Hisun HS450ATV-4 Owner'S Manual Download Page 142 | Manualshive

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Periodic Maintenance and Adjustment 8-46

Check and solution to Common Problems in Vehicle

The following tables contain common problems which commonly arise while operating an ATV.
Potential solutions to these problems are also listed beside each problem.
Some ATV repairs require technical skill. If you cannot repair the ATV yourself contact an
Authorized dealer.

WARNING

POTENTIAL HAZARD

Checking the fuel system while smoking or near an open flame.

WHAT CAN HAPPEN

Fuel can ignite or explode, causing severe injury or property damage.

HOW TO AVOID THE HAZARD

Do not smoke when checking the fuel
system. Make sure there are no open flames or sparks in the area, including
pilot lights from water heaters or furnaces.

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Summary of Contents for HS450ATV-4

Page 1: ...hisunmotors com FORGE 450 550 750 OWNER S MANUAL TM ATV Owners Manual Rev06301501 indd 1 6 30 2015 2 13 59 PM ...

Page 2: ...Owner s Manual ...

Page 3: ...all of the instructions herein will provide the knowledge needed to operate this ATV in a safe and enjoyable manner For questions regarding this ATV please call 972 446 0760 IMPORTANT SAFETY MESSAGES READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR ATV MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV NEVER OPERATE THE ATV WIT...

Page 4: ...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 passenger bystander or a person inspecting or repairing the machine A CAUTION indicates special precautions that must be taken to avoid damage to the machine A NOTE provides key information to make procedures easie...

Page 5: ...e 6 2 on the warming up process When the temperature is higher than 100 F 38 and you park the ATV after operating at high speeds please keep the engine running for 3 minutes at idle and make sure that the radiator fan continues for 3 minutes to prevent the coolant from boiling Then turn off the power switch Your ATV may have a 3 minute automatic continuous fan after ignition shut down When you par...

Page 6: ...ck time adjustment 4 6 Fault Code indicator 4 8 Fuel level indicator 4 8 Handlebar Switches 4 9 Throttle Lever 4 14 Speed Limiter 4 15 Front brake lever 4 16 Brake pedal and rear brake lever 4 16 Drive select lever 4 17 Fuel Tank Cap 4 18 Seat 4 18 Front Carrier 4 19 Rear Carrier 4 20 Front and rear shock absorber adjustment 4 20 Auxiliary DC jack 4 22 Pre Operation Checks 5 1 Front and rear brake...

Page 7: ...d good Judgment 7 1 Apparel 7 4 Speed Limiter 7 8 Loading and Accessories 7 8 During Operation 7 9 Modifications 7 11 Exhaust System 7 11 Pay attention to the road conditions 7 12 Turning Your ATV 7 16 Climbing Uphill 7 19 Crossing a slope 7 21 Riding Downhill 7 23 Crossing Through Shallow Water 7 25 Riding Over Rough Terrain 7 27 Sliding and Skidding 7 28 Periodic Maintenance and Adjustment 8 1 P...

Page 8: ...t Brake Lever Free Play 8 33 Adjusting the rear Brake Lever 8 34 Adjusting the Brake Pedal 8 35 Adjusting the rear brake light switch 8 36 Lubricating the Brake Lever and Brake Pedal 8 37 Rear Knuckle Upper and Lower Pivot Lubrication 8 38 Wheel Removal 8 39 Wheel Installation 8 39 Battery 8 40 Battery Maintenance 8 41 Fuse Replacement 8 41 Replacing A Headlight Bulb 8 43 Tail brake light bulb rep...

Page 9: ...ION LABELS Read and understand all of the labels on your machine They contain important information for safe and proper operation of your ATV Never remove any labels from your ATV If a label becomes difficult to read or comes off a replacement label is available from your dealer 1 2 3 ...

Page 10: ...Location of the Warning and Safety Labels 1 2 4 5 6 7 ...

Page 11: ...1 3 Location of the Warning and Safety Labels 8 9 10 11 ...

Page 12: ...ual and all labels carefully and follow the operating procedures described Never operate an ATV without proper training or instruction Take a Training Course Beginners should receive training from a certified instructor Always follow the age recommendation This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age Never permit anyone to operate this ATV unless t...

Page 13: ...or while operating or being a passenger on this ATV Never operate at speeds too fast for your skills or the conditions Always go at a speed that is proper for the terrain visibility and operating conditions and your experience Never attempt wheelies jumps or other stunts Always inspect your ATV each time you use it to make sure it is in safe operating condition Always follow the inspection and mai...

Page 14: ...abilities Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills as described in this manual Check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly Never go over the top of a hill at high speed Always follow proper procedure...

Page 15: ...g a hill If you stall or roll backwards follow the special procedure for braking described in this manual Dismount on the uphill side or to a side if pointed straight uphill Turn the ATV around and remount following the procedure described in this manual Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as large rocks or fallen trees Alway...

Page 16: ...s or people behind you when you operate in reverse When it is safe to proceed in reverse go slowly Always use the size and type tires specified in this manual Always maintain proper tire pressure as described in this manual Never modify an ATV through improper installation or use of accessories Never exceed the stated load capacity for an ATV Cargo should be properly distributed and securely attac...

Page 17: ...ARD Starting or running the engine in a closed area WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time HOW TO AVOID THE HAZARD Always operate your ATV in an area with adequate ventilation ...

Page 18: ...oking or while in the vicinity of sparks open flames or other sources of ignition such as the pilot lights of water heaters and clothes dryers When transporting the ATV in another vehicle be sure it is kept upright Otherwise fuel may leak out of the fuel tank WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries HOW TO AVOID THE HAZARD If you swallow some gasoline or inhale a lot of gasolin...

Page 19: ...3 1 Description and Vehicle Identification ...

Page 20: ...Description and Vehicle Identification 3 2 ...

Page 21: ... vehicle identification number and model label information in the spaces provided for assistance when ordering spare parts from a dealer or for reference in case the vehicle is stolen 1 VEHICLE IDENTIFICATION NUMBER Vehicle identification number The vehicle identification number is stamped into the frame 1 Vehicle identification number NOTE The vehicle identification number VIN is used to identify...

Page 22: ...pective switch positions are as follows 1 Ignition switch 2 OFF 3 ON ON The engine can be started only at this position and the headlights and taillight come on when the light switch is on OFF All electrical circuits are switched off The key can be removed in this position ...

Page 23: ...temperature gauge Low Range Indicator Light L This indicator light comes on when the drive select lever is in the L position Mechanical Parking Brake Indicator Light This indicator light comes on when the mechanical parking brake is applied High Range Indicator Light H This indicator light comes on when the drive select lever is in the H position Neutral Indicator Light N This indicator light come...

Page 24: ...ine to cool down for about 15 minutes CAUTION The engine may overheat if the vehicle is overloaded If this happens reduce the load to specification After restarting make sure that the light is out Continuous use while the light is on may cause damage to the engine High beam indicator The light being on means headlight is at high beam mode Position light indicator The light being on means that the ...

