Name: Hisun Motors HS800UTV 2014
Brand: Hisun Motors
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ENGINE

- 144 -

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 Dowel pin 16

2 Cylinder head gasket 2

3 Cylinder 2

4 Cylinder gasket 2

5 Piston pin clip 4

6 Piston pin 2

7 Piston 2

8 Piston ring set 2

For installation, reverse the removal

procedure.

Default Chapter2
- Table of Contents2
Chapter 1 General Information13
Watnings , Cautions and Notes13
Description14
Identification Code15
- Frame no15
- Engine no15
Safety16
- Handing Gasoline Safely16
- Cleaning Parts17
- Warning Labels17
Serial Numbers18
Fasteners18
- Torque Specifications18
- Self-Locking Fasteners18
- Washers18
- Cotter Pins19
- Snap Rings and E-Clips19
Shop Supplies20
- Lubricants and Fluids20
- Engine Oils20
- Greases20
- Brake Fluid21
- Coolant21
- Cleaners, Degreasers and Solvents21
- Gasket Sealant21
- Gasket Remover22
- Thread Locking Compound22
Basic Tools22
- Screwdrivers23
Precision Measuring Tools28
- Feeler Gauge29
- Calipers29
- Micrometers30
- Adjustment30
- Care31
- Metric Micrometer31
- Standard Inch Micrometer32
- Telescoping and Small Bore Gauges33
- Dial Indicator33
- Compression Gauge34
- Multimeter34
- Cltp-On Ammeter34
- Magneto Puller35
Electrical System Fundamentals35
- Voltage35
- Resistance35
- Amperage35
Basic Service Methods36
- Removing Frozen Fasteners37
- Removing Broken Fasteners37
- Repairing Damaged Threads38
- Stud Removal/Installation38
- Removing Hoses39
- Bearings39
- Removal39
- Installation40
- 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 Warm46
- 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
- The Engine Is Not Idling or Cannot Idle Stably49
- Poor Fuel Mileage49
- Engine will Not Idle or Idles Roughly50
- Low Engine Power50
- Poor Idle or Low Speed Performance51
- Poor High Speed Performance51
Fuel System52
- Rich Mixture52
- Lean Mixture52
Engine53
- Engine Smoke53
- Black Smoke53
- Blue Smoke53
- White Smoke or Steam53
- Low Engine Compression53
- High Engine Compression54
- Engine Overheating (Cooling System)54
- Engine Overheating (Engine)54
- 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 Pressure56
- Oil Level too Low57
- Oil Contamination57
Cylinder Leak down Test57
Electrical Testing59
- Preliminary Checks and Precautions59
- Intermittent Problems60
- Electrical Component Replacement61
- Test Equipment61
- Ammeter61
- Self-Powered Test Light62
- Ohmmeter62
- Jumper Wire62
Test Procedures63
- Voltage Test63
Brake System65
- Soft or Spongy Brake Lever or Pedal65
- Brake Drag66
- Hard Brake Lever or Pedal Operation67
- Brake Grabs67
- Brake Squeal or Chatter67
- Leaking Brake Caliper68
- Leaking Master Cylinder68
Chapter 2 Specifications69
How to Use Conversion Table of Unit69
- How to Use Conversion Table69
- Definition of Unit69
Geberar Specifications70
Engine Specifications73
Chassis Specifications79
Electrical Specifications81
Tightening Torques83
- Engine Tightening Torques83
- Chassis Tightening Torques86
General Tightening Torque Specifications88
Lubrication Pionts and Lubricant Types89
- Engine89
- Chassis90
Hydrographic Chart91
Engine Gearbox Lubrication Oil Parth Circuit93
Maintenance Schedule94
Chapter 396
- Adjusting the Valve Clearance96
- Checking the Spark Plug99
- Checking the Ignition Timing100
- Measuring the Compression Pressure101
- Checking the Engine Oil Level102
- Changing the Engine Oil103
Engine96
Chassis105
- Cleaning the Air Filter105
- Checking the Coolant Level106
- Changing the Coolant107
- Checking the Coolant Temperature Warning Light110
- Checking the V-Belt111
- Cleaning the Spark Arrester112
- Adjusting the Brake Pedal113
- Checking the Brake Fluid Level114
- Checking the Front Brake Pads115
- Checking the Rear Brake Pads115
- Checking the Brake Hoses and Brake Pipes116
