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Hisun HS1P65MM Operator'S Manual Download Page 33

Periodic Service 

 

10-4

 

 

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  under  the  vehicle  for  such 
items  as  loose  bolts,  trash  build-up,  oil  or 
coolant leaks, broken or worn parts 

 

■

 Checking and Refueling 

 CAUTION 

To avoid personal injury: 

 

Do not smoke while refueling. 

 

Be sure to stop the engine before

refueling. 

1.  Turn  the  key  switch  to  “ON”,  check  the 

amount of fuel by the fuel gauge. 

2.  Fill fuel tank when fuel gauge shows1/4 or 

less fuel in the tank. 

 

IMPORTANT 

If oil level is low, do not run the engine. 
Checking engine oil level 
1.  Park the vehicle on a flat surface, remove 

Fuel tank capacity  13.5 (3.6

±0

.1U.S.GALS)

the seat, open the adjust hatch cover.  

2.  To  check  the  oil  level,  draw  out  the 

dipstick, wipe it clean, replace it, and draw 
it out again, check to see if the level is too 
low, add new oil to the prescribed level on 
the dipstick. 

 

~

① ②

  Oil level is acceptable within this range 

①

  Oil Level 

②

  Oil dipstick 

④

  Oil cap 

 

■

 Checking Coolant Level 

 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 

removing the cap completely. 

1.  Park the vehicle on a flat surface, access 
the  panel  under  the  hood,  set  the  parking 
brake, and shut off the engine. 
2.      Check  to  see  that  the  coolant  level  is 
between  the  “FULL”  and”  LOW”  marks  of 
recovery tank. 
3.  When the coolant level drops due to 

 

Summary of Contents for HS1P65MM

Page 1: ...safe and enjoyable vehicle operation If you have any questions regarding the operation or maintenance of your UTV please call Monkija Trail Park Oy at 0086 23 61020546 or go to Pajalantie 6a 37550 Lempaala Finland 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 LAB...

Page 2: ...al 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 procedures ...

Page 3: ...lace where the temperature is higher than 4 F 20 C Start the vehicle after the vehicle 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 vehicle for the first time will take longer because t...

Page 4: ...riodic Service Hood Operator s Seat The Cargo Bed Shock Adjustment Jack up point Coolant Level radiator screen 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 3 8 4 8 5 8 5 8 5 8 6 9 1 9 1 9 1 10 1 10 1 10 1 10 2 10 2 10 3 10 4 10 5 Subject brake fluid level brake pedal parking brake Greasing engine start Wheel ...

Page 5: ...Introduction HS164 4 1 5 LOCATION OF PARTS Roll over protective structure Front hood Headlights Turn signal lights Front bumper ...

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

Page 7: ...Introduction HS164 4 1 7 Seat belts Seat ...

Page 8: ...d always wear protective equipment such as helmet boots eye protection ear 5 Only a qualified driver should operate this vehicle 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...

Page 9: ...er area of the vehicle Never try to stand while operating the vehicle 14 Do not tow passengers or attempt to jump the vehicle 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 a...

Page 10: ... 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 7 Instructions for carrier 1 Never carry a passenger in the cargo area 2 Evenly distribute the cargo to maintain proper stability Avoid overloading the carrier Cargo should be secu...

Page 11: ...ld 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...

Page 12: ...Warning Labels 3 1 Warning and caution labels 1 2 3 4 5 6 7 8 9 10 11 12 ...

Page 13: ...y yourself However when in need 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 Num...

Page 14: ...ark plug DR8EA Fuel Capacity L 13 5 Transmission CVT Wheels 4 Differential lock Electric control switch Gear selection Hi Lo range forward Neutral Reverse Brakes Front Rear Wet disk brake Parking brake Rear wheel hand lever Steering Electronic power Suspension Front Independent Dual A arm type Rear Independent Dual A arm type Dimensions Length mm in 2410 94 9 Width mm in 1235 48 6 Height mm in 162...

