Hisun HS700UTV-4 - Cylinder and Piston

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ENGINE

- 151 -

CYLINDER AND PISTON

No. Part Name Qty Remarks

Removing the cylinder and piston Remove the parts in the order listed.

Water pump outlet hose

Cylinder head

1 Coolant inlet joint 1

2 Cylinder/O-ring 1/1

3 Cylinder gasket 1

4 Dowel pin 2

5 Piston pin clip 2

6 Piston pin 1

7 Piston 1

8 Piston ring set 1

For installation, reverse the removal

procedure.

Main Page

Default Chapter2
- Table of Contents2
Chapter 1 General Information14
Watnings , Cautions and Notes14
Description15
Identification Code16
- Frame no16
- Engine no16
Safety17
- Handing Gasoline Safely18
- Cleaning Parts18
- Warning Labels19
Serial Numbers19
Fasteners19
- Torque Specifications19
- Self-Locking Fasteners19
- Washers20
- Cotter Pins20
- Snap Rings and E-Clips20
Shop Supplies21
- Lubricants and Fluids21
- Engine Oils21
- Greases22
- Brake Fluid22
- Coolant22
- Cleaners, Degreasers and Solvents22
- Gasket Sealant23
- Gasket Remover23
- Thread Locking Compound23
Basic Tools24
- Screwdrivers24
Precision Measuring Tools30
- Feeler Gauge31
- Calipers31
- Micrometers32
- Adjustment33
- Care33
- Metric Micrometer33
- Standard Inch Micrometer34
- Telescoping and Small Bore Gauges35
- Dial Indicator35
- Compression Gauge36
- Multimeter36
- Cliop-On Ammeter37
- Magneto Puller37
Electrical System Fundamentals37
- Voltage37
- Resistance37
- Amperage38
Basic Service Methods38
- Removing Frozen Fasteners39
- Removing Broken Fasteners40
- Repairing Damaged Threads40
- Stud Removal/Installation40
- Removing Hoses41
- Bearings41
- Removal42
- Installation42
- 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 Engine49
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
Fuel System55
- Rich Mixture55
- Lean Mixture56
Engine56
- Engine Smoke56
- Black Smoke56
- Blue Smoke56
- White Smoke or Steam56
- Low Engine Compression56
- High Engine Compression57
- Engine Overheating (Cooling System)57
- Engine Overheating (Engine)57
- The Ignition Advance Angle Is too Large58
  - Detonation58
  - Power Loss58
- Engine Noises58
Englne Lubrication59
High Oil Consumption or Excessive59
- Exhaust Smoke59
- Low Oil Pressure59
- High Oil Pressure59
- No Oil Pressure60
- Oil Level too Low60
- Oil Contamination60
Cylinder Leak down Test60
Electrical Testing63
- Preliminary Checks and Precautions63
- Intermittent Problems63
- Electrical Component Replacement64
- Test Equipment65
- Ammeter65
- Self-Powered Test Light65
- Ohmmeter65
- Jumper Wire66
Test Procedures67
- Voltage Test67
Brake System69
- Soft or Spongy Brake Lever or Pedal69
- Brake Drag70
- Hard Brake Lever or Pedal Operation71
- Brake Grabs71
- Brake Squeal or Chatter71
- Leaking Brake Caliper71
- Leaking Master Cylinder72
Chapter 2 Specifications73
How to Use Conversion Table of Unit73
- How to Use Conversion Table73
- Definition of Unit73
Geberar Specifications74
Engine Specifications77
Chassis Specifications83
Electrical Specifications85
Tightening Torques87
- Engine Tightening Torques87
- Chassis Tightening Torques90
General Tightening Torque Specifications92
Lubrication Pionts and Lubricant Types93
- Engine93
- Chassis94
Hydrographic Chart95
Lubrication Oil Way96
Maintenance Schedule97
CHAPTER 3 Adjusting the Valve Clearance99
- Checking the Spark Plug102
- Checking the Ignition Timing102
- Measuring the Compression Pressure104
- Checking the Engine Oil Level105
- Changing the Engine Oil106
Engine99
Chassis109
- Cleaning the Air Filter109
- Checking the Coolant Level110
- Changing the Coolant111
- Checking the Coolant Temperature Warning Light114
- Checking the V-Belt115
- Cleaning the Spark Arrester116
- Adjusting the Brake Pedal117
- Adjusting the Parking Brake118
- Checking the Brake Fluid Level118
- Checking the Front Brake Pads119
- Checking the Rear Brake Pads119
- Checking the Brake Hoses and Brake Pipes120
- Bleeding the Hydraulic Brake System121
