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Hisun HS200UTV User Manual

Hisun HS200UTV
312 pages
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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:
(972)446-0760
hisunmotors.com
Rev. 06031601
No one under the age of 12
should operate this vehicle.
Provincial / Municipal
governments have dierent
regulations pertaining to
owning and operating an
o-road vehicle; learn the
regulations in your area.
STRIKE 250
SERVICE MANUAL
TM
GRAB SOME SUN

Table of Contents

Questions and Answers:

Hisun HS200UTV Specifications

General IconGeneral
BrandHisun
ModelHS200UTV
CategoryMotorcycle
LanguageEnglish

Summary

Foreword

Chapter 1 General Information

Warnings, Cautions, and Notes

Explains the specific meanings of WARNING, CAUTION, and NOTE messages.

Description

Provides an overview of the vehicle's components with numbered illustrations.

Identification Code

Shows the locations for frame and engine serial numbers.

Safety

Guidelines and practices for safe servicing of the UTV and handling gasoline.

Fasteners

Importance of proper fastener selection and installation for efficient servicing.

Shop Supplies

Information on lubricants, fluids, cleaners, and sealants for shop use.

Basic Tools

Importance of quality basic hand tools and test equipment for mechanic work.

Precision Measuring Tools

Importance of accurate measurements using specialized tools for procedures.

Electrical System Fundamentals

Basic understanding of voltage, resistance, and amperage in electrical circuits.

Basic Service Methods

General guidelines and practices for performing various service tasks.

Seal Replacement

Procedures for removing and installing seals to prevent leakage.

Storage

Guidelines for preparing the UTV for long-term storage.

Troubleshooting

General approach to diagnosing and resolving vehicle problems.

Engine Principles and Operating Requirements

Basic requirements for engine operation: air/fuel mix, compression, and spark.

Starting the Engine

Recommended procedures for starting the engine, including EFI system faults.

Engine Will Not Start

Steps to identify the cause when the engine fails to start.

Poor Engine Performance

General guide to diagnosing unsatisfactory engine performance.

Fuel System

Troubleshooting common fuel system problems.

Engine Smoke

How engine smoke color indicates operating conditions or problems.

Low Engine Compression

Causes of low engine compression and diagnostic steps.

Engine Overheating

Causes and troubleshooting for engine overheating issues.

Power Loss

Refers to troubleshooting poor engine performance for power loss issues.

Engine Noises

Identifying and troubleshooting unusual engine noises.

Engine Lubrication

Importance of proper lubrication system operation for engine health.

Cylinder Leak Down Test

Procedure for performing a cylinder leak-down test to pinpoint engine leakage.

Electrical Testing

Overview of basic electrical testing methods and equipment.

Preliminary Checks and Precautions

Essential preliminary checks and safety precautions before electrical testing.

Intermittent Problems

Locating and repairing intermittent electrical issues.

Electrical Component Replacement

Considerations and precautions for replacing electrical components.

Test Equipment

Description and use of common electrical test equipment.

Test Procedures

Procedures for performing voltage, voltage drop, and continuity tests.

Brake System

Preparation for checking the brake system and its components.

Soft or Spongy Brake Lever or Pedal

Causes and checks for soft or spongy brake lever/pedal action.

Brake Drag

Causes for brake pads not retracting from the disc, leading to drag.

Hard Brake Lever or Pedal Operation

Causes for excessively hard brake lever or pedal operation.

Brake Grabs

Potential causes for sudden, harsh brake engagement.

Brake Squeal or Chatter

Causes for brake squealing or chattering noises during operation.

Leaking Brake Caliper

Causes for leaks from the brake caliper assembly.

Leaking Master Cylinder

Causes for leaks from the brake master cylinder.

Chapter 2 Specifications

How to Use Conversion Table of Unit

Guide on converting between metric and imperial units.

Geberar Specifications

Vehicle dimensions, engine model, displacement, and other specifications.

Engine Specifications

Detailed specifications for engine cylinder, camshaft, and valve components.

Chassis Specifications

Specifications for steering, suspension, wheels, and brakes.

Electrical Specifications

Specifications for voltage, ignition, charging, and battery systems.

Tightening Torques

Table of engine tightening torques for various parts.

General Tightening Torque Specifications

General tightening torques for standard fasteners based on ISO thread pitch.

Lubrication Points and Lubricant Types

Lists lubrication points and recommended lubricants for the engine.

Chapter 3 Maintenance and Adjustment of the UTV

Maintenance Schedule

Outlines routine maintenance tasks and intervals for the UTV.

Engine

Procedures for engine maintenance and adjustment.

