Hisun HS500UTV Service Manual

390 pages

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Contents3
General Information17
Description17
Identification Code18
Safety19
Handling Gasoline Safety20
Cleaning Parts20
Warning Labels21
Serial Numbers, Fasteners21
Trorque Specifications21
Washers22
Cotter Pins22
Snap Rings and E-Clips22
Shop Supplies23
Lubricants and Fluids23
Engine Oils23
Greases24
Brake Fluid24
Coolant24
Cleaners, Degreasers and Solvents24
Gasket Sealant25
Gasket Remover25
Thread Locking Compound25
Basic Tools26
Screwdrivers26
Wrenches, Adjustable Wrenches27
Socket Wrenches, Ratchets and Handles28
Impact Drivers29
Allen Wrenches29
Torque Wrenches29
Torque Adapters30
Pliers, Snap Ring Pliers31
Precision Measuring Tools32
Hammers32
Ignition Grounding Tool32
Feeler Gauge33
Calipers33
Micrometers34
Micrometers Adjustment, Care35
Metric Micrometer35
Standard Inch Micrometer36
Telescoping and Small Bore Gauges37
Dial Indicator37
Compression Gauge38
Multimeter38
Electrical System Fundamentals39
Voltage39
Resistance39
Amperage39
Basic Service Methods40
Removing Frozen Fasteners41
Removing Broken Fasteners41
Repairing Damaged Threads42
Stud Removal/Installation42
Removing Hoses42
Bearings Removal43
Bearings Installation44
Interface Fit44
Seal Replacement46
Storage Area Selection46
Preparing the Motorcycle for Storage47
Returning the UTV to Service47
Troubleshooting48
Engine Principles and Operating Requirements48
Starting the Engine49
Engine Is Cold/War49
Starting the Engine after a Fall or after the Engine Stalls49
Flooded Engine49
Engine Cold with Air Temperature between 10-35C/Above 35C/Below 10C50
Engine Is Hot51
Engine will Not Start52
Spark Test53
Poor Engine Performance54
Starter Does Not Turn over or Turns over Slowly54
Engine Starts but Stalls and Is Hard to Restart54
Engine Backfires, Cuts out or Misfires During Acceleration55
Engine Backfires on Deceleration55
Poor Fuel Mileage55
Engine will Not Idle or Idles Roughly56
Low Engine Power56
Poor Idle or Low Speed Performance57
Fuel System58
Rich Mixture58
Poor High Speed Performance58
Engine Smoke59
Lean Mixture59
Engine Overheating (Cooling System)60
Low/High Engine Compression60
Engine Overheating (Engine)61
Preignition, Detonation61
Power Loss61
Engine Noises61
Engine Lubrication62
High Oil Consumption or Excessive62
Cylinder Leak down Test63
High Oil Pressure, no Oil Pressure63
Oil Level too Low63
Oil Contamination63
Electrical Testing66
Preliminary Checks and Precautions66
Intermittent Problems67
Electrical Component Replacement68
Test Equipment68
Ammeter68
Self-Powered Test Light68
Ohmmeter69
Jumper Wire69
Test Procedures70
Voltage Test, Voltage Drop Test70
Peak Voltage Test71
Continuity Test71
Testing for a Short with a Self-Powered Test Light of Ohmmeter71
Brake System72
Testing for a Short with a Test Light or Voltmeter72
Soft or Sponge Brake Lever or Pedal72
Brake Drag73
Hard Brake Lever or Pedal Operation74
Brake Grabs74
Brake Squeal or Chatter74
Leaking Brake Caliper75
Specifications76
How to Conversion Table of Unit76
Definition of Unit76
Geberar Specifications77
Engine Specifications80
Chassis Specifications86
Electrical Specifications88
Engine Tightening Torques90
Chassis Tightening Torques93
General Tightening Torque Specifications96
Lubrication Points and Lubricant Types: Engine97
Hydrographic Chart98
Lubrication Oil Way99
Maintenance and Adjustment of the UTV100
Maintenance Schedule100
Engine102
Idle Adjustment105
Adjusting the Throttle Cable105
Adjusting the Starter Cable106
Checking the Spark Plug107