Page 25: ...PS system the fault indicator light will illuminate At the same time fault indicator of EPS system will display the fault code for maintenance If the fault indicator light is illuminated stop the ATV and turn the ATV to the off position After a few moments turn the ATV to the on position and see if the EPS indicator light is still illuminated If the EPS indicator light is not illuminated the ATV c...

Page 26: ...h shows the speed an odometer which shows the total distance covered a tripometer which can be cleared and then show any new distances traveled an RPM indicator which shows the revolutions per minute of the engine a clock an EFI fault code indicator which shows the fault code for problems with the EFI Odometer and trip meter modes On the display panel there are two large buttons one located on the...

Page 27: ...el This information will enable you to judge the fuel consumption To change the display from miles per hour to kilometers per hour press the right side button on the display This will also change the displayed mileage from miles to kilometers Clock time adjustment Press the left button and hold for three seconds and the clock goes into the hour set mode 1 Press the right button to set the hour 2 P...

Page 28: ... differential is not operational and is locked When riding an ATV on muddy and slippery roads or when climbing a steep hill make sure the 4WD lock indicator is on When riding on a flat road at a comparatively high speed adjust the settings to 2WD UNLOCK and there are no symbols in either of the 4WD indicators Riding an ATV while the differential is functioning and is NOT locked may improve the sta...

Page 29: ...e are more than one fault code they will be shown in rolling sequence When fault codes are present in order to see the time press the clock button the time will be shown Then after five seconds the fault code returns again Only after the fault is fixed will the time show automatically The description for the fault codes are shown in Chapter 11 of this manual Fuel level indicator The fuel level dis...

Page 30: ...illight Set the switch to to turn on the high beam and the taillight Set the switch to OFF to turn off all the lights Turn switch to position the emergency light inside of headlights and tail light are lit CAUTION Do not use the headlights with the engine turned off for more than thirty minutes The battery may discharge to the point that the starter motor will not operate properly If this should h...

Page 31: ...d to the left when turning left Engine stop switch Make sure that the engine stop switch is set to before starting the engine The engine stop switch controls ignition and can be used at all times to stop the engine especially in an emergency The engine will not start or run when the engine stop switch is set to Horn switch Press this switch to activate the horn Emergency light switch Press this sw...

Page 32: ...ial gear lock switch LOCK 4WD Select the appropriate drive according to terrain and the conditions Two wheel drive 2WD Power is supplied to the rear wheels only Four wheel drive 4WD Power is supplied to the rear and front wheels Four wheel drive with the differential gear locked 4WD LOCK Power is supplied to the rear and front wheels when the differential gear is locked Unlike the 4WD mode all whe...

Page 33: ... moving may cause the vehicle to unexpectedly handle differently This could distract the operator and increase the risk of losing control and an accident HOW TO AVOID THE HAZARD Always stop the vehicle before changing from 2WD to 4WD or from 2WD to 2WD Differential UNLOCK or vice versa On Command Four Wheel Drive Switch 2WD 4WD 1 2WD 4 WD lever switch 2 2WD selector button To change from 2WD to 4W...

Page 34: ...K button 2 2WD 4WD lever switch To lock the differential gear in 4WD make sure the On Command four wheel drive switch is set to 4WD stop the ATV move the lever to position and then set the switch to LOCK When the differential gear is locked the differential gear lock indicator light will come on along with the indicator in the speedometer unit display To release the differential gear lock stop the...

Page 35: ...ot make a sharp enough turn for the speed you are traveling HOW TO AVOID THE HAZARD Always ride at a slow speed when the vehicle is in 4WD LOCK and allow extra time and distance for maneuvers Throttle lever Once the engine is running movement of the throttle lever will increase the engine speed Regulate the speed of the machine by varying the throttle position Because the throttle is spring loaded...

Page 36: ...se an accident HOW TO AVOID THE HAZARD Check the operation of the throttle lever before you start the engine If it does not work smoothly check for the cause Correct the problem before riding the ATV Consult a dealer if you can t find or solve the problem yourself Speed limiter The speed limiter keeps the throttle from fully opening even when the throttle lever is pushed to the maximum Turning in ...

Page 37: ...screw out more than 12 mm 0 47 in Always make sure the throttle lever free play is adjusted to 3 5 mm 0 12 0 20 in See page 8 42 Front brake lever The front brake lever is located on the right handlebar Pull it toward the handlebar to apply the front brake 1 Brake lever Brake pedal and rear brake lever The brake pedal is located on the right side of the ATV and the rear brake lever is located on t...

Page 38: ...pedal 1 Parking brake lever Drive select lever The drive select lever is used to shift your machine into the low high neutral reverse and park positions Refer to pages 6 2 6 4 for the drive select lever operation 1 Drive select lever ...

Page 39: ...ol Functions Fuel tank cap Remove the fuel tank cap by turning it counterclockwise 1 Fuel tank cap SEAT To remove the seat pull the seat lock lever upward and pull up the seat at the rear 1 Seat 2 Seat lock lever ...

Page 40: ...the seat insert the projections on the front of the seat into the seat holders and push down on the seat at the rear NOTE Make sure that the seat is securely filed Front carrier Front carrier Maximum load limit 20kg 44lb 1 Front carrier ...

Page 41: ...ted to suit rider s weight and any passenger weight NOTE When adjusting the rear shock absorbers the Rear wheels need to be removed See pages 8 47 8 48 for removal and installation procedures Adjust the spring proud as follows To increase the spring preload turn the adjusting ring in direction a To decrease the spring preload turn the adjusting ring in direction b ...

Page 42: ... Functions 4 21 1 Spring preload adjusting ring 2 Position indicator NOTE A special wrench can be obtained at a dealer to make this adjustment Standard position B A Minimum soft E Maximum hard 1 Special wrench ...

Page 43: ...s on the left and right side to the same setting Auxiliary DC jack The auxiliary DC jack is located at the front right side of the ATV The auxiliary DC jack can be used for suitable work lights radios etc The auxiliary DC jack should only be used when the engine is running 1 Auxiliary DC jack cap 1 Set the light switch to OFF 2 Start the engine See pages 6 1 6 3 3 Open the auxiliary DC jack cap an...

Page 44: ... accessories requiring move than the above maximum capacity This may overload the circuit and cause the fuse to blow If accessories are used without the engine running or with the headlights turned on the battery will lose its charge and engine starting may become difficult Do not use an automotive cigarette lighter or other accessories with a plug that gets hot because the jack can be damaged ...

Page 45: ... necessary 5 6 Coolant reservoir Check coolant level in reservoir Fill with coolant if necessary 5 7 8 24 8 29 Final gear oil Differential gear oil Check for leakage 5 6 5 7 8 21 8 23 Throttle Check for proper throttle cable operation and free play 5 8 8 38 Wheels and tires Check tire pressure wear and damage 5 9 5 11 8 47 8 48 Fittings and fasteners Check all fittings and fasteners 5 8 Lights and...

Page 46: ...d schedules described in the Owner s Manual Front and rear brakes Brake levers and brake pedal Check that there is no free play in the front brake lever If there is free play have a dealer adjust it Check for correct free play in the rear brake lever If the free play is incorrect adjust it See page 8 42 8 43 Check for correct brake pedal height If the pedal height is incorrect have a dealer adjust...

