2009-2012 Hisun HS700 UTV Service & Repair Manual

FOREWORD Brief introduction to maintenance handbook of HS700UTV The handbook is edited by Chongqing Hsun Industries (Group) Ltd, and is supplied to dealers and technicians as document of technique. Mainly, the handbook gives methods to check, maintain and repair UTV, and supplies some relevant technique and performance data. Some techniques and method inside may be used to check, maintain and repair other models of UTV, although it is mainly for HS700UTV. Please read the handbook through and fully understand it; otherwise, any improper repairing and amounting would bring you problems, and accident may occur in your use. Proper use and maintenance can guarantee UTV being driven safely, reduce its malfunction, and help the vehicle remain its best performance. The standards, performances and specifications mentioned in interpretation are based on the sample in design, and they are subject to changes according to the product’s improvement without prior notice. Brief introduction to maintenance handbook of HS700UTV second version , June,2009 Published by Chongqing Hsun Industries (Group) Ltd Chongqing Hsun Industries (Group) Ltd holds the copy right. No publishing and reprinting without permission.

1 CONTENT DESCRIPTION AND MACHINE IDENTIFICATION 1-1 IDENTIFICATION CODE ………………………………………………………………… 1-2 Frame No. ……………………………………………………………………………… 1-2 Engine No. ……………………………………………………………………………… 1-2 CHAPTER 1 GENERAL INFORMATION MANUAL ORGANIZATION………………………………………………………………… 1-3 WATNINGS ,CAUTIONS AND NOTES…………………………………………………… 1-3 SAFETY ……………………………………………………………………………………… 1-3 Handing gasoline safely ……………………………………………………………… 1-4 Cleaning parts…………………………………………………………………………… 1-5 Warning labels…………………………………………………………………………… 1-5 SERIAL NUMBERS………………………………………………………………………… 1-6 FASTENERS………………………………………………………………………………… 1-6 Torque specifications…………………………………………………………………… 1-6 Self-locking fasteners………………………………………………………………… 1-6 Washers…………………………………………………………………………………… 1-7 Cotter pins………………………………………………………………………………… 1-7 Snap Rings and E-clips………………………………………………………………… 1-7 SHOP SUPPLIES 1-8 Lubricants and Fluids…………………………………………………………………… 1-8 Engine oils………………………………………………………………………………… 1-8 Greases…………………………………………………………………………………… 1-9 Brake fluid………………………………………………………………………………… 1-9 Coolant…………………………………………………………………………………… 1-9 Cleaners degreasers and solvents…………………………………………………… 1-10 Gasket sealant…………………………………………………………………………… 1-10 Applying RTV sealant…………………………………………………………………… 1-10 Gasket remover………………………………………………………………………… 1-10 Thread locking Compound……………………………………………………………… 1-10 BASIC TOOLS……………………………………………………………………………… 1-11 Screwdrivers……………………………………………………………………………… 1-11 Wrenches………………………………………………………………………………… 1-12 Adjustable wrenches…………………………………………………………………… 1-13