Checking the Ignition Timing108
Measuring the Compression Pressure109
Checking the Engine Oil Level111
Changing the Engine Oil112
Chassis115
Cleaning the Air Filter115
Checking the Coolant Level116
Changing the Coolant117
Checking the Coolant Temperature120
Warning Light120
Coolant Temperature Warning Light Checking Method121
Checking the V-Belt121
Cleaning the Spark Arrester122
Adjusting the Brake Pedal123
Adjusting the Parking Brake124
Checking the Brake Fluid Level125
Checking the Front Brake Pads125
Checking the Rear Brake Pads126
Checking the Brake Hoses and Brake Pipes126
Bleeding the Hydraulic Brake System127
Adjusting the Select Lever Shift Rod129
Adjusting the Brake Light Switch129
Checking the Final Gear Oil Level130
Changing the Final Gear Oil130
Checking/Changing the Differential Gear Oil131
Checking the Constant Velocity Joint Dust Boots132
Checking the Steering System133
Adjusting the Toe-In134
Adjusting the Front/Rear Shock Absorbers135
Checking the Tires136
Checking the Wheels138
Checking and Lubricating the Cables138
Checking and Charging the Battery139
Charging Method Using a Constant Voltage Charger143
Checking the Fuses144
Adjusting the Headlight Beam145
Changing the Headlight Bulb146
Changing the Tail/Brake Light Bulb147
Engine Note148
Engine Removal149
Cylinder Head and Cylinder Head Cover151
Engine Check153
Rocker Arms and Camshaft156
Checking the Rocker Arms158
Installing the Rocker Arms159
Valves and Valve Springs162
Valves and Valve Springs Check, Measure163
Valves and Valve Springs Install166
Cylinder and Piston168
Cylinder and Piston Check, Measure169
Cylinder and Piston - Install171
Engine Cooling Fan and A.C. Magneto172
Engine Cooling Fan and A.C. Magneto Check174
Engine Cooling Fan and A.C. Magneto Install175
Balancer Gears and Oil Pump Gears177
Balancer Gears and Oil Pump Check178
Balancer Gears and Oil Pump Install178
Primary and Secondary Sheaves180
Primary Sheave181
Secondary Sheave182
Primary/Secondary Sheave Check183
Primary/Secondary Sheave Measure, Install184
Clutch187
Clutch Check, Measure189
Clutch Install190
Crankcase191
Starter Motor and Oil Filter191
Crankcase Overview193
Crankcase Bearings194
Crankcase Check195
Crankcase Install196
Crankshaft and Oil Pump198
Oil Pump199
Crankshaft and Oil Pump Check, Measure200
Crankshaft Install201
Transmission202
Drive Axle Assembly203
Drive Axle Check204
Drive Axle Install206
Middle Gear207
Middle Drive Shaft207
Middle Driven Shaft208
Middle Drive Shaft Check, Measure210
Middle Drive Shaft Install211
Carburetor214
Carburetor Check216
Carburetor Measure217
Carburetor Install218
Malfunction Inspection219
Direction System222
The Structure of the Steering222
The Structure of Steering Wheel Part224
Disassembling the Parts of the Steering Wheel225
Checking the Parts of the Steering Wheel225
Disassembling the Steering Column Parts226
Checking and Service the Steering Column Parts227
Steering Drive Axle228
Checking and Service the Steering Drive Axle228
Steering Machine Parts229
Disassembling the Steering Machine Part229
Reinstalls the Steering System Parts230
Preparation for Checking before the Maintenance of the Brake System232
Front Disk Brake Components233
Front Brake Discs234
Checking the Front Brake Disc235
Front Brake Pads236
Replacing the Front Brake Pads237
Front Brake Caliper238
Disassembling the Front Brake Calipers240
Assembling/Installing the Front Brake Calipers241
Rear Brake Disc243
Checking the Rear Brake Disc244
Rear Brake Caliper and Brake Pads245
Replacing the Rear Brake Pads248
Disassembling the Rear Brake Caliper248
