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HS800UTV 2014
Hisun Motors HS800UTV 2014 User Manual
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HYDROGRAPHIC CHART
Hydrographic
chart
：
Pressure
90
92
Table of Contents
Default Chapter
2
Table of Contents
2
Chapter 1 General Information
13
Watnings , Cautions and Notes
13
Description
14
Identification Code
15
Frame no
15
Engine no
15
Safety
16
Handing Gasoline Safely
16
Cleaning Parts
17
Warning Labels
17
Serial Numbers
18
Fasteners
18
Torque Specifications
18
Self-Locking Fasteners
18
Washers
18
Cotter Pins
19
Snap Rings and E-Clips
19
Shop Supplies
20
Lubricants and Fluids
20
Engine Oils
20
Greases
20
Brake Fluid
21
Coolant
21
Cleaners, Degreasers and Solvents
21
Gasket Sealant
21
Gasket Remover
22
Thread Locking Compound
22
Basic Tools
22
Screwdrivers
23
Wrenches
23
Adjustable Wrenches
24
Socket Wrenches, Ratchets and Handles
24
Impact Drivers
25
Allen Wrenches
25
Torque Wrenches
25
Torque Adapters
26
Pliers
27
Snap Ring Pliers
27
Hammers
28
Ignition Grounding Tool
28
Precision Measuring Tools
28
Feeler Gauge
29
Calipers
29
Micrometers
30
Adjustment
30
Care
31
Metric Micrometer
31
Standard Inch Micrometer
32
Telescoping and Small Bore Gauges
33
Dial Indicator
33
Compression Gauge
34
Multimeter
34
Cltp-On Ammeter
34
Magneto Puller
35
Electrical System Fundamentals
35
Voltage
35
Resistance
35
Amperage
35
Basic Service Methods
36
Removing Frozen Fasteners
37
Removing Broken Fasteners
37
Repairing Damaged Threads
38
Stud Removal/Installation
38
Removing Hoses
39
Bearings
39
Removal
39
Installation
40
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
46
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
The Engine Is Not Idling or Cannot Idle Stably
49
Poor Fuel Mileage
49
Engine will Not Idle or Idles Roughly
50
Low Engine Power
50
Poor Idle or Low Speed Performance
51
Poor High Speed Performance
51
Fuel System
52
Rich Mixture
52
Lean Mixture
52
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 (Cooling System)
54
Engine Overheating (Engine)
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
56
Oil Level too Low
57
Oil Contamination
57
Cylinder Leak down Test
57
Electrical Testing
59
Preliminary Checks and Precautions
59
Intermittent Problems
60
Electrical Component Replacement
61
Test Equipment
61
Ammeter
61
Self-Powered Test Light
62
Ohmmeter
62
Jumper Wire
62
Test Procedures
63
Voltage Test
63
Voltage Drop Test
63
Peak Voltage Test
64
Continuity Test
64
Testing for a Short with a Self-Powered Test Light or Ohmmeter
65
Testing for a Short with a Test Light or Voltmeter
65
Brake System
65
Soft or Spongy Brake Lever or Pedal
65
Brake Drag
66
Hard Brake Lever or Pedal Operation
67
Brake Grabs
67
Brake Squeal or Chatter
67
Leaking Brake Caliper
68
Leaking Master Cylinder
68
Chapter 2 Specifications
69
How to Use Conversion Table of Unit
69
How to Use Conversion Table
69
Definition of Unit
69
Geberar Specifications
70
Engine Specifications
73
Chassis Specifications
79
Electrical Specifications
81
Tightening Torques
83
Engine Tightening Torques
83
Chassis Tightening Torques
86
General Tightening Torque Specifications
88
Lubrication Pionts and Lubricant Types
89
Engine
89
Chassis
90
Hydrographic Chart
91
Engine Gearbox Lubrication Oil Parth Circuit
93
Maintenance Schedule
94
Chapter 3
96
Adjusting the Valve Clearance
96
Checking the Spark Plug
99
Checking the Ignition Timing
100
Measuring the Compression Pressure
101
Checking the Engine Oil Level
102
Changing the Engine Oil
103
Engine
96
Chassis
105
Cleaning the Air Filter
105
Checking the Coolant Level
106
Changing the Coolant
107
Checking the Coolant Temperature Warning Light
110
Checking the V-Belt
111
Cleaning the Spark Arrester
112
Adjusting the Brake Pedal
113
Checking the Brake Fluid Level
114
Checking the Front Brake Pads
115
