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Hisun HS500ATV User Manual

Hisun HS500ATV
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HS500ATV Maintenance Manual

Table of Contents

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Hisun HS500ATV Specifications

General IconGeneral
BrandHisun
ModelHS500ATV
CategoryOffroad Vehicle
LanguageEnglish

Summary

General Information

1 Description

Provides a general overview and description of the vehicle.

1.1 Identification Code

Details on identifying the vehicle's frame and engine numbers.

1.2 Special Tools, Instruments, and Meters

Lists and describes specialized tools for maintenance and measurement.

1.3 Periodic Maintenance Chart

Schedule for regular maintenance tasks based on time or usage.

Engine

2. Inspection and Adjustment of Engine

Procedures for inspecting and adjusting engine components.

2.1 Inspection of Cylinder Head, Intake, and Exhaust Valve

Check cylinder head, intake and exhaust valve for proper function and wear.

2.1.2 Spark Plug Checking

Inspect and check the spark plug's condition, gap, and sealing washer.

2.1.3 Cylinder, Piston, and Piston Ring Specifications

Details specifications for cylinder bore, piston diameter, and piston ring clearances.

2.1.4 Inspection of Crank and Connecting Rod

Check crank and connecting rod for rotation and clearance.

2.1.6 Inspection of Carburetor

Inspect the idle speed and acceleration of the carburetor.

2.1.11 Inspection of Cylinder Head

Inspect cylinder head for cracks, shape, and valve seat condition.

3. Disassembly of Engine

Step-by-step guide for disassembling the engine.

3.1 Cylinder Head and Block Disassembly

Steps for removing the cylinder head and block assembly.

3.1.2 Piston and Connecting Rod Disassembly

Procedures for removing the piston and connecting rod.

3.1.8 Clutch Disassembly

Steps for removing the clutch assembly.

3.2 Inspection and Adjusting Carburetor

Procedures for inspecting and adjusting the carburetor.

Chassis

4.1 Steering System

Information regarding the vehicle's steering system components and operation.

4.1.1 Disassembly, Inspection, and Assembly of Steering Vertical Column

Procedures for disassembling, inspecting, and assembling the steering vertical column.

4.1.2 Disassembly, Inspection, and Assembly of Steering Tube

Steps for disassembling, inspecting, and assembling the steering tube.

4.2 Brake System

Comprehensive details on the vehicle's brake systems.

4.2.1 Preparation for Inspection and Maintenance of the Front Brake System

Pre-maintenance checks for the front brake system.

4.2.2 Disassembly, Inspection, and Assembly of the Front Disk Brake System

Procedures for front disk brake system disassembly, inspection, and assembly.

4.2.3 Preparation for Inspection and Maintenance of the Rear Brake System

Pre-maintenance checks for the rear brake system.

4.2.4 Disassembly, Inspection, and Assembly of Rear Disk Brake System

Procedures for rear disk brake system disassembly, inspection, and assembly.

4.3 Wheel and Tyre

Information and procedures related to wheels and tires.

4.3.1 Preparation for Maintenance of Wheel

Initial checks and preparation for wheel maintenance.

4.3.2 Specification and Operation Guide of Wheel Hub and Tyre

Specifications and operational guidelines for wheel hubs and tires.

4.4 Transmission System

Details on the transmission system and its components.

4.5 Gear Shift Mechanism

Operation and maintenance of the gear shift mechanism.

4.5.1 Inspection and Maintenance of Gear Shift Mechanism

Inspection and maintenance procedures for the gear shift mechanism.

4.6 Suspension

Information on the suspension units.

Rear Suspension Unit

Details on the rear suspension unit.

Front Suspension Unit

Details on the front suspension unit.

4.5.1 Disassembly, Maintenance and Assembly of Upper and Lower Rocker Arm

Procedures for disassembling, maintaining, and assembling rocker arms.

Electrical System

5. Electrical System

Overview of the vehicle's electrical systems and components.

5.1 Ignition System

Explanation of the ignition system's operation and components.

5.2 Magneto and Charge System

Details on the magneto and charging system.

5.3 Battery

Information on battery maintenance and replacement.

5.4 Lighting System

Operation and wiring of the lighting system.

5.5 Meter and Signal System

Explanation of meters and signal systems.

5.6 Electrical Starting System

Working process and notes for the electrical starting system.

Appendix

6.1 Specification

Technical specifications and dimensions of the vehicle.

6.2 Requirements for Torque of Fastener

Specified torque values for various fasteners.

6.3 Electrical Circuits

Electrical circuit diagrams for the vehicle.

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