Hisun HS 200UTV-2 Owner'S Manual Download Page 50

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Introduction HS 200UTV-2/HS 250UTV-2

1-50

radiator

pressure

cap

which

permits

the

development of pressure within the cooling

system.

5. Adding the LLC

1) Add only water if the mixture reduces in

amount by evaporation.

2) If there is a mixture leak, add the LLC of

the same manufacturer and type in the

same mixture percentage.

* Never add any long-life coolant of

different manufacturer.(Different brands

may have different additive components,

and the engine may fail to perform as

specified.)

6. When the LLC is mixed, do not employ

any radiator cleaning agent. The LLC

contains anticorrosive agent. If mixed with

the cleaning agent, sludge may build up,

adversely affecting the engine parts.

The vehicle’s genuine long-life coolant has

a service life of 2 years. Be sure to change

the coolant every 2 years.

NOTE:



The

above

data

represent

industry

standards that necessitate a minimum

glycol

content

the

concentrated

antifreeze.



When the coolant level drops due to

evaporation, add water only to keep the

antifreeze mixing ratio less than 50%. In

case of leakage, add antifreeze and water

in the specified mixing ratio before filling

into the radiator.

■

Replacing Radiator Hose (Water pipes)

Replace the hoses and clamps.

(See “Checking Radiator Hose and Clamp” in
“EVERY 200 HOURS” in “PERIODIC
SERVICE” section.)

■

Replacing Fuel Hose

Consult your local Hisun Dealer for this

service.

■

Replacing Brake Master Cylinder (Inner

parts)

Consult your local dealer for this service.

■

Replacing Front Brake Seal

Consult your local dealer for this service.

■

Replacing Rear Brake Cylinder Seal

Consult your local dealer for this service.

■

Replacing Intake Air Line

Consult your local dealer for this service.

EVERY 4 YEARS

■

Replacing Brake Hose

Consult your local Dealer for this service.

■

Replacing Mini Fuses

The Mini fuses are intended to protect the

electrical cabling. If any of them have blown

out, be sure to pinpoint the cause.

◆

Replacing procedure

1) Disconnect the negative cable of the

battery.

2) Open the Mini fuse box cover.

3) Pull out the Mini fuse.

4) Insert a new Mini fuse into the box.

Summary of Contents for HS 200UTV-2

Page 1: ...wing all of the instructions herein will provide the knowledge needed to have safe and enjoyable UTV operation For questions regarding this UTV please call 972 446 0760 IMPORTANT SAFETY MESSAGES READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR UTV MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE UTV NEVER OPERATE THE UTV WITHOUT ...

Page 2: ...his manual by the following notations The Safety Alert Symbol means ATTENTION YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the machine operator bystander or a person inspecting or repairing the machine A CAUTION indicates special precautions that must be taken to avoid damage to the machine NOTE A NOTE provides key information to make pro...

Page 3: ... temperature is below 4 F 20 C park the UTV in a place where the temperature is higher than 4 F 20 C Start the UTV after the UTV has warmed up Please see page 7 3 on the warming up process Follow the proper parking procedures when the temperature is higher than 100 F 38 C turn off the engine make sure the radiator fan is on for 3 minutes before turning off the power switch Starting the UTV for the...

Page 4: ... Plate Transporting vehicle Service intervals Periodic Service Hood Jack up point Coolant Level radiator screen brake fluid level brake pedal parking brake Page 1 1 1 2 1 3 1 4 1 5 1 6 2 1 2 2 2 2 2 2 2 2 2 3 2 3 2 3 2 3 2 3 2 4 3 1 4 1 5 1 5 2 5 3 6 1 7 1 7 2 7 3 8 1 8 1 8 2 8 2 8 2 8 3 8 4 8 5 8 5 8 5 8 5 8 6 9 1 9 1 9 1 10 1 10 1 10 2 10 3 10 4 10 4 10 5 10 5 Subject Greasing engine start Wheel...

Page 5: ...Introduction HS 200UTV 2 HS 250UTV 2 1 5 LOCATION OF PARTS Roll over protective structure Front hood Headlights Turn signal lights Front bumper ...

Page 6: ...V 2 1 6 ILLUSTRATED CONTENTS Parking brake lever Steering wheel Range gear shift lever Accelerate pedal Brake pedal Fuel gauge Headlights switch High beam Low beam Emergency light switch DC socket 11 Winch in out 12 Turn signal lights ...

Page 7: ...Introduction HS 200UTV 2 HS 250UTV 2 1 7 Seat belts Seat ...