- Bleeding the Hydraulic Brake System116
- Adjusting the Select Lever Shift Rod118
- Adjusting the Brake Light Switch118
- Checking the Final Gear Oil Level119
- Changing the Final Gear Oil119
- Checking the Differential Gear Oil120
- Changing the Differential Gear Oil120
- Checking the Constant Velocity Joint Dust Boots121
- Checking the Steering System122
- Adjusting the Toe-In123
- Adjusting the Front and Rear Shock Absorbers124
- Checking the Tires127
- Checking the Wheels129
- Checking and Lubricating the Cables129
Electrical130
- Checking and Charging the Battery130
- Checking the Fuses136
- Adjusting the Headlight Beam138
- Changing the Headlight Bulb138
- Changing the Tail/Brake Light Bulb139
Chapter 4 Engine141
Engine Note141
Engine Removal142
Cylinder Head and Cylinder Head Cover143
Rocker Arms and Camshaft148
Valves and Valve Springs151
Cylinder and Piston156
Engine Left Crankcase Cover A.C. Magneto160
Starter Motor and Oil Filter164
Primary and Secondary Sheaves167
Crankcase Cover and Oil Pump171
Crankcase and Middle Driven Shaft175
Output Shaft180
Gearcase181
- Gearcase182
- Shift Lever and Oil Pump184
- Gearcase Transmission186
Chapter 5192
Malfunction Inspection192
Direction System195
- The Steering Wheel Part195
Brake System204
- Disk Brake Components205
Footrest Assembly229
Wheel and Tyre Parts232
- Front Wheels232
- Rear Wheels233
Transmission System237
- C.V Axle, Front Axle237
- Front Bridge238
- C.V Axle, Rear Axle244
- Rear Bridge Reducer245
  - Rear Bridge249
Shift Operating System250
Suspension254
- Front Swing Arm254
- Front Suspension256
- Rear Anti-Roll Bar262
  - Rear Swing Arm263
Cooling System268
- Water and Oil Radiator268
- Water Pump275
Seat282
Fuel Tank286
Chapter 6 Electrical Components290
Electrical System Malfunction Inspection290
Electrical291
Electricalcomponents291
- Checking the Switch293
- Checking the Switch Continuity294
- Checking the Bulbs and Bulb Sockets295
Ignition System295
- Circuit Diagram295
- Troubleshooting296
Electric Starting System299
- Circuit Diagram299
- Troubleshooting300
Starter Motor303
- Checking the Starter Motor304
- Assembling the Starter Motor305
Charging System305
- Circuit Diagram305
- Troubleshooting306
Lighting System307
- Circuit Diagram307
- Troubleshooting308
- Checking the Lighting System309
Signaling System310
- Circuit Diagram310
- Troubleshooting311
- Checking the Signal System312
Cooling System321
- Circuit Diagram321
- Troubleshooting322
2Wd/4Wd Selecting System324
- Circuit Diagram324
- Troubleshooting325
Chapter 7 Engine Management System326
Introduction326
- Ems (Engine Management System)326
- Typical Components of EMS326
- Layout of EMS Components327
Components of Ems327
- Electronic Control Unit327
- Multec 3.5 Injectors328
- Throttle Body Assembly(with Stepper Motor)332
- Engine Coolant Temperature Sensor334
- Intake Air Pressure and Temperature Sensor335
- Oxygen Sensor335
- Ignition Coil335
- Fuel Pump Module339
Ems Fault Diagnosis345
- EME Fault Diagnosis345
- Fault Code List345
Chapter 8 Troubleshooting347
Starting Failure/Hard Starting347
- Fuel System347
- Electrical System347
- Compression System348
Poor Idle Speed Performance348
Faulty Gear Shifting349
- Shift Lever Does Not Move349
- Jumps out of Gear349
Poor Medium and High-Speed Performance349
Enging Overheating350
- Overheating350
Faulty Brake350
- Poor Braking Effect350
Shock Absorber Malfunction351
- Loss of Damping Function351
Unstable Handling351
Lighting System351
- Head Light Is out of Work351
- Bulb Burnt out352
- Error Display of Meter352

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Hisun Motors HS800UTV 2014 Specifications

General

Brand	Hisun Motors
Model	HS800UTV 2014
Category	Utility Vehicle
Language	English

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