Hisun HS800 User manual
Forth version , May, 2014
Published by Chongqing
Huansong Industries
(Group) Co., Ltd and
Hisun Motors Corp USA.
Chongqing Huansong
Industries (Group)
Co., Ltd and Hisun
Motors Corp USA
holds the copy right.
No publishing and
reprinting without
permission
READ THIS
MANUAL
CAREFULLY
For questions regarding
this UTV, please
contact HISUN at:
(877) 838-6188
www.hisunmotors.com
REV. 06051401
SERVICE
MANUAL
HS800
Foreword
Brief introduction to maintenance handbook of
HS800UTV
The handbook is edited by Technical Center of Chongqing Huansong Industries (Group)
Co., Ltd., and is supplied to dealers and technicians as a docu ent of technique.
This anual gives ethods to check, aintain and repair utility terrain vehicles (UTV’s),
and supplies so e relevant techniques and perfor ance data. So e
techniques and ethods inside ay be used to check, aintain and repair other odels
of UTV, although it is ainly for the HS800UTV.
Please read the handbook through and fully understand it; otherwise, any i proper
repairing could bring you proble s, and or an accident ay occur.
Proper use and aintenance can guarantee the UTV being driven safely, reduce its
alfunctions, and help the vehicle re ain at its best perfor ance level.
The standards, procedures and specifications entioned in this anual are based on
the sa ple in design, and they are subject to changes according to the product’s
i prove ent without prior notice.
Third version , May, 2014
Published by Chongqing Huansong Industries (Group) Co., Ltd.
Chongqing Huansong Industries (Group) Co., Ltd holds the copy right.
No publishing and reprinting without per ission.
INDEX
Chapter 2
Specifications
Chapter 3
Periodic
Maintenance and
Adjustments
Chapter 4
Engine
Chapter
Chassis
Chapter 6
Electrical
Chapter 7
Engine
Management
System
Chapter 8
Troubleshooting
???
Wiring
Diagrams
Index
1.
2.
3.
Chapter 1
General
INDEX
INDEX
Chapter 1 General Information
Warnings, Cautions, Notes
Description, Location
Identification Code, Frame
Number, Engine Number
Safety
Handling Gasoline, cleaning parts
Warning Labels, Serial Numbers,
Fasteners, orque specs, Self
Locking fasteners
Washers, Cotter pins, Snap rings,
and E-clips
Shop Supplies, Lubricants, Engine
Oils
Greases, Brake Fluid, Coolant
Cleaners, Degreasers and
Solvents
Basic ools
Precision Measuring ools
Compression Gauge, Multimeter
Basic Service Methods
Storage
Chapter 2 Specifications
Conversion ables
General Specs
Engine Specs
Suspension Specs
Electrical Specs
Engine orques
Chassis orques
General orques
Lubrications
Chapter 3 Periodic Maintenance
and Adjustment
Maintenance Schedule
Valve Adjustment
Compression est
Engine Oil
Air Filter
Coolant Level
V-Belt
1-3
1-4
1-5
1-6
1-7
1-8
1-9
1-10
1-11
1-12
1-12
1-19
1-25
1-27
1-28
2-3
2-4
2-7
2-13
2-15
2-17
2-20
2-22
2-23
3-3
3-5
3-6
3-7
3-8
3-10
3-13
Spark Arrester
Brake Pedal
Brake Pads
Shift Lever Adjustment
Final Gear Oil
Steering System
Shock absorbers
ires
Headlight Adjustment
Chapter 4 Engine
Special notes
hrottle and Intake Manifold
Removal
Cylinder Head Cover and
Cylinder Head
Rocker Arms and Camshaft
Valves and Valve springs
Cylinder and Piston
Left Crankcase Cover and A.C.
