………………………………….27 3.2 Piston and connecting rod……………………………….31 3.3 Manual starting mechanism……………………………….32 3.4 Sensor………………………………………………….…….32 3.5 Left crankcase cover……………………………….…….33 3.6 Magneto…………………………………………………..….33 3.7 Oil pump………………………………………….……..….34 3.8 Clutch…………………………………………………...….35 3.9 Carburetor……………………………………………...….36 3.9.1 Structure of carburetor………………………...…..36 3.9.2 Inspection and adjustment of carburetor…....….37 4.Chassis 4.1 Steering operation system………………………...…..39 4.2 Brake system…………………………………………...….51 4.3 Wheels and tires……………………………………...….67 4.4 Transmission system…………………………….…...….70 4.5．gear gear gear gearshiftmechanism……………………………………..77 4.6 Suspension…………………………..……....….。。。。。.79

4 5. Electrical system………………………..……....….84 5.1 Ignition system…………………………..……....….87 5.2 Magneto and charging system…………..……....….88 5.3 Battery……………………………………..……....….88 5.4 Lighting system…………………………..……....….90 5.5 Meterand signal system…………………………..……91 5.6 Electrical starting system…………….……..…….92 6.Appendix………………..…………………..……....…93 6.1 Specification………..…………………..……....….93 6.2 Requirements for torque of fastener……………….99 6.3 Electrical circuits……………………………....….100

5 General Information 1 Description

7 1.1 Identification code 1.1.1. Frame No. The frame No. is engraved in the right bottom of the supporting frame. See Figure 1-1 Figure 1-1 1.1.2. Engine No. The engine No. is engraved in the right side of the engine. See figure 1-2

8 Figure 1-2 1.2 Special tools, instruments and meters 1.2.1 Oil filter detacher To fasten and detach the oil filter 1.2.2 Height gauge To gauge the height of various components 1.2.3 Vernier To measure the length of various components 1.2.4 尺 Outside micrometer To accurately measure external diameter of a column

9 1.2.5 Inside micrometer To accurately measure internal diameter of a hole 1.2.6 Dial indicator To accurately measure a small distance 1.2.7 Torque Spanner To measure torque force 1.2.8 Feeler gauge To measure gap-width 1.2.9 Multimeter To check electrical circuits and parts 1.2.10 Barometer To measure pressure of the tyre

10 1.2.11 Magneto drawing device To detach the magneto 1.2.12 Snap ring clampTo install and detach snap rings 1.3 Periodic maintenance chart EVERY INITAL month 1 3 6 6 12 km 320 1,200 2,400 2,400 4,800 (mi) (200) (750) (1,500) (1,500) (3,000) ITEM ROUTINE Whicheve comes first hours 20 75 150 150 300 Valves ● Check valve clearance. ● Adjust if necessary. ○ ○ ○ ○ Sparkplug ● Check condition. ● Adjust gap and clean. ● Rep;ace if necessary. ○ ○ ○ ○ ○ Air fiter element ● clean. ● Replace if necessary. Every20-40hours （More often in wet of dusty areas.） Carburetor* ● Checkandadjustidlespeed/starteroperation. ● Adjust if necessary. ○ ○ ○ ○ Crankcase breathersystem* ● Check breather hose for cracks of damage. ● Replace if necessary. ○ ○ ○ Exhaust system* ● Check for lecakage. ● Tighten if necessany. ● Replace gasket(s) if necessary. ○ ○ ○ Spark arrester ● Clean. ○ ○ ○ Fuel line* ● Check fuel hose for cracks or damage. ● Replace if necessaly. ○ ○ ○ Engine oil ●Replace.(Wamenginebefore draining.) ○ ○ ○ ○

HISUN 500 HS500 4X4 ATV Service Repair Manual

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