Assembling the Rear Brake Caliper249
Installing the Rear Brake Caliper251
Brake Master Cylinder253
Checking the Master Cylinder254
Assembling/Installing the Brake Master Cylinder254
Footrest Assembly256
Wheel and Tyre Parts259
Front Wheels259
Rear Wheels260
Checking the Wheel Tyre261
Checking/Installing the Wheel Hub261
Installing the Wheel Tyre262
Specification of Wheel and Tyre262
Transmission System263
Front Bridge263
Disassembling the Front Bridge268
Disassembling the Universal Joint268
Removing the Differential Gear Assembly268
Checking the Joints269
Checking the Differential Gear269
Checking the Gear Motor270
Assembling the Universal Joint271
Adjusting the Differential Gear Lash271
Assembling the Differential Gear272
Installing the Front Bridge Parts273
Rear Bridge274
Reverse Mechanism Parts280
Adjusting Reverse Mechanism Parts282
Checking and Service of Reverse Mechanism282
Suspension284
Front Suspension and Arm284
Disassembling, Service and Assembly the Supporting Rocker Parts286
Checking the Front Arms287
Checking the Front Shock Absorber287
Installing the Front Arms and Front Shock Absorber288
Rear Suspension289
Rear Arm Shaft290
Rear Suspension and Arm291
Checking and Service of Rear Suspension291
Checking the Stabilizer291
Checking the Rear Arms291
Checking the Rear Shock Absorber292
Installing the Rear Arms and Rear Shock Absorber292
Cooling System293
Radiator293
Checking/Installing the Radiator296
Checking the Oil Cooler297
Water Pump298
Disassembling the Water Pump300
Checking the Water Pump300
Assembling the Water Pump301
Seat303
Oil System305
Fuel Tank305
Checking the Fuel Pump Operation308
Disassembling Oil Cooling System308
Checking and Service the Oil Cooling System308
Installing Oil Cooling System309
Electrical System Malfunction Inspection310
Electrical Components311
Checking the Switch313
Checking the Switch Continuity314
Checking the Bulbs and Bulb Sockets315
Ignition System316
Circuit Diagram316
Electrical Components Troubleshooting317
Electric Starting System: Circuit Diagram321
Electric Starting System: Troubleshooting322
Starter Motor325
Checking the Starter Motor326
Assembling the Starter Motor327
Charging System: Circuit Diagram328
Charging System: Troubleshooting329
Lighting System: Circuit Diagram331
Lighting System Troubleshooting332
Checking the Lighting System333
Signaling System: Circuit Diagram335
Signaling System: Troubleshooting336
Checking the Signal System337
Cooling System: Circuit Diagram347
Cooling System Troubleshooting348
2WD/4WD Selecting System: Circuit Diagram351
2WD/4WD Selecting System: Troubleshooting352
Troubleshooting the Product356
Starting Failure/Hard Starting356
Poor Idle Speed Performance358
Poor Medium and High Speed Performance358
Faulty Gear Shifting358
Overheating359
Faulty Brake360
Shock Absorber Malfunction360
Unstable Handling360
HS600UTV Specifications363
HS500UTV Specifications366
HS500UTV Engine Removal372
HS500UTV: Cylinder Head and Cylinder Head Cover374
HS500UTV Rocker Arms and Camshaft377
HS500UTV Valves and Valve Springs381
HS500UTV Cylinder and Piston386
HS700UTV/HS600UTV/HS500UTV Wiring Diagram390

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Owner's Manual173 pages

Questions and Answers:

T
taylorsamuelJul 29, 2025
How to fix cracked covers on Hisun Utility Vehicle?
- S
  Sandra ShannonJul 29, 2025
  If the covers of your Hisun Utility Vehicle are cracked, you can have the cover repaired at an authorized service center, change them for new plastic covers, or replace the stickers and re-rivet the warning labels.