2008-2017 Hisun HS700/600/500 UTV Service & Repair Manual

FOREWORD Brief introduction to maintenance handbook of HS700/600/500UTV The handbook is edited by Technical Center of Chongqing Huansong Industries (Group) Co., Ltd., and is supplied to dealers and technicians as document of technique. Mainly, the handbook gives methods to check, maintain and repair utility terrain vehicles （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. Third version , May, 2010 Published by Chongqing Huansong Industries (Group) Co., Ltd. Chongqing Huansong Industries (Group) Co., Ltd holds the copy right. No publishing and reprinting without permission.

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

- 2 - Wrenches ………………………………………………………………………………… 12 Adjustable wrenches …………………………………………………………………… 12 Socket wrenches, ratchets and handles ……………………………………………… 13 Impact drivers …………………………………………………………………………… 14 Allen wrenches…………………………………………………………………………… 14 Torque wrenches………………………………………………………………………… 14 Torque adapters ………………………………………………………………………… 15 Pliers……………………………………………………………………………………… 16 Snap ring pliers…………………………………………………………………………… 16 Hammers ………………………………………………………………………………… 17 Ignition grounding tool…………………………………………………………………… 17 PRECISION MEASURING TOOLS ………………………………………………………… 17 Feeler gauge ……………………………………………………………………………… 18 Calipers…………………………………………………………………………………… 18 Micrometers……………………………………………………………………………… 19 Adjustment ……………………………………………………………………………… 20 Care ……………………………………………………………………………………… 20 Metric micrometer………………………………………………………………………… 20 Standard inch micrometer……………………………………………………………… 21 Telescoping and small bore gauges…………………………………………………… 22 Dial Indicator……………………………………………………………………………… 22 Compression gauge……………………………………………………………………… 23 Multimeter………………………………………………………………………………… 23 ELECTRICAL SYSTEM FUNDAMENTALS……………………………………………… 24 Voltage …………………………………………………………………………………… 24 Resistance………………………………………………………………………………… 24 Amperage………………………………………………………………………………… 24 BASIC SERVICE METHODS……………………………………………………………… 25 Removing frozen fasteners……………………………………………………………… 26 Removing broken fasteners …………………………………………………………… 26 Repairing damaged threads …………………………………………………………… 27 Stud Removal/Installation ……………………………………………………………… 27 Removing hoses ………………………………………………………………………… 27 Bearings…………………………………………………………………………………… 28

- 3 - Removal…………………………………………………………………………………… 28 Installation………………………………………………………………………………… 29 Interference fit …………………………………………………………………………… 29 Seal replacement………………………………………………………………………… 31 STORAGE……………………………………………………………………………………… 31 Storage area selection…………………………………………………………………… 31 Preparing the motorcycle for storage …………………………………………………… 32 Returning the UTV to service…………………………………………………… 32 TROVBLESHOOTING……………………………………………………………………… 33 ENGINE PRINCIPLES AND OPERATING REQUIREMENTS………………………… 34 STARTING THE ENGINE ………………………………………………………………… 34 Engine is cold …………………………………………………………………………… 34 Engine is warm…………………………………………………………………………… 34 Starting the engine after a fall or after the engine stalls……………………………… 34 Flooded engine…………………………………………………………………………… 34 Engine cold with air temperature ……………………………………………………… 35 Engine cold with air temperature above 35℃（95°F）……………………………… 35 Cold engine with air temperature below 10℃(50°F) ……………………………… 35 Engine is hot……………………………………………………………………………… 36 Starting the engine after a fall or after the engine stalls……………………………… 36 Flooded engine…………………………………………………………………………… 36 ENGINE WILL NOT START ……………………………………………………………… 37 Identifying the problem ………………………………………………………………… 37 Spark test………………………………………………………………………………… 38 Starter does not turn over or turns over slowly ……………………………………… 39 POOR ENGINE PERFORMANCE………………………………………………………… 39 Engine starts but stalls and is hard to restart…………………………………………… 39 Engine backfires, cuts out or misfires during acceleration…………………………… 40 Engine backfires on deceleration……………………………………………………… 40 Poor fuel mileage………………………………………………………………………… 40 Engine will not idle or idles roughly …………………………………………………… 41 Low engine power ………………………………………………………………………… 41 Poor idle or low speed performance…………………………………………………… 42