2 Socket wrenches, ratchets and handles…………………………………………… 1-13 Impact drivers…………………………………………………………………………… 1-14 Allen wrenches………………………………………………………………………… 1-14 Torque wrenches………………………………………………………………………… 1-14 Torque adapters………………………………………………………………………… 1-15 Pliers……………………………………………………………………………………… 1-16 Snap ring pliers………………………………………………………………………… 1-16 Hammers………………………………………………………………………………… 1-16 Ignition grounding tool………………………………………………………………… 1-17 PRECISION MEASURING TOOLS……………………………………………………… 1-17 Feeler gauge…………………………………………………………………………… 1-18 Calipers…………………………………………………………………………………… 1-18 Micrometers……………………………………………………………………………… 1-19 Adjustment……………………………………………………………………………… 1-19 Care……………………………………………………………………………………… 1-20 Metric micrometer……………………………………………………………………… 1-20 Standard inch micrometer……………………………………………………………… 1-21 Telescoping and Small Bore Gauges………………………………………………… 1-22 Dial Indicator……………………………………………………………………………… 1-22 Cylinder bore gauge…………………………………………………………………… 1-23 Compression gauge…………………………………………………………………… 1-23 Multimeter………………………………………………………………………………… 1-23 Ohmmeter(analog)calibration…………………………………………………………… 1-23 ELECTRICAL SYSTEM FUNDAMENTALS 1-23 Voltage…………………………………………………………………………………… 1-24 Resistance………………………………………………………………………………… 1-24 BADIC SERVICE METHODS……………………………………………………………… 1-24 Removing frozen fasteners…………………………………………………………… 1-26 Removing broken fasteners…………………………………………………………… 1-26 Repairing damaged threads…………………………………………………………… 1-26 Stud Removal/Installation……………………………………………………………… 1-27 Removing hoses………………………………………………………………………… 1-27 Bearings…………………………………………………………………………………… 1-27 Removal…………………………………………………………………………………… 1-28 Installation………………………………………………………………………………… 1-28 Interference fit…………………………………………………………………………… 1-29 Seal replacement……………………………………………………………………… 1-31 STORAGE 1-31 Storage area selection………………………………………………………………… 1-31

3 Preparing the Motorcycle for Storage………………………………………………… 1-31 Returning the Motorcycle to Service…………………………………………………… 1-32 CHAPTER TWO TROVBLESHOOTING………………………………………………… 1-33 ENGINE PRINCIPLES AND OPERATING REQUIREMENTS………………………… 1-34 STARTING THE ENGINE ………………………………………………………………… 1-34 Engine is cold …………………………………………………………………………… 1-34 Engine is warm…………………………………………………………………………… 1-34 Starting the engine after a fall or after the engine stalls……………………………… 1-35 Flooded engine…………………………………………………………………………… 1-35 Engine cold with air temperature ……………………………………………………… 1-35 Engine cold with air temperature above 35℃（95°F）……………………………… 1-35 Cold engine with air temperature below 10℃(50°F) ………………………………… 1-35 Engine is hot……………………………………………………………………………… 1-36 Starting the engine after a fall or after the engine stalls……………………………… 1-36 Flooded engine…………………………………………………………………………… 1-36 ENGINE WILL NOT START ……………………………………………………………… 1-37 Identifying the Problem ………………………………………………………………… 1-37 Spark Test………………………………………………………………………………… 1-37 Starter Does Not Turn Over or Turns Over Slowly ………………………………… 1-39 POOR ENGINE PERFORMANCE………………………………………………………… 1-39 Engine Starts But Stalls and is Hard to Restart……………………………………… 1-39 Engine Backfires, Cuts Out or Misfires During Acceleration………………………… 1-40 Engine Backfires on Deceleration……………………………………………………… 1-41 Poor fuel mileage………………………………………………………………………… 1-41 Engine Will Not Idle or Idles Roughly ………………………………………………… 1-41 Low engine power ……………………………………………………………………… 1-41 Poor Idle or Low Speed Performance………………………………………………… 1-43 Poor high speed performance………………………………………………………… 1-43 FUEL SYSTEM……………………………………………………………………………… 1-43 Rich Mixture……………………………………………………………………………… 1-44 Lean Mixture……………………………………………………………………………… 1-44 ENGINE……………………………………………………………………………………… 1-44 Engine smoke…………………………………………………………………………… 1-44 Black smoke…………………………………………………………………………… 1-45 Blue smoke…………………………………………………………………………… 1-45 White smoke or steam…………………………………………………………………… 1-45

