Hisun HS800UTV - CHASSIS MAINTENANCE

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SPECIFICATIONS

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Default Chapter2
- Table of Contents2
Chapter 1 General Information15
Watnings , Cautions and Notes15
Description16
Identification Code17
- Frame no17
- Engine no17
Safety18
- Handing Gasoline Safely18
- Cleaning Parts19
- Warning Labels19
Serial Numbers20
Fasteners20
- Torque Specifications20
- Self-Locking Fasteners20
- Washers20
- Cotter Pins21
- Snap Rings and E-Clips21
Shop Supplies22
- Lubricants and Fluids22
- Engine Oils22
- Greases22
- Brake Fluid23
- Coolant23
- Cleaners, Degreasers and Solvents23
- Gasket Sealant23
- Gasket Remover24
- Thread Locking Compound24
Basic Tools24
- Screwdrivers25
Precision Measuring Tools30
- Feeler Gauge31
- Calipers31
- Micrometers32
- Adjustment32
- Care33
- Metric Micrometer33
- Standard Inch Micrometer34
- Telescoping and Small Bore Gauges35
- Dial Indicator35
- Compression Gauge36
- Multimeter36
Electrical System Fundamentals36
- Voltage36
- Resistance37
- Amperage37
Basic Service Methods37
- Removing Frozen Fasteners38
- Removing Broken Fasteners39
- Repairing Damaged Threads39
- Stud Removal/Installation39
- Removing Hoses40
- Bearings40
- Removal40
- Installation41
- Interference Fit42
- Seal Replacement43
Storage44
- Storage Area Selection44
- Preparing the Motorcycle for Storage44
- Returning the UTV to Service44
Trovbleshooting45
Engine Principles and Operating Requirements46
Starting the Engine46
- Engine Is Cold46
- Engine Is Warm46
- Starting the Engine after a Fall or after the Engine Stalls47
- Flooded Engine47
- Engine Cold with Air Temperature47
- Engine Cold with Air Temperature above 35℃（95°F47
- Cold Engine with Air Temperature below 10℃(50°F)47
- Engine Is Hot48
- Starting the Engine after a Fall or after the Engine Stalls48
- Flooded Engine48
Engine will Not Start49
- Identifying the Problem49
- Spark Test50
- Starter Does Not Turn over or Turns over Slowly51
Poor Engine Performance51
- Engine Starts but Stalls and Is Hard to Restart51
- Engine Backfires, Cuts out or Misfires During Acceleration51
- Engine Backfires on Deceleration52
- Poor Fuel Mileage52
- Engine will Not Idle or Idles Roughly52
- Low Engine Power53
- Poor Idle or Low Speed Performance54
- Poor High Speed Performance54
Fuel System55
- Rich Mixture55
- Lean Mixture55
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
- Preignition57
- Detonation58
- Power Loss58
- Engine Noises58
Englne Lubrication59
High Oil Consumption or Excessive59
- Exhaust Smoke59
- Low Oil Pressure59
- High Oil Pressure59
- No Oil Pressure59
- Oil Level too Low60
- 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
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 Caliper71
- Leaking Master Cylinder71
Chapter 2 Specifications72
How to Use Conversion Table of Unit72
- How to Use Conversion Table72
- Definition of Unit72
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
Engine Gearbox Lubrication Oil Parth Circuit96
Chapter 3 Maintence and Adjustment of the Utv97
Maintenance Schedule97
Engine99
- Adjusting the Valve Clearance99
- Checking the Spark Plug102
- Checking the Ignition Timing103
- Measuring the Compression Pressure104
- Checking the Engine Oil Level105
- Changing the Engine Oil106
Chassis108
- Cleaning the Air Filter108
- Checking the Coolant Level109
- Changing the Coolant110
- Checking the Coolant Temperature Warning Light113
- Checking the V-Belt114
- Cleaning the Spark Arrester115
- Adjusting the Brake Pedal116
- Checking the Brake Fluid Level117
- Checking the Front Brake Pads118
- Checking the Rear Brake Pads118
- Checking the Brake Hoses and Brake Pipes119
- Bleeding the Hydraulic Brake System119
- Adjusting the Select Lever Shift Rod121
- Adjusting the Brake Light Switch121
- Checking the Final Gear Oil Level122
- Changing the Final Gear Oil122
- Checking the Differential Gear Oil123
- Changing the Differential Gear Oil123
- Checking the Constant Velocity Joint Dust Boots124
- Checking the Steering System125
- Adjusting the Toe-In126
- Adjusting the Front and Rearshock Absorbers127
- Checking the Tires128
- Checking the Wheels130
- Checking and Lubricating the Cables130
Electrical131
- Checking and Charging the Battery131
- Checking the Fuses137
- Adjusting the Headlight Beam139
- Changing the Headlight Bulb139
- Changing the Tail/Brake Light Bulb140
Chapter 4 Engine142
Engine Note142
Engine Removal143
Cylinder Head and Cylinder Head Cover145