Page 15: ...g lbs 353 778 2 Cargo bed Width mm in 730 28 7 Length mm in 1020 40 2 Depth mm in 250 9 8 Cargo bed capacity kg lbs 50 110 2 Tire Front 180 85 10 or 175 85 10 Rear 255 60 10 Max speed km h T3a 40 T3b 60 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 ...

Page 16: ...sult 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 200kg 440 lb operator one passenger opt acc weight Max rolling weight 2...

Page 17: ... 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 OPERATION CHEC...

Page 18: ...erator 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 PARK Rele...

Page 19: ... 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 Operatio...

Page 20: ... 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 the engine...

Page 21: ...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 clearances Smal...

Page 22: ... 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 half of the turn toggle switch To indicate a left turn push on the upper half of the...

Page 23: ... on icy wet or loose surface make sure the vehicle is correctly loaded to avoid skidding or loss of steering control Reduce the speed The brake pedal is the left pedal on the foot board Depress the pedal to slow or stop the vehicle Brake pedal 4 Selecting the correct gear Gear Shift Lever CAUTION To avoid personal injury Avoid changing gears when ascending or descending a slope Before ascending or...

Page 24: ...t force the lever Set the parking brake slightly depress the accelerator pedal and release it to neutral position then shift the lever When the lever is hard to disengage do not force the lever Depress the brake pedal fully then shift the lever Damage may occur with wrong shifting operation AN accident could occur through improper use of the gear shift lever 5 Release the parking brake and start s...

Page 25: ...itch to ON the fuel gauge will indicate the fuel level Be careful not to fully empty the fuel tank Otherwise air may enter the fuel system Fuel gauge Coolant Temperature Gauge CAUTION To avoid personal injury Do not remove radiator cap until coolant temperature is well below its boiling point Then loosen cap slightly to relieve pressure before removing cap completely 1 With the key switch ON the t...

Page 26: ...Operating the Vehicle 8 6 Speedometer The hour meter indicates in five digits the hours the vehicle has been used Hour meter The speedometer indicates the traveling speed Speedometer ...

Page 27: ...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 done aft...

Page 28: ...e 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 Fuel l...

Page 29: ...very 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 have an...

Page 30: ... to release the latch and lift the hood off Operator s Seat To open the seat raise the seat to the forward position Operator s seat WARNING POTENTIAL HAZARD Aloose seat WHAT CAN HAPPEN The operator could lose control or the operator or passenger could fall if the seat is loose during operation HOW TO AVOID THE HAZARD Make sure the seat is mounted firmly Moving the Seat Forward and Backward Pull ha...

Page 31: ...le to raise the cargo bed with the gas spring elasticity Cargo bed handle UP DOWN To lower the cargo bed Press down the cargo bed hard to make the gas spring contractive till it is locked Gas spring Front and Rear Shock Adjustment The spring preload can be adjusted to suit rider s weight and any passenger weight NOTE Never turn an adjusting mechanism beyond the minimum and maximum settings Adjust ...

Page 32: ...TO AVOID THE HAZARD Always adjust the shock absorbers on the left and right side to the same setting JACK UP POINT WARNING To avoid personal injury death or vehicle damage Do not work under the vehicle unless it is secured by safe stands or suitable blocking Front End Jack stand at the front bumper only Jack Front bumper Rear End Jack the rear only after placing a wooden block under the right and ...

Page 33: ... IMPORTANT If oil level is low do not run the engine Checking engine oil level 1 Park the vehicle on a flat surface remove Fuel tank capacity 13 5 3 6 0 1U S GALS the seat open the adjust hatch cover 2 To check the oil level draw out the dipstick wipe it clean replace it and draw it out again check to see if the level is too low add new oil to the prescribed level on the dipstick Oil level is acce...

Page 34: ...personal injury Be sure to stop the engine before removing the screen 1 Park the vehicle on a flat surface 2 Remove the radiator cover 3 Detach the screen and remove all foreign materials Radiator screen IMPORTANT Radiator screen must be cleaned from debris to prevent engine from overheating Checking brake fluid level CAUTION TO avoid personal injury Never operate the vehicle if the brake fluid is...