Page 47: ...cted by a dealer Brake operation Test the brakes at slow speed after starting out to make sure they are working properly If the brakes do not provide proper braking performance inspect the brake pads for wear See page 8 38 8 39 WARNING POTENTIAL HAZARD Riding with improperly operating brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD Alwa...

Page 48: ...se regular unleaded gasoline with a pump octane number R M 2 of 86 or higher or research octane number of 91 or higher If knocking or pinging occurs use a different brand of gasoline or premium unleaded fuel Unleaded fuel will give you longer spark plug life and reduced maintenance cost Gasohol The ATV uses an electric fuel injection system and its emissions completely meet the requirements of rel...

Page 49: ... severe injury Fuel expands when it heats up If the fuel tank is overfilled fuel could spill out due to heat from the engine or the sun HOW TO AVOID THE HAZARD Do not overfill the fuel tank Be careful not to spill fuel especially on the engine or exhaust pipe Wipe up any spilled fuel immediately Be sure the fuel tank cap is closed securely Do not refuel right after the engine has been running and ...

Page 50: ...cified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign material enters the crankcase Recommended engine oil type and quantity See page 10 2 Final gear oil Make sure the final gear oil is at the specified level Add oil as necessary See pages 8 21 8 22 for details Recommended oil SAE 80 API GL 4 Hypoid gear oil If desired an SAE 80W90 hypoid gear oil may ...

Page 51: ...engine temperature The coolant level is satisfactory if it is between the minimum and maximum level marks on the coolant reservoir If the coolant level is at or below the minimum level mark add distilled water to bring the level up to maximum level mark Change the coolant every two years See pages 8 25 8 26 for details CAUTION Hard water or salt water is harmful to the engine You may use soft wate...

Page 52: ...ever Check to see that the throttle lever operates correctly It must open smoothly and spring back to the idle position when released Have a dealer repair as necessary for proper operation Fittings and fasteners Always check the tightness of chassis fittings and fasteners before a ride Take the machine to a dealer or refer to the Service Manual for correct tightening torque Lights Check the headli...

Page 53: ...ecommended tire pressure Front 10psi 70kpa 0 7 kgf cm2 Rear 10psi 70kpa 0 7 kgf cm 2 Check and adjust tire pressures when the tires are cold Tire pressures must be equal on both sides 3 Tire pressure below the minimum specified could cause the tire to dislodge from the rim under severe riding conditions The following are minimums Front 9psi 63 kpa 0 64kgf cm2 Rear 9psi 63 kpa 0 64kgf cm2 4 Use no ...

Page 54: ...nd use the second reading Dust or dirt in the gauge could cause the first reading to be incorrect Set pressure with tires cold Set tire pressures to the following specifications Recommended pressure Minimum Maximum Front 10psi 70kpa 0 70kgf cm2 9 psi 63kpa 0 64kgf cm 2 11psi 77kpa 0 77kgf cm 2 Rear 10psi 70kpa 0 70kgf cm2 9 psi 63kpa 0 64kgf cm 2 11psi 77kpa 0 77kgf cm 2 1 Low pressure tire gauge ...

Page 55: ...5 11 Pre Operation Checks Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire a Tire wear limit ...

Page 56: ...ask your dealer Starting a cold engine WARNING POTENTIAL HAZARD Freezing control cables in cold weather WHAT CAN HAPPEN You could be unable to control the ATV which could lead to an accident or collision HOW TO AVOID THE HAZARD When riding in cold weather always make sure all control cables work smoothly before you begin riding 1 Apply the rear brake pedal 2 Turn the main switch to ON and the engi...

Page 57: ...r to operating the engine for the first time Starting a warm engine To start a warm engine refer to the Starting a cold engine section The throttle should be opened slightly Warming up To get maximum engine life always warm up the engine before starting off Never accelerate hard with a cold engine To warm up the engine operate the ATV a one third throttle for approximately 3 km or let the engine r...

Page 58: ...t the drive select lever is completely shifted into position 3 Open the throttle lever gradually Shifting Neutral to Reverse NOTE The drive select lever cannot be shifted into or from reverse or park without applying the rear brake 1 Bring the ATV to a complete stop and return the throttle lever to the closed position 2 Apply the brake pedal 3 Shift from neutral to reverse or from reverse to park ...

Page 59: ...the ATV starts moving 4 Check behind for people or obstacles and then release the brake pedal 5 Open the throttle lever gradually and continue to watch to the rear while backing WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN You could hit an obstacle or person behind you resulting in serious injury HOW TO AVOID THE HAZARD When you shift into reverse make sure there are no...

Page 60: ...d drive components Do not operate at full throttle or high speeds during the first three hours of use Use of any engine oil not mentioned in this manual will cause severe damage to the engine Engine Break In There is never a more important period in the life of your vehicle than the period between zero and 25 hours For this reason we ask that you carefully read the following material Because the e...

Page 61: ...time to time Do not operate it at one set throttle position 10 25 Hours Avoid prolonged operation above 3 4 throttle Rev the vehicle freely but do not use full throttle at any time After Break In The vehicle can now be operated normally Brake System Break in Apply only moderate braking force for the first 50 stops Aggressive or overly forceful braking when the brake system is new could damage brak...

Page 62: ... inclines If you must park on an incline place the machine transversely across the incline apply the parking brake and block the front and rear wheels with rocks or other objects Do not park the ATV at all on hills that are so steep you could not walk up them easily 1 Bring the machine to a stop by applying the brakes 2 Stop the engine 3 With the brake pedal applied shift the drive select lever to...

Page 63: ...y and securely mounted An accessory which will shift position or come off while you are riding could affect your ability to control the ATV Do not mount an accessory where it could interfere with your ability to control the ATV Examples include but are not limited to a heavy or bulky object attached to the handlebars which could make steering difficult an accessory that limits your ability to move...

Page 64: ...argo 550kgf 1 212lbf Tongue weight vertical weight on trailer hitch point 30kgf 66lbf Do not exceed the maximum tongue weight You can measure tongue weight with a bathroom scale Put the tongue of the loaded trailer on the scale with the tongue at hitch height Adjust the load in the trailer if necessary to reduce the weight on hitch If you are carrying cargo and towing a trailer include the tongue ...

Page 65: ...top Avoid making sharp turns unless at very slow speeds Avoid hills and rough terrain Choose terrain carefully Added weight affects the stability and handling of the ATV WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capa...

Page 66: ...ctivity providing you with hours of pleasure But it is essential to familiarize yourself with the operation of the ATV to achieve the skill necessary to enjoy riding safely Before you begin to ride be sure you have read this Owner s Manual completely and understand the operation of the controls Pay particular attention to the safety information on pages 2 1 2 7 Please also read all caution and war...

Page 67: ...n accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain Riding your ATV requires skills acquired through practice over a period of time Take the time to learn the basic techniques well before attempting more difficult maneuvers Not recommended for children under 16 years of age ...

Page 68: ...is ATV WHAT CAN HAPPEN Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child HOW TO AVOID THE HAZARD A child under 16 should neve operate this ATV or any Adult sized ATV This ATV is designed to carry the operator and only one passenger ...

