Name: Hisun Motors HS750UTV-2
Brand: Hisun Motors
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ENGINE

- 147 -

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.

Default Chapter2
- Table of Contents2
Chapter 1 General Information11
Description12
Identification Code13
- Frame no13
- Engine no13
Safety14
- Handling Gasoline Safely15
- Cleaning Parts15
- Warning Labels16
Serial Numbers16
Fasteners16
- Torque Specifications16
- Self-Locking Fasteners16
- Washers17
- Cotter Pins17
- Snap Rings and E-Clips17
Shop Sipplies18
- Lubricants and Fluids18
- Engine Oils18
- Greases19
- Brake Fluid19
- Coolant19
- Cleaners, Degreasers and Solvents19
- Gasket Sealant20
- Gasket Remover20
- Thread Locking Compound20
Basic Tools21
- Screwdrivers21
- Wrenches22
- Adjustable Wrenches22
- Socket Wrenches, Ratchets and Handles23
- Impact Drivers24
- Allen Wrenches24
- Torque Wrenches24
- Torque Adapters25
- Pliers26
- Snap Ring Pliers26
- Hammers27
- Ignition Grounding Tool27
Precision Measuring Tools27
- Feeler Gauge28
- Calipers28
- Micrometers29
- Adjustment30
- Care30
- Metric Micrometer30
- Standard Inch Micrometer31
- Telescoping and Small Bore Gauges32
- Dial Indicator32
- Compression Gauge33
- Multimeter33
- Clip-On Ammeter34
- Magneto Puller34
Electrical System Fundamentals34
- Voltage34
- Resistance34
- Amperage35
Basic Service Methods35
- Removing Frozen Fasteners36
- Removing Broken Fasteners37
- Repairing Damaged Threads37
- Stud Removal/Installation37
- Removing Hoses38
- Bearings38
- Removal39
- Installation39
- Interference Fit40
- Seal Replacement42
Storage42
- Storage Area Selection42
- Preparing the Motorcycle for Storage42
- Returning the UTV to Service43
Trovbleshooting43
Engine Principles and Operating Requirements44
Starting the Engine44
- Engine Is Cold45
- Engine Is Warm45
- Flooded Engine46
Engine will Not Start46
- Identifying the Problem46
- Spark Test47
- The Starter Cannot Work Repeatedly or Can Only Work Slowly48
Poor Engine Performance48
- The Engine Starts Slowly or Difficultly48
- Engine Backfires, Cuts out or Misfires During Acceleration49
- Engine Backfires on Deceleration49
- Poor Fuel Mileage50
- Engine will Not Idle or Idles Roughly50
- Low Engine Power50
- Poor Idle or Low Speed Performance51
- Poor High Speed Performance52
Fuel System52
- Rich Mixture52
- Lean Mixture53
Engine53
- Engine Smoke53
- Black Smoke53
- Blue Smoke53
- White Smoke or Steam53
- Low Engine Compression53
- High Engine Compression54
- Engine Overheating54
- The Ignition Advance Angle Is too Large55
- Detonation55
- Power Loss55
- Engine Noises55
Englne Lubrication56
High Oil Consumption or Excessive56
- Exhaust Smoke56
- Low Oil Pressure56
- High Oil Pressure56
- No Oil Pressure57
- Oil Level too Low57
- Oil Contamination57
Cylinder Leak down Test57
Electrical Testing60
- Preliminary Checks and Precautions60
- Intermittent Problems60
- Electrical Component Replacement61
- Test Equipment62
- Ammeter62
- Self-Powered Test Light62
  - Ohmmeter62
  - Jumper Wire63
Test Procedures64
- Voltage Test64
- Voltage Drop Test64
- Peak Voltage Test65
- Continuity Test65
- Testing for a Short with a Self-Powered Test Light or Ohmmeter65
- Testing for a Short with a Test Light or Voltmeter66
Brake System66
- Soft or Spongy Brake Lever or Pedal66
- Brake Drag67
- Hard Brake Lever or Pedal Operation68
- Brake Grabs68
- Brake Squeal or Chatter68
- Leaking Brake Caliper68
- Leaking Master Cylinder69
Chapter 2 Specifications70
How to Use Conversion Table of Unit70
- How to Use Conversion Table70
- Definition of Unit70
Geberar Specifications71
Engine Specifications74
Chassis Specifications80
Electrical Specifications82
Tightening Torques84
- Engine Tightening Torques84
- Chassis Tightening Torques87
General Tightening Torque Specifications89
Lubrication Pionts and Lubricant Types90
- Engine90
- Chassis91
Hydrographic Chart92
Lubrication Oil Way93
Chapter 3 Maintence and Adjustment of the Utv94
Maintenance Schedule94
Engine96
- Adjusting the Valve Clearance96
- Checking the Spark Plug99
- Checking the Ignition Timing99
- Measuring the Compression Pressure101
- Checking the Engine Oil Level102
- Changing the Engine Oil103
Chassis106
- Cleaning the Air Filter106
- Checking the Coolant Level107
- Changing the Coolant108