4 Low engine compression……………………………………………………………… 1-45 High engine compression……………………………………………………………… 1-46 Engine overheating (Cooling System) ……………………………………………… 1-46 Engine overheating (Engine) ………………………………………………………… 1-46 Preignition………………………………………………………………………………… 1-47 Detonation………………………………………………………………………………… 1-47 Power Loss Engine Noises……………………………………………………………… 1-47 ENGLNE LUBRICATION…………………………………………………………………… 1-48 High Oil Consumption or Excessive ……………………………………………………… 1-48 Exhaust smoke…………………………………………………………………………… 1-48 Low oil pressure………………………………………………………………………… 1-48 High oil pressure………………………………………………………………………… 1-49 No oil pressure…………………………………………………………………………… 1-49 Oil level too low…………………………………………………………………………… 1-49 Oil contamination………………………………………………………………………… 1-49 CYLINDER LEAKDOWN TEST…………………………………………………………… 1-49 ELECTRICAL TESTING…………………………………………………………………… 1-52 Preliminary Checks and Precautions………………………………………………… 1-52 Intermittent problems…………………………………………………………………… 1-52 Electrical component replacement…………………………………………………… 1-54 Test equipment ………………………………………………………………………… 1-54 Ammeter………………………………………………………………………………… 1-54 Self-powered test light ………………………………………………………………… 1-54 Ohmmeter ……………………………………………………………………………… 1-55 Jumper wire……………………………………………………………………………… 1-55 Test procedures………………………………………………………………………… 1-56 Voltage drop test………………………………………………………………………… 1-56 Peak voltage test………………………………………………………………………… 1-57 Continuity test…………………………………………………………………………… 1-57 Testing for a short with a self-powered test light or ohmmeter……………………… 1-58 Testing for a short with a test light or voltmeter……………………………………… 1-58 BRAKE SYSTEM…………………………………………………………………………… 1-58

5 Soft or Spongy Brake Lever or Pedal………………………………………………… 1-58 Brake drag……………………………………………………………………………… 1-60 Hard Brake Lever or Pedal Operation………………………………………………… 1-60 Hard Brake Lever or Pedal Operation………………………………………………… 1-60 Brake Squeal or Chatter………………………………………………………………… 1-61 Leaking brake caliper…………………………………………………………………… 1-61 Leaking master cylinder………………………………………………………………… 1-61 CHAPTER 2 SPECIFICATIONS HOW TO USE CONVERSION TABLE OF UNIT……………………………………… 2-1 How to use conversion table ………………………………………………………… 2-1 Definition of unit ……………………………………………………………………… 2-1 GEBERAR SPECIFICATIONS…………………………………………………………… 2-2 ENGINE SPECIFICATIONS……………………………………………………………… 2-5 CHASSIS SPECIFICATIONS …………………………………………………………… 2-12 ELECTRICAL SPECIFICATIONS ……………………………………………………… 2-14 TIGHTENING TORQUES………………………………………………………………… 2-16 Engine tightening torques …………………………………………………………… 2-16 Chassis tightening torques…………………………………………………………… 2-19 GENERAL TIGHTENING TORQUE SPECIFICATIONS……………………………… 2-21 LUBRICATION PIONTS AND LUBRICANT TYPES ………………………………… 2-22 Engine…………………………………………………………………………………… 2-22 HYDROGRAPHIC CHART ……………………………………………………………… 2-23 LUBRICATION OIL WAY ………………………………………………………………… 2-24 CHAPTER 3 MAINTENCE AND ADJUSTMENT OF THE UTV MAINTENANCE SCHEDULE………………………………………………………………… 3-1 ENGINE ADJUSTING THE VALVE CLEARANCE………………………………………………… 3-3 IDLE ADJUSTMENT ……………………………………………………………………… 3-5 ADJUSTING THE THROTTLE CABLE…………………………………………………… 3-6