Page 69: ...ssenger HOW TO AVOID THE HAZARD Never carry more than one passenger The long seat and passenger area is designed to allow the operator to shift position as needed during operation It is not designed for carrying more than one passenger Apparel WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved motorcycle helmet eye protection and protective clothing WHAT CAN HAPPEN Operating w...

Page 70: ...hout protective clothing increases your chances of severe injury in the event of an accident HOW TO AVOID THE HAZARD Operators and any passenger should always wear an approved motorcycle helmet which fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket long pants Do not operate after consuming alcohol or drugs Operator s performance cap...

Page 71: ...TV Pre operation checks Always perform the pre operation checks listed on page 5 1 before riding for safety and proper care of the ATV WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure ...

Page 72: ...E HAZARD Always use the size and type tires specified in the Owner s Manual for this vehicle on pages Always maintain proper tire pressure as described in the Owner s Manual on page 5 13 WARNING POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions WHAT CAN HAPPEN Increases your chances of losing control of the ATV which can result in an accident HOW TO AVOID THE...

Page 73: ...rew in decreases top speed and turning it out increases top speed 1 Locknut 2 Adjusting screw Loading and accessories Use extra caution when riding the ATV with additional loads such as accessories or cargo The ATV s handling may be adversely affected Reduce your speed when adding additional loads MAXIMUM LOADING LIMIT Vehicle loading limit 288kg 635 lb Total weight of cargo rider and accessories ...

Page 74: ... Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking Always follow the instructions in your Owner s Manual for carrying cargo or pulling a trailer During operation Always keep your feet on the footboards during operation Otherwise your feet may contact ...

Page 75: ...leg may come into contact with the rear wheels which could injure you or cause an accident HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footboards of your ATV during operation Avoid wheelies and jumping You may lose control of the ATV or overturn WARNING POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an a...

Page 76: ...uine or equivalent components designed for use on this ATV and should be installed and used according to instructions If you have questions consult an authorized ATV dealer Exhaust system The exhaust system on the ATV is very hot during and following operation To prevent burns avoid touching the exhaust system Park the ATV in a place where pedestrians or children are not likely to touch it WARNING...

Page 77: ...ot park the ATV in a place where others might be likely to touch it Pay attention to road conditions Know the terrain where you ride Ride cautiously in unfamiliar areas Stay alert for holes rocks or roots in the terrain and for other hidden hazards which may cause the ATV to roll over WARNING You can come upon hidden rocks bumps or holes without enough time to react This could result in the ATV ov...

Page 78: ...rating on excessively rough slippery or loose terrain could cause loss of traction or vehicle control which could result in an accident including an overturn Do not operate on excessively rough slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain Always be especially cautious on these types of surfaces ...

Page 79: ...ain mount a caution flag on the ATV DO NOT use the flag pole bracket as a trailer hitch WARNING Always mount a caution flag on the ATV to make you more visible Keep a lookout for other vehicles Do not ride in areas posted no trespassing Do not ride on private property without obtaining permission ...

Page 80: ...ing on paved surfaces the ATV is designed for off road use and handling maneuvers are more difficult to perform on pavement Shift to the gear position N and follow the instructions to start the engine Once it has warmed up you are ready to begin riding your ATV Remember that the engine and exhaust pipe will be hot while riding and shortly afterwards do not allow skin or clothing to come in contact...

Page 81: ...ion reducing control and increasing the possibility of an accident 1CAUTION Do not shift from low gear L to high H N R or any other shift maneuver without first coming to a complete stop This could damage the engine or drive train Turning your ATV To achieve maximum traction while riding off road in 2WD or 4WD the two rear wheels turn together at the same speed Furthermore when riding in 4WD LOCK ...

Page 82: ...ter speeds Do not turn at speeds too fast for your skills or the surface conditions Operate at a slow speed and allow extra time and distance for maneuvers when in 4WD LOCK As you approach a curve slow down and begin to turn the handlebars in the desired direction As you do so put your weight on the footboard to the inside of the turn opposite the direction you are turning and lean your upper body...

Page 83: ... the front wheels by moving forward on the seat Once you have learned this technique you should be able to do it at higher speeds or in tighter curves Improper riding procedures such as abrupt throttle changes excessive braking incorrect body movements or too much speed for the sharpness of the turn may cause the ATV to tip If the ATV begins to tip over to the outside while negotiating a turn lean...

Page 84: ...rol WARNING The vehicle can overturn more easily on extremely steep hills than on level surfaces or small hills Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting large hills It is important when climbing a hill to make sure that your weight is transferred forward on the ATV This can be accomplished by leaning forward and on steep...

Page 85: ...e other side of the hill If you are climbing a hill and you find that you have misjudged being able to make it to the top you should turn the ATV around while you still have forward motion provided you have the room to do so and go down the hill WARNING Use proper gear and maintain a steady speed when climbing a hill If you lose all forward speed Keep weight uphill Apply the brakes Shift to the pa...

Page 86: ...on slopes be sure not to make sharp turns either uphill or downhill If your ATV does begin to tip gradually steer in the downhill direction if there are no obstacles in your path As you regain steady balance gradually steer in the direction you wish to travel WARNING Improperly crossing hills or turning on hills could cause loss of control or cause the ATV to overturn Never attempt to turn the ATV...

Page 87: ...ould cause you to lose control If you are unable to continue up the hill dismount the ATV on the uphill side Physically turn the ATV around and then descend the hill When descending hills application of ANY of the brakes will brake the wheels on the downhill side Avoid sudden application of any of the brakes because the rear wheels could lift off the ground The ATV might tip rear end over the fron...

Page 88: ...t to the uphill side of the ATV Riding downhill When riding your ATV downhill shift your weight as far to the rear and uphill side of the ATV as possible Move back on the seat and sit with your arms straight Engine compression will do most of the braking for you For maximum engine compression braking effect select low range L and change to 4WD or 4WD LOCK before beginning to descend the hill Impro...

Page 89: ...le ride your ATV straight down a hill Avoid sharp angles which could allow the ATV to tip or roll over Carefully choose your path and ride no faster than you will be able to react to obstacles which may appear in front of you WARNING Going down a hill improperly could cause loss of control or cause the ATV to overturn Always follow proper procedures for going down hills as described in this Owner ...

Page 90: ...y and carefully WARNING Operating this ATV through deep or fast flowing water Tires may float causing loss of traction and loss of control which could lead to an accident Never operate this ATV in fast flowing water or in water deeper than that specified in your Owner s Manual Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them se...

Page 91: ...sure to drain any trapped water by removing the check hose plugs at the bottom of the air filter case the V belt cooling duct the gear shift lever box Also remove the V belt case drain plug to drain any water that may have accumulated Wash the ATV in fresh water if it has been operated in salt water or muddy conditions ...

Page 92: ...uld lead to a rollover or accident Be sure to keep your feet placed firmly on the floorboards at all times Avoid jumping with the ATV as loss of control and damage to the ATV may result WARNING Before operating in a new area check for obstacles Never attempt to ride over large obstacles such as large rocks or fallen trees When you go over obstacles always follow proper procedures as described in t...

