Massimo MSU 400 Owner'S Manual Download | Manualshive

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Your Vehicle 7-15

CAUTION:

Make sure all components that are washed
and assembled are coated lightly with
grease.

1

．

Air filter case check hose

1

．

CVT Gear Box inspection hole

Front Axle Differential Lock

When driving on rugged or muddy roads,
locking the differential case in the front axle
gearbox will give you the best traction. In this
case, the two front wheels will be driven at
the same rate. It may not be useful to lock
the differential case after you have lost
traction, because the skid process has

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Summary of Contents for MSU 400

Page 1: ...MASSIMO MSU 400 Owner s Manual...

Page 2: ...so includes basic maintenance and inspection procedures If you have any questions regarding the operation or maintenance of your vehicle please consult you dealer AN IMPORTANT SAFETY MESSAGE READ THIS...

Page 3: ......

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 Fault code indicator 4 8 Switches 4 10 On Command Four Wheel Drive and Differential Gear Lock Switches 4 11 Throttle Pedal 4 15 Brake Pedal 4 16 Parking brake pedal 4 16 Drive Select Lever 4 17 Fue...

Page 7: ...ners 5 10 Lights 5 10 Switches 5 10 Tires 5 11 Measuring Tire Pressure 5 13 Tire Wear Limit 5 14 Operation 6 1 Starting a Cold Engine 6 1 Starting a Warm Engine 6 3 Jump Starting 6 3 Warming Up 6 5 Dr...

Page 8: ...8 7 EFI System 8 8 EFI System inspection 8 11 Engine Oil and Oil Filter Cartridge 8 11 To Check Engine Oil Level 8 11 To Change the Engine Oil With or Without Oil Fliter Cartridge Replacement 8 12 Che...

Page 9: ...l and Accelerator Pedal Lubrication 8 38 Rear Knuckle Upper and Lower Pivot Lubrication 8 39 Steering Shaft Lubrication 8 39 Wheel Installation 8 41 Battery 8 42 Battery Maintenance 8 44 Fuse Replacem...

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 5 6 7 8 9 10...

Page 13: ...1 4 Location of the Warning and Safety Labels 11 12 13 14 15...

Page 14: ...Location of the Warning and Safety Labels 1 5 16 18 17 19...

Page 15: ...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 16: ...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 17: ...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 18: ...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 19: ...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 20: ...ttery 6 Fuses 7 Left body protection plate 8 Driver seat belt 9 Air filter element 10 Cargo bed 11 Tail brake lights 12 Spark arrester 13 Rear shock absorber assembly 14 CVT belt case 15 Fuel tank cap...

Page 21: ...ight switch 26 On Command four wheel drive and differential lock switches 27 Multi function display gauge 28 Auxiliary DC jack 29 Drive select lever 30 Accelerator pedal 31 Brake pedal 32 Release park...

Page 22: ...for 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 Th...

Page 23: ...electrical circuits are supplied with power Headlights and taillights come on when the light switch is turned to the on position OFF All electrical circuits are switched off The key can be removed in...

Page 24: ...d 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 EPS system 3 Dif...

Page 25: ...r is in the R reverse position Coolant Temperature Warning Light When the coolant temperature reaches a specified level this light comes on to warn that the coolant temperature is too hot If the light...

Page 26: ...ult indicator of EPS system so the driver can acknowledge fault of EPS in time and take some measures to keep himself herself safe When fault occurs on EPS system fault indicator light will be lit up...

Page 27: ...been inspected and repaired by a service center Low Battery charge indicator Indicates a low charge on the battery If light is illuminated re charge battery If recharging the battery does not fix the...

Page 28: ...pressing the button on the left side toggles the display from the odometer to the tripometer and then to the hours meter then it starts the cycle over The odometer displays the total distance travele...

Page 29: ...ere are two 4WD indicators on the display panel The left 4WD indicator has a blinking circle on the front axle when the grey and yellow 4WD selector buttons are pressed in indicating the 4WD function...

Page 30: ...an X in the middle When riding on good surfaces you should unlock the differential and press in the yellow and the gray buttons to the 2WD unlocked position There should be no symbols showing in eithe...

Page 31: ...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 display will indicate the...

Page 32: ...the switch to to turn on the high beam and the taillights Set the switch to OFF to turn off all lights CAUTION Do not use the headlights with the engine turned off for an extended period The battery...

Page 33: ...rential gear lock switch 4WD LOCK Select the appropriate drive according to terrain and the conditions z Two wheel drive 2WD Power is sup plied to the rear wheels only z Four wheel drive 4WD Power is...

Page 34: ...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 cha...

Page 35: ...cle make sure the On Command four wheel drive switch is set to 4WD move the select lever to position and then set the switch to LOCK 1 On Command differential lock switch 4WD LOCK 2 Select lever When...

Page 36: ...ZARD Always ride at a slow speed when the vehicle is in 4WD LOCK and allow extra time and distance for maneuvers NOTE z When the switch is set to LOCK the differential gear lock indicator and indicato...

Page 37: ...he pedal to the rest position when released Always check that the throttle pedal returns normally before staring the engine 1 Throttle pedal Before starting the engine check the throttle pedal to be s...

Page 38: ...ARD Check the operation of the accelerator pedal before you start the engine If the accelerator pedal does not work smoothly check for the cause Correct the problem before operating the vehicle Consul...

Page 39: ...the parking brake gradually Spring pressure helps return the pedal to the released position Be sure to fully release the parking brake before starting out Failure to do so may result in poor performan...

Page 40: ...ap by turning it counter clockwise 1 Fuel tank cap Starter choke Starting a cold engine requires a richer air fuel mixture A separate choke cable supplies this mixture Move in direction to open choke...

Page 41: ...Half open 3 Closed Seats To remove the seat bench pull front of seat upward then slide seat forward 1 Driver Passenger seat To install seat bench insert tabs on rear of seat into the seat holders loc...

Page 42: ...r and or passenger could fall if the seat is loose during operation HOW TO AVOID THE HAZARD Make sure the seat is securely latched Seat belts This vehicle is equipped with three point seat belts