6 Adjusting the starter cable …………………………………………………………… 3-7 Checking the spark plug……………………………………………………………… 3-8 Checking the ignition timing ………………………………………………………… 3-9 Measuring the compression pressure ……………………………………………… 3-10 Checking the engine oil level ……………………………………………………… 3-11 Changing the engine oil ……………………………………………………………… 3-12 CHASSIS Cleaning the air filter ………………………………………………………………… 3-15 Checking the coolant level …………………………………………………………… 3-16 Changing the coolant ………………………………………………………………… 3-16 Checking the coolant temperature warning light ………………………………… 3-19 Checking the v-belt ………………………………………………………………… 3-20 Cleaning the spark arrester ……………………………………………………… 3-21 Adjusting the brake pedal …………………………………………………………… 3-22 Adjusting the parking brake ………………………………………………………… 3-23 Checking the brake fluid level ……………………………………………………… 3-23 Checking the front brake pads …………………………………………………… 3-24 Checking the rear brake pads …………………………………………………… 3-24 Checking the brake hoses and brake pipes ………………………………………… 3-25 Bleeding the hydraulic brake system ……………………………………………… 3-25 Adjusting the select lever shift rod ………………………………………………… 3-26 Adjusting the brake light switch ……………………………………………………… 3-27 Checking the final gear oil level …………………………………………………… 3-27 Changing the final gear oil ………………………………………………………… 3-28 Checking the differential gear oil …………………………………………………… 3-28 Changing the differential gear oil …………………………………………………… 3-29 Checking the constant velocity joint dust boots …………………………………… 3-30 Checking the steering system …………………………………………………… 3-30 Adjusting the toe-in …………………………………………………………………… 3-31 Adjusting the front shock absorbers ……………………………………………… 3-32 Adjusting the rear shock absorbers ………………………………………………… 3-32 CHECKING THE TIRES ………………………………………………………………… 3-33 CHECKING THE WHEELS ………………………………………………………… 3-34 CHECKING AND LUBRICATING THE CABLES………………………………………… 3-35 ELECTRICAL Checking and charging the battery ……………………………………………………… 3-36 Checking the fuses ………………………………………………………………… 3-41 Adjusting the headlight beam …………………………………………………………… 3-43

7 Changing the headlight bulb …………………………………………………………… 3-43 Changing the tail/brake light bulb ………………………………………………………… 3-44 CHAPTER 4 ENGINE ENGINE NOTE …………………………………………………………………………… 4-1 ENGINE REMOVAL………………………………………………………………………… 4-2 CYLINDER HEAD AND CYLINDER HEAD COVER ………………………………… 4-4 ROCKER ARMS AND CAMSHAFT …………………………………………………… 4-10 VALVES AND VALVE SPRINGS ……………………………………………………… 4-16 CYLINDER AND PISTON………………………………………………………………… 4-22 ENGINE COOLING FAN AND A.C. MAGNETO ……………………………………… 4-26 BALANCER GEARS AND OIL PUMP GEARS ……………………………………… 4-31 PRIMARY AND SECONDARY SHEAVES Primary and secondary sheaves …………………………………………………… 4-34 Primary sheave………………………………………………………………………… 4-35 Secondary sheave …………………………………………………………………… 4-36 CLUTCH …………………………………………………………………………………… 4-41 CRANKCASE Starter motorand oil filter …………………………………………………………… 4-45 Crankcase ……………………………………………………………………………… 4-47 Crankcase bearings…………………………………………………………………… 4-48 CRANKSHAFT AND OIL PUMP Crankshaft and oil pump ……………………………………………………………… 4-52 Oil pump………………………………………………………………………………… 4-53 TRANSMISSION Transmission……………………………………………………………………………… 4-56 Drive axle assembly……………………………………………………………………… 4-57 MIDDLE GEAR Middle drive shaft………………………………………………………………………… 4-62 Middle driven shaft ……………………………………………………………………… 4-63 CARBURETOR……………………………………………………………………………… 4-70 CHAPTER 5 CHASSIS MALFUNCTION INSPECTION…………………………………………………………… 5-1

