Hisun HS500UTV Owner'S Manual Download | Manualshive

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8-58 Periodic Maintenance and Adjustment

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.

WARNING

POTENTIAL HAZARD
Removing the radiator 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.

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Summary of Contents for HS500UTV

Page 1: ......

Page 2: ...Owner Manual...

Page 3: ...dge needed to have safe and enjoyable UTV operation If you have any questions regarding the operation or maintenance of your UTV please consult the dealer IMPORTANT SAFETY MESSAGES READ THIS MANUAL CA...

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 bystander or...

Page 5: ...below 4 F 20 C park the UTV in a place where the temperature is higher than 4 F 20 C Start the UTV after the UTV has warmed up Please see page 6 3 on the warming up process Follow the proper parking...

Page 6: ...6 Odometer and Trip Meter Modes 4 6 Clock Mode 4 6 To Set the Clock 4 7 Fault Codes Display of the Electronic 4 7 Fuel meter 4 7 Switches 4 8 Accelerator Pedal 4 13 Brake Pedal 4 14 Parking Brake Leve...

Page 7: ...djustment 5 9 Steering Wheel Inspection 5 10 Seat Belts 5 10 Fittings and Fasteners 5 10 Lights 5 10 Switches 5 11 Tires 5 11 How to Measure Tire Pressure 5 12 Tire Wear Limit 5 13 Operation 6 1 Start...

Page 8: ...em 8 3 General Maintenance and Lubrication Chart 8 4 Hood 8 7 Console 8 8 Engine Oil and Oil Filter Cartridge 8 9 To Check the Engine Oil Level 8 9 To Change the Engine Oil 8 10 Final Gear Oil 8 13 Ch...

Page 9: ...Lower Pivot Lubrication 8 37 Steering Shaft Lubrication 8 37 Wheel Removal 8 37 Wheel Installation 8 38 Battery 8 39 Battery Maintenance 8 41 Fuse Replacement 8 41 Replacing Headlight Bulb 8 43 Headl...

Page 10: ...Location of the Warning and Safety Labels 1 1...

Page 11: ...ll of the labels on your vehicle They contain important information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or come...

Page 12: ...Location of the Warning and Safety Labels 1 3...

Page 13: ...1 4 Location of the Warning and Safety Labels...

Page 14: ...Location of the Warning and Safety Labels 1 5...

Page 15: ...1 6 Location of the Warning and Safety Labels 9 10...

Page 16: ...Location of the Warning and Safety Labels 1 7 11 12...

Page 17: ...handgrip fixed before the seat Always avoid operating the vehicle on any paved surfaces including sidewalks driveways parking lots and streets Never operate this vehicle on any public street road or h...

Page 18: ...right and left as they respond to the terrain and this movement will be felt in the steering wheel A sudden jolt could wrench the steering wheel around and your thumbs or fingers could be injured if...

Page 19: ...er than the floorboards on this model Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply the brake several times to let friction dry out...

Page 20: ...the vicinity of sparks open flames or other sources of ignition such as the pilot light of water heaters and clothes dryers When transporting the vehicle in another vehicle be sure it is kept in an u...

Page 21: ...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 yo...

Page 22: ...r intake duct 5 V belt case 6 Driver seat 7 Driver seat belt 8 Spark plug 9 Cargo bed 10 Tail brake lights 11 Rear shock absorber assembly adjusting ring 12 Cargo bed release levers 13 Spark arrester...

Page 23: ...in switch 27 On Command four wheel drive and differential lock switches 28 Multi function meter unit 29 Auxiliary DC jack 30 Drive select lever 31 Parking brake lever 32 Accelerator pedal 33 Brake ped...

Page 24: ...assistance when ordering spare parts from a service center or for reference in case the vehicle is stolen 1 VEHICLE IDENTIFICATION NUMBER 2 MODEL LABEL INFORMATION Vehicle Identification Number The Ve...

Page 25: ...ll electrical circuits are supplied with power and the headlights and taillights illuminate when the light switch is on OFF All electrical circuits are switched off The key can be removed in this posi...

Page 26: ...ectric starter can result See starting instructions prior to starting the engine See pages 6 1 6 3 for details Indicator and warning lights 1 Four wheel locked showing light 2 Fault indicator light of...

Page 27: ...h until the differential gear is locked Low range indicator light L This indicator light comes on when the drive select lever is in the L position High range indicator light H This indicator light com...

