Hisun HS800UTV - Repair, Service Manual, Wiring Diagrams, Parts Catalog and Owners Manual

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HISUN HS800UTV - WORKSHOP, REPAIR, SERVICE, PARTS, OWNERS MANUAL

- English Service Manual, Parts Catalogue, Owners Manual and Wiring Diagrams for UTV Hisun HS800UTV.


CONTENTS:

SERVICE MANUAL

GENERAL INFORMATION

- General information1
- Watnings, cautions and notes1
- Description2
- Identification code 3
- Frame no.  3
- Engine no.  3
- Safety  4
- Handing gasoline safely 4
- Cleaning parts 5
- Warning labels 5
- Serial numbers 6
- Fasteners 6
- Torque specifications  6
- Self-locking fasteners 6
- Washers 6
- Cotter pins 7
- Snap rings and e-clips  7
- Shop supplies 8
- Lubricants and fluids 8
- Engine oils 8
- Greases 8
- Brake fluid 9
- Coolant 9
- Cleaners, degreasers and solvents  9
- Gasket sealant 9
- Gasket remover  10
- Thread locking compound 10
- Basic tools  10
- Screwdrivers 11
- Wrenches  11
- Adjustable wrenches  12
- Socket wrenches, ratchets and handles  12
- Impact drivers  13
- Allen wrenches 13
- Torque wrenches 14
- Torque adapters  14
- Pliers 15
- Snap ring pliers 15
- Hammers  16
- Ignition grounding tool 16
- Precision measuring tools  16
- Feeler gauge  17
- Calipers 17
- Micrometers 18
- Adjustment  18
- Care  19
- Metric micrometer 19
- Standard inch micrometer 20
- Telescoping and small bore gauges 21
- Dial indicator 21
- Compression gauge 22
- Multimeter 22
- Electrical system fundamentals 22
- Voltage  22
- Resistance 23
- Amperage 23
- Basic service methods 23
- Removing frozen fasteners 24
- Removing broken fasteners  25
- Repairing damaged threads  25
- Stud removal/installation  25
- Removing hoses  26
- Bearings 26
- Removal 26
- Installation 27
- Interference fit  28
- Seal replacement 29
- Storage 30
- Storage area selection 30
- Preparing the motorcycle for storage  30
- Returning the utv to service 30
- Trovbleshooting 31
- Engine principles and operating requirements 32
- Starting the engine  32
- Engine is cold  32
- Engine is warm 32
- Starting the engine after a fall or after the engine stalls 33
- Flooded engine 33
- Engine cold with air temperature  33
- Engine cold with air temperature above 35.(95°f) 33
- Cold engine with air temperature below 10.(50°f)  33
- Engine is hot 34
- Starting the engine after a fall or after the engine stalls 34
- Flooded engine 34
- Engine will not start  35
- Identifying the problem  35
- Spark test 36
- Starter does not turn over or turns over slowly  37
- Poor engine performance 37
- Engine starts but stalls and is hard to restart 37
- Engine backfires, cuts out or misfires during acceleration 37
- Engine backfires on deceleration 38
- Poor fuel mileage 38
- Engine will not idle or idles roughly  38
- Low engine power  38
- Poor idle or low speed performance 40
- Poor high speed performance  40
- Fuel system 41
- Rich mixture 41
- Lean mixture 41
- Engine 42
- Engine smoke 42
- Black smoke  42
- Blue smoke 42
- White smoke or steam 42
- Low engine compression  42
- High engine compression  43
- Engine overheating (cooling system)  43
- Engine overheating (engine) 43
- Preignition 43
- Detonation 44
- Power loss  44
- Engine noises 44
- Englne lubrication 45
- High oil consumption or excessive 45
- Exhaust smoke 45
- Low oil pressure  45
- High oil pressure  45
- No oil pressure 45
- Oil level too low 46
- Oil contamination 46
- Cylinder leak down test 46
- Electrical testing 48
- Preliminary checks and precautions  48
- Intermittent problems 49
- Electrical component replacement  50
- Test equipment  50
- Ammeter  50
- Self-powered test light  50
- Ohmmeter  51
- Jumper wire 51
- Test procedures 52
- Voltage test 52
- Voltage drop test 52
- Peak voltage test 53
- Continuity test 53
- Testing for a short with a self-powered test light or ohmmeter 54
- Testing for a short with a test light or voltmeter 54
- Brake system 54
- Soft or spongy brake lever or pedal 54
- Brake drag 55
- Hard brake lever or pedal operation 56
- Brake grabs 56
- Brake squeal or chatter  56
- Leaking brake caliper  57
- Leaking master cylinder 57