Page 93: ...ccident To reduce the tendency for the front wheels to slide on loose or slippery conditions positioning your weight over the front wheels will sometimes help If the rear wheels of your ATV start to slide sideways control can usually be regained if there is room to do so by steering in the direction of the slide Applying the brakes or accelerating is not recommended until you have corrected the sl...

Page 94: ...voided on extremely slippery surfaces such as ice since all control may be lost WARNING Skidding or sliding improperly You may lose control of this ATV You may also regain traction unexpectedly which may cause the ATV to overturn Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cauti...

Page 95: ... of the slide if you have the room Applying the brakes or accelerating is not recommended until you have corrected the slide 4 If your ATV can t make it up a hill you are trying to climb Turn the ATV around if you still have forward speed If not stop dismount on the uphill side of the ATV and physically turn the ATV around If the ATV starts to slip backwards DO NOT USE THE REAR BRAKE the ATV may t...

Page 96: ...6 If your ATV encounters shallow water Ride slowly and carefully through slow moving water watching for obstacles Be sure to let water drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water Do not continue to ride your ATV until you have regained adequate brake performance ...

Page 97: ...s or can start fires HOW TO AVOID THE HAZARD Turn off the engine when performing maintenance unless otherwise specified Have a dealer perform service if you are not familiar with machine service WARNING POTENTIAL HAZARD Operating this ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situ...

Page 98: ... ROUTINE Whichever Comes first INITIAL EVERY Month 1 3 6 6 12 Km Mi 320 200 1 200 750 2 400 1 500 2 400 1 500 4 800 3 000 Hours 20 75 150 150 300 Valves Check valve clearance Adjust if necessary Spark plug Check condition Adjust gap and clean Replace if necessary Air filter element Clean Replace if necessary Every 20 40 hours More often in wet or dusty areas Crankcase breather system Check breathe...

Page 99: ...ssary Engine oil strainer Clean Drive chain Check and adjust slack alignment clean lube Brakes Check operation fluid leakage See NOTE Correct if necessary Clutch Check operation Adjust if necessary Wheels Check balance damage run out Replace if necessary Wheels bearings Check bearing assemblies for looseness damage Replace if damaged Steering system Check operation Repair if damaged Check toe in A...

Page 100: ...fasteners Correct if necessary Lights and a witches Check operation Adjust headlight beams Meter Checking if the function is complete and instruction isaccurate Items which require special tools data or technical skills Have a dealer service repair these items NOTE Recommended brake fluid DOT4 Brake fluid replacement When disassembling the master cylinders or calipers replace the brake fluid Norma...

Page 101: ...uses carburetor it consist of ECU EFI cables sensors actuators and other advanced components As the following pictures For HS500ATV 6 HS550ATV HS450ATV 4 1 Oxygen sensor assy 2 Oxygen sensor threaded sleeve 3 Exhaust Pipe For HS700ATV 8 HS750ATV 1 Oxygen sensor assy 2 Oxygen sensor threaded sleeve 3 Exhaust Pipe ...

Page 102: ...Periodic Maintenance and Adjustment 8 6 1 High voltage wire 2 Ignition signal plug 3 Ignition coil 1 Fuel injector 2 Water temperature sensor 3 Intake air temperature sensor pressure sensor ...

Page 103: ...or Inspect engine intake air temperature according to the temperature the ECU will automatically adjust the fuel injection volume Air intake pipe pressure sensor Replace this entire paragraph with For testing the negative pressure of the air intake pipe the engine will have two different working conditions Opening the air damper and testing the pressure of the air intake can change engine performa...

Page 104: ... originated int he magneto and provides the ECU with the correct ignition timing ECU The ECU is the central core of the entire EFI system This micro chip controller monitors and regulates all EFI systems during different conditions and ensures fuel efficiency low emissions and performance EFI System inspection It the EFI system has a failure the meter will display a corresponding failure code Auth...

Page 105: ...t To check the engine oil level 1 Place the ATV on a level surface 2 Start the engine warm it up for several minutes and then turn it off 3 Wait a few minutes until the oil settles 4 Remove the engine oil filler cap and wipe off the dipstick with a clean rag 1 Engine oil filler cap 2 Dipstick 5 Insert the dipstick in the oil filler hole without screwing it in and then remove it again to check the ...

Page 106: ...ler hole and then tighten the oil filler cap To change the engine oil with or without oil filter cartridge replacement 1 Start the engine warm it up for several minutes and then turn it off 2 Place an oil pan under the engine to collect the used oil and then remove the engine oil filler cap 3 Remove the engine oil drain bolt to drain the oil from the crankcase 1 Engine oil drain bolt NOTE Skip ste...

Page 107: ... filter wrench NOTE An oil filter wrench is available at a nearby dealer 5 Apply a light coat of engine oil to the O ring of the new oil filter cartridge NOTE Make sure the O ring is seated properly 1 O ring 6 Install the new oil filter cartridge with an oil filter wrench and then tighten it to the specified torque with a torque wrench ...

Page 108: ... oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign material enters the crankcase 7 Start the engine and warm it up for several minutes While warming up check for oil leakage If oil leakage is found turn the engine off immediately and check for the cause 8 Turn the engine off...

Page 109: ...ide If any leakage is found have a dealer check and repair the ATV Replacing the final gear oil 1 Place the ATV on a level surface 2 Place a container under the final gear case to collect the used oil 3 Remove the oil filler bolt and the drain bolt to drain the oil 1 Final gear oil drain bolt 1 Final gear oil filler bolt ...

Page 110: ... 26 US qt CAUTION Be sure no foreign material enters the final gear case 6 Install the filler bolt and tighten it to the specified torque Tightening torque Final gear oil filler bolt 23 Nm 2 3m kgf 17ft lbf 7 Check for oil leakage If oil leakage is found check for the cause Differential gear oil Checking the differential gear oil 1 Place the ATV on a level surface 2 Remove the differential gear oi...

Page 111: ...e differential gear oil filler bolt and then tighten it to the specified torque Tightening torque Differential gear oil filler bolt 23 Nm 2 3m kgf 17ft lbf Replacing the differential gear oil 1 Place the ATV on a level surface 2 Place a container under the differential gear case to collect the used oil 3 Remove the differential gear oil filler bolt and differential gear oil drain bolt to drain the...

Page 112: ...tial gear case with the recommended oil Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity 0 28 L 0 25 Imp qt 0 3 US qt CAUTION Be sure no foreign material enters the differential gear case 6 Install the differential gear oil filler bolt and then tighten it to the specified torque Tightening torque Differential gear oil filler bolt 23 Nm 2 3m kgf 17ft lbf Cooling system 1 Place the ATV o...

Page 113: ...he coolant is at or below the minimum level mark remove the reservoir cap add coolant to the maximum level mark install the reservoir cap 1 Coolant reservoir tank cap 2 Maximum level mark 3 Minimum level mark Coolant reservoir capacity up to the maximum level mark 0 3 L 0 26 Imp qt 0 32 US qt CAUTION Hard water or salt water is harmful to the engine You may use soft water if you cannot get distill...

Page 114: ...iator cap when the engine and radiator are still hot WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap Always use a thick rag over the cap Allow any remaining pressure to escape before completely removing the cap 1 Place the ATV on a level surface 2 Place a container under the eng...

