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Hisun Motors HS750UTV-2 User Manual

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FOREWORD
Brief introduction to maintenance handbook of HS750UTV-2
The handbook is edited by Technical Center of Chongqing Huansong Science And
Technology Industrial 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 HS750UTV-2.
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.
First version , November,2015
Published by Chongqing Huansong Science And Technology Industrial Co.,Ltd
Chongqing Huansong Science And Technology Industrial Co.,Ltd holds the copy right.
No publishing and reprinting without permission.

Table of Contents

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Hisun Motors HS750UTV-2 Specifications

General IconGeneral
BrandHisun Motors
ModelHS750UTV-2
CategoryUtility Vehicle
LanguageEnglish

Summary

FOREWORD

Brief introduction to maintenance handbook of HS750UTV-2

Provides an overview of the maintenance handbook for the HS750UTV-2.

CHAPTER 1 GENERAL INFORMATION

Vehicle Description and Identification

Details on vehicle parts, identification codes, and serial numbers.

Service Supplies and Tools

Information on shop supplies, lubricants, basic tools, and precision measuring tools.

Torque Measurement Tools

Guidelines for using torque wrenches and adapters for proper assembly.

Precision Measurement Tools

Covers feeler gauges, calipers, micrometers, and other measuring instruments.

Micrometers

Instructions for using metric and inch micrometers for accurate measurements.

Basic Service Methods

Essential procedures for common maintenance tasks and component handling.

Bearings and Seals

Procedures for removing, installing, and replacing bearings and seals.

Storage and Maintenance

Guidance on vehicle storage preparation and procedures for returning to service.

Engine Troubleshooting Guide

Covers engine principles, starting procedures, and diagnosis for starting failures.

Engine Starting Issues

Explains cold, warm, and flooded engine starting procedures and common faults.

Engine Will Not Start

Step-by-step guide to identify and resolve issues when the engine fails to start.

CHAPTER 2 SPECIFICATIONS

Unit Conversion and General Specs

Tables for unit conversion and general vehicle specifications.

Component Specifications

Detailed specifications for engine, chassis, and electrical systems.

Tightening Torques

Crucial assembly information including specific torque values.

Engine and Chassis Torques

Lists specific torque values for engine and chassis fasteners.

Lubrication Points and Types

Identifies lubrication points and recommended lubricant types for engine and chassis.

CHAPTER 3 MAINTENANCE AND ADJUSTMENT OF THE UTV

Maintenance Schedule Overview

Recommended maintenance intervals for various vehicle systems and components.

Engine Maintenance Procedures

Step-by-step guides for engine adjustments and checks.

Engine Oil Change

Instructions for draining and refilling engine oil and replacing the oil filter.

Chassis Maintenance Procedures

Guides for cleaning filters, checking fluids, and inspecting chassis components.

Brake System Maintenance

Procedures for checking brake pads, hoses, fluid, and bleeding the system.

Wheel and Tire Maintenance

Instructions for checking tire pressure, wear, balance, and wheel hub condition.

Electrical System Maintenance

Procedures for checking and maintaining the battery, fuses, and lighting.

Battery Maintenance

Guidance on checking battery condition, charging, and terminal maintenance.

CHAPTER 4 ENGINE

Engine Removal and Disassembly

Detailed instructions for removing and disassembling major engine assemblies.

Cylinder Head and Components

Procedures for removing and inspecting cylinder head, tappet covers, and related parts.

Piston and Rings

Steps for checking, measuring, and installing pistons and piston rings.

Crankshaft and Oil Pump Assembly

Procedures for disassembling and assembling the crankshaft and oil pump.

Transmission System

Information on the vehicle's transmission system components and operations.

Drive Axle Assembly

Procedures for disassembling and checking the drive axle components.

Middle Gear and Shaft

Details on disassembling and checking the middle gear and shaft assemblies.

CHAPTER 5 CHASSIS

Steering System Components

Information on steering wheel parts, columns, drive axles, and machine parts.

Brake System Components

Comprehensive guide to brake system parts, checks, and maintenance.

Parking Brake System

Procedures for removing, checking, and replacing parking brake caliper and pads.

Wheel and Tire Assembly

Details on front and rear wheels, tires, hubs, and installation procedures.

Transmission System Components

Information on the vehicle's transmission system components and operations.

Front and Rear Axles/Bridges

Procedures for disassembling and checking front/rear axles, differential, and reverse mechanism.

Suspension System Components

Information on front and rear suspension arms, shock absorbers, and stabilizers.

Front Suspension Assembly

Procedures for disassembling, servicing, and installing front suspension components.

Rear Suspension Assembly

Procedures for disassembling, servicing, and installing rear suspension components.

Cooling System Components

Details on radiators, oil coolers, and water pump systems.

Radiator and Water Pump

Procedures for checking, installing, and servicing radiators and water pumps.

Fuel Tank and Oil System

Information on the fuel tank, oil cooler, and associated systems.

CHAPTER 6 ELECTRICAL COMPONENTS

Electrical System Malfunction Inspection

Guide for diagnosing common electrical system problems and their causes.

Electrical Component Identification

Visual guide to locate key electrical components on the vehicle.

Switch and Bulb Checks

Procedures for testing switches, bulbs, and bulb sockets for continuity and function.

Ignition System Troubleshooting

Steps to diagnose and resolve issues with the ignition system, including spark tests.

Starting System Troubleshooting

Troubleshooting guide for starter motor, relay, and related electrical circuits.

Charging System Troubleshooting

Steps to diagnose battery charging issues, including fuses, battery, and charging coil.

Lighting System Troubleshooting

Procedures for diagnosing and fixing problems with headlights, taillights, and indicators.

CHAPTER 7 ENGINE MANAGEMENT SYSTEM

EMS Introduction and Components

Overview of the Engine Management System and its typical components.

Key EMS Components

Detailed information on ECU, fuel injectors, and throttle body assembly.

Other EMS Sensors and Components

Information on coolant temp sensor, intake sensors, oxygen sensor, and ignition coil.

Fuel Pump Module

Description, handling, diagnosis, and removal/installation of the fuel pump module.

CHAPTER 8 TROUBLESHOOTING

Starting and Performance Issues

Addresses starting failures, poor idle, and performance issues in the EFI system.

Shifting and Overheating Problems

Troubleshooting guide for faulty gear shifting and engine overheating issues.

Brake and Suspension Malfunctions

Diagnosing poor braking effects, shock absorber, and steering instability issues.

Lighting System Issues

Troubleshooting steps for headlights out, bulbs burnt out, and meter display errors.

CHAPTER 9 HS750UTV-2 WIRING DIAGRAM

HS750UTV-2 WIRING DIAGRAM

Comprehensive electrical wiring diagram for the HS750UTV-2 model.

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