Page 35: ... pedal 1 Inspect the brake pedals for free play and smooth operation Adjust if incorrect free play is found see checking brake pedal in EVERY 200 HOURS in PERIODIC SERVICE section Brake pedal FREE TRAVEL PEDAL STROKE Checking parking brake Pull the parking brake lever to apply the brakes with the key switch in the ON position and the parking brake indicator should come on To release the brake push...

Page 36: ...efore operating vehicle 2 Replace if damaged Checking tire inflation pressure Though the tire pressure is factory set to the prescribed level it naturally drops slowly in the course of time thus check it every day and inflate as necessary tire sizes inflation pressure Front 180 85 10 or 175 85 10 45kPa 0 46kgf cm2 7psi Rear 255 60 10 45kPa 0 46kgf cm2 7psi EVERY 50 HOURS Greasing Apply a small amo...

Page 37: ...ting If the vehicle does not pass the test do not operate the vehicle Preparation before testing 1 Place all control levers in the NEUTRAL position 2 Set the parking brake and stop the 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 cran...

Page 38: ...primary element 2 Clean the primary elements 1 When dry dust adheres to the element blow compressed air from the inside turning the element Pressure of compressed air must be under 205kpa 2 When carbon or oil adheres to the element soak the element in detergent for 15 minutes then wash it several times in water rinse with clean water and dry it naturally after element is fully dried inspect inside...

Page 39: ...y or every 100 service hours whichever comes first 1 Park the vehicle on a flat surface and tilt the cargo bed 2 The fuel line is made of rubble and ages regardless of service period 3 If the fuel line and clamps are found to be damaged or deteriorated replace them 4 Check fuel filter if it is clogged by debris or contaminated with water replace it IMPORTANT When the fuel line is disconnected for ...

Page 40: ...he battery start with the negative terminal first when connection the cable to the battery start with the positive terminal first Always check battery charge by using a voltmeter Battery 1 To slow charge the battery connect the battery positive terminal to the charger positive terminal and the negative to the negative then recharge in the standard fashion 2 A boost charge is only for emergencies i...

Page 41: ...injury Before touching any part of an exhaust system be absolutely sure that it has sufficient time to cool Always wear safety goggles and face mask The particulate matter contained in the muffler contains chemicals that are harmful to people animals and marine life If you are unable to do this work have it done by your dealer Cleaning spark arrester of muffler Maintenance cleanout procedure The s...

Page 42: ...to stop the engine before replacing oil Allow engine to cool down sufficiently oil can be hot and can burn oil can be hot and can burn 1 Park the vehicle on flat surface and remove the seat open the adjust hatch cover 2 To drain the used oil remove the drain plug at the bottom of the engine and completely drain the oil into an oil pan 3 After draining reinstall the drain plug 4 Fill with the new o...

Page 43: ...T To prevent serious damage to the engine use only a genuine filter Checking Brake Pedal CAUTION Stop the engine and chock the wheels before checking brake pedal If movement is outside of the specifications contact your local dealer for adjusting the brake Checking the brake pedal free travel Proper brake pedal free travel 7 to 14mm 0 3 to in On the pedal 1 Release the parking brake 2 Slightly dep...

Page 44: ...or six months whichever comes first 1 If hose clamps are loose or water leaks tighten bands securely 2 Replace hoses and tighten hose clamps securely if radiator hoses are swollen hardened or cracked Replace hoses and hose clamps every 2 years or earlier if checked and found that hoses are swollen hardened or cracked Radiator hose Clamp bands Precaution at Overheating Take the following actions in...

Page 45: ...at once Tire Tread Depth Always replace the tires when the tread depth is worn to minimum allowable 3mm 0 12in EVERY 500 HOURS Replacing Fuel Filter Consult your local dealer for this service EVERY 600 HOURS Adjusting Engine Valve Clearance Consult your local dealer for this service EVERY 1500 HOURS Checking Injection and Fuel Pump Consult your local dealer for this service EVERY 1 YEAR Replacing ...

