2010-2013 Hisun 800 HS800 UTV Service & Repair Manual

Forth version , May, 2014 Published by Chongqing Huansong Industries (Group) Co., Ltd and Hisun Motors Corp USA. Chongqing Huansong Industries (Group) Co., Ltd and Hisun Motors Corp USA holds the copy right. No publishing and reprinting without permission READ THIS MANUAL CAREFULLY For questions regarding this UTV, please contact HISUN at: (877) 838-6188 www.hisunmotors.com REV. 06051401 SERVICE MANUAL HS800

Foreword Brief introduction to maintenance handbook of HS800UTV The handbook is edited by Technical Center of Chongqing Huansong Industries (Group) Co., Ltd., and is supplied to dealers and technicians as a document of technique. This manual gives methods to check, maintain and repair utility terrain vehicles (UTV’s), and supplies some relevant techniques and performance data. Some techniques and methods inside may be used to check, maintain and repair other models of UTV, although it is mainly for the HS800UTV. Please read the handbook through and fully understand it; otherwise, any improper repairing could bring you problems, and or an accident may occur. Proper use and maintenance can guarantee the UTV being driven safely, reduce its malfunctions, and help the vehicle remain at its best performance level. The standards, procedures and specifications mentioned in this manual 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, 2014 Published by Chongqing Huansong Industries (Group) Co., Ltd. Chongqing Huansong Industries (Group) Co., Ltd holds the copy right. No publishing and reprinting without permission.

INDEX Chapter 2 Specifications Chapter 3 Periodic Maintenance and Adjustments Chapter 4 Engine Chapter 5 Chassis Chapter 6 Electrical Chapter 7 Engine Management System Chapter 8 Troubleshooting ??? Wiring Diagrams Index 1. 2. 3. Chapter 1 General

INDEX Chapter 1 General Information Warnings, Cautions, Notes Description, Location Identification Code, Frame Number, Engine Number Safety Handling Gasoline, cleaning parts Warning Labels, Serial Numbers, Fasteners, Torque specs, Self Locking fasteners Washers, Cotter pins, Snap rings, and E-clips Shop Supplies, Lubricants, Engine Oils Greases, Brake Fluid, Coolant Cleaners, Degreasers and Solvents Basic Tools Precision Measuring Tools Compression Gauge, Multimeter Basic Service Methods Storage Chapter 2 Specifications Conversion Tables General Specs Engine Specs Suspension Specs Electrical Specs Engine Torques Chassis Torques General Torques Lubrications Chapter 3 Periodic Maintenance and Adjustment Maintenance Schedule Valve Adjustment Compression Test Engine Oil Air Filter Coolant Level V-Belt 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1-10 1-11 1-12 1-12 1-19 1-25 1-27 1-28 2-3 2-4 2-7 2-13 2-15 2-17 2-20 2-22 2-23 3-3 3-5 3-6 3-7 3-8 3-10 3-13 Spark Arrester Brake Pedal Brake Pads Shift Lever Adjustment Final Gear Oil Steering System Shock absorbers Tires Headlight Adjustment Chapter 4 Engine Special notes Throttle and Intake Manifold Removal Cylinder Head Cover and Cylinder Head Rocker Arms and Camshaft Valves and Valve springs Cylinder and Piston Left Crankcase Cover and A.C. Magneto Starter motor and Oil Filter Primary and Secondary Sheaves Crankcase Cover and Oil Pump Crankcase and Middle Driven Shaft Output Shaft Gearcase Shift Lever and Oil Pump Gearcase Transmission Chapter 5 Chassis Steering Assembly Disc Brake components Front Brake Caliper Rear Brake Caliper Parking Brake Caliper Footrest Front Wheel and Tire Rear Wheel and Tire Cv Axle, Front Axle Front Bridge Cv Axle, Rear Axle Rear Bridge Reeducer 3-13 3-14 3-15 3-16 3-17 3-18 3-19 3-19 3-20 4-3 4-4 4-5 4-8 4-10 4-14 4-17 4-19 4-21 4-24 4-27 4-30 4-33 4-35 5-3 5-9 5-11 5-15 5-16 5-20 5-23 5-24 5-27 5-28 5-32 5-33