Magneto
Starter motor and Oil Filter
Primary and Secondary Sheaves
Crankcase Cover and Oil Pump
Crankcase and Middle Driven
Shaft
Output Shaft
Gearcase Shift Lever and Oil
Pump
Gearcase ransmission
Chapter Chassis
Steering Assembly
Disc Brake components
Front Brake Caliper
Rear Brake Caliper
Parking Brake Caliper
Footrest
Front Wheel and ire
Rear Wheel and ire
Cv Axle, Front Axle
Front Bridge
Cv Axle, Rear Axle
Rear Bridge Reeducer
3-13
3-14
3-15
3-16
3-17
3-18
3-19
3-19
3-20
4-3
4-4
4-5
4-8
4-10
4-14
4-17
4-19
4-21
4-24
4-27
4-30
4-33
4-35
5-3
5-9
5-11
5-15
5-16
5-20
5-23
5-24
5-27
5-28
5-32
5-33
INDEX
Gear Shift Assembly
Front Swing Arm
Front Suspension
Rear Anti-roll Bar
Rear Swing Arm
Radiator and Oil Cooler
Water Pump
Seat
Fuel ank
Chapter 6 Electrical
Electrical Basics
Charging a Lead Acid Battery
Charging a Maintenance Free
Battery
Checking the Fuses
Electrical Components
Inspection of the Main Switch
Component Locations
roubleshoot (NO SPARK)
roubleshoot (Starter Motor
Failure)
Starter Motor Removal
roubleshoot (Battery is not
Charging)
Chapter 7 Engine Management
System
EMS Introduction, Components
Layout
ECU
Multec 3.5 Injectors
hrottle Body Assembly
Engine Coolant emp Sensor,
Oxygen Sensor
Fuel Pump Module
Fault Codes
5-36
5-39
5-40
5-43
5-44
5-47
5-51
5-56
5-59
6-3
6-4
6-6
6-7
6-8
6-10
6-11
6-12
6-15
6-16
6-17
7-3
7-4
7-4
7-5
7-7
7-8
7-9
7-12
Chapter 8 Troubleshoot
roubleshoot Basics
Principles and Requirements
Special Faults
Flooded Engine
Engine will not start
Spark est
Poor Engine Performance
Fuel System
Engine Smoke
Compression
Engine Lubrication
Cylinder Leak Down est
Electrical esting
est Equipment
Brake System
Headlight/ aillight
Lighting System
Brake Light
Reverse Indicator
Coolant emp Warning Light
4 Wheel drive Switch
Radiator Fan Motor
2/4WD Switch, Rear Differential
Fuel System, Electrical System
Starter Motor, Gear Shifting
8-3
8-4
8-4
8-6
8-6
8-7
8-8
8-12
8-13
8-14
8-16
8-17
8-20
8-22
8-27
8-30
8-31
8-32
8-36
8-37
8-39
8-42
8-44
8-45
8-46
General Information
1-1
Warnings, Cautions, Notes
Description, Location
Identification Code, Frame
Number, Engine Number
Safety
Handling Gasoline, cleaning
parts
Warning Labels, Serial Numbers,
Fasteners, orque specs, Self
Locking fasteners
Washers, Cotter pins, Snap
rings and E-clips
1-3
1-4
1-5
1-6
1-7
1-8
1-9
Shop Supplies, Lubricants,
Engine Oils
Greases, Brake Fluid, Coolant
Cleaners, Degreasers and
Solvents
Basic ools
Precision Measuring ools
Compression Gauge,
Multimeter
Basic Service Methods
Storage
1-10
1-11
1-12
1-12
1-19
1-25
1-27
1-33
General Information
1-2
General Information
1-3
This manual provides complete information on maintenance, tune-up, repair and
overhaul. Hundreds of photographs and illustrations created during the complete
disassembly of Utility Terrain Vehicles (UTV) guide the reader through every job.
ll procedures are in step by step format and designed for the reader who may
be working on the UTV for the first time.
Warnings, Cautions and Notes
The terms Warning, Caution and Note have specific meanings in this manual.
Warning
Emphasizes areas where injury or even death could result from
negligence.
Caution
Emphasizes areas where equipment damage could result.
Disregarding a Caution could cause permanent permanent
Mechanical damage, although injury is unlikely.
Note
Provides additional information to make a step or procedure easier
or clearer. Disregarding a Note could cause inconvenience, but
would not cause equipment damage or injury.
General Information
1-4
Description
1. Headlights/Front turning lights/
Position lights
2. Front shock absorber spring
preload djusting ring
3. Rear Brake Fluid Reservoir
4. Parking Brake Lever
5. Driver Seat
6. Battery
7. Fuses
8. Left shoulder protection plate
9. Driver’s seat belt
10. ir Filter case (Engine and ir
intake duct)
11. Cargo Bed
12. Tail light / Rear turning lights
13. Spark arrester
14. Rear Shock absorber assembly
adjusting ring
15. V-belt case
16. Passenger seat belt
17. Right shoulder protection plate
18. Spark plug
19. Oil filter
20. Fuel cap
21. Passenger seat
22. Rear view mirror
23. Coolant reservoir
24. Radiator cap
25. Steering wheel
26. Light switch
27. Main switch
28. On-Command four-wheel-drive
and differential lock switches
29. Multi-function Display
30. uxiliary DC jack
31. Brake pedal
32. ccelerator pedal
33. Drive select lever
34. Passenger handrail
Note:
The vehicle you have purchased
may differ slightly from those in the
figures of this manual.
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