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HS750UTV-2
Hisun Motors HS750UTV-2 User Manual
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CHASSIS
- 212-
FRONT AND REAR BRAKE DISCS
No. Part
Name
Qty
Remarks
Removing the
brake discs
1
Brake caliper assembly
1
2 Brake
disc
1
3 Bolt
4
4 Turn
join
4
5 Bolt
4
6
Brake disc guard
1
221
223
Table of Contents
Default Chapter
2
Table of Contents
2
Chapter 1 General Information
11
Description
12
Identification Code
13
Frame no
13
Engine no
13
Safety
14
Handling Gasoline Safely
15
Cleaning Parts
15
Warning Labels
16
Serial Numbers
16
Fasteners
16
Torque Specifications
16
Self-Locking Fasteners
16
Washers
17
Cotter Pins
17
Snap Rings and E-Clips
17
Shop Sipplies
18
Lubricants and Fluids
18
Engine Oils
18
Greases
19
Brake Fluid
19
Coolant
19
Cleaners, Degreasers and Solvents
19
Gasket Sealant
20
Gasket Remover
20
Thread Locking Compound
20
Basic Tools
21
Screwdrivers
21
Wrenches
22
Adjustable Wrenches
22
Socket Wrenches, Ratchets and Handles
23
Impact Drivers
24
Allen Wrenches
24
Torque Wrenches
24
Torque Adapters
25
Pliers
26
Snap Ring Pliers
26
Hammers
27
Ignition Grounding Tool
27
Precision Measuring Tools
27
Feeler Gauge
28
Calipers
28
Micrometers
29
Adjustment
30
Care
30
Metric Micrometer
30
Standard Inch Micrometer
31
Telescoping and Small Bore Gauges
32
Dial Indicator
32
Compression Gauge
33
Multimeter
33
Clip-On Ammeter
34
Magneto Puller
34
Electrical System Fundamentals
34
Voltage
34
Resistance
34
Amperage
35
Basic Service Methods
35
Removing Frozen Fasteners
36
Removing Broken Fasteners
37
Repairing Damaged Threads
37
Stud Removal/Installation
37
Removing Hoses
38
Bearings
38
Removal
39
Installation
39
Interference Fit
40
Seal Replacement
42
Storage
42
Storage Area Selection
42
Preparing the Motorcycle for Storage
42
Returning the UTV to Service
43
Trovbleshooting
43
Engine Principles and Operating Requirements
44
Starting the Engine
44
Engine Is Cold
45
Engine Is Warm
45
Flooded Engine
46
Engine will Not Start
46
Identifying the Problem
46
Spark Test
47
The Starter Cannot Work Repeatedly or Can Only Work Slowly
48
Poor Engine Performance
48
The Engine Starts Slowly or Difficultly
48
Engine Backfires, Cuts out or Misfires During Acceleration
49
Engine Backfires on Deceleration
49
Poor Fuel Mileage
50
Engine will Not Idle or Idles Roughly
50
Low Engine Power
50
Poor Idle or Low Speed Performance
51
Poor High Speed Performance
52
Fuel System
52
Rich Mixture
52
Lean Mixture
53
Engine
53
Engine Smoke
53
Black Smoke
53
Blue Smoke
53
White Smoke or Steam
53
Low Engine Compression
53
High Engine Compression
54
Engine Overheating
54
The Ignition Advance Angle Is too Large
55
Detonation
55
Power Loss
55
Engine Noises
55
Englne Lubrication
56
High Oil Consumption or Excessive
56
Exhaust Smoke
56
Low Oil Pressure
56
High Oil Pressure
56
No Oil Pressure
57
Oil Level too Low
57
Oil Contamination
57
Cylinder Leak down Test
57
Electrical Testing
60
Preliminary Checks and Precautions
60
Intermittent Problems
60
Electrical Component Replacement
61
Test Equipment
62
Ammeter
62
Self-Powered Test Light
62
Ohmmeter
62
Jumper Wire
63
Test Procedures
64
Voltage Test
64
Voltage Drop Test
64
Peak Voltage Test
65
Continuity Test
65
Testing for a Short with a Self-Powered Test Light or Ohmmeter
65
Testing for a Short with a Test Light or Voltmeter
66
Brake System
66
Soft or Spongy Brake Lever or Pedal
66
Brake Drag
67
Hard Brake Lever or Pedal Operation
68
Brake Grabs
68
Brake Squeal or Chatter
68
Leaking Brake Caliper
68
Leaking Master Cylinder
69
Chapter 2 Specifications
70
How to Use Conversion Table of Unit
70
How to Use Conversion Table
70
Definition of Unit
70
Geberar Specifications
71
Engine Specifications
74
Chassis Specifications
80
Electrical Specifications
82
Tightening Torques
84
Engine Tightening Torques
84
Chassis Tightening Torques
87
General Tightening Torque Specifications
89
Lubrication Pionts and Lubricant Types
90
Engine
90
Chassis
91
Hydrographic Chart
92
Lubrication Oil Way
93
Chapter 3 Maintence and Adjustment of the Utv
94
Maintenance Schedule
94
Engine
96
Adjusting the Valve Clearance
96
Checking the Spark Plug
99
Checking the Ignition Timing
99
Measuring the Compression Pressure
101
Checking the Engine Oil Level
102
Changing the Engine Oil