Page 46: ...6 After flushing fill with clean water and anti freeze until the coolant level is just below the radiator cap Install the radiator cap securely 7 Fill with fresh water up to the FULL mark on the recovery tank 8 Start and operate the engine for few minutes 9 Stop the engine and let it cool 10 Check coolant level of recovery tank and coolant if necessary Coolant capacity 2 2 2 3U S qts Recovery tank...

Page 47: ...hylene glycol EG type for this engine 2 Before employing LLC mixed cooling water fill the radiator with fresh water and empty it again Repeat this procedure 2 or 3 times to clean up the inside 3 Mixing the LLC 4 The procedure for the mixing of water and antifreeze differs according to the make of the antifreeze and the ambient temperature Refer to SEA J1034 standard more specifically also to SAE J...

Page 48: ...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 loca...

Page 49: ...he 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 the tire to a pressure a little higher than usual 5 Charge the engine oil and run the engine to circulate oil throughout the engine block and internal moving parts for about 5 minutes 6 With all implements lowered to the ground co...

Page 50: ...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 outside park the vehicle and let the engine idle for at least five minutes Shut the engine off and work around vehicle and make a visual inspection looking for evidence of oil or water leak...

Page 51: ...xtensions These installation and operating instructions have to be kept with the vehicle documents Installation instructions The Coupling ball is a safety component and should only be installed by qualified personnel The Coupling ball can be easily installed and removed with the normal force of your hands Any alteration and or conversion of the device will be locked automatically Coupling ball is ...

Page 52: ...tery 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 Clean or rep...

Page 53: ...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 2 Ignition Coil Malfunction P0505 Idle Speed Control Erro...

Page 54: ...scription P0500 VSS No Signal P0850 Park Neutral Switch Error P0445 CCP short to high P0444 CCP short to low open P0171 BLM Max Adapt Kohler Special P0172 BLM Min Adapt Kohler Special P0174 PE System Lean Kohler Special If you have any questions consult your local dealer ...

Page 55: ...ates 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 heat up Po...

Page 56: ...rance for the inner and 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 t...

Page 57: ...OPTIONS 13 1 Consult your local dealer for further details 1 Roof 2 Windscreen 3 Windlass 4 Motor Scan KF90121 ...

Page 58: ...1 2 Type HS164 4 1 2 1 Variant s HS164 4 1 2 2 Version s A 1 2 3 Commercial name s if available N A 1 2 4 Type approval number s of the previous stage s N A 1 3 Category subcategory and speed index of the vehicle T3a The Driver s exposure to noise level result is 88 8 dB A Limit 86 dB A according to test method 1 of Annex XIII to EU 1322 2014 Place Chongqing China Date July 2018 Signature Name and...

Page 59: ...1 2 Type HS164 4 1 2 1 Variant s HS164 4 1 2 2 Version s B 1 2 3 Commercial name s if available N A 1 2 4 Type approval number s of the previous stage s N A 1 3 Category subcategory and speed index of the vehicle T3b The Driver s exposure to noise level result is 89 9 dB A Limit 86 dB A according to test method 1 of Annex XIII to EU 1322 2014 Place Chongqing China Date July 2018 Signature Name and...

Page 60: ...ry subcategory and speed index of the vehicle T3a The value of the vibration level measured according to Annex XIV to EU 1322 2014 is Driver mass awS m s 2 Requirement 59 1kg Test run 1 1 22 Deviation 10 between test run 1 2 and Arithmetic mean awS 1 25 m s 2 Test run 2 1 24 Arithmetic mean 1 23 98 5kg Test run 1 1 21 Deviation 10 between test run 1 2 and Arithmetic mean awS 1 25 m s 2 Test run 2 ...

Page 61: ...e s N A 1 3 Category subcategory and speed index of the vehicle T3b The value of the vibration level measured according to Annex XIV to EU 1322 2014 is Driver mass awS m s 2 Requirement 59 1kg Test run 1 1 22 Deviation 10 between test run 1 2 and Arithmetic mean awS 1 25 m s 2 Test run 2 1 24 Arithmetic mean 1 23 98 5kg Test run 1 1 21 Deviation 10 between test run 1 2 and Arithmetic mean awS 1 25...

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