INDEX Gear Shift Assembly Front Swing Arm Front Suspension Rear Anti-roll Bar Rear Swing Arm Radiator and Oil Cooler Water Pump Seat Fuel Tank Chapter 6 Electrical Electrical Basics Charging a Lead Acid Battery Charging a Maintenance Free Battery Checking the Fuses Electrical Components Inspection of the Main Switch Component Locations Troubleshoot (NO SPARK) Troubleshoot (Starter Motor Failure) Starter Motor Removal Troubleshoot (Battery is not Charging) Chapter 7 Engine Management System EMS Introduction, Components Layout ECU Multec 3.5 Injectors Throttle Body Assembly Engine Coolant Temp Sensor, Oxygen Sensor Fuel Pump Module Fault Codes 5-36 5-39 5-40 5-43 5-44 5-47 5-51 5-56 5-59 6-3 6-4 6-6 6-7 6-8 6-10 6-11 6-12 6-15 6-16 6-17 7-3 7-4 7-4 7-5 7-7 7-8 7-9 7-12 Chapter 8 Troubleshoot Troubleshoot Basics Principles and Requirements Special Faults Flooded Engine Engine will not start Spark Test Poor Engine Performance Fuel System Engine Smoke Compression Engine Lubrication Cylinder Leak Down Test Electrical Testing Test Equipment Brake System Headlight/Taillight Lighting System Brake Light Reverse Indicator Coolant Temp Warning Light 4 Wheel drive Switch Radiator Fan Motor 2/4WD Switch, Rear Differential Fuel System, Electrical System Starter Motor, Gear Shifting 8-3 8-4 8-4 8-6 8-6 8-7 8-8 8-12 8-13 8-14 8-16 8-17 8-20 8-22 8-27 8-30 8-31 8-32 8-36 8-37 8-39 8-42 8-44 8-45 8-46

General Information 1-1 Warnings, Cautions, Notes Description, Location Identification Code, Frame Number, Engine Number Safety Handling Gasoline, cleaning parts Warning Labels, Serial Numbers, Fasteners, Torque specs, Self Locking fasteners Washers, Cotter pins, Snap rings and E-clips 1-3 1-4 1-5 1-6 1-7 1-8 1-9 Shop Supplies, Lubricants, Engine Oils Greases, Brake Fluid, Coolant Cleaners, Degreasers and Solvents Basic Tools Precision Measuring Tools Compression Gauge, Multimeter Basic Service Methods Storage 1-10 1-11 1-12 1-12 1-19 1-25 1-27 1-33

General Information 1-2

General Information 1-3 This manual provides complete information on maintenance, tune-up, repair and overhaul. Hundreds of photographs and illustrations created during the complete disassembly of Utility Terrain Vehicles (UTV) guide the reader through every job. All procedures are in step by step format and designed for the reader who may be working on the UTV for the first time. Warnings, Cautions and Notes The terms Warning, Caution and Note have specific meanings in this manual. Warning Emphasizes areas where injury or even death could result from negligence. Caution Emphasizes areas where equipment damage could result. Disregarding a Caution could cause permanent permanent Mechanical damage, although injury is unlikely. Note Provides additional information to make a step or procedure easier or clearer. Disregarding a Note could cause inconvenience, but would not cause equipment damage or injury.

General Information 1-4 Description 1. Headlights/Front turning lights/ Position lights 2. Front shock absorber spring preload Adjusting ring 3. Rear Brake Fluid Reservoir 4. Parking Brake Lever 5. Driver Seat 6. Battery 7. Fuses 8. Left shoulder protection plate 9. Driver’s seat belt 10. Air Filter case (Engine and Air intake duct) 11. Cargo Bed 12. Tail light / Rear turning lights 13. Spark arrester 14. Rear Shock absorber assembly adjusting ring 15. V-belt case 16. Passenger seat belt 17. Right shoulder protection plate 18. Spark plug 19. Oil filter 20. Fuel cap 21. Passenger seat 22. Rear view mirror 23. Coolant reservoir 24. Radiator cap 25. Steering wheel 26. Light switch 27. Main switch 28. On-Command four-wheel-drive and differential lock switches 29. Multi-function Display 30. Auxiliary DC jack 31. Brake pedal 32. Accelerator pedal 33. Drive select lever 34. Passenger handrail Note: The vehicle you have purchased may differ slightly from those in the figures of this manual.

2010-2013 Hisun 800 HS800 UTV Service & Repair Manual

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