- Adjusting the Select Lever Shift Rod122
- Adjusting the Brake Light Switch122
- Checking the Final Gear Oil Level123
- Changing the Final Gear Oil123
- Checking the Differential Gear Oil124
- Changing the Differential Gear Oil124
- Checking the Constant Velocity Joint Dust Boots125
- Checking the Steering System126
- Adjusting the Toe-In127
  - Adjusting the Front Shock Absorbers128
- Adjusting the Front and Rear Shock Absorbers(Option 1)128
- Adjusting the Front and Rear Shock Absorbers(Option 2)129
- Spring Preload130
- Rebound Damping Force130
- Compression Damping Force131
  - Checking the Tires131
  - Checking the Wheels133
  - Checking and Lubricating the Cables133
  - Checking and Charging the Battery134
  - Checking the Fuses140
  - Adjusting the Headlight Beam141
  - Changing the Headlight Bulb142
  - Changing the Tail/Brake Light Bulb143
Chapter 4 Engine144
Engine Note144
Engine Removal145
Cylinder Head and Cylinder Head Cover148
Rocker Arms and Camshaft153
Valves and Valve Springs159
Cylinder and Piston164
Engine Cooling Fan and A.C. Magneto168
Balancer Gears and Oil Pump Gears173
Primary and Secondary Sheaves176
- Primary Sheave177
- Secondary Sheave178
Clutch183
Clutch Housing184
Crankcase Starter Motorand Oil Filter187
Crankcase189
- Crankcase Bearings190
Crankshaft and Oil Pump194
- Oil Pump195
- Transmission198
- Drive Axle Assembly199
Middle Gear203
- Middle Drive Shaft204
Chapter 5210
Malfunction Inspection210
DIRECTION SYSTEM the Steering Wheel Parts(EPA Type)213
- The Steering Wheel Parts(E-Mark Type)216
Brake System226
- Disk Brake Components227
Footrest Assembly251
Wheel and Tyre Parts254
- Front Wheels254
- Rear Wheels255
Transmission System258
- Front Axle258
  - Front Bridge259
  - Rear Axle269
- Rear Bridge270
- Speed Reducer Component with Differential274
Reverse Mechanism Parts280
Suspension284
- Front Suspension and Arm284
- Rear Suspension290
- Rear Arm Shaft292
- Rear Suspension and Arm294
Cooling System296
- Radiator 1296
- Radiator 2298
  - Oil Cooler301
  - Water Pump302
Seat307
Oil System309
Fuel Tank309
Chapter 6 Electrical Components314
Electrical System Malfunction Inspection314
Electrical315
Electricalcomponents315
- Checking the Switch317
- Checking the Switch Continuity318
Checking the Bulbs and Bulb Sockets319
Ignition System319
- Circuit Diagram319
- Troubleshooting320
Electric Starting System323
- Circuit Diagram323
- Troubleshooting324
Starter Motor327
- Checking the Starter Motor328
- Assembling the Starter Motor329
Charging System329
- Circuit Diagram329
- Troubleshooting330
Lighting System331
- Circuit Diagram331
- Troubleshooting332
Checking the Lighting System333
Signaling System334
- Circuit Diagram334
- Troubleshooting335
- Checking the Signal System336
Cooling System345
- Circuit Diagram345
2Wd/4Wd Selecting System348
- Circuit Diagram348
Chapter 7 Engine Management System353
- Ems (Engine Management System)353
- Typical Components of EMS353
- Layout of EMS Components354
Components of Ems354
- Electronic Control Unit354
- Multec 3.5 Injectors355
- Throttle Body Assembly(with Stepper Motor)359
- Engine Coolant Temperature Sensor361
- Intake Air Pressure and Temperature Sensor361
- Oxygen Sensor362
- Ignition Coil362
- Fuel Pump Module366
Ems Fault Diagnosis372
- EME Fault Diagnosis372
- Fault Code List372
Chapter 8 Troubleshooting374
Starting Failure/Hard Starting374
- Fuel System374
- Electrical System374
- Compression System375
Poor Idle Speed Performance375
Poor Medium and High-Speed Performance376
Faulty Gear Shifting376
- Shift Lever Does Not Move376
- Jumps out of Gear376
Engine Overheating377
- Overheating377
Faulty Brake377
- Poor Braking Effect377
Shock Absorber Malfunction378
- Loss of Damping Function378
Unstable Handling378
Lighting System378
- Head Light Is out of Work378
- Bulb Burnt out379
- Error Display of Meter379

Hisun HS700UTV-4 - Cylinder and Piston

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