- Checking the Coolant Temperature Warning Light111
- Checking the V-Belt112
- Cleaning the Spark Arrester113
- Adjusting the Brake Pedal114
- Adjusting the Parking Brake114
- Checking the Brake Fluid Level115
- Checking the Front Brake Pads116
- Checking the Rear Brake Pads116
- Checking the Brake Hoses and Brake Pipes117
- Bleeding the Hydraulic Brake System117
- Adjusting the Select Lever Shift Rod118
- Checking the Final Gear Oil Level119
- Changing the Final Gear Oil120
- Checking the Differential Gear Oil120
- Changing the Differential Gear Oil121
- Checking the Constant Velocity Joint Dust Boots121
- Checking the Steering System122
- Adjusting the Toe-In123
- Adjusting the Front Shock Absorbers124
- Checking the Tires125
- Checking the Wheels126
Electrical128
- Checking and Charging the Battery128
- Checking the Fuses134
- Adjusting the Headlight Beam135
- Changing the Headlight Bulb136
- Changing the Tail/Brake Light Bulb137
Chapter 4138
Engine Note138
Engine Removal139
Cylinder Head and Cylinder Head Cover142
Rocker Arms and Camshaft147
Valves and Valve Springs152
Cylinder and Piston157
Engine Cooling Fan and A.C. Magneto161
Balancer Gears and Oil Pump Gears166
Primary and Secondary Sheaves169
Primary Sheave170
Secondary Sheave171
Clutch176
Clutch Housing177
Crankcase Starter Motorand Oil Filter180
Crankcase182
Crankcase Bearings183
Crankshaft and Oil Pump187
Oil Pump188
Transmission191
Drive Axle Assembly192
Middle Gear196
Middle Drive Shaft197
Chapter 5 Chassis203
Direction System206
- The Steering Wheel Parts (Epa Type)206
- The Steering Wheel Parts (E-Mark Type)209
Brake System219
- Disk Brake Components220
- Front and Rear Brake Discs222
- Front and Rear Brake Pads224
- Front and Rear Brake Caliper226
- Parking Brake Disc231
- Parking Brake Caliper and Brake Pads233
- Brake Master Cylinder241
Footrest Assembly244
Wheel and Tyre Parts247
- Front Wheels247
- Rear Wheels248
Transmission System251
- Front Axle251
- Front Bridge252
- Rear Axle262
- Rear Bridge263
- Reverse Mechanism Parts267
Suspension271
- Front Suspension and Arm271
- Rear Suspension277
- Rear Arm Shaft279
Cooling System283
- Radiator 1283
- Radiator 2285
- Water Pump289
Seat294
Oil System296
Fuel Tank296
Chapter 6 Electrical Components299
Electrical System Malfunction Inspection299
Electrical300
Electricalcomponents(Bucket Seat)300
- Checking the Switch302
- Checking the Switch Continuity(Bucket)303
- Checking the Bulbs and Bulb Sockets304
Ignition System305
Electric Starting System308
- Circuit Diagram（See348308
- Troubleshooting309
Starter Motor312
Charging System313
- Circuit Diagram313
- Troubleshooting314
Lighting System315
- Circuit Diagram（See348315
- Troubleshooting316
- Checking the Lighting System317
Signaling System318
- Circuit Diagram（See348318
- Troubleshooting319
- Checking the Signal System320
Cooling System326
- Circuit Diagram326
- Troubleshooting327
2Wd/4Wd Selecting System329
- CIRCUIT Diagram（See348329
Troubleshooting330
- Check if the 2/4WD Switch Is Working330
- Check if the Rear Differential Is Working330
Chapter 7 Engine Management System331
EMS (Engine Management System)331
Typical Components of Ems331
Layout of Ems Components332
Components of Ems332
- Electronic Control Unit332
- Multec 3.5 Injectors333
- Throttle Body Assembly(with Stepper Motor)337
- Engine Coolant Temperature Sensor339
- Intake Air Pressure and Temperature Sensor339
- Oxygen Sensor340
- Ignition Coil340
- Fuel Pump Module344
Ems Fault Diagnosis350
- EME Fault Diagnosis350
- Fault Code List350
Chapter 8 Troubleshooting352
Starting Failure/Hard Starting352
- Fuel System352
- Electrical System352
- Compression System353
Poor Idle Speed Performance353
Faulty Gear Shifting354
- Shift Lever Does Not Move354
- Jumps out of Gear354
Poor Medium and High-Speed Performance354
Engine Overheating355
- Overheating355
Faulty Brake355
- Poor Braking Effect355
Shock Absorber Malfunction356
Unstable Handling356
Lighting System356
- Head Light Is out of Work356
- Bulb Burnt out357
- Error Display of Meter357

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Hisun Motors HS750UTV-2 Specifications

General

Brand	Hisun Motors
Model	HS750UTV-2
Category	Utility Vehicle
Language	English

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