Hsun HS700UTV User Manual

FOREWORD
Brief introduction to maintenance handbook of HS700UTV
The handbook is edited by Chongqing Hsun Industries (Group) Ltd, and is supplied to
dealers and technicians as document of technique.
Mainly, the handbook gives methods to check, maintain and repair UTV, and supplies
some relevant technique and performance data. Some techniques and method inside may
be used to check, maintain and repair other models of UTV, although it is mainly for
HS700UTV.
Please read the handbook through and fully understand it; otherwise, any improper
repairing and amounting would bring you problems, and accident may occur in your use.
Proper use and maintenance can guarantee UTV being driven safely, reduce its
malfunction, and help the vehicle remain its best performance.
The standards, performances and specifications mentioned in interpretation are based
on the sample in design, and they are subject to changes according to the product’s
improvement without prior notice.
Brief introduction to maintenance handbook of HS700UTV
second version , June,2009
Published by Chongqing Hsun Industries (Group) Ltd
Chongqing Hsun Industries (Group) Ltd holds the copy right.
No publishing and reprinting without permission.

Hsun HS700UTV Specifications

General

Brand	Hsun
Model	HS700UTV
Category	Utility Vehicle
Language	English

Summary

FOREWORD

CHAPTER 1 GENERAL INFORMATION

DESCRIPTION AND MACHINE IDENTIFICATION

Details on identifying the vehicle's components and serial numbers.

SAFETY

Guidelines for safe operation and maintenance practices.

LUBRICANTS AND FLUIDS

Details on types, classifications, and uses of lubricants and fluids.

BASIC TOOLS

Overview of essential hand tools for maintenance and repair.

PRECISION MEASURING TOOLS

Tools used for accurate measurements of engine and chassis components.

BASIC SERVICE METHODS

General techniques and precautions for performing service procedures.

STORAGE

Procedures for preparing and storing the vehicle for extended non-use.

CHAPTER 2 SPECIFICATIONS

ENGINE SPECIFICATIONS

Detailed technical specifications for the engine.

CHASSIS SPECIFICATIONS

Detailed technical specifications for the chassis components.

ELECTRICAL SPECIFICATIONS

Technical specifications for the vehicle's electrical system.

TIGHTENING TORQUES

Torque values for various assembly points across the vehicle.

CHAPTER 3 MAINTENCE AND ADJUSTMENT OF THE UTV

MAINTENANCE SCHEDULE

Recommended maintenance intervals and tasks for the UTV.

ENGINE

Procedures for engine maintenance and adjustments.

ADJUSTING THE VALVE CLEARANCE

Steps to adjust the engine's valve clearance.

CHASSIS

Procedures for chassis maintenance and adjustments.

CLEANING THE AIR FILTER

Steps to clean the air filter element and case.

ADJUSTING THE BRAKE PEDAL

Procedure for adjusting the brake pedal free play.

BLEEDING THE HYDRAULIC BRAKE SYSTEM

Procedure to remove air from the hydraulic brake system.

CHECKING THE STEERING SYSTEM

Inspection of steering system components for play.

ELECTRICAL

Procedures for electrical system maintenance and checks.

CHECKING AND CHARGING THE BATTERY

Procedures for checking battery condition and charging.

CHECKING THE FUSES

How to check and replace fuses in the electrical system.

CHAPTER 4 ENGINE

ENGINE REMOVAL

Step-by-step procedure for removing the engine.

CYLINDER HEAD AND CYLINDER HEAD COVER

Procedures for servicing the cylinder head and cover.

VALVES AND VALVE SPRINGS

Service procedures for valves and valve springs.

CARBURETOR

Maintenance and adjustment procedures for the carburetor.

CHAPTER 5 CHASSIS

MALFUNCTION INSPECTION

Troubleshooting procedures for chassis malfunctions.

DIRECTION SYSTEM

Maintenance procedures for the steering system.

BRAKE SYSTEM

Information and procedures related to the brake system.

SUSPENSION

Information and adjustments for the suspension system.

COOLING SYSTEM

Maintenance procedures for the vehicle's cooling system.

CHAPTER 6 ELECTRICAL COMPONENTS

Electrical System Malfunction Inspection

Troubleshooting procedures for electrical system malfunctions.

ELECTRIC STARTING SYSTEM

Details and troubleshooting for the electric starting system.

LIGHTING SYSTEM

Information and troubleshooting for the lighting system.

SIGNALING SYSTEM

Information and troubleshooting for the signaling system.

CHAPTER 7 TROUBLESHOOTING

STARTING FAILURE/HARD STARTING

Troubleshooting procedures for engine starting failures.

POOR IDLE SPEED PERFORMANCE

Diagnosing and resolving poor engine idle performance.

OVERHEATING

Troubleshooting procedures for engine overheating.

FAULTY BRAKE

Diagnosing and resolving brake system faults.

UNSTABLE HANDLING

Diagnosing and resolving vehicle handling instability.