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Hisun
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HS400
Hisun HS400 Service Manual
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Engine
4-50
Drive Axle Assembl
y
No.
Part Name
Qty
Remarks
1
2
3
4
5
Disassembl
ing the drive axle
Driven gear , gea
r R
DR adapter sle
eve
Intermed
iate axle
Driven gear , gea
r D
Bush 26x42x14.
7
1
1
1
1
1
Remove the
parts in the order
listed.
For installat
ion, reverse the
order listed
.
142
144
Table of Contents
Default Chapter
3
Wiring Diagrams
3
Table of Contents
5
Chapter 1 General Information
9
Warnings, Cautions, Notes
9
Description
10
Identification Code, Frame
11
Safety
12
Handling Gasoline Safely
13
Serial Numbers, Fasteners
14
Self Locking Fasteners, Cotter
15
Torque Specifications
15
Snap Rings and E-Clips
16
Index
17
Shop Supplies
17
Basic Tools
19
Wrenches
20
Torque Wrenches
23
Ignition Grounding Tool
25
Precision Measuring Tools
26
Micrometers
27
Compression Gauge
32
Cylinder Bore Gauge
32
Electrical System
33
Electrical System Fundamentals
33
Basic Service Methods
34
Storage
42
Chapter 2 Specifications
44
Conversion Table
46
General Specs
47
Engine Specs
49
Electrical Specs
57
General Torque Specs
64
Maintenance Schedule
69
Maintenance and Adjustment
70
Idle Adjustment
72
Engine Oil
74
Air Filter
76
Coolant Level
77
V-Belt
81
Spark Arrester
82
Brake Pads
84
Brake Lines
85
Final Gear Oil
87
Steering System
89
Tires
90
Shock Absorbers
91
Engine Notes
96
Engine Removal
97
Cylinder Head and Cylinder Head
98
Valves and Valve Springs
106
Cylinder and Piston
111
Engine Cooling Fan and A.C
115
Primary Sheave
123
Secondary Sheave
124
Clutch
128
Clutch Housing Assembly
129
Crankcase, Starter Motor and Oil
132
Crankcase Bearings
135
Crankshaft and Oil Pump
138
Oil Pump
139
Transmission
142
Drive Axle Assembly
143
Middle Drive Shaft
146
Middle Driven Shaft
147
Intake Manifold Assembly
151
Chapter 5 Chassis
155
Front Bumper and Hood
155
Panels and Footrest Cover
156
Seat Support and Seat Cushion
157
Cargo Bed
159
Steering System
161
Brake System
167
Front Brake Discs
168
Rear Brake Caliper
172
Front Wheel
178
Rear Wheel
179
Front Bridge
182
Rear Bridge
190
Gearshift, Parking Brake
193
Pedal Assembly
198
Front Suspension
200
Front Arm
202
Rear Suspension
206
Cooling System
209
Water Pump
213
Seat
216
Roll-Over Protection System
217
Fuel Tank
219
Chapter 6 Electrical
222
Battery Basics
222
Ignition System
233
EMS Introduction, Components
263
Engine Management System
265
Layout
266
Multec 3.5 Injectors
267
Throttle Body Assembly
269
Engine Coolant Temperature
270
Fault Codes
274
Mechanical Problems Spark Test
276
Troubleshooting
278
Spark Test
279
Fuel System
280
Valve Adjustment
280
Engine Noises
282
Cylinder Leak down Test
283
Electrical Testing, Preliminary
285
Intermittent Problems
286
Ecu
287
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Hisun HS400 Specifications
General
Brand
Hisun
Model
HS400
Category
Offroad Vehicle
Language
English
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