Page 115: ... and Adjustment 1 Coolant drain bolt 1 Trough 1 Radiator cap 3 Remove the radiator cap 4 Remove the coolant reservoir cap 5 Disconnect the hose on the coolant reservoir side and then drain the coolant from the coolant reservoir ...

Page 116: ...2ft lbf 8 Install the coolant reservoir hose 9 Pour the recommended coolant into the reservoir to the maximum level mark and then install the reservoir cap 10 Pour the recommended coolant into the radiator until it is full and then install the radiator cap Recommended antifreeze High quality ethylene glycol antifreeze Containing corrosion inhibitors for aluminum engines Antifreeze and water mixing...

Page 117: ...and then check the coolant level in the radiator If it is low add more coolant until it reaches the top of the radiator 12 Check for coolant leakage NOTE If any leakage is found have a dealer check the cooling system 13 Install the panels and the front carrier Axle boots Check the protective boots for holes or tears If any damage is found have them replaced by a dealer 1 Front axle boot 2 each sid...

Page 118: ...g is an important engine component and is easy to inspect The condition of the spark plug can indicate the condition of the engine The ideal color on the white insulator around the center electrode is a medium to light tan color for a ATV that is being ridden normally Do not attempt to diagnose such problems yourself Instead take the ATV to a dealer You should ...

Page 119: ...or HS550ATV HS500ATV 6 HS450ATV 4 Installation 1 Measure the electrode gap with a wire thickness gauge and if necessary adjust the gap to specification Spark plug gap 0 023 0 027 in 0 6 0 7 mm 2 Clean the gasket surface Wipe off any grime from the threads 3 Install the spark plug and tighten it to the specified torque a Spark plug gap Tightening torque Spark plug 17 5 Nm 1 75m kgf 12 7ft lbf NOTE ...

Page 120: ...tom of the air filter case If dust or water collects in this hose empty the hose and clean the air filter element and air filter case 1 Air filter case check hose 1 Remove the seat See page 4 19 for seat removal and installation procedures 2 Remove the air filter case cover by unhooking the holders 3 Remove the air filter element 4 Remove the air filter element from its frame ...

Page 121: ...8 25 Periodic Maintenance and Adjustment 1 Holder 5 2 Air filter case cover 1 Air filter element 1 Frame 2 Air filter element ...

Page 122: ...HE HAZARD Use parts cleaning solvent to clean the air filter element 6 Squeeze the excess solvent out of the air filter element and let it dry CAUTION Do not twist the air filter element when squeezing it 7 Inspect the air filter element and replace it if damaged 8 Apply foam air filter oil or other quality foam air filter oil to the air filter element NOTE The air filter element should be wet but...

Page 123: ...d air entering the engine CAUTION Never operate the engine with the air filter element removed This will allow unfiltered air to enter causing rapid engine wear and possible engine damage Additionally operation without the air filter element will affect carburetor jetting with subsequent poor performance and possible engine overheating Spark arrester cleaning Be sure the exhaust pipe and muffler a...

Page 124: ...d cause burns Could cause carbon monoxide poisoning possibly leading to death Could start a fire HOW TO AVOID THE HAZARD When cleaning the spark arrester Always let the exhaust system cool prior to touching exhaust components Do not start the engine when cleaning the exhaust system V belt cooling duct check hose If dust or water collects in the V belt cooling duct check hose remove the hose and cl...

Page 125: ...NOTE If water drains from the V belt case after removing the plug have the dealer inspect the ATV as the water may affect other engine parts 1 V belt case drain plug Valve clearance adjustment The correct valve clearance changes with use resulting in improper fuel air supply or engine noise To prevent this the valve clearance must be adjusted regularly This adjustment however should be left to a p...

Page 126: ... left to a dealer Throttle lever adjustment NOTE Adjust the engine idling speed before adjusting the throttle lever free play 1 Loosen the locknut 2 Turn the adjusting bolt until the throttle lever free play is 3 5 mm 0 12 0 20 in 3 Tighten the locknut 1 Locknut 2 Adjusting bolt a Throttle lever free play Front brake pad check Check the brake pads for damage and wear If a brake pad thickness is le...

Page 127: ... damage and wear If the thickness is less than 1 0 mm 0 04 in have a dealer replace the pads 1 Brake pad 2 Brake pad plate a Brake pad thickness Checking the brake fluid level Insufficient brake fluid may let air enter the brake system possibly causing the brakes to become ineffective Before riding check that the brake fluid is above the minimum level and replenish when necessary A low brake fluid...

Page 128: ...r brake fluid master cylinder reservoir is located 1 Minimum level mark 1 Minimum level mark Observe these precautions When checking the fluid level make sure the top of the master cylinder reservoirs are level Use only the designated quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor brake performance Recommended brake fluid DOT 4 ...

Page 129: ...s or plastic parts Always clean up spilled fluid immediately Have a dealer check the cause if the brake fluid level goes down Brake fluid replacement Only trained service personnel should do complete fluid replacement Have a dealer replace the following components during periodic maintenance or when they are damaged or leaking Replace the oil seals every two years Replace the brake hoses every fou...

Page 130: ... not drag Make sure the brakes are not spongy All air must be bled from the brake system Replacement of brake components requires professional knowledge A dealer should perform these procedures Adjusting the rear brake lever The rear brake lever free play should be 0 5 2 mm 0 02 0 08 in 1 Loosen the locknut 1 Locknut 2 Adjusting bolt c Rear brake lever free play 2 Turn the adjusting bolt in direct...

Page 131: ...gent brake lever free play Be sure not to step on the brake pedal Make sure the brake pedal does not move Adjusting the brake pedal The top of the brake pedal should be positioned 72 mm 2 8 in above the top of the footrest If not ask a dealer to adjust it a Distance between brake pedal and footrest ...

Page 132: ...uires professional knowledge A dealer should perform these procedures Adjusting the rear brake light switch The rear brake light switch which is activated by the brake pedal and rear brake lever is properly adjusted when the brake light comes on just before braking takes effect If necessary adjust the brake light switch as follows 1 Turn the adjusting nut while holding the rear brake light switch ...

Page 133: ...e restricted which could cause an accident or injury HOW TO AVOID THE HAZARD Inspect cables frequently Replace dam aged cables Lubricate the inner cables and the cable ends If the cables do not operate smoothly ask a dealer to replace them Recommended lubricant The chain and cable lube or SAE 10W 40 motor oil Lubricating the brake levers and brake pedal Lubricate the pivoting parts NOTE To access ...

Page 134: ...Periodic Maintenance and Adjustment 8 38 Rear knuckle upper and lower pivot lubrication Lubricate the knuckle upper and lower pivots with a grease gun ...

Page 135: ...vate the ATV and place a suitable stand under the frame 3 Remove the nuts from the wheel 4 Remove the wheel 1 Nut 4 Wheel installation 1 Install the wheel and the nuts NOTE The arrow mark on the tire must point toward the rotating direction of the wheel Tapered nuts are used for both the front and rear wheels Install the nut with its tapered side towards the wheel ...

