Hisun HS200UTV - Page 312

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HISUN MOTORS

310 East University Dr

McKinney, Texas 75069

PH (972) 446-0760

TF (877) 838-6188

hisunmotors.com

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Default Chapter4
- Table of Contents4
Cautions and Notes16
Chapter 1 General Information16
Description17
Identification Code18
- Frame no18
- Engine no18
Safety19
- Handing Gasoline Safely19
- Cleaning Parts20
- Warning Labels20
Serial Numbers21
Fasteners21
- Torque Specifications21
- Self-Locking Fasteners21
- Washers21
- Cotter Pins22
- Snap Rings and E-Clips22
Shop Supplies23
- Lubricants and Fluids23
- Engine Oils23
- Greases23
- Brake Fluid24
- Coolant24
- Cleaners, Degreasers and Solvents24
- Gasket Sealant24
- Gasket Remover25
- Thread Locking Compound25
Basic Tools25
- Screwdrivers26
Precision Measuring Tools31
- Feeler Gauge31
- Calipers32
- Micrometers32
- Adjustment33
- Care34
- Metric Micrometer34
- Standard Inch Micrometer35
- Telescoping and Small Bore Gauges36
- Dial Indicator36
- Compression Gauge37
- Multimeter37
- Cltp-On Ammeter37
- Magneto Puller38
Electrical System Fundamentals38
- Voltage38
- Resistance38
- Amperage38
Basic Service Methods39
- Removing Frozen Fasteners40
- Removing Broken Fasteners40
- Repairing Damaged Threads41
- Stud Removal/Installation41
- Removing Hoses41
- Bearings42
- Removal42
- Installation43
- Interference Fit43
- Seal Replacement45
Storage45
- Storage Area Selection45
- Preparing the Motorcycle for Storage45
- Returning the UTV to Service46
Trovbleshooting46
Engine Principles and Operating Requirements47
Starting the Engine47
- Engine Is Cold48
- Engine Is Warm48
  - Flooded Engine48
Engine will Not Start49
- Identifying the Problem49
- Spark Test50
- The Starter Cannot Work Repeatedly or Can Only Work Slowly51
Poor Engine Performance51
- The Engine Starts Slowly or Difficultly51
- Engine Backfires, Cuts out or Misfires During Acceleration51
- The Engine Is Not Idling or Cannot Idle Stably52
- Poor Fuel Mileage52
- Engine will Not Idle or Idles Roughly52
- Low Engine Power53
- Poor Idle or Low Speed Performance54
- Poor High Speed Performance54
Fuel System54
- Rich Mixture55
- Lean Mixture55
Engine55
- Engine Smoke55
- Engine Noises58
Englne Lubrication59
High Oil Consumption or Excessive59
- Exhaust Smoke59
- Low Oil Pressure59
- High Oil Pressure59
- No Oil Pressure59
- Oil Level too Low59
- Oil Contamination60
Cylinder Leak down Test60
Electrical Testing62
- Preliminary Checks and Precautions62
- Intermittent Problems63
- Electrical Component Replacement64
- Test Equipment64
- Ammeter64
- Self-Powered Test Light64
- Ohmmeter65
- Jumper Wire65
Test Procedures66
- Voltage Test66
- Testing for a Short with a Self-Powered Test Light or Ohmmeter67
- Testing for a Short with a Test Light or Voltmeter68
- Brake System68
- Soft or Spongy Brake Lever or Pedal68
- Brake Drag69
- Hard Brake Lever or Pedal Operation70
- Brake Grabs70
- Brake Squeal or Chatter70
- Leaking Brake Caliper70
- Leaking Master Cylinder71
How to Use Conversion Table of Unit72
- How to Use Conversion Table72
- Definition of Unit72
Specifications72
Geberar Specifications73
Engine Specifications76
Chassis Specifications82
Electrical Specifications84
Tightening Torques86
- Engine Tightening Torques86
- Chassis Tightening Torques89
General Tightening Torque Specifications91
Lubrication Pionts and Lubricant Types92
- Engine92
- Chassis93
Hydrographic Chart94
Lubrication Oil Way95
Maintenance Schedule96
- Engine97
Chapter 398
- Adjusting the Valve Clearance98
- Checking the Spark Plug101
- Checking the Ignition Timing102
- Measuring the Compression Pressure103
- Checking the Engine Oil Level104
- Changing the Engine Oil105
- Cleaning the Air Filter107
- Checking the Coolant Level108
- Changing the Coolant109
- Checking the Coolant Temperature Warning Light112
- Checking the V-Belt113
- Cleaning the Spark Arrester114
- Adjusting the Brake Pedal115
- Checking the Brake Fluid Level116
- Checking the Front Brake Pads117
- Checking the Brake Hoses and Brake Pipes118
Chapter 5120
- Adjusting the Select Lever Shift Rod120
- Checking the Steering System121
- Adjusting the Toe-In122
- Adjusting the Front and Rear Shock Absorbers123
- Checking the Tires124
- Checking the Wheels126
- Checking and Charging the Battery127
- Checking the Fuses133
Engine Note139
Engine Removal140
Cylinder Head and Cylinder Head Cover141
Rocker Arms Vales and Camshaft145
Cylinder and Piston153
Engine Left Crankcase Cover and A.C. Magneto157
Starter Motor and Water Pump161
Right Crankcase Cover and Oil Filter163
Primary and Secondary Sheaves165
Crankcase and Oil Pump169
Balance Shaft171
Shift and Control Mechanism176
Gearcase Transmission178
Malfunction Inspection182
- Front Panel184
Side Cover186
- Side Cover Parts187
- Cargo Bed190
- Head Shed Frame191
Brake System200
- Front and Rear Disk Brake Parts201
Footrest Part216
Wheel and Tyre Parts217
- Rear Wheels219
Shift Operating System223
Suspension227
- Front Suspension229
- Rear Swing Arm235
- Cooling System240
Seat244
Fuel Tank247
Chapter 6 Electrical System Malfunction Inspection249
- Electrical250
Chapter 7252
- Checking the Switch252
- Checking the Switch Continuity253
- Checking the Bulbs and Bulb Sockets254
- Troubleshooting255
Electric Starting System258
- Troubleshooting259
Starter Motor262
Lighting System264
- Troubleshooting265
- Checking the Lighting System266
Signaling System267
- Troubleshooting268
- Checking the Signal System269
Cooling System274
CHAPTER 8 Troubleshooting275
- Ems (Engine Management System)277
- Layout of EMS Components278
- Electronic Control Unit279
- Multec 3.5 Injectors280
- Throttle Body Assembly(with Stepper Motor)283
- Engine Coolant Temperature Sensor285
- Intake Air Pressure and Temperature Sensor286
- Fuel Pump Module290
- EME Fault Diagnosis296
Starting Failure/Hard Starting298
- Compression System299
Poor Medium and High-Speed Performance300
- Overheating301
Shock Absorber Malfunction302
- Bulb Burnt out303

Hisun HS200UTV - Page 312

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