Rocker Arms and Camshaft150
Valves and Valve Springs153
Cylinder and Piston158
Engine Left Crankcase Cover A.C. Magneto162
Starter Motor and Oil Filter166
Primary and Secondary Sheaves170
Crankcase Cover and Oil Pump174
Crankcase and Middle Driven Shaft178
Output Shaft184
Gearcase188
- Shift Lever and Oil Pump188
- Gearcase Transmission190
Chapter 5195
Malfunction Inspection195
DIRECTION SYSTEM the Structure of the Steering198
- The Structure of Steering Wheel Part202
- Diassembling the Parts of the Steering Wheel202
- Checking the Parts of the Steering Wheel202
- Diassembling the Steering Column Parts203
- Checking and Service the Steering Column Parts204
- Diassembling the Steering Drive Axle204
- Checking and Service the Steering Drive Axle205
- The Machine Parts206
- The Structure of the Steering206
Brake System207
- Preparation for Checking before the Maintenance of the Brake System207
- Disk Brake Components208
- Installing the Rear Brake Caliper226
  - Checking the Master Cylinder227
- Assembling the Brake Master Cylinder227
  - Installing the Brake Master Cylinder228
Footrest Assembly229
Wheel and Tyre Parts232
- Front Wheels232
- Rear Wheels233
- Checking the Wheel Tyre234
- Checking the Wheel Hub234
- Installing the Wheel Hub235
- Installing the Wheel Tyre235
  - Specification of Wheel and Tyre236
Transmission System237
- Front Bridge237
- Disassembling the Universal Joint243
- Checking the Joints244
- Assembling the Universal Joint245
  - Rear Bridge246
Reverse Mechanism Parts253
- Adjusting Reverse Mechanism Parts255
- Checking and Service of Reverse Mechanism256
Suspension257
- Front Suspension257
- Front Arm259
- Disassembling, Service and Assembly the Supporting Rocker Parts261
- Checking the Stabilizer262
- Checking the Steering Knuckles262
- Checking the Front Arms262
- Checking the Front Shock Absorber263
- Checking the Stabilizer269
- Checking the Steering Knuckles269
- Checking the Rear Arms269
- Checking the Rear Shock Absorber269
  - Installing the Rear Arms and Rear Shock Absorber270
Cooling System271
- Radiator271
- Checking the Radiator275
- Installing the Radiator276
- Oil Cooler277
Seat287
- Disassembling the Seat291
- Moving Seat Forward and Backward291
Fuel Tank292
Chapter 6 Electrical Components295
Electrical System Malfunction Inspection295
Electrical296
Electricalcomponents296
Checking the Switch298
- Checking the Switch Continuity299
Checking the Bulbs and Bulb Sockets300
Ignition System301
Circuit Diagram301
Troubleshooting302
Electric Starting System305
Circuit Diagram305
Troubleshooting306
Starter Motor309
- Checking the Starter Motor310
- Assembling the Starter Motor311
Charging System312
- Circuit Diagram312
Troubleshooting313
Lighting System315
Circuit Diagram315
Troubleshooting316
Checking the Lighting System317
- If the Headlights Fail to Come on317
- If the Taillights Fail to Come on318
Signaling System319
Circuit Diagram319
Troubleshooting320
Checking the Signal System321
- If the Brake Lights Fail to Come on321
- If the Neutral Lights Fail to Come on322
- If the Parking Brake Indicator Light Fails to Come on323
- If the Reverse Indicator Light Fails to Come on324
- If the Coolant Temperature Warning325
- If the Differential Gear Lock Indicator Light Fails to Come on327
- If the Four-Wheel Drive Indicator Light Fails to Come on329
Cooling System331
Circuit Diagram331
Troubleshooting332
2Wd/4Wd Selecting System335
Circuit Diagram335
Troubleshooting336
Chapter 7 Engine Management System337
- Ems (Engine Management System)337
- Typical Components of EMS337
- Layout of EMS Components338
Components of Ems338
- Electronic Control Unit338
- Multec 3.5 Injectors339
- Throttle Body Assembly(with Stepper Motor)343
- Engine Coolant Temperature Sensor345
- Intake Air Pressure and Temperature Sensor345
- Oxygen Sensor346
- Ignition Coil346
- Fuel Pump Module350
Ems Fault Diagnosis356
- EME Fault Diagnosis356
- Fault Code List356
Chapter 8 Troubleshooting358
Starting Failure/Hard Starting358
- Fuel System358
- Electrical System358
- Compression System359
Poor Idle Speed Performance359
- Unstable Handling359
Poor Medium and High-Speed Performance360
Faulty Gear Shifting360
- Shift Lever Does Not Move360
- Jumps out of Gear360
Overheating360
Shock Absorber Malfunction361
- Malfunction361
Unstable Handling361
Faulty Brake361
- Poor Braking Effect361
Lighting System362
- Head Light Is out of Work362
- Bulb Burnt out362

Hisun HS800UTV - CHASSIS MAINTENANCE

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