Page 136: ... nut torque Front 55 Nm 5 5m kgf 40ft lbf Rear 55 Nm 5 5m kgf 40ft lbf Battery This machine is equipped with a sealed type battery Therefore it is not necessary to check the electrolyte or add distilled water in the battery If the battery seems to have discharged consult a dealer CAUTION Do not try to remove the sealing caps of the battery cells You may damage the battery ...

Page 137: ...mpt medical attention EYES Flush with water for 15 minutes and get prompt medical attention Keep batteries away from sparks flames cigarettes or other sources of ignition Ventilate when charging or using in a closed space Battery maintenance 1 When the machine is not used for a month or longer remove the battery and store it in a cool dark place Completely recharge the battery before reinstallatio...

Page 138: ...rake and steering fuses 6 Backup fuse 7 Dash board and ECU constant power fuses Specified fuses Dash board and ECU switch fuses Headlight fuses Auxiliary DC jack fuses EPS and relay fuses Brake and steering fuse Backup fuse Dash board and ECU constant power fuse 15A 15A 10A 10A 10A 5A 10A 15A 5A WARNING POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause damage to th...

Page 139: ...use Replacing a headlight bulb If a headlight bulb burns out replace it as follows 1 Remove the cover at the rear of the headlight by pulling it off 1 Cover 2 Remove the headlight bulb holder cover by pulling it off 3 Remove the headlight bulb holder by pushing it in and turning it counterclockwise 4 Remove the defective bulb by pulling it out ...

Page 140: ...ID THE HAZARD Wait for the bulb to cool before touching or removing it 5 Insert a new headlight bulb into the bulb holder by pushing it in CAUTION Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thoroughly clean off any dirt and fingerprints on the headlight bu...

Page 141: ...e rear of the headlight Tail brake light bulb replacement 1 Remove the bulb holder together with the bulb by turning it counterclockwise 1 Tail brake light bulb holder 2 Remove the defective bulb from the bulb holder by pushing it inward and turning it counterclockwise 3 Install a new bulb in the bulb holder by pushing it inward and turning it clockwise 4 Install the bulb holder together with the ...

Page 142: ...Some ATV repairs require technical skill If you cannot repair the ATV yourself contact an Authorized dealer WARNING POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame WHAT CAN HAPPEN Fuel can ignite or explode causing severe injury or property damage HOW TO AVOID THE HAZARD Do not smoke when checking the fuel system Make sure there are no open flames or sparks in the are...

Page 143: ...re bent or broken Repair and touch up paint as necessary 2 Replace any damaged body panels 3 Re paste stickers and install the warning placards with rivets 2 The skid plate is damaged by an object 1 Check the front and rear differentials to ensure they are not damaged or leaking oil 2 Check to see if the bottom of the engine housing is broken or leaking oil 3 Replace with a new skid plate as neces...

Page 144: ...k whether the rotors or the disc brake pads have worn beyond limits or gotten contaminated by oil or other material which could reduce the brake performance 3 Check if any brake lines are leaking 4 Check if any push rods to the master cylinder are damaged 5 Check if the oil lines have any air and if they do use special brake bleeding tools to remove the air 6 Check to see if there is sufficient oi...

Page 145: ... between the left and right side 2 Check if the brake force for the front brake has been reduced allowing the rear wheels to lock before the front wheels during braking 3 Check if there is a difference in the spring force on the shock absorbers between the left and right side suspension 4 Check to see if the rubber spring ring which connects the chassis and the swing arm is damaged ...

Page 146: ...s damaged 3 Check to see if the wires are damaged 3 Rear axle gearbox is inoperative 1 Check and be sure the control switch for 2WD 4WD on the display panel is working properly 2 Check if electromagnet inside the rear axle gearbox is damaged 3 Check to see if the wires are damaged 4 Display is abnormal on the display panel 1 Check to see if the sensor is damaged 2 Check to be sure the display pane...

Page 147: ...e front wheels and the front wheel axles are loose or damaged 3 Check to see if the internal splines on the front wheel hub or the outer splines of the front wheel axle are worn abraded or damaged 4 Check to be sure the rubber spring ring which connects the front suspension and chassis is NOT damaged 1 Check to see if the bearing in the rear axle bearing seat is damaged 3 Rear wheels shake when dr...

Page 148: ...med or become weak over time 3 Check and be sure the damping force is present during compression and extension of shock absorber 6 Abnormal sounds from front rear axle during operation 1 Check to see if the splines on the front or rear transmission shaft are damaged 2 Check to see if the splines on either end of the left or right axle shafts on the front or rear bridge are damaged 3 Check to be su...

Page 149: ...ngine power reduction 1 Check and see if a cylinder is not working 2 Check to be sure that an injector is NOT blocked 3 Check and clean the air filter element 4 Check to see if the muffler is blocked and clean the spark arrestor 3 Engine backfires 1 Check to see if there are any air leaks in the air filter or air inlet pipe 2 Check to see if the connection between the exhaust pipe and engine or th...

Page 150: ... start 1 Check to see if the battery charge is sufficient to make the starter motor crank 2 Check to see if the starter motor is damaged 3 Check to be sure the EFI system works properly 4 Check and be sure the ignition circuit is working properly 5 Check to see if the spark plug has a carbon deposit or the spark plug element is burned 6 Check to see if the ignition signal to the magneto is working...

Page 151: ...steam blown out under pressure HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap Always use a thick rag over the cap Allow any remaining pressure to escape before completely removing the cap NOTE If it is difficult to get the recommended coolant tap water can be temporarily used provided that it is changed to the recommended coolant as soon as possible ...

Page 152: ...degreaser to the wheel axles 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job CAUTION Excessive water pressure may cause water seepage and deterioration of wheel bearings brakes transmission seals and electrical devices Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin operated ca...

Page 153: ...t the engine and let it idle for several minutes WARNING POTENTIAL HAZARD Operation with wet brakes after washing WHAT CAN HAPPEN Wet brakes may have reduced stopping ability increasing the chance of an accident HOW TO AVOID THE HAZARD Test the brakes after washing Apply the brakes several times at slow speeds to let friction dry out the linings STORAGE Long term storage 60 days or more of your ma...

Page 154: ... the spark plug hole and reinstall the spark plug Ground the spark plug wire and turn the engine over several times to coat the cylinder wall with oil 3 Lubricate all control cables 4 Block up the frame to raise all wheels off the ground 5 Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering 6 If storing in a humid or salt air atmosphere coat all exposed metal surfaces ...

Page 155: ...g radius 2 345mm 92 3in 1 280mm 50 4in 1 380mm 54 3in 930 mm 36 6in 1 455mm 57 3in 295mm 11 6in 3 500mm 137 8in Basic weight With oil and full fuel tank 387kg 853 lb Engine Engine type Cylinder arrangement Displacement Liquid cooled 4 stroke SOHC Forward inclined single cylinder 735cm3 for HS750ATV 686cm3 for HS700ATV 8 546cm3 for HS550ATV 471cm3 for HS500ATV 6 454cm3 for HS450ATV 4 ...