Page 8: ...cur You should always wear protective equipment 5 Only a qualified driver should operate this UTV Never operate after drinking using drugs or controlled products or while fatigued 6 Always perform the pre operation checks as following 1 Check seat belt for wear or damage if necessary replace it 2 Check brakes throttle brake pedal and other mechanical parts for proper operation If you discover any ...

Page 9: ...Introduction HS 200UTV 2 HS 250UTV 2 1 9 such as helmet boots eye protection ear protection and gloves etc ...

Page 10: ...osition your hands on the steering wheel Always keep your hands and feet inside passenger area of the vehicle Never try to 3 Children safety instructions Always watch children when they are around the vehicle Children like to imitate adults and this could lead to an accident Do not leave children alone beside the vehicle Keep children from the operating area of the vehicle Turn off the engine and ...

Page 11: ...Introduction HS 200UTV 2 HS 250UTV 2 1 11 stand while operating the vehicle 14 Do not tow passengers or attempt to jump the vehicle come to a stop Release the brake and begin to coast down the hill ...

Page 12: ...h speed may result in overturn or even death 3 Turn on your headlights at high speeds 4 Drive only when the vehicle speed can be controlled 5 When driving at high speeds sudden turning of the steering wheel will reduce vehicle stability Never sharply turn the steering wheel at high speeds 1 Never carry a passenger in the cargo area 2 Evenly distribute the cargo to maintain proper stability Avoid o...

Page 13: ...Introduction HS 200UTV 2 HS 250UTV 2 1 13 7 Instructions for carrier vehicle 2 When loading or unloading pay attention to your surroundings and others in the area ...

Page 14: ... accelerate the risk of explosion 4 Read and follow the instructions before replacing the battery 5 During maintenance first aid kits and fire extinguishers should be placed at your fingertips 6 During maintenance you should disconnect the battery cables Battery 7 Do not open radiator cap before coolant has cooled down When the coolant is cold open slowly and let the coolant pressure reduced and t...

Page 15: ...Introduction HS 200UTV 2 HS 250UTV 2 1 15 1 2 3 4 5 6 7 8 9 10 11 ...

Page 16: ...Introduction HS 200UTV 2 HS 250UTV 2 1 16 SERVICING OF VEHICLE ...

Page 17: ...d of parts or major service be sure to see your dealer For service contact the dealership from which you purchased your vehicle or your local dealer When in need of parts be prepared to give your dealer both the vehicle and engine serial numbers Locate the serial numbers now and record them in the space provided Type Serial No Vehicle Engine Product Identification Number Date of Purchase Name of D...

Page 18: ...k brake Parking brake Rear wheel hand lever Steering Mechanical power Steering wheel Suspension Front Independent short long arm type Rear Integral rear driving axle type Dimensions Length mm in 2450 96 47 Wide mm in 1300 51 18 Height mm in 1660 65 35 Front tread centers mm in 973 38 3 Rear tread centers mm in 975 38 38 Wheelbase mm in 1780 70 08 Ground Clearance front axle mm in 180 7 08 rear axl...

Page 19: ...r ear db A 85 Tire Front 22 7 10 6PR Rear 22 10 10 6PR Body color Red Black White Blue Yellow Orange Camo NOTE The values in Ground clearance and Weight are those of the machine equipped with the tires in the table above The company reserves the right to change the specifications without notice TRAVELING SPEEDS Range gear shift lever km h mph Low 13 8 High 40 25 Reverse 16 10 VEHICLE LIMITATIONS ...

Page 20: ...or use vehicle may result in vehicle malfunction or failures with a possibility of the vehicle damage property damage and injury to the operator or others Any malfunctions or failures of the vehicle resulting from use with improper implements are not covered by the warranty Max Cargo loading weigh Cargo Bed Capacity 50kg 110 lb Cargo Load Capacity 176kg 388 lb operator one passenger opt acc weight...

Page 21: ...Check engine oil level Check transmission oil level Check brake fluid level Check coolant level Clean radiator screen When used in a dusty place Check brake and pedal Check parking brake Check indicators gauges and meters Check lights Check seat belts and roll over protective structures Check front and rear joint boots Check tire inflation pressure Check backup beeper if equipped Refuel See PRE OP...

Page 22: ... from operator s seat Never start engine while standing on ground Make it a rule to set gear shift lever to NEUTRAL position before starting the engine IMPORTANT Do not use starting fluid or ether To protect the battery and the starter make sure that the starter is not continuously turned for more than 5 seconds STARTING THE ENGINE 1 Make sure the parking brake is set Parking brake lever Pull to P...

