Huansong UTV 700 2009

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HUANSONG

UTV 700

SERVICE MANUAL

2009

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
- General Specifications75
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
  - Changing the Headlight Bulb140
  - Changing the Tail/Brake Light Bulb141
Chapter 4 Engine142
Engine Note142
Engine Removal143
Cylinder Head and Cylinder Head Cover145
- Cylinder Head147
Rocker Arms and Camshaft151
Valves and Valve Springs157
Cylinder and Piston163
Engine Cooling Fan and A.C. Magneto167
Balancer Gears and Oil Pump Gears172
Primary and Secondary Sheaves175
- Primary Sheave176
- Secondary Sheave177
Clutch182
- Starter Motorand Oil Filter186
- Crankcase Bearings189
CRANKSHAFT and OIL PUMP Crankshaft and Oil Pump193
- Oil Pump194
TRANSMISSION Transmission197
Drive Axle Assembly197
MIDDLE GEAR Middle Drive Shaft203
Middle Driven Shaft204
Carburetor211
Chapter 5216
Malfunction Inspection216
- The Structure of Steering Wheel Part221
- Diassembling the Parts of the Steering Wheel222
The Structure of Steering Wheel Part222
Diassembling the Steering Column Parts224
Checking and Service the Steering Column Parts225
- Steering Drive Axle226
- Steering Machine Parts227
Brake System231
- Front Disk Brake Components232
- Front Brake Discs233
- Checking the Front Brake Disc234
- Front Brake Pads235
- Replacing the Front Brake Pads236
- Front Brake Caliper237
- Disassembling the Front Brake Calipers238
- Assembling the Front Brake Calipers240
- Installing the Front Brake Calipers241
- Rear Brake Disc242
- Checking the Rear Brake Disc243
- Rear Brake Caliper and Brake Pads244
- Replacing the Rear Brake Pads247
- Disassembling the Rear Brake Caliper248
- Assembling the Rear Brake Caliper249
- Installing the Rear Brake Caliper252
- Brake Master Cylinder253
- Checking the Master Cylinder254
- Installing the Brake Master Cylinder255
Footrest Assembly256
Wheel and Tyre Parts260
- Rear Wheels260
- Specification of Wheel and Tyre263
Transmission System264
- Front Bridge264
- Disassembling the Front Bridge269
- Checking the Joints270
- Checking the Differential Gear271
- Installing the Front Bridge Parts272
- Rear Bridge273
Reverse Mechanism Parts279
- Adjusting Reverse Mechanism Parts281
- Checking and Service of Reverse Mechanism282
Suspension283
- Front Suspension and Arm283
- Disassembling, Service and Assembly the Supporting Rocker Parts285
- Installing the Front Arms and Front Shock Absorber288
- Rear Suspension289
- Rear Arm Shaft290
- Checking and Service of Rear Suspension291
- Installing the Rear Arms and Rear Shock Absorber293
Cooling System294
- Radiator294
- Checking the Radiator297
- Installing the Radiator298
- Checking the Oil Cooler299
- Water Pump300
- Disassembling the Water Pump302
- Checking the Water Pump303
- Assembling the Water Pump304
Seat305
Fuel Tank307
- Checking the Fuel Pump Operation310
- Installing Oil Cooling System312
Chapter 6 Electricalcomponents313
Electrical System Malfunction Inspection313
Electrical314
- Electricalcomponents314
Checking the Switch316
- Checking the Switch Continuity317
Checking the Bulbs and Bulb Sockets318
Ignition System319
Troubleshooting319
Electric Starting System323
Circuit Diagram323
Troubleshooting324
Starter Motor324
- Checking the Starter Motor328
- Assembling the Starter Motor329
Charging System330
Circuit Diagram330
Troubleshooting331
Lighting System333
Circuit Diagram333
Troubleshooting334
Checking the Lighting System335
- If the Headlights Fail to Come on335
Signaling System337
Circuit Diagram337
Troubleshooting338
Checking the Signal System339
If the Brake Lights Fail to Come on339
If the Neutral Lights Fail to Come on340
If the Parking Brake Indicator Light Fails to Come on341
If the Reverse Indicator Light Fails to Come on342
If the Coolant Temperature Warning343
If the Differential Gear Lock Indicator Light Fails to Come on345
If the Four-Wheel Drive Indicator Light Fails to Come on347
Cooling System348
Circuit Diagram348
Troubleshooting349
2Wd/4Wd Selecting System352
Circuit Diagram352
Troubleshooting353
Chapter 7 Troubleshooting356
Starting Failure/Hard Starting356
- Fuel System356
- Electrical System356
- Compression System357
Poor Idle Speed Performance358
Poor Medium and High-Speed Performance358
Faulty Gear Shifting358
Shift Lever Does Not Move358
Jumps out of Gear359
Overheating359
Faulty Brake359
Poor Braking Effect359
Shock Absorber Malfunction360
Malfunction360
Unstable Handling360
Lighting System361
- Head Light Is out of Work361
- Bulb Burnt out361

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Huansong UTV 700 2009 Specifications

General

Brand	Huansong
Model	UTV 700 2009
Category	Utility Vehicle
Language	English

Huansong UTV 700 2009 - User Manual

Table of Contents

Huansong UTV 700 2009 Specifications