SPECIFICATIONS

- How to use conversion table of unit 58
- How to use conversion table 58
- Definition of unit  58
- Geberar specifications  59
- Engine specifications  62
- Chassis specifications 68
- Electrical specifications 70
- Tightening torques  72
- Engine tightening torques 72
- Chassis tightening torques  75
- General tightening torque specifications  77
- Lubrication pionts and lubricant types 78
- Engine 78
- Chassis 79
- Hydrographic chart 80
- Engine gearbox lubrication oil parth circuit 81

MAINTENCE AND ADJUSTMENT OF THE UTV

- Maintenance schedule 83
- Engine
- Adjusting the valve clearance 85
- Checking the spark plug  88
- Checking the ignition timing 89
- Measuring the compression pressure 90
- Checking the engine oil level  91
- Changing the engine oil  92
- Chassis
- Cleaning the air filter 94
- Checking the coolant level  95
- Changing the coolant 96
- Checking the coolant temperature warning light  99
- Checking the v-belt 100
- Cleaning the spark arrester  101
- Adjusting the brake pedal 102
- Checking the brake fluid level  103
- Checking the front brake pads 104
- Checking the rear brake pads 104
- Checking the brake hoses and brake pipes  105
- Bleeding the hydraulic brake system  105
- Adjusting the select lever shift rod  107
- Adjusting the brake light switch  107
- Checking the final gear oil level  108
- Changing the final gear oil 108
- Checking the differential gear oil 109
- Changing the differential gear oil 109
- Checking the constant velocity joint dust boots 110
- Checking the steering system 111
- Adjusting the toe-in  112
- Adjusting the front and rearshock absorbers 113
- Checking the tires  114
- Checking the wheels 116
- Checking and lubricating the cables  116
- Electrical
- Checking and charging the battery 117
- Checking the fuses  123
- Adjusting the headlight beam  125
- Changing the headlight bulb  125
- Changing the tail/brake light bulb  126

ENGINE

- Engine note 128
- Engine removal 129
- Cylinder head and cylinder head cover 131
- Rocker arms and camshaft 136
- Valves and valve springs 139
- Cylinder and piston 144
- Engine left crankcase cover a.c. Magneto148
- Starter motor and oil filter152
- Primary and secondary sheaves156
- Crankcase cover and oil pump 160
- Crankcase and middle driven shaft 164
- Output shaft170
- Gearcase
- Shift lever and oil pump 174
- Gearcase transmission  176
 
CHASSIS

- Malfunction inspection 181
- Direction system
- The structure of the steering 184
- The structure of steering wheel part 188
- Diassembling the parts of the steering wheel  188
- Checking the parts of the steering wheel 188
- Diassembling the steering column parts 189
- Checking and service the steering column parts 190
- Diassembling the steering drive axle  190
- Checking and service the steering drive axle 191
- The machine parts 192
- The structure of the steering 192
- Brake system 193
- Preparation for checking before the maintenance of the brake system  193
- Disk brake components  194
- Front brake caliper  196
- Checking the front brake disc  198
- Replacing the front brake pads 199
- Disassembling the front brake calipers  201
- Assembling the front brake calipers 202
- Installing the front brake calipers  202
- Rear brake calipers 204
- Checking the rear brake disc 207
- Replacing the rear brake pads 208
- Disassembling the rear brake caliper  209
- Assembling the rear brake caliper  210
- Installing the rear brake caliper  212
- Checking the master cylinder  213
- Assembling the brake master cylinder 213
- Installing the brake master cylinder 214
- Footrest assembly  215
- Wheel and tyre parts  218
- Front wheels 218
- Rear wheels 219
- Checking the wheel tyre 220
- Checking the wheel hub 220
- Installing the wheel hub 221
- Installing the wheel tyre 221
- Specification of wheel and tyre 222
- Transmission system  223
- Front bridge 223
- Disassembling the universal joint  229
- Checking the joints 230
- Assembling the universal joint231
- Rear bridge  232
- Reverse mechanism parts  239
- Adjusting reverse mechanism parts  241
- Checking and service of reverse mechanism 242
- Suspension 243
- Front suspension 243
- Front arm 245
- Disassembling, service and assembly the supporting rocker parts 247
- Checking the stabilizer 248
- Checking the steering knuckles 248
- Checking the front arms  248
- Checking the front shock absorber 249
- Installing the front arms and front shock absorber  250
- Rear suspension  251
- Rear arm shaft 252
- Checking and service of rear suspension  254
- Checking the stabilizer 255
- Checking the steering knuckles 255
- Checking the rear arms 255
- Checking the rear shock absorber  255
- Installing the rear arms and rear shock absorber  256
- Cooling system 257
- Radiator  257
- Checking the radiator 261
- Installing the radiator 262
- Oil cooler  263
- Checking the oil cooler  265
- Water pump 266
- Disassembling the water pump  270
- Checking the water pump 271
- Assembling the water pump 272
- Seat  273
- Disassembling the seat 277
- Moving seat forward and backward  277
- Fuel tank 278