- 4 - Poor high speed performance ………………………………………………………… 43 FUEL SYSTEM……………………………………………………………………………… 43 Rich mixture……………………………………………………………………………… 43 Lean mixture……………………………………………………………………………… 44 ENGINE………………………………………………………………………………………… 44 Engine smoke……………………………………………………………………………… 44 Black smoke ……………………………………………………………………………… 44 Blue smoke………………………………………………………………………………… 44 White smoke or steam…………………………………………………………………… 44 Low engine compression ………………………………………………………………… 45 High engine compression ……………………………………………………………… 45 Engine overheating (cooling system) ………………………………………………… 45 Engine overheating (engine)…………………………………………………………… 46 Preignition………………………………………………………………………………… 46 Detonation………………………………………………………………………………… 46 Power loss ……………………………………………………………………………… 46 engine noises……………………………………………………………………………… 46 ENGLNE LUBRICATION…………………………………………………………………… 47 HIGH OIL CONSUMPTION OR EXCESSIVE……………………………………………… 47 Exhaust smoke…………………………………………………………………………… 47 Low oil pressure ………………………………………………………………………… 47 High oil pressure ………………………………………………………………………… 48 No oil pressure…………………………………………………………………………… 48 Oil level too low…………………………………………………………………………… 48 Oil contamination………………………………………………………………………… 48 CYLINDER LEAK DOWN TEST…………………………………………………………… 48 ELECTRICAL TESTING…………………………………………………………………… 51 Preliminary checks and precautions …………………………………………………… 51 Intermittent problems…………………………………………………………………… 52 Electrical component replacement ……………………………………………………… 53 Test equipment …………………………………………………………………………… 53 Ammeter …………………………………………………………………………………… 53 Self-powered test light …………………………………………………………………… 53 Ohmmeter ………………………………………………………………………………… 54

- 5 - Jumper wire……………………………………………………………………………… 54 TEST PROCEDURES………………………………………………………………………… 55 Voltage test……………………………………………………………………………… 55 Voltage drop test………………………………………………………………………… 55 Peak voltage test………………………………………………………………………… 56 Continuity test……………………………………………………………………………… 56 Testing for a short with a self-powered test light or ohmmeter……………………… 56 Testing for a short with a test light or voltmeter………………………………………… 57 BRAKE SYSTEM……………………………………………………………………………… 57 Soft or spongy brake lever or pedal…………………………………………………… 57 Brake drag………………………………………………………………………………… 58 Hard brake lever or pedal operation…………………………………………………… 59 Brake Grabs……………………………………………………………………………… 59 Brake squeal or chatter ………………………………………………………………… 59 Leaking brake caliper …………………………………………………………………… 60 Leaking master cylinder………………………………………………………………… 60 CHAPTER 2 SPECIFICATIONS HOW TO USE CONVERSION TABLE OF UNIT…………………………………………… 61 How to use conversion table…………………………………………………………… 61 Definition of unit ………………………………………………………………………… 61 GEBERAR SPECIFICATIONS ……………………………………………………………… 62 ENGINE SPECIFICATIONS ………………………………………………………………… 65 CHASSIS SPECIFICATIONS………………………………………………………………… 71 ELECTRICAL SPECIFICATIONS…………………………………………………………… 73 TIGHTENING TORQUES …………………………………………………………………… 75 Engine tightening torques………………………………………………………………… 75 Chassis tightening torques ……………………………………………………………… 78 GENERAL TIGHTENING TORQUE SPECIFICATIONS ………………………………… 81 LUBRICATION PIONTS AND LUBRICANT TYPES……………………………………… 82 Engine……………………………………………………………………………………… 82 Chassis……………………………………………………………………………………… 83

- 6 - HYDROGRAPHIC CHART…………………………………………………………………… 84 LUBRICATION OIL WAY…………………………………………………………………… 85 CHAPTER 3 MAINTENCE AND ADJUSTMENT OF THE UTV MAINTENANCE SCHEDULE……………………………………………………………… 86 ENGINE Adjusting the valve clearance…………………………………………………………… 88 Idle adjustment …………………………………………………………………………… 91 Adjusting the throttle cable……………………………………………………………… 91 Adjusting the starter cable……………………………………………………………… 92 Checking the spark plug ………………………………………………………………… 93 Checking the ignition timing……………………………………………………………… 94 Measuring the compression pressure………………………………………………… 95 Checking the engine oil level …………………………………………………………… 97 Changing the engine oil ………………………………………………………………… 98 CHASSIS Cleaning the air filter………………………………………………………………… 101 Checking the coolant level …………………………………………………………… 102 Changing the coolant…………………………………………………………………… 103 Checking the coolant temperature warning light …………………………………… 106 Checking the v-belt……………………………………………………………………… 107 Cleaning the spark arrester …………………………………………………………… 108 Adjusting the brake pedal……………………………………………………………… 109 Adjusting the parking brake…………………………………………………………… 110 Checking the brake fluid level ………………………………………………………… 111 Checking the front brake pads………………………………………………………… 111 Checking the rear brake pads………………………………………………………… 112 Checking the brake hoses and brake pipes ………………………………………… 113 Bleeding the hydraulic brake system ………………………………………………… 113 Adjusting the select lever shift rod …………………………………………………… 115 Adjusting the brake light switch ……………………………………………………… 115 Checking the final gear oil level ……………………………………………………… 116