Page 23: ...nsert the key into the key switch and turn it to OFF Stop the Engine ON Engine runs or headlights on START Start the Engine Engine and other Check Lamps The parking brake warning lamp 1 parking brake comes on while parking brake is applied and goes off when it is released IMPORTANT Relying on the engine warning lights is never enough Never fail to conduct daily checks carefully by referring to Pre...

Page 24: ...ery cold If the engine fails to start after 5 seconds turn off the key for 30 seconds and start again STOPPING THE ENGINE 1 After slowing the engine to idle turn the key to OFF 2 Remove the key WARMING UP CAUTION To avoid personal injury Be sure to set the parking brake during warm up Be sure to set the shift lever to the NEUTRAL position during warm up For 5 minutes after engine start up allow th...

Page 25: ...not run the engine at speeds faster than prescribed On rough roads slow down to suitable speeds The above precautions are not limited to new vehicles However they should be especially observed for new vehicles Changing Lubricating Oil for New Vehicles The lubricating oil is especially important for a new vehicle Various parts need time to wear and polish themselves to the correct operating clearan...

Page 26: ...op half of the emergency light switch the light flash along with the indicator on the instrument panel Press the bottom half of the emergency light switch to turn off the light Note The emergency light switch will operate when the key switch is in the ON position and OFF position Keeping the switch ON causes the battery to run out Turn Signal Light Switch To indicate a right turn push on the lower...

Page 27: ...eam High beam headlight switch Key switch Head light Head turn signal lamp Tail turn signal lamp 3 Checking the brake pedal Brake Pedal CAUTION To avoid personal injury If the operator suddenly brakes an accident may occur due to loss of control or the shifting forward of heavy loads When driving on icy wet or loose surface make sure the vehicle is correctly loaded to avoid skidding or loss of ste...

Page 28: ...the vehicle using the brake pedal before shifting gears 3 Select proper gear depending on the types of job 4 Before exiting vehicle shift the gear shift lever to the NEUTRAL position and set parking brake Range gear shift lever L LOW Range H HIGH Range N NEUTRAL POSITION R REVEREE NOTE When gear shift lever is hard to engage do not force the lever Set the parking brake slightly depress the acceler...

Page 29: ...lease the speed accelerator pedal 2 Step on the brake pedal CHECK DURING DRIVING Immediately Stop the Engine if The engine suddenly slows down or accelerates Unusual noises are suddenly heard Exhaust fumes suddenly become very white While driving check the following items to see if all parts are functioning normally Fuel Gauge Park the vehicle on a flat place When the key switch to ON the fuel gau...

Page 30: ...ly 1 With the key switch ON the temperature gauge indicates the temperature of the coolant White Zone for cold and Red zone for hot 2 If the indicator reaches the Red zone the engine coolant is overheated Check the v e h i c l e b y r e f e r r i n g t o TROUBLESHOOTING section Speedometer The hour meter indicates in five digits the hours the vehicle has been used Hour meter The speedometer indica...

Page 31: ... you have sufficient knowledge experience the proper replacement parts and tools before you attempt any vehicle maintenance task If you don t have the knowledge and equipment which are necessary to perform the maintenance task consult your local dealer Have your local dealer perform inspection items which are marked 4 in the chart below SERVICE INTERVALS IMPORTANT The jobs indicated by must be don...

Page 32: ... Engine oil filter Replace Every 200 hrs 3 Transmission fluid Change Every 400 hrs 4 Engine start system Check Every 50 hrs 5 Greasing Apply Every 50 hrs 6 Muffler Clean Every 100 hrs 7 Spark arrester Clean Every 100 hrs 8 Wheel bolt torque Check Every 100 hrs 9 Battery condition Check Every 100 hrs 10 Toe in Adjust Every 100 hrs 11 Fuel filter element Check Every 100 hrs Replace Every 100 hrs 12 ...

Page 33: ...eck Every 3900 hrs 26 Brake fluid Change Every 2 years 27 Remote hydraulic hose Replace Every 2 years 28 Rear brake cylinder seal Replace Every 2 years 29 Front brake seal Replace Every 2 years 30 Cooling system Flush Every 2 years 31 Coolant Change Every 2 years 32 Fuel system Bleed Service as required 33 Fuse Replace 34 Light bulb Replace NOTE Engine Oil 10W 40SL Oil used in the engine should ha...

