Hisun HS700UTV-4, Maintenance Handbook

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GENERAL INFORMATION
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ELECTRICAL TESTING
This section describes basic electrical testing and test equipment use.
Preliminary Checks and Precautions
Refer to the color wiring diagrams at the end of the manual for component and connector
identification; Use the wiring diagrams to determine how the circuit should work by tracing the current
paths from the power source through the circuit components to ground. Also, check any circuits that
share the same fuse (if used), ground or switch. If the other circuits work properly and the shared
wiring is good, the cause must be in the wiring used only by the suspect circuit. If all related circuits are
faulty at the same time, the probable cause is a poor ground connection or a blown fuse (if used).
As with all troubleshooting procedures, analyze typical symptoms in a systematic manner. Never
assume anything and do not overlook the obvious like a blown fuse or an electrical connector that has
separated. Test the simplest and most obvious items first and try to make tests at easily accessible
points on the UTV.
Before starting any electrical troubleshooting, perform the following:
1. Check the fuse if the fuse is blown, replace it.
2. Inspect the battery. Make sure it is fully charged, and the battery leads are clean and securely
attached to the battery terminals.
3. Disconnect each electrical connector in the suspect circuit and make sure there are no bent
terminals in the electrical connector
4. Make sure the terminals on the end of each wire are pushed all the way into the connector. If not.
Carefully push them in with a narrow blade screwdriver
5. Check the wires where they connect to the terminals for damage
6. Make sure all terminals within the connector are clean and free of corrosion. Clean them. If
necessary. And pack the connectors with dielectric grease
7. Push the connectors with dielectric grease. The connectors are fully engaged and locked
together
8. Never pull the electrical wires when disconnecting an electrical connector-pull only on the
connector
Intermittent Problems
Intermittent problems are problems that do not occur all the time and can be difficult to locate. For
example. When a problem only occurs when the UTV is ridden over rough roads (vibration) or in wet
conditions (water penetration). It is intermit-ten. To locate and repair intermittent problems. Simulate
the condition when testing the compo-nets. Note the following:
1. Vibration---This is a common problem with loose or damaged electrical connectors
a. Perform a continuity test as described in the appropriate service procedure. Or under
Continuity Test in this section
b. Lightly pull or wiggle the connectors while repeating the test. Do the same when checking the
wiring harness and individual components. especially where the wires enter a housing or
connector