8 DIRECTION SYSTEM The structure of the steering…………………………………………………………… 5-4 The structure of steering wheel part…………………………………………………… 5-6 Diassembling the parts of the steering wheel ………………………………………… 5-7 The structure of steering wheel part …………………………………………………… 5-8 Diassembling the steering column parts……………………………………………… 5-9 Checking and service the steering column parts …………………………………… 5-10 Steering drive axle ……………………………………………………………………… 5-11 Steering machine parts………………………………………………………………… 5-12 BRAKE SYSTEM…………………………………………………………………………… 5-16 Front disk brake components ………………………………………………………… 5-17 Front brake discs ……………………………………………………………………… 5-18 Checking the front brake disc ………………………………………………………… 5-19 Front brake pads………………………………………………………………………… 5-20 Replacing the front brake pads………………………………………………………… 5-21 Front brake caliper……………………………………………………………………… 5-21 Disassembling the front brake calipers ……………………………………………… 5-24 Assembling the front brake calipers…………………………………………………… 5-25 Installing the front brake calipers …………………………………………………… 5-26 Rear brake disc ………………………………………………………………………… 5-27 Checking the rear brake disc…………………………………………………………… 5-28 Rear brake caliper and brake pads…………………………………………………… 5-29 Replacing the rear brake pads………………………………………………………… 5-32 Disassembling the rear brake caliper ………………………………………………… 5-33 Assembling the rear brake caliper …………………………………………………… 5-34 Installing the rear brake caliper………………………………………………………… 5-37 Brake master cylinder ………………………………………………………………… 5-38 Checking the master cylinder………………………………………………………… 5-39 Installing the brake master cylinder…………………………………………………… 5-40 FOOTREST ASSEMBLY……………………………………………………………………… 5-41 WHEEL AND TYRE PARTS ……………………………………………………… 5-44 Front wheels …………………………………………………………………………… 5-44 Rear wheels……………………………………………………………………………… 5-45 Checking the wheel tyre and wheel hub……………………………………………… 5-46 Installing the wheel hub and wheel tyre ……………………………………………… 5-47 Specification of wheel and tyre………………………………………………………… 5-48 TRANSMISSION SYSTEM ……………………………………………………………… 5-49 Front bridge……………………………………………………………………………… 5-49 Disassembling the front bridge………………………………………………………… 5-54

9 Checking the joints……………………………………………………………………… 5-55 Checking the differential gear ………………………………………………………… 5-56 Installing the front bridge parts………………………………………………………… 5-57 Rear bridge ……………………………………………………………………………… 5-58 REVERSE MECHANISM PARTS ……………………………………………………… 5-64 Adjusting reverse mechanism parts ………………………………………………… 5-67 Checking and service of reverse mechanism………………………………………… 5-67 SUSPENSION……………………………………………………………………………… 5-68 Front Suspension and arm …………………………………………………………… 5-68 Disassembling, service and assembly the supporting rocker parts………………… 5-70 Checking the front arms and shock absorber………………………………………… 5-72 Installing the front arms and front shock absorber ………………………………… 5-73 Rear suspension ……………………………………………………………………… 5-74 Rear arm shaft…………………………………………………………………………… 5-75 Checking and service of rear suspension …………………………………………… 5-76 Checking the stabilizer and shock absorber ………………………………………… 5-77 Installing the rear arms and rear shock absorber …………………………………… 5-78 COOLING SYSTEM……………………………………………………………………… 5-79 Radiator ………………………………………………………………………………… 5-79 Checking the radiator…………………………………………………………………… 5-82 Installing the radiator…………………………………………………………………… 5-83 Checking the oil cooler ………………………………………………………………… 5-84 Water pump……………………………………………………………………………… 5-85 Disassembling the water pump ……………………………………………………… 5-87 Checking the water pump……………………………………………………………… 5-88 Assembling the water pump…………………………………………………………… 5-89 SEAT ………………………………………………………………………………………… 5-92 FUEL TANK………………………………………………………………………………… 5-93 Checking the fuel pump operation …………………………………………………… 5-95 Disassembling and checking ,service oil cooling system…………………………… 5-96 Installing oil cooling system…………………………………………………………… 5-97 CHAPTER 6 ELECTRICAL COMPONENTS Electrical System Malfunction Inspection ………………………………………… 6-1 ELECTRICAL ……………………………………………………………………………… 6-2 ELECTRICALCOMPONENTS ………………………………………………………… 6-2

2009-2012 Hisun HS700 UTV Service & Repair Manual

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