Page 34: ...turn the switch to release the latch and lift the hood off HOW TO TILT THE CARGO BED CAUTION To avoid personal injury When servicing under the tilted bed make sure safety support is properly mounted Do not touch muffler or exhaust pipes while they are hot Otherwise they may cause severe burns Tilting and Lowering the Cargo Bed To tilt the cargo bed 1 Pull up the handle on the cargo bed To lower th...

Page 35: ...jack pressure on the steel plate directly under the engine Jack DAILY CHECK For your own safety and maximum service life of the vehicle make a thorough daily inspection before starting the engine or operating the vehicle CAUTION To avoid personal injury Be sure to check and service the vehicle on a flat surface with the engine off and the parking brake ON Walk Around Inspection Look around and und...

Page 36: ...NT If oil level is low do not run engine Checking Coolant Level Fuel tank capacity 13 5 3 6 0 1U S GALS CAUTION TO avoid personal injury Do not remove radiator cap while coolant is hot when cool slowly rotate to the first stop and allow sufficient time for excess pressure to escape before removing the cap completely Park the vehicle on a flat surface access the panel under the hood set the parking...

Page 37: ...g brake fluid level CAUTION TO avoid personal injury Never operate the vehicle if the brake fluid is below the minimum mark Use only DOT3 from a sealed container Other types of brake fluid may ruin synthetic resin or rubber installed in brake system components and may cause brake failure Avoid contamination of the brake fluid thoroughly clean before removing the filler cap Do not open the brake fl...

Page 38: ... of the parking brake lever and tilt the lever down NOTE Make sure the parking brake warning lamp on the display goes off when parking brake lever and tilt the lever down NOTE Make sure the parking brake warning lamp on the display goes off when parking brake lever is down Parking brake lever Release button RELEASE PULL Checking gauges meter and warning lamps 1 Inspect the instrument panel for bro...

Page 39: ... 49kPa 0 49kgf cm2 7psi 22 10 10 49kPa 0 49kgf cm2 7psi EVERY 50 HOURS Greasing Apply a small amount of multi purpose grease to the following points every 50 hours If you operated the vehicle in extremely wet and muddy conditions lubricate grease fittings more often Parking brake pivot spray type grease Cargo brace rod turning point spray type grease Cargo bed rotating axle spray type grease ...

Page 40: ...engine Test gear shift range lever safety switch 1 Sit on the operator s seat 2 Shift the gear shift range lever to L H N or REVERSE position 3 Turn the key to START position 4 The engine must not crank 5 If it cranks consult your local dealer for this service Gear shift lever Accelerator pedal Checking wheel bolt torque CAUTION To avoid personal injury Never operate vehicle with a loose wheel bol...

Page 41: ...pect inside of the element with a light and check if it is damaged or not 3 Replace the primary element Once yearly or after every sixth cleaning whichever comes first First air cleaner Air cleaner case Air cleaner element Cover IMPORTANT The air cleaner uses a dry element never apply oil Do not run the engine with filter element removed Be sure to refit the cower with the arrow on the rear of cow...

Page 42: ...ering Particular care must be taken not to admit dust and dirt into the fuel pump entrance Even a small amount of dust or dirt will cause premature wear and malfunction of the fuel pump and injector components Pipe clamp fuel line fuel pump Checking battery condition DANGER If you store a battery in a diminished state of charge you will probably have to replace the battery CAUTION To avoid persona...

Page 43: ...olts 12V8Ah 12 Direction for storage 1 When storing the vehicle for a long period remove the battery from the vehicle store in a dry place out of direct sunlight 2 The battery will self discharge while it is shored recharge it once every three months in hot seasons and once every six months in cold seasons Adjusting toe in Proper toe in 0 to12 mm 0 to 0 47 in 1 Park vehicle on flat place 2 Turn st...

Page 44: ...the muffler body and fastened with bolts 2 Loosen the bolts and remove the spark arrester 3 Shake loosened particles out of the screen assembly and lightly clean the screen with wire brush Soak in solvent and again clean with wire brush if necessary 4 If any breaks in the screen or welds are discovered the assembly must be replaced 5 Return the spark arrester to the muffler body and refasten the b...

Page 45: ...this range Dipstick Oil inlet Drain plug Replacing Engine Oil Filter CAUTION To avoid personal injury Be sure to stop the engine before changing the oil filter cartridge Allow engine to cool down sufficiently oil can be hot and can burn 1 Park the vehicle on a flat surface and raise the cargo bed 2 Remove the oil filter 3 Put a film of clean engine oil on the rubber seal of the new filter 4 After ...

