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HS200UTV
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312 pages
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-179-
CHASSIS
- 179-
No. Part
Name Qty
Remarks
21
Socket hexagon flat head sc
rews M6×16
2
22
Passenger handle bar assy
.
1
23
Handle bar locating seat
1
24
Handle bar grip
2
25
Hexagon flange bolt M8×35
1
26
Hexagon flange self-locked nut M8
1
193
195
Table of Contents
Main Page
Default Chapter
4
Table of Contents
4
Cautions and Notes
16
Chapter 1 General Information
16
Description
17
Identification Code
18
Frame no
18
Engine no
18
Safety
19
Handing Gasoline Safely
19
Cleaning Parts
20
Warning Labels
20
Serial Numbers
21
Fasteners
21
Torque Specifications
21
Self-Locking Fasteners
21
Washers
21
Cotter Pins
22
Snap Rings and E-Clips
22
Shop Supplies
23
Lubricants and Fluids
23
Engine Oils
23
Greases
23
Brake Fluid
24
Coolant
24
Cleaners, Degreasers and Solvents
24
Gasket Sealant
24
Gasket Remover
25
Thread Locking Compound
25
Basic Tools
25
Screwdrivers
26
Wrenches
26
Adjustable Wrenches
27
Socket Wrenches, Ratchets and Handles
27
Impact Drivers
28
Allen Wrenches
28
Torque Wrenches
28
Torque Adapters
29
Pliers
30
Snap Ring Pliers
30
Hammers
31
Ignition Grounding Tool
31
Precision Measuring Tools
31
Feeler Gauge
31
Calipers
32
Micrometers
32
Adjustment
33
Care
34
Metric Micrometer
34
Standard Inch Micrometer
35
Telescoping and Small Bore Gauges
36
Dial Indicator
36
Compression Gauge
37
Multimeter
37
Cltp-On Ammeter
37
Magneto Puller
38
Electrical System Fundamentals
38
Voltage
38
Resistance
38
Amperage
38
Basic Service Methods
39
Removing Frozen Fasteners
40
Removing Broken Fasteners
40
Repairing Damaged Threads
41
Stud Removal/Installation
41
Removing Hoses
41
Bearings
42
Removal
42
Installation
43
Interference Fit
43
Seal Replacement
45
Storage
45
Storage Area Selection
45
Preparing the Motorcycle for Storage
45
Returning the UTV to Service
46
Trovbleshooting
46
Engine Principles and Operating Requirements
47
Starting the Engine
47
Engine Is Cold
48
Engine Is Warm
48
Flooded Engine
48
Engine will Not Start
49
Identifying the Problem
49
Spark Test
50
The Starter Cannot Work Repeatedly or Can Only Work Slowly
51
Poor Engine Performance
51
The Engine Starts Slowly or Difficultly
51
Engine Backfires, Cuts out or Misfires During Acceleration
51
The Engine Is Not Idling or Cannot Idle Stably
52
Poor Fuel Mileage
52
Engine will Not Idle or Idles Roughly
52
Low Engine Power
53
Poor Idle or Low Speed Performance
54
Poor High Speed Performance
54
Fuel System
54
Rich Mixture
55
Lean Mixture
55
Engine
55
Engine Smoke
55
Black Smoke
55
Blue Smoke
56
White Smoke or Steam
56
Low Engine Compression
56
High Engine Compression
56
Engine Overheating (Cooling System)
57
Engine Overheating (Engine)
57
The Ignition Advance Angle Is too Large
57
Detonation
57
Power Loss
58
Engine Noises
58
Englne Lubrication
59
High Oil Consumption or Excessive
59
Exhaust Smoke
59
Low Oil Pressure
59
High Oil Pressure
59
No Oil Pressure
59
Oil Level too Low
59
Oil Contamination
60
Cylinder Leak down Test
60
Electrical Testing
62
Preliminary Checks and Precautions
62
Intermittent Problems
63
Electrical Component Replacement
64
Test Equipment
64
Ammeter
64
Self-Powered Test Light
64
Ohmmeter
65
Jumper Wire
65
Test Procedures
66
Voltage Test
66
Voltage Drop Test
66
Peak Voltage Test
67
Continuity Test
67