103
Chassis
106
Cleaning the Air Filter
106
Checking the Coolant Level
107
Changing the Coolant
108
Checking the Coolant Temperature Warning Light
111
Checking the V-Belt
112
Cleaning the Spark Arrester
113
Adjusting the Brake Pedal
114
Adjusting the Parking Brake
114
Checking the Brake Fluid Level
115
Checking the Front Brake Pads
116
Checking the Rear Brake Pads
116
Checking the Brake Hoses and Brake Pipes
117
Bleeding the Hydraulic Brake System
117
Adjusting the Select Lever Shift Rod
118
Checking the Final Gear Oil Level
119
Changing the Final Gear Oil
120
Checking the Differential Gear Oil
120
Changing the Differential Gear Oil
121
Checking the Constant Velocity Joint Dust Boots
121
Checking the Steering System
122
Adjusting the Toe-In
123
Adjusting the Front Shock Absorbers
124
Checking the Tires
125
Checking the Wheels
126
Electrical
128
Checking and Charging the Battery
128
Checking the Fuses
134
Adjusting the Headlight Beam
135
Changing the Headlight Bulb
136
Changing the Tail/Brake Light Bulb
137
Chapter 4
138
Engine Note
138
Engine Removal
139
Cylinder Head and Cylinder Head Cover
142
Rocker Arms and Camshaft
147
Valves and Valve Springs
152
Cylinder and Piston
157
Engine Cooling Fan and A.C. Magneto
161
Balancer Gears and Oil Pump Gears
166
Primary and Secondary Sheaves
169
Primary Sheave
170
Secondary Sheave
171
Clutch
176
Clutch Housing
177
Crankcase Starter Motorand Oil Filter
180
Crankcase
182
Crankcase Bearings
183
Crankshaft and Oil Pump
187
Oil Pump
188
Transmission
191
Drive Axle Assembly
192
Middle Gear
196
Middle Drive Shaft
197
Chapter 5 Chassis
203
Direction System
206
The Steering Wheel Parts (Epa Type)
206
The Steering Wheel Parts (E-Mark Type)
209
Brake System
219
Disk Brake Components
220
Front and Rear Brake Discs
222
Front and Rear Brake Pads
224
Front and Rear Brake Caliper
226
Parking Brake Disc
231
Parking Brake Caliper and Brake Pads
233
Brake Master Cylinder
241
Footrest Assembly
244
Wheel and Tyre Parts
247
Front Wheels
247
Rear Wheels
248
Transmission System
251
Front Axle
251
Front Bridge
252
Rear Axle
262
Rear Bridge
263
Reverse Mechanism Parts
267
Suspension
271
Front Suspension and Arm
271
Rear Suspension
277
Rear Arm Shaft
279
Cooling System
283
Radiator 1
283
Radiator 2
285
Water Pump
289
Seat
294
Oil System
296
Fuel Tank
296
Chapter 6 Electrical Components
299
Electrical System Malfunction Inspection
299
Electrical
300
Electricalcomponents(Bucket Seat)
300
Checking the Switch
302
Checking the Switch Continuity(Bucket)
303
Checking the Bulbs and Bulb Sockets
304
Ignition System
305
Electric Starting System
308
Circuit Diagram（See348
308
Troubleshooting
309
Starter Motor
312
Charging System
313
Circuit Diagram
313
Troubleshooting
314
Lighting System
315
Circuit Diagram（See348
315
Troubleshooting
316
Checking the Lighting System
317
Signaling System
318
Circuit Diagram（See348
318
Troubleshooting
319
Checking the Signal System
320
Cooling System
326
Circuit Diagram
326
Troubleshooting
327
2Wd/4Wd Selecting System
329
CIRCUIT Diagram（See348
329
Troubleshooting
330
Check if the 2/4WD Switch Is Working
330
Check if the Rear Differential Is Working
330
Chapter 7 Engine Management System
331
EMS (Engine Management System)
331
Typical Components of Ems
331
Layout of Ems Components
332
Components of Ems
332
Electronic Control Unit
332
Multec 3.5 Injectors
333
Throttle Body Assembly(with Stepper Motor)
337
Engine Coolant Temperature Sensor
339
Intake Air Pressure and Temperature Sensor
339
Oxygen Sensor
340
Ignition Coil
340
Fuel Pump Module
344
Ems Fault Diagnosis
350
EME Fault Diagnosis
350
Fault Code List
350
Chapter 8 Troubleshooting
352
Starting Failure/Hard Starting
352
Fuel System
352
Electrical System
352
Compression System
353
Poor Idle Speed Performance
353
Faulty Gear Shifting
354
Shift Lever Does Not Move
354
Jumps out of Gear
354
Poor Medium and High-Speed Performance
354
Engine Overheating
355
Overheating
355
Faulty Brake
355
Poor Braking Effect
355
Shock Absorber Malfunction
356
Unstable Handling
356
Lighting System
356
Head Light Is out of Work
356
Bulb Burnt out
357
Error Display of Meter
357
4
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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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