Checking the Rear Brake Pads
115
Checking the Brake Hoses and Brake Pipes
116
Bleeding the Hydraulic Brake System
116
Adjusting the Select Lever Shift Rod
118
Adjusting the Brake Light Switch
118
Checking the Final Gear Oil Level
119
Changing the Final Gear Oil
119
Checking the Differential Gear Oil
120
Changing the Differential Gear Oil
120
Checking the Constant Velocity Joint Dust Boots
121
Checking the Steering System
122
Adjusting the Toe-In
123
Adjusting the Front and Rear Shock Absorbers
124
Checking the Tires
127
Checking the Wheels
129
Checking and Lubricating the Cables
129
Electrical
130
Checking and Charging the Battery
130
Checking the Fuses
136
Adjusting the Headlight Beam
138
Changing the Headlight Bulb
138
Changing the Tail/Brake Light Bulb
139
Chapter 4 Engine
141
Engine Note
141
Engine Removal
142
Cylinder Head and Cylinder Head Cover
143
Rocker Arms and Camshaft
148
Valves and Valve Springs
151
Cylinder and Piston
156
Engine Left Crankcase Cover A.C. Magneto
160
Starter Motor and Oil Filter
164
Primary and Secondary Sheaves
167
Crankcase Cover and Oil Pump
171
Crankcase and Middle Driven Shaft
175
Output Shaft
180
Gearcase
181
Gearcase
182
Shift Lever and Oil Pump
184
Gearcase Transmission
186
Chapter 5
192
Malfunction Inspection
192
Direction System
195
The Steering Wheel Part
195
Brake System
204
Disk Brake Components
205
Front Brake Caliper
207
Rear Brake Calipers
215
Parking Brake Caliper
218
Footrest Assembly
229
Wheel and Tyre Parts
232
Front Wheels
232
Rear Wheels
233
Transmission System
237
C.V Axle, Front Axle
237
Front Bridge
238
C.V Axle, Rear Axle
244
Rear Bridge Reducer
245
Rear Bridge
249
Shift Operating System
250
Suspension
254
Front Swing Arm
254
Front Suspension
256
Rear Anti-Roll Bar
262
Rear Swing Arm
263
Cooling System
268
Water and Oil Radiator
268
Water Pump
275
Seat
282
Fuel Tank
286
Chapter 6 Electrical Components
290
Electrical System Malfunction Inspection
290
Electrical
291
Electricalcomponents
291
Checking the Switch
293
Checking the Switch Continuity
294
Checking the Bulbs and Bulb Sockets
295
Ignition System
295
Circuit Diagram
295
Troubleshooting
296
Electric Starting System
299
Circuit Diagram
299
Troubleshooting
300
Starter Motor
303
Checking the Starter Motor
304
Assembling the Starter Motor
305
Charging System
305
Circuit Diagram
305
Troubleshooting
306
Lighting System
307
Circuit Diagram
307
Troubleshooting
308
Checking the Lighting System
309
Signaling System
310
Circuit Diagram
310
Troubleshooting
311
Checking the Signal System
312
Cooling System
321
Circuit Diagram
321
Troubleshooting
322
2Wd/4Wd Selecting System
324
Circuit Diagram
324
Troubleshooting
325
Chapter 7 Engine Management System
326
Introduction
326
Ems (Engine Management System)
326
Typical Components of EMS
326
Layout of EMS Components
327
Components of Ems
327
Electronic Control Unit
327
Multec 3.5 Injectors
328
Throttle Body Assembly(with Stepper Motor)
332
Engine Coolant Temperature Sensor
334
Intake Air Pressure and Temperature Sensor
335
Oxygen Sensor
335
Ignition Coil
335
Fuel Pump Module
339
Ems Fault Diagnosis
345
EME Fault Diagnosis
345
Fault Code List
345
Chapter 8 Troubleshooting
347
Starting Failure/Hard Starting
347
Fuel System
347
Electrical System
347
Compression System
348
Poor Idle Speed Performance
348
Faulty Gear Shifting
349
Shift Lever Does Not Move
349
Jumps out of Gear
349
Poor Medium and High-Speed Performance
349
Enging Overheating
350
Overheating
350
Faulty Brake
350
Poor Braking Effect
350
Shock Absorber Malfunction
351
Loss of Damping Function
351
Unstable Handling
351
Lighting System
351
Head Light Is out of Work
351
Bulb Burnt out
352
Error Display of Meter
352
4
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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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