Chassis

Procedures for chassis maintenance and adjustment.

Electrical

Procedures for maintaining and checking electrical system components.

Chapter 4 Engine

Engine Note

General notes and precautions before engine disassembly or assembly.

Engine Removal

Step-by-step instructions for removing the engine assembly.

Cylinder Head and Cylinder Head Cover

Exploded view and part list for cylinder head and cover removal.

Rocker Arms, Valves, and Camshaft

Exploded view and part list for rocker arms, valves, and camshaft removal.

Cylinder and Piston

Exploded view and part list for cylinder and piston removal.

Engine Left Crankcase Cover and A.C. Magneto

Exploded view and part list for left crankcase and A.C. magneto removal.

Starter Motor and Water Pump

Exploded view and part list for starter motor and water pump removal.

Right Crankcase Cover and Oil Filter

Exploded view and part list for right crankcase cover and oil filter removal.

Primary and Secondary Sheaves

Exploded view and part list for primary and secondary sheaves removal.

Crankcase and Oil Pump

Exploded view and part list for crankcase separation and oil pump removal.

Balance Shaft

Exploded view and part list for balance shaft removal.

Shift and Control Mechanism

Exploded view and part list for the shift operating system removal.

Gearcase Transmission

Exploded view and part list for gearcase transmission removal.

Chapter 5 Chassis

Malfunction Inspection

Checklist for appearance-related chassis malfunctions.

Brake System Malfunction Inspection

Inspects brake system for locked brakes, poor performance, and noises.

Off Tracking by Braking at High-Speed

Checks for issues causing off-tracking during high-speed braking.

Other System Malfunction Inspection

Inspects steering, wheel, and suspension systems for malfunctions.

Panel and Cargo Bed

Exploded view and part list for front panel and cargo bed components.

Direction System

Components and procedures related to the vehicle's direction system.

Brake System

Preparation for checking the brake system and its components.

Footrest Part

Exploded view and part list for the footrest assembly.

Wheel and Tyre Parts

Exploded views and part lists for front and rear wheel assemblies.

Shift Operating System

Exploded view and part list for the shift operating system.

Suspension

Exploded views and part lists for front and rear suspension components.

Cooling System

Exploded views and part lists for cooling system components.

Seat

Exploded view and part list for the seat assembly.

Fuel Tank

Exploded view and part list for the fuel tank assembly.

Chapter 6 Electrical Components

Electrical System Malfunction Inspection

Checklist for electrical system malfunctions like abnormal lights or starting failures.

Electrical Components

Overview of various electrical components with their identification numbers.

Ignition System

Information about the ignition system, including circuit diagrams and troubleshooting.

Electric Starting System

Information about the electric starting system, including circuit diagrams and troubleshooting.

Chapter 7 Engine Management System

Introduction

Introduction to the EMS, its functions, and components.

Typical Components of EMS

Identification of key EMS components with a diagram.

Layout of EMS Components

Diagram illustrating the interconnection of EMS components and data flow.

Components of EMS

Detailed information on EMS components like ECU, injectors, sensors, and coils.

EMS Fault Diagnosis

Fault code list for diagnosing EMS malfunctions.

Chapter 8 Troubleshooting

Starting Failure/Hard Starting

Lists potential causes for starting failures in fuel and electrical systems.

Poor Idle Speed Performance

Potential causes for poor idle speed performance, especially in EFI systems.

Poor Medium and High-Speed Performance

Potential causes for poor performance at medium and high engine speeds.

Faulty Gear Shifting

Troubleshooting for issues with gear shifting, including lever movement and engagement.

Engine Overheating

Causes and troubleshooting steps for engine overheating.

Faulty Brake

Troubleshooting for poor braking effect and related issues.

Shock Absorber Malfunction

Diagnosing loss of damping function in shock absorbers.

Unstable Handling

Identifying causes of unstable vehicle handling.

Lighting System

Troubleshooting for headlight and taillight failures.

Chapter 9 Wiring Diagram

HS250UTV/HS200UTV Wiring Diagram

Overall wiring diagram for the vehicle.

HS250UTV/HS200UTV Wiring EFI Diagram

Wiring diagram specific to the EFI system.

Ignition System Circuit Diagram

Circuit diagram for the ignition system.

Electric Starting System Circuit Diagram

Circuit diagram for the electric starting system.

Charging System Circuit Diagram

Circuit diagram for the charging system.

Lighting System Circuit Diagram

Circuit diagram for the lighting system.

Signaling System Circuit Diagram

Circuit diagram for the signaling system.

Cooling System Circuit Diagram

Circuit diagram for the cooling system.

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