Page 156: ...m 84mm for HS700ATV 8 91mm 84mm for HS550ATV 84 5mm 84mm for HS500ATV 6 83mm 84mm for HS450ATV 4 Compression ratio Starting system Lubrication system 9 7 1 for HS750ATV 9 2 1 for HS700ATV 8 9 6 1 for HS550ATV 9 4 1 for HS500ATV 6 HS450ATV 4 Electric starter Wet sump Engine oil Type API Service SE SF SG type or higher ...

Page 157: ...any chemical additives Do not use oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher 1 9 0L 2 01 qt 2 10 L 2 22 qt Final gear case oil Type Quantity SAE80 API GL 4 Hypoid gear oil 0 25 L 0 22 Imp qt 0 26 US qt Differential gear case oil Type Quantity SAE80 API GL 5 Hypoid gear oil 0 28 L 0 25 Imp qt 0...

Page 158: ...rk plug Type manufacturer Spark plug gap DR8EA for HS550ATV HS500ATV 6 HS450ATV 4 DCPR7E for HS750ATV HS700ATV 8 0 6 0 7 mm 0 023 0 027 in Clutch type Wet centrifugal automatic Transmission Primary reduction system Secondary reduction system Transmission type Operation Reverse gear Sub transmission ratio low high V belt Shaft drive V belt automatic Left hand operation 1 471 2 059 1 238 ...

Page 159: ... Operation Rear brake Type Operation Dual disc brake Right hand operation Single disc brake Left hand and right foot operation Suspension Front suspension Rear suspension Double wishbone Double wishbone Shock absorber Front shock absorber Rear shock absorber Coil spring oil damper Coil spring oil damper Wheel travel Front wheel travel Rear wheel travel 130 mm 5 12 in 150 mm 5 91 in ...

Page 160: ...L BS 12 V 18 Ah Headlight type Krypton bulb Bulb voltage wattage quantity Head light Tail brake light Indicator light Neutral indicator light Reverse indicator light Coolant temperature warning light Park indicator light High range indicator light Low range indicator light Differential gear lock indicator light 12 V 30 W 30 W 2 12 V 5 W 21 W 1 LED LED LED LED LED LED LED ...

Page 161: ...el HS750ATV HS700ATV 8 HS550ATV HS500ATV 6 HS450ATV 4 Fuses Main fuse Speedometer unit Signaling system fuse Four wheel drive fuse Auxiliary DC jack fuse ECU Headlight fuse Backup fuse 30 A 15A 10A 15A 10A 10A 15A 5A 10A 15A ...

Page 162: ...cuit Low Voltage KsDGDM_IAT_ShortLow 112 274 P0113 IAT Circuit High Voltage or Open KsDGDM_IAT_ShortHigh 113 275 P0117 Coolant Oil Temperature Sensor Circuit Low Voltage KsDGDM_CoolantShortLow 117 279 P0118 Coolant Oil Temperature Sensor Circuit High Voltage or Open KsDGDM_CoolantShortHigh 118 280 P0122 TPS Circuit Low Voltage or Open KsDGDM_TPS_ShortLow 122 290 P0123 TPS Circuit High Voltage KsDG...

Page 163: ...on KsDGDM_INJ_CYL_B_Fault 202 514 P0230 FPR Coil Circuit Low Voltage or Open KsDGDM_FPP_CircuitShortLow 230 560 P0232 FPR Coil Circuit High Voltage KsDGDM_FPP_CircuitShortHigh 232 562 P0336 CKP Sensor Noisy Signal KsDGDM_CrankNoisySignal 336 822 P0337 CKP Sensor No Signal KsDGDM_CrankNoSignal 337 823 P0351 Cylinder 1 Ignition Coil Malfunction KsDGDM_EST_A_Fault 351 849 P0352 Cylinder 2 Ignition Co...

Page 164: ...GDM_O2_2_ShortHigh 138 312 P0038 O2S Heater 2 Circuit High Voltage KsDGDM_O2_HeaterShortHigh 38 56 P0037 O2S Heater 2 Circuit Low Voltage KsDGDM_O2_HeaterShortLow 37 55 P0500 VSS No Signal KsDGDM_VSS_NoSignal 500 1280 P0850 Park Neutral Switch Error KsDGDM_ParkNeutralSwitch 850 2128 P0445 CCP short to high KsDGDM_CCP_CircuitShortHigh 445 1093 P0444 CCP short to low open KsDGDM_CCP_CircuitShortLow ...

Page 165: ...control system on your vehicle for 5 000 km or at least 30 months whichever comes first provided that there has been no abuse neglect or improper maintenance of your vehicle This off road vehicle was designed to meet the emission standards for 10 000 km or five years whichever comes first Your emission control system warranty covers components whose failure would increase an engine s emissions of ...

Page 166: ...performance of the required maintenance listed in your owner s manual HISUN recommends that you retain all receipts covering maintenance on your vehicle but HISUN cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance You are responsible for presenting your vehicle to the HISUN dealer as soon as a problem exists The warranty ...

Page 167: ...use your vehicle in any type of competitive event this warranty is immediately and completely void If you have any questions regarding your warranty rights and responsibilities you should contact Hisun Motors Corp U S A 310 E University Drive McKinney TX 75069 Phone 972 446 0760 or Toll Free 877 838 6188 or the U S Environmental Protection Agency at 2000 Traverwood Drive Ann Arbor MI 48105 ...

Page 168: ... free from defects in material and workmanship which cause such vehicle to fail to conform to applicable regulations of the United States Environmental Protection Agency for the periods specified above I Coverage Warranty defects shall be remedied during customary business hours at any authorized HISUN dealer located within the United States of America in compliance with the Clean Air Act and appl...

Page 169: ...suse 3 repairs improperly performed or replacements improperly installed unless performed by a HISUN authorized dealer 4 use of improper replacement parts or accessories not conforming to specifications set forth by HISUN which adversely affect performance and or 5 Use in competitive racing or related events B Inspections replacement of parts and other services and adjustments required for require...

Page 170: ...al or workmanship by an authorized HISUN dealer at its place of business during customary business hours This warranty does not cover inconvenience or loss of use of the vehicle or transportation of the vehicle to or from the HISUN dealer HISUN shall not be liable for any other expenses loss or damage whether direct indidental consequential or exemplary arising in connection with the sale or use o...

Page 171: ... this warranty The foregoing statements of warranty are exclusive and in lieu of all other remedies Some states do not allow limitations on how long an implied warranty lasts so the above limitations may not apply to you C No dealer is authorized to modify this Limited Emission Control System Warranty issued by HISUN IV LEGAL RIGHTS This warranty gives you specific legal rights and you may also ha...

Page 172: ...nce Such maintenance may be performed at a service establishment or by any individual The warranty period begins when the vehicle is placed into service If you have any questions regarding your warranty rights and responsibilities you should contact Hisun Motors Corp U S A or the U S Environmental Protection Agency at 2000 Traverwood Drive Ann Arbor MI 48105 Hisun Motors Corp U S A 310 E Universit...

Page 173: ...afety Training Course at atvsafety org TM GRAB SOME SUN For your nearest HISUN dealer call 1 972 446 0760 or visit hisunmotors com HISUN Motors Corp USA McKinney TX 75069 HISUN 2015 All rights reserved Rev 06301501 ATV Owners Manual Rev06301501 indd 2 6 30 2015 2 13 59 PM ...

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