Hsun HS700UTV - Leaking Master Cylinder

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GENERAL INFORMATION

1-61

1. Damaged dust and piston seals.

2. Damaged cylinder bore.

3. Loose caliper body bolts.

4. Loose banjo bolt.

5. Damaged banjo bolt washers.

6. Damaged banjo bolt threads in caliper body.

Leaking Master Cylinder

1. Damaged piston secondary seal.

2. Damaged piston snap ring/ snap ring groove.

3. Worn or damaged master cylinder bore.

4. Loose banjo bolt washers.

5. Damaged banjo bolt washers.

6. Damaged banjo bolt threads in master cylinder body.

7. Loose or damaged reservoir cap.

Main Page

Default Chapter2
- Table of Contents2
Description and Machine Identification13
Chapter 1 General Information14
Identification Code14
- Frame no14
- Engine no14
Manual Organization15
Watnings ,Cautions and Notes15
Safety15
- Handing Gasoline Safely16
- Cleaning Parts17
- Warning Labels17
Serial Numbers18
Fasteners18
- Torque Specifications18
- Self-Locking Fasteners18
- Washers19
- Cotter Pins19
- Snap Rings and E-Clips19
Shop Supplies20
- Lubricants and Fluids20
- Engine Oils20
- Greases21
- Brake Fluid21
- Coolant21
- Cleaners Degreasers and Solvents22
- Gasket Sealant22
- Applying RTV Sealant22
- Gasket Remover22
- Thread Locking Compound22
Basic Tools23
- Screwdrivers23
- Wrenches24
- Adjustable Wrenches25
- Socket Wrenches, Ratchets and Handles25
- Impact Drivers26
- Allen Wrenches26
- Torque Wrenches26
- Torque Adapters27
- Pliers28
- Snap Ring Pliers28
- Hammers28
- Ignition Grounding Tool29
Precision Measuring Tools29
- Feeler Gauge30
- Calipers30
- Micrometers31
- Adjustment31
- Care32
- Metric Micrometer32
- Standard Inch Micrometer33
- Telescoping and Small Bore Gauges34
- Dial Indicator34
- Cylinder Bore Gauge34
- Compression Gauge35
- Multimeter35
- Ohmmeter(Analog)Calibration35
Electrical System Fundamentals35
- Voltage36
- Resistance36
Badic Service Methods36
- Removing Frozen Fasteners38
- Removing Broken Fasteners38
- Repairing Damaged Threads38
- Stud Removal/Installation39
- Removing Hoses39
- Bearings39
- Removal40
- Installation40
- Interference Fit41
- Seal Replacement43
Storage43
- Storage Area Selection43
- Preparing the Motorcycle for Storage43
Chapter Two 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)48
- Engine Is Hot48
- Starting the Engine after a Fall or after the Engine Stalls48
- Flooded Engine49
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 Acceleration52
- Engine Backfires on Deceleration52
- Poor Fuel Mileage53
- Engine will Not Idle or Idles Roughly53
- Low Engine Power53
- Poor Idle or Low Speed Performance55
- Poor High Speed Performance55
Fuel System55
- Rich Mixture56
- Lean Mixture56
Engine56
- Engine Smoke56
- Black Smoke56
- Blue Smoke57
- White Smoke or Steam57
- Low Engine Compression57
- High Engine Compression57
- Engine Overheating (Cooling System)58
- Engine Overheating (Engine)58
- Preignition58
- Detonation59
Englne Lubrication60
- High Oil Consumption or Excessive60
Cylinder Leakdown Test61
Electrical Testing64
- Preliminary Checks and Precautions64
- Intermittent Problems64
- Electrical Component Replacement65
- Test Equipment66
- Ammeter66
- Self-Powered Test Light66
- Ohmmeter67
- Jumper Wire67
- Test Procedures68
- Voltage Drop Test68
- Peak Voltage Test69
- Continuity Test69
- Testing for a Short with a Self-Powered Test Light or Ohmmeter69
- Testing for a Short with a Test Light or Voltmeter70
Brake System70
- Soft or Spongy Brake Lever or Pedal70
- Brake Drag71
- Hard Brake Lever or Pedal Operation72
- Brake Squeal or Chatter72
- Leaking Brake Caliper72
- Leaking Master Cylinder73
Chapter 2 Specifications74
How to Use Conversion Table of Unit74
- How to Use Conversion Table74
Engine Specifications78
Chassis Specifications85
Electrical Specifications87
Tightening Torques89
Engine Tightening Torques89
Chassis Tightening Torques92
General Tightening Torque Specifications94
Lubrication Pionts and Lubricant Types95
- Engine95
Hydrographic Chart96
Lubrication Oil Way97
Chapter 3 Maintence and Adjustment of the Utv98
Maintenance Schedule98
Engine100
- Adjusting the Valve Clearance100
- Idle Adjustment102
- Adjusting the Throttle Cable103
- Adjusting the Starter Cable104
- Checking the Spark Plug105
- Checking the Ignition Timing106
- Measuring the Compression Pressure107
- Checking the Engine Oil Level108
- Changing the Engine Oil109
- Cleaning the Air Filter112
- Checking the Coolant Level113
- Changing the Coolant113
- Checking the Coolant Temperature Warning Light116
- Checking the V-Belt117
- Cleaning the Spark Arrester118
- Adjusting the Brake Pedal119
- Adjusting the Parking Brake120
- Checking the Brake Fluid Level120
- Checking the Front Brake Pads121
- Checking the Rear Brake Pads121
- Checking the Brake Hoses and Brake Pipes122
- Bleeding the Hydraulic Brake System122
- Adjusting the Select Lever Shift Rod123
- Adjusting the Brake Light Switch124
- Checking the Final Gear Oil Level124
- Changing the Final Gear Oil125
- Checking the Differential Gear Oil125
- Changing the Differential Gear Oil126
- Checking the Constant Velocity Joint Dust Boots127
- Checking the Steering System127
- Adjusting the Toe-In128
- Adjusting the Front Shock Absorbers129
- Adjusting the Rear Shock Absorbers129
- Checking the Tires130
- Checking the Wheels131
- Checking and Lubricating the Cables132
Electrical133
- Checking and Charging the Battery133
- Checking the Fuses138
- Adjusting the Headlight Beam140
- Cylinder Head142

Hsun HS700UTV - Leaking Master Cylinder

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