Page 28: ...indicator in the On Command four wheel drive indicator also comes on when the On Command differential gear lock switch is set to the LOCK position NOTE Due to the synchronizing mechanism in the differ...

Page 29: ...nitors working condition of EPS system Fault can be displayed by fault indicator light and fault indicator of EPS system so the driver can acknowledge fault of EPS in time and take some measures to ke...

Page 30: ...mile button 5 TRIP ODO button 6 Right turn indicator 7 Left turn indicator 8 Clock Hour fault code reset button The multi function meter unit is equipped with the following z Speedometer which shows t...

Page 31: ...ton to set the minutes 5 Press the watch button for 3 5 seconds and then release it the clock will begin to work Fault Codes Display of the Electronic Injection System When faults occur the meter will...

Page 32: ...g indicator 2 Fuel meter Switches 1 Light switch OFF Light switch OFF Set the switch to to turn on the low beam and the taillights Set the switch to to turn on the high beam and the taillights Set the...

Page 33: ...e properly If this happens remove the battery and recharge it On Command Four Wheel Drive and Differential Gear Lock Switches 1 On Command four wheel drive switch 2WD 4 WD 2 Differential gear lock swi...

Page 34: ...POTENTIAL HAZARD Changing from 2WD to 4WD or from 2WD to 2WD Differential UNLOCK or vice versa while the vehicle is moving WHAT CAN HAPPEN The vehicle handles differently in 4WD than in 2WD and in 2W...

Page 35: ...ll come on in the multi function meter unit display To change from 4WD to 2WD stop the vehicle be sure the select lever is set to position and then set the switch to 2WD On Command Differential Gear L...

Page 36: ...he amount of effort required is greater the faster you go You may lose control and have an accident if you cannot make a sharp enough turn for the speed you are traveling HOW TO AVOID THE HAZARD Alway...

Page 37: ...speed Spring pressure returns the pedal to the rest position when released Always check that the accelerator pedal returns normally before staring the engine 1 Accelerator pedal Before starting the e...

Page 38: ...ration of the accelerator pedal before you start the engine If it does not work smoothly check for the cause Correct the problem before operating the vehicle Consult a service center if you cannot fin...

Page 39: ...ase the parking brake before starting out Failure to do so may result in poor performance and premature wearing of the rear brake and V belt 1 Parking brake lever 2 Release button Drive select lever T...

Page 40: ...ove the fuel tank cap by turning it counterclockwise 1 Fuel tank cap Seats To remove a seat pull its seat lock lever upward lift the front of the seat and then slide the seat forward and up 1 Driver s...

Page 41: ...L HAZARD A loose 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 secure...

Page 42: ...portion of the vehicle your clothing or any equipment you are carrying 2 Push the latch plate into the buckle until it clicks Pull up on the latch plate to make sure it is secure 1 Buckle 2 Latch pla...

Page 43: ...se button 1 Buckle 2 Release button WARNING POTENTIAL HAZARD Not wearing the seat belt or wearing the seat belt improperly WHAT CAN HAPPEN There is increased risk of being killed or seriously injured...

Page 44: ...To protect from damage do not put metal products like tools or sharply edged products directly in the glove compartment If they must be stored wrap them in appropriate cushion material a Unlock b Open...

Page 45: ...gate in the original position and then hook the latches Lifting and lowering the cargo bed 1 Cargo bed release lever To lift Push down cargo bed release lever on left or right side of the vehicle slow...

Page 46: ...away from the vehicle Keep hands and fingers away from the pinch points between the bed and the frame WARNING POTENTIAL HAZARD Overloading the cargo bed WHAT CAN HAPPEN Could cause changes in vehicle...

Page 47: ...ly Front and rear shock absorber adjustment The spring preload can be adjusted to suit the operating conditions You can reduce preload for a softer ride or increase preload if frequent bottoming out o...

Page 48: ...tions 4 24 1 Spring preload adjusting ring 2 Position indicator NOTE A special wrench can be obtained at a service center to make this adjustment Standard position B A Minimum soft E Maximum hard 1 Sp...

Page 49: ...could lead to an accident HOW TO AVOID THE HAZARD Always adjust the shock absorbers on the left and right side to the same setting Trailer hitch bracket This vehicle is equipped with a 1 in receiver...

Page 50: ...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 auxil...