Testing for a Short with a Self-Powered Test Light or Ohmmeter
67
Testing for a Short with a Test Light or Voltmeter
68
Brake System
68
Soft or Spongy Brake Lever or Pedal
68
Brake Drag
69
Hard Brake Lever or Pedal Operation
70
Brake Grabs
70
Brake Squeal or Chatter
70
Leaking Brake Caliper
70
Leaking Master Cylinder
71
How to Use Conversion Table of Unit
72
How to Use Conversion Table
72
Definition of Unit
72
Specifications
72
Geberar Specifications
73
Engine Specifications
76
Chassis Specifications
82
Electrical Specifications
84
Tightening Torques
86
Engine Tightening Torques
86
Chassis Tightening Torques
89
General Tightening Torque Specifications
91
Lubrication Pionts and Lubricant Types
92
Engine
92
Chassis
93
Hydrographic Chart
94
Lubrication Oil Way
95
Maintenance Schedule
96
Engine
97
Chapter 3
98
Adjusting the Valve Clearance
98
Checking the Spark Plug
101
Checking the Ignition Timing
102
Measuring the Compression Pressure
103
Checking the Engine Oil Level
104
Changing the Engine Oil
105
Cleaning the Air Filter
107
Checking the Coolant Level
108
Changing the Coolant
109
Checking the Coolant Temperature Warning Light
112
Checking the V-Belt
113
Cleaning the Spark Arrester
114
Adjusting the Brake Pedal
115
Checking the Brake Fluid Level
116
Checking the Front Brake Pads
117
Checking the Brake Hoses and Brake Pipes
118
Chapter 5
120
Adjusting the Select Lever Shift Rod
120
Checking the Steering System
121
Adjusting the Toe-In
122
Adjusting the Front and Rear Shock Absorbers
123
Checking the Tires
124
Checking the Wheels
126
Checking and Charging the Battery
127
Checking the Fuses
133
Changing the Headlight Bulb Ⅰ
135
Changing the Headlight Bulb Ⅱ
136
Changing the Tail/Brake Light Bulb
137
Engine Note
139
Engine Removal
140
Cylinder Head and Cylinder Head Cover
141
Rocker Arms Vales and Camshaft
145
Cylinder and Piston
153
Engine Left Crankcase Cover and A.C. Magneto
157
Starter Motor and Water Pump
161
Right Crankcase Cover and Oil Filter
163
Primary and Secondary Sheaves
165
Crankcase and Oil Pump
169
Balance Shaft
171
Shift and Control Mechanism
176
Gearcase Transmission
178
Malfunction Inspection
182
Front Panel
184
Side Cover
186
Side Cover Parts
187
Cargo Bed
190
Head Shed Frame
191
Brake System
200
Front and Rear Disk Brake Parts
201
Footrest Part
216
Wheel and Tyre Parts
217
Rear Wheels
219
Shift Operating System
223
Suspension
227
Front Suspension
229
Rear Swing Arm
235
Cooling System
240
Seat
244
Fuel Tank
247
Chapter 6 Electrical System Malfunction Inspection
249
Electrical
250
Chapter 7
252
Checking the Switch
252
Checking the Switch Continuity
253
Checking the Bulbs and Bulb Sockets
254
Troubleshooting
255
Electric Starting System
258
Troubleshooting
259
Starter Motor
262
Lighting System
264
Troubleshooting
265
Checking the Lighting System
266
Signaling System
267
Troubleshooting
268
Checking the Signal System
269
Cooling System
274
CHAPTER 8 Troubleshooting
275
Ems (Engine Management System)
277
Layout of EMS Components
278
Electronic Control Unit
279
Multec 3.5 Injectors
280
Throttle Body Assembly(with Stepper Motor)
283
Engine Coolant Temperature Sensor
285
Intake Air Pressure and Temperature Sensor
286
Fuel Pump Module
290
EME Fault Diagnosis
296
Starting Failure/Hard Starting
298
Compression System
299
Poor Medium and High-Speed Performance
300
Overheating
301
Shock Absorber Malfunction
302
Bulb Burnt out
303
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