ELECTRICAL COMPONENTS

- Electrical system malfunction inspection  281
- Electrical  282
- Electricalcomponents 282
- Checking the switch 284
- Checking the switch 284
- Checking the switch continuity  285
- Checking the bulbs and bulb sockets  286
- Ignition system  287
- Circuit diagram  287
- Troubleshooting  288
- Electric starting system  291
- Circuit diagram  291
- Troubleshooting  292
- Starter motor  295
- Checking the starter motor  296
- Assembling the starter motor  297
- Charging system  298
- Circuit diagram 298
- Troubleshooting  299
- Lighting system  301
- Circuit diagram  301
- Troubleshooting  302
- Checking the lighting system  303
- If the headlights fail to come on  303
- If the taillights fail to come on  304
- Signaling system  305
- Circuit diagram  305
- Troubleshooting  306
- Checking the signal system  307
- If the brake lights fail to come on  307
- If the neutral lights fail to come on  308
- If the parking brake indicator light fails to come on  309
- If the reverse indicator light fails to come on  310
- If the coolant temperature warning  311
- If the differential gear lock indicator light fails to come on  313
- If the four-wheel drive indicator light fails to come on  315
- Cooling system  317
- Circuit diagram  317
- Troubleshooting  318
- 2wd/4wd selecting system  321
- Circuit diagram  321
- Troubleshooting  322

ENGINE MANAGEMENT SYSTEM

- Introduction
- Ems (engine management system)  323
- Typical components of ems323
- Layout of ems components324
- Components of ems
- Electronic control unit  324
- Multec 3.5 injectors  325
- Throttle body assembly(with stepper motor) 329
- Engine coolant temperature sensor  331
- Intake air pressure and temperature sensor 331
- Oxygen sensor  332
- Ignition coil 332
- Fuel pump module336
- Ems fault diagnosis
- Eme fault diagnosis 342
- Fault code list342

TROUBLESHOOTING

- Starting failure/hard starting 344
- Fuel system  344
- Electrical system  344
- Compression system  345
- Poor idle speed performance  345
- Poor idle speed performance 345
- Poor medium and high-speed performance  346
- Poor medium and high-speed performance 346
- Faulty gear shifting 346
- Shift lever does not move  346
- Jumps out of gear 346
- Overheating 346
- Overheating 346
- Faulty brake 347
- Poor braking effect 347
- Shock absorber malfunction 347
- Malfunction  347
- Unstable handling 347
- Unstable handling  345
- Lighting system 348
- Head light is out of work 348
- Bulb burnt out 348


OWNERS MANUAL

- Introduction
- Important Manual Information
- Important Notice
- Contents
- Location Of The Warning And Specification Labels
- Description And Vehicle Identification
- Control Functions
- Pre-Operation Checks
- Operation
- Driving Your Vehicle
- Periodic Maintenance And Adjustment
- Cleaning And Storage
- Specifications
- Fault Code Of Eleclronic Injection System


SPARE PARTS CATALOGUE

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