Page 46: ...pedal stroke 3 If brake pedal stroke is outside of the specifications contact your local dealer for adjusting the brake Brake pedal FREE TRAVEL PEDAL STROKE Checking Brake Hose and Pipe 1 Check to see that brake hose and lines are not swollen hardened or cracked 2 Check the brake hose and pipe joints for oil leaks 3 If there is any abnormality consult your local dealer for this service Checking Br...

Page 47: ...r about 5 minutes of unloaded idling 3 Keep yourself well away from the vehicle for at least 10 minutes or while the steam is blowing out 4 Check to see if there is no danger such as burning get rid of the causes of overheating according to the TROUBLESHOOTING section of the manual and then start the engine again Checking Intake Air Line 1 Check to see if the hoses and hose 2 clamps are tight and ...

Page 48: ...adiator cap while coolant is hot When cool slowly rotate cap to the first stop and allow sufficient time for excess pressure to escape before removing the cap completely 1 Stop the engine and let it cool down 2 To drain the coolant open the radiator drain plug and remove radiator cap The radiator cap must be removed to completely drain the coolant 3 After all coolant is drained close the drain plu...

Page 49: ... body Do not pour waste onto the grounds down a drain or into any water source Also observe the relevant environmental protection regulations when disposing of antifreeze If it freezes coolant can damage the cylinders and radiator If the ambient temperature falls below 0 32 F or before a long term storage let out cooling water completely or mix fresh water with long life coolant and fill the radia...

Page 50: ... the coolant level drops due to evaporation add water only to keep the antifreeze mixing ratio less than 50 In case of leakage add antifreeze and water in the specified mixing ratio before filling into the radiator Replacing Radiator Hose Water pipes Replace the hoses and clamps See Checking Radiator Hose and Clamp in EVERY 200 HOURS in PERIODIC SERVICE section Replacing Fuel Hose Consult your loc...

Page 51: ...u intend to store your vehicle for an extended period of time follow the procedures outlined below These procedures will insure that the vehicle is ready to operate with minimum preparation when it is removed from storage 1 Check the bolts and nuts for looseness and tighten if necessary 2 Apply grease to vehicle areas where bare metal will rust also to pivot areas 3 Unload from cargo bed 4 Inflate...

Page 52: ...ressure and inflate the tires if they are low 2 Install battery before installing the battery Be sure it is fully charged 3 Check to see if the fan works 4 Check all fluid levels engine oil transmission oil engine coolant transmission coolant and any attached implements 5 Start the engine Observe all gauges If all gauges are functioning properly and reading normal move the vehicle outside Once out...

Page 53: ...ove the battery from the vehicle charge and store it indoors install it on the vehicle only when the vehicle is going to be used Engine power is insufficient Insufficient fuel The injector is clogged Crankshaft position sensor is Bad The air cleaner is clogged Spark plug is dirty or fouled Ignition coil is bad Check the fuel system Clean or replace the injector Replace crankshaft position sensor C...

Page 54: ...1 O2A Circuit Low Voltage P0132 O2A Circuit High Voltage P0031 O2A Heater Circuit High Voltage P0032 O2A Heater Circuit Low Voltage P0201 Injector 1 Circuit Malfunction P0202 Injector 2 Circuit Malfunction P0230 FPR Coil Circuit Low Voltage or Open P0232 FPR Coil Circuit High Voltage P0336 CKP Sensor Noisy Signal P0337 CKP Sensor No Signal P0351 Cylinder 1 Ignition Coil Malfunction P0352 Cylinder ...

Page 55: ... top of plates look whitish Refillable type battery only Battery was used with an insufficient amount of electrolyte Add distilled water and charge the battery Regularly check the electrolyte level Battery was used with too much without recharging Charge battery Insufficiently Charge battery properly Recharging is impossible Battery life expired Replace battery Terminals are severely corroded and ...

Page 56: ...d outside gears of transmission shaft Replace the gears Big clearance of transmission gears Replace the gears Non good connection of gear end face Replace the gears Less vehicle power Parking brake Loosen the lay up rod Non full Uncoupling for disc brake Contact the distributor CVT transmission sliding Removing the grease for the clutch Replace CVT transmission belt Replace the clutch No good brak...

Page 57: ...Introduction HS 200UTV 2 HS 250UTV 2 1 57 3 Windlass 4 Motor Scan KF90121 ...

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