- 7 - Changing the final gear oil……………………………………………………………… 116 Checking the differential gear oil……………………………………………………… 117 Changing the differential gear oil……………………………………………………… 117 Checking the constant velocity joint dust boots……………………………………… 118 Checking the steering system………………………………………………………… 119 Adjusting the toe-in …………………………………………………………………… 120 Adjusting the front shock absorbers………………………………………………… 121 Adjusting the rear shock absorbers …………………………………………………… 121 Checking the tires ……………………………………………………………………… 122 Checking the wheels…………………………………………………………………… 124 Checking and lubricating the cables ………………………………………………… 124 ELECTRICAL Checking and charging the battery…………………………………………………… 125 Checking the fuses …………………………………………………………………… 130 Adjusting the headlight beam ………………………………………………………… 131 Changing the headlight bulb ………………………………………………………… 132 Changing the tail/brake light bulb …………………………………………………… 133 CHAPTER 4 ENGINE ENGINE NOTE……………………………………………………………………………… 134 ENGINE REMOVAL………………………………………………………………………… 135 CYLINDER HEAD AND CYLINDER HEAD COVER…………………………………… 137 ROCKER ARMS AND CAMSHAFT……………………………………………………… 142 VALVES AND VALVE SPRINGS………………………………………………………… 148 CYLINDER AND PISTON………………………………………………………………… 154 ENGINE COOLING FAN AND A.C. MAGNETO ……………………………………… 158 BALANCER GEARS AND OIL PUMP GEARS………………………………………… 163 PRIMARY AND SECONDARY SHEAVES Primary and secondary sheaves ……………………………………………………… 166 Primary sheave………………………………………………………………………… 167 Secondary sheave ……………………………………………………………………… 168 CLUTCH ……………………………………………………………………………………… 173

- 8 - CRANKCASE Starter motorand oil filter……………………………………………………………… 177 Crankcase……………………………………………………………………………… 179 Crankcase bearings…………………………………………………………………… 180 CRANKSHAFT AND OIL PUMP Crankshaft and oil pump ……………………………………………………………184 Oil pump…………………………………………………………………………………185 TRANSMISSION Transmission…………………………………………………………………………… 188 Drive axle assembly…………………………………………………………………… 189 MIDDLE GEAR Middle drive shaft………………………………………………………………………… 193 Middle driven shaft ……………………………………………………………………… 194 CARBURETOR……………………………………………………………………………… 200 CHAPTER 5 CHASSIS MALFUNCTION INSPECTION…………………………………………………………… 205 DIRECTION SYSTEM The structure of the steering…………………………………………………………… 208 The structure of steering wheel part…………………………………………………… 210 Diassembling the parts of the steering wheel ………………………………………… 211 Checking the parts of the steering wheel……………………………………………… 211 Diassembling the steering column parts……………………………………………… 212 Checking and service the steering column parts……………………………………… 213 Diassembling the steering drive axle ………………………………………………… 213 Checking and service the steering drive axle………………………………………… 214 Diassembling the steering machine part……………………………………………… 215 The structure of the steering………………………………………………………… 215 Reinstalls the steering system parts…………………………………………………… 216 BRAKE SYSTEM…………………………………………………………………………… 217 Front disk brake components ………………………………………………………… 219 Front brake discs ……………………………………………………………………… 220

- 9 - Checking the front brake disc ………………………………………………………… 221 Front brake pads………………………………………………………………………… 222 Replacing the front brake pads………………………………………………………… 223 Front brake caliper……………………………………………………………………… 224 Disassembling the front brake calipers ……………………………………………… 226 Assembling the front brake calipers…………………………………………………… 227 Installing the front brake calipers …………………………………………………… 227 Rear brake disc ………………………………………………………………………… 229 Checking the rear brake disc…………………………………………………………… 230 Rear brake caliper and brake pads…………………………………………………… 231 Replacing the rear brake pads………………………………………………………… 234 Disassembling the rear brake caliper ………………………………………………… 234 Assembling the rear brake caliper …………………………………………………… 235 Installing the rear brake caliper………………………………………………………… 237 Brake master cylinder…………………………………………………………………… 239 Checking the master cylinder ………………………………………………………… 240 Assembling the brake master cylinder………………………………………………… 240 Installing the brake master cylinder…………………………………………………… 240 FOOTREST ASSEMBLY ………………………………………………………………… 242 WHEEL AND TYRE PARTS ……………………………………………………………… 245 Front wheels……………………………………………………………………………… 245 Rear wheels……………………………………………………………………………… 246 Checking the wheel tyre………………………………………………………………… 247 Checking the wheel hub………………………………………………………………… 247 Installing the wheel hub………………………………………………………………… 247 Installing the wheel tyre………………………………………………………………… 248 Specification of wheel and tyre………………………………………………………… 248 TRANSMISSION SYSTEM ………………………………………………………………… 249 Front bridge……………………………………………………………………………… 249 Disassembling the front bridge………………………………………………………… 254 Disassembling the universal joint …………………………………………………… 254 Removing the differential gear assembly…………………………………………… 254 Checking the joints……………………………………………………………………… 255 Checking the differential gear…………………………………………………………… 255

2008-2017 Hisun HS700/600/500 UTV Service & Repair Manual

You're Reading a Preview

Recently Viewed