Page 51: ...maximum capacity This may overload the circuit and cause the fuse to blow z If accessories are used without the engine running or with the headlights turned on the battery will lose its charge and en...

Page 52: ...Check coolant level Fill with coolant if necessary 5 6 8 19 8 20 Final gear oil Differential gear oil Check for leakage 5 7 Accelerator pedal Check for proper accelerator pedal operation 5 8 Seat bel...

Page 53: ...ion Always follow the inspection and maintenance procedures and schedules described in the Owner s Manual Brakes Check for correct brake pedal free play If the brake pedal free play is incorrect have...

Page 54: ...working properly If the brakes do not provide proper braking performance inspect the brake system See pages 8 30 8 35 WARNING POTENTIAL HAZARD Driving with improperly operating brakes WHAT CAN HAPPEN...

Page 55: ...signed to use regular unleaded gasoline with a pump octane number R M 2 of 91 or higher or research octane number of 91 or higher If knocking or pinging occurs use a different brand of gasoline or pre...

Page 56: ...ially on the engine or exhaust pipe Wipe up any spilled fuel immediately Be sure the fuel tank cap is closed securely Engine oil Make sure the engine oil is at the specified level Add oil as necessary...

Page 57: ...and maximum level marks on the coolant reservoir If the coolant level is at or below the minimum level mark add additional coolant to bring the level up to maximum level mark If coolant is not availa...

Page 58: ...maining pressure to escape before completely removing the cap Final gear oil Make sure the final gear oil is at the specified level Add oil as necessary See pages 8 14 8 15 for details Recommended oil...

Page 59: ...operation WARNING Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation Never...

Page 60: ...if necessary Throttle Freeplay Inspection 1 Lift the parking brake to the top to park the car 2 Apply the brakes Start the engine Allow it to warm up thoroughly 3 Measure the distance the throttle pe...

Page 61: ...lts Make sure that both seat belts are not frayed or damaged The seat belt must move smoothly when pulled out and retract on its own when released The latch plate should click securely into the buckle...

Page 62: ...improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires on this vehicle or operation of this vehicle with improper or uneven tire pressure may cause loss of contr...

Page 63: ...Front 9psi 63 kpa 0 64kgf cm2 Rear 9psi 63 kpa 0 64kgf cm2 5 Use no more than the following pressures when seating the tire beads Front 36psi 250kpa 2 5kgf cm2 Rear 36psi 250kpa 2 5kgf cm2 Higher pre...

Page 64: ...Pressure Minimum Maximum Front 10psi 70kpa 0 70kgf cm2 9 psi 63kpa 0 64kgf cm 2 11 psi 77kpa 0 77kgf cm 2 Rear 10psi 70kpa 0 70kgf cm2 9 psi 63kpa 0 64kgf cm 2 11 psi 77kpa 0 77kgf cm 2 1 Tire pressur...

Page 65: ...our service center Starting the engine in low temperatures WARNING POTENTIAL HAZARD Freezing control cables due to cold weather conditions WHAT CAN HAPPEN Loss of vehicle control which could lead to a...

Page 66: ...ion N the neutral indicator light should come on If the neutral indicator light does not come on ask a service center to inspect the electric circuit The engine can be started in any gear if the brake...

Page 67: ...N and press the throttle pedal to make the engine run at 2500RPM to charge the battery for 5 10 minutes when the voltage of battery is over 12V the idle speed will be normal If the idle speed is still...

Page 68: ...Driving In Reverse CAUTION Before shifting you must stop the UTV and return the throttle lever to the closed position otherwise the transmission may be damaged Shifting Neutral to High and High to Low...

Page 69: ...to reverse or vice versa by moving the drive select lever along the shift guide NOTE Please kick the brake pedal first before place gearshifts lever to reverse position In the brake pedal there is a c...

Page 70: ...ce center to inspect the reverse indicator light electrical circuit Due to the synchronizing mechanism in the engine the light may not come on until the vehicle starts moving 4 Check behind for people...

Page 71: ...s or people behind you When it is safe to proceed go slowly WARNING POTENTIAL HAZARD Parking on a hill or other incline WHAT CAN HAPPEN The vehicle could roll out of control increasing the chance of a...

Page 72: ...lever into the neutral position b Push the brake pedal down and pull the parking brake to top position to park the vehicle 1 Parking handbar Parking on a Slope 1 Bring the vehicle to a stop by applyi...

Page 73: ...takes to use the first three tanks full of gasoline No single action on your part is as important as a proper break in period Careful treatment of a new engine and drive components will result in more...

Page 74: ...s During this period prolonged full throttle operation or any condition which might result in excessive engine heating must be avoided However momentary 2 3 seconds maximum full throttle operation und...

Page 75: ...drive belt will ensure a longer life and better performance Break in the clutches and belt by operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggressiv...

Page 76: ...ot limited to an object that limits your ability to turn the steering wheel or one that limits your view Use extra caution when driving a vehicle with accessories The vehicle may handle differently th...

Page 77: ...load limit MAXIMUM LOADING LIMIT Vehicle loading limit total weight of cargo operator passenger and accessories and tongue weight 882 lb 400Kg Cargo bed 350 lb 159Kg Trailer hitch Pulling load total w...

Page 78: ...hout a load The more weight you carry the slower you should go Although conditions vary it is good practice not to exceed low range whenever you are carrying heavier loads or when towing a trailer All...

Page 79: ...CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this vehicle Cargo should be properly distributed a...

Page 80: ...1 2 5 Please read all the caution and warning labels on your vehicle This vehicle is designed for the operator and one passenger The driver and passenger must always wear a seat belt Never carry pass...

Page 81: ...senger could fall or be struck by objects in the cargo bed HOW TO AVOID THE HAZARD Never carry a passenger in the cargo bed The cargo bed is designed to carry cargo only The total weight of operator p...

Page 82: ...e 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...

Page 83: ...increases your chances of a severe head injury or death in the event of an accident Operating without eye protection can result in an accident and increases your chances of a severe injury in the even...

Page 84: ...peration before attempting maneuvers that are more difficult Perform the Pre Operation Checks on pages 5 1 5 11 Set the parking brake shift to neutral and follow the instructions on page 6 1 to start...

Page 85: ...go out of control if you attempt sharp high speed turns You should also be careful making sharp turns on rough terrain Do not attempt to turn around or make abrupt maneuvers on slope Position your han...

Page 86: ...ow these precautions when operating in reverse 1 Always check for obstacles or people behind the vehicle 2 Apply the throttle lightly Never open the throttle suddenly 3 Back up slowly 4 Apply the brak...

Page 87: ...loose or slippery surfaces GOING UPHILL Do not attempt to climb hills until you have mastered basic maneuvers on flat ground Use proper driving techniques to avoid overturns on hills and slopes Drive...

Page 88: ...erating on excessively steep hills WHAT CAN HAPPEN The vehicle can over turn more easily on extremely steep hills than on level surfaces or small hills HOW TO AVOID THE HAZARD Never operate your vehic...

Page 89: ...when climbing and you decide you will be unable to continue use the brakes to come to a stop Do not attempt to turn the vehicle around With your foot on the brake look behind you and plan your descent...

Page 90: ...downhill make sure the vehicle is in low range 4WD On most slopes this will let you use engine braking to help you go downhill slowly Go as slowly as possible If you pick up too much speed apply the b...

Page 91: ...water test your brakes If necessary apply the brakes several times to let friction dry out the linings WARNING POTENTIAL HAZARD Operating this vehicle through deep or fast flowing water WHAT CAN HAPP...

Page 92: ...water or muddy conditions Vehicle Immersion CAUTION If your vehicle becomes immersed major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your service center b...

Page 93: ...possible whether you succeed in starting it or not 8 If water has been ingested into the CVT make sure to inspect the hole without water left inside If it is muddy water open the CVT cap and wash the...

Page 94: ...k hose 1 V belt case drain plug Riding Over Rough Terrain Operating over rough terrain should be done with caution Look for obstacles that could cause damage to the vehicle or could lead to a rollover...

Page 95: ...terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the vehicle overturning or going out of control HOW TO AVOID THE HAZARD Go slowly an...

Page 96: ...cle such as a fallen tree trunk or a ditch stop the vehicle where it is safe to do so Set the parking brake and get out to inspect the area thoroughly Look from both your approach side and the exit si...

Page 97: ...bstacles WHAT CAN HAPPEN Could cause loss of control or a collision Could cause the vehicle to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Use extreme caution w...

Page 98: ...service information included in this manual is intended to provide you the owner with the necessary information for completing your own preventive maintenance and minor repairs The tools provided in t...

Page 99: ...with vehicle service WARNING POTENTIAL HAZARD Operating this vehicle with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes...

Page 100: ...h an asterisk should be performed by service center as they require special tools data and technical skills INITIAL EVERY Month 1 3 6 6 12 miles km 200 320 750 1 200 1 500 2 400 1 500 2 400 3 000 4 80...

Page 101: ...warm engine before draining Engine oil filter cartridge Replace Final gear oil Differential gear oil Check oil lever oil leakage Replace Accelerator pedal Check operation and free play V belt Check op...

Page 102: ...shings Check for cracks or damage Fittings and fasteners Check all chassis fittings and fasteners Check if necessary Rear upper and lower knuckle pivots Drive shaft universal joint Lubricate with lith...

Page 103: ...ement When disassembling the master cylinder or caliper replace the brake fluid Check the brake fluid level and add fluid as required On the inner parts of the master cylinder and caliper replace the...

Page 104: ...t the hood up until it stops 1 Latch 2 1 Hood To close Lower the hood slowly to its original position and then hook the hood latches Secure projections on the underside of the hood into slots on the b...

Page 105: ...ing the hood z Do not drive the vehicle with the hood open unlatched or removed Console To remove 1 Remove the seats See pages 4 16 4 17 for seat removal and installation procedures 2 Remove the parki...

Page 106: ...intervals specified in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the vehicle on a level surface 2 Remove the console See page 8 9 for console removal and ins...

Page 107: ...ct level 7 Insert the dipstick into the oil filler hole and then tighten the oil filler cap 8 Install the console To change the engine oil with or without oil filter cartridge replacement 1 Remove the...

Page 108: ...not being replaced 4 Remove the oil filter cartridge with an oil filter wrench 1 Oil filter cartridge 2 Oil filter wrench NOTE An oil filter wrench is available at a nearby service center 5 Apply a l...

Page 109: ...torque wrench Tightening torque Oil filter cartridge 12 ft lbf 17Nm 1 7m kgf 1 Oil filler cartridge 2 Torque wrench 7 Install the engine oil drain bolt and then tighten it to the specified torque Tig...

Page 110: ...an specified In addition do not use oils labeled ENERGY CONSERVING II or higher z Make sure that no foreign material enters the crankcase 9 Start the engine and then let it idle for several minutes wh...

Page 111: ...is below the brim of the filler hole add sufficient oil of the recommended type to raise it to the correct level CAUTION 1 Be sure no foreign material enters the final gear case 2 Please clean the se...

Page 112: ...inal gear oil drain bolt 4 Install the drain bolt and then tighten it to the specified torque Tightening torque Final gear oil drain bolt 14 ft lbf 20 Nm 2 0 m kgf 5 Add the recommended final gear oil...

Page 113: ...gear oil filler bolt and check the oil level It should be up to the brim of the filler hole If the level is low add sufficient oil of the recommended type to raise it to the specified level CAUTION Be...

Page 114: ...Differential gear oil drain bolt 4 Install the differential gear oil drain bolt and tighten it to the specified torque Tightening torque Differential gear oil drain bolt 7 1 ft lbf 9 8Nm 0 98 m kgf 5...

Page 115: ...surface 2 Open the hood See pages 8 8 8 9 for hood opening and closing procedures 3 Check the coolant level in the coolant reservoir when the engine is cold as the coolant level varies with engine tem...

Page 116: ...center at the intervals specified in the periodic maintenance and lubrication chart NOTE Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolan...

Page 117: ...1 Rear axle boot 2 each side Spark plug inspection Removal 1 Lift the cargo bed up See pages 4 20 4 21 for cargo bed lifting and lowering procedures 2 Remove the spark plug cap 1 Spark plug cap 3 Use...

Page 118: ...attempt to diagnose such problems yourself Instead take the vehicle to a service center You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug t...

Page 119: ...5 m kgf NOTE If a torque wrench is not available when you are installing the spark plug a good estimate of the correct torque is 1 4 to 1 2 turn past finger tight Have the spark plug tightened to the...

Page 120: ...17 for seat removal and installation procedures 2 Remove the console See page 8 9 for console removal and installation procedures 3 Remove the air filter case cover by unhooking the holders 1 Holder 4...

Page 121: ...ly but thoroughly in solvent WARNING POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the sponge material WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or exp...

Page 122: ...0 Pull the sponge material over its frame 11 Install the air filter element 12 Install the air filter case cover and be sure the crankcase breather hose is connected 1 Crankcase breather hose 13 Insta...

Page 123: ...ausing rapid engine wear and possible engine damage Additionally operation without the air filter element will affect performance with subsequent poor performance and possible engine overheating V bel...

Page 124: ...p enough to allow water to enter the V belt case remove the drain plug to drain any water from the case NOTE If water drains from the V belt case after removing the drain plug have a service center in...

Page 125: ...remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing 1 Tailpipe 2 Spark arrester 4 Insert the tailpipe into the muffler and align the bolt hole...

Page 126: ...xhaust system Valve clearance 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 adj...

Page 127: ...ear brake pad check Each brake pad is provided with wear indicator grooves which allow you to check the brake pad wear without having to disassemble the brake To check the brake pad wear check the wea...

Page 128: ...ystem for leakage The brake fluid reservoir is located under the hood See pages 8 8 8 9 for hood opening and closing procedures Observe these precautions z When checking the fluid level make sure the...

Page 129: ...r replace the following components during periodic maintenance or when they are damaged or leaking z Replace the oil seals every two years z Replace the brake hoses every four years Checking the brake...

Page 130: ...acement of brake components requires professional knowledge These procedures should be performed by a service center Parking brake lever free play adjustment Periodically check the parking brake lever...

Page 131: ...er must be released when checking and adjusting the parking brake lever free play 5 Loosen the locknut 1 Locknut 2 Adjusting nut 6 Turn the adjusting nut in direction to increase the free play or in d...

Page 132: ...r hood opening and closing procedures 2 Turn the adjusting nut while holding the brake light switch in place To make the brake light switch in place To make the brake light come on earlier turn the ad...

Page 133: ...amaged Cables can also become frayed or kinked Operation of controls could be restricted which could cause an accident or injury HOW TO AVOID THE HAZARD Inspect cables frequently Replace damaged cable...

Page 134: ...and lower pivot lubrication Lubricate the knuckle upper and lower pivots with a grease gun Recommended lubricant Lithium soap based grease Steering shaft lubrication Lubricate the pivot points Recomme...

Page 135: ...the frame Remove the nuts from the wheel 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 wh...

Page 136: ...hicle 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 service cent...

Page 137: ...ARD Avoid contact with skin eyes or clothing Always shield eyes when working near batteries Keep out of reach of children Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or...

Page 138: ...aled type battery Using a conventional battery charger may shorten the battery life 2 Always make sure the connections are correct when putting the battery back in the vehicle 1 Negative battery lead...

Page 139: ...ent accidental short circuiting turn off the main switch when checking or replacing a fuse 3 Remove the blown fuse and then install a new fuse of the specified amperage 1 Main fuse 2 Spare main fuse 3...

Page 140: ...ve a service center check the electrical system 6 Install the battery compartment cover 7 Close the hood WARNING POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause dama...

Page 141: ...and Adjustment 1 Cover at the rear of the headlight 3 Remove the headlight bulb holder cover by pulling it off 1 Headlight bulb holder cover 4 Remove the headlight bulb holder by pushing it in and tu...

Page 142: ...HAZARD A headlight bulb is hot when it is on and immediately after it is turned off WHAT CAN HAPPEN You can be burned or a fire could start if the bulb touches something flammable HOW TO AVOID THE HAZ...

Page 143: ...oth moistened with alcohol or thinner 7 Install the bulb holder by pushing it is and turning it clockwise 8 Install the bulb holder cover and the cover at the rear of the headlight CAUTION Make sure t...

Page 144: ...screw Tail brake light bulb replacement If a tail brake light bulb burns out replace it as follows 1 Remove panel A if replacing the left tail brake bulb or panel B if replacing the right tail brake...

Page 145: ...light bulb holder 3 Push the defective bulb in and turn it counterclockwise to remove it from the bulb holder 4 Push a new bulb in and turn it clockwise to install in the bulb holder 5 Install the bul...

Page 146: ...to a service center The skilled technicians at a service center ship have the tools experience and know how to properly service your vehicle Imitation parts may look like genuine parts but they are o...

Page 147: ...olution of Common Problems in Appearance Parts and Impact Fittings S N Problems Solutions 1 Repair cover at authorized service center 2 Change for new plastic covers 1 Covers are cracked 3 Replace the...

Page 148: ...in calipers are over worn or contaminated by dirt or debris that can reduce friction 3 Check if there is any leakage in brake system s oil lines or junctions 4 Check if the post rod in brake master cy...

Page 149: ...k if the brake force of front brake goes down which causes the rear wheels to lock up before the front wheels 3 Check if spring force deviation of shock absorbers in front left and right suspension ar...

Page 150: ...2 Vehicle cannot go into 4 wheel drive mode 3 Check if the wire is broken 1 Check if the control switch on meter board works well 2 Check if the differential lock control magneto plug in rear bridge r...

Page 151: ...bearings in knuckles if they are broken 2 Check the main ball pins to find out if they are broken 3 Check the lock screws of front wheels and axles to find out if they are loose or broken 4 Check the...

Page 152: ...are bent 4 Wheels jump during use 3 Check if the tires are worn or damaged 1 Check if overloaded 2 Check if the springs are two soft and need replacing 5 Shock absorbers become soft and not comfortab...

Page 153: ...r and admission line for leak 2 Check the connection joint of exhaust pipe with engine or muffler for leak 4 Popping noise in engine 3 Check the grade of gasoline to see if it s too low 1 Check to det...

Page 154: ...onnection 3 Check the starter for damage 4 Check if the ignition loop is in good condition 5 Check if the spark plug creating sparks 6 Check if the ignition signal is in good condition 7 Check if the...

Page 155: ...oon as possible WARNING POTENTIAL HAZARD Removing the radiator 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...

Page 156: ...ntbrush Do not apply 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...

Page 157: ...leaner waxes as many contain abrasives that may scratch the paint or protective finish When finished start the engine and let it idle for several minutes WARNING POTENTIAL HAZARD Operation with wet br...

Page 158: ...the fuel from the fuel system as much as possible and pour the drained fuel into the fuel tank Specified amount 1 oz of stabilizer to each gallon of fuel or 7 5 ml of stabilizer to each liter of fuel...

Page 159: ...all exposed metal surfaces with a light film of oil Do not apply oil to any rubber parts or the seat covers 8 Remove the battery and charge Store it in a dry place and recharge it once a month Do not...

Page 160: ...57 5 in 1940mm 76 4 in 818mm 32 2 in 1890mm 74 4 in 280mm 11 0 in 3900mm 154 in Basic weight with oil and full fuel tank 543 kg 1 197 l b Engine Engine type Cylinder arrangement Displacement Bore str...

Page 161: ...placement API service SG type or higher JASO standard MA CAUTION In order to prevent clutch slippage since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils w...

Page 162: ...0 26 qt Differential gear case oil Type Quantity SAE80 API GL 5 Hypoid gear oil 0 32L 0 34 qt Radiator capacity including all routes 2 50L 2 64 qt Air filter Engine Intake duct Wet element Dry element...

Page 163: ...l automatic Transmission Primary reduction system Secondary reduction system Secondary reduction ratio Transmission type Operation Reverse gear Sub transmission ratio low High V belt Shaft drive V bel...

Page 164: ...peration Front brake Type Operation Rear brake Type Operation Dual disc brake Foot operation Single disc brake Foot operation Dual disc brake Foot operation Dual disc brake Foot operation Suspension F...

Page 165: ...capacity ECU AC magneto U1L 11 12V3 2 0Ah Bulb voltage wattage quantity Headlight Tail brake light 12V30 3W 30 0W 2 12V5 0W 21 0W 2 Indicator lights Neutral Reverse indicator light Coolant temperature...

Page 166: ...500UTV High range Low range indicator light LED Specified fuses Main fuse Headlight fuse Ignition fuse Auxiliary DC jack fuse Four wheel drive motor fuse Signaling system fuse Backup fuse 30 0A 15 0A...

Page 167: ...uit 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...

Page 168: ...n 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...

Page 169: ...DM_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_N...

Page 170: ...ed pollutant Where a warrantable condition exists HISUN will repair your vehicle at no cost to you including diagnosis parts and labor If an emission related part on your vehicle is defective the part...

Page 171: ...ach new 2012 HISUN brand off road vehicle A is designed built and equipped so as to conform at the time of initial retail purchase with all applicable regulations of the United States Environmental Pr...

Page 172: ...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 li...

Page 173: ...by the owner However HISUN is not liable for these parts The owner is responsible for the performance of all required maintenance Such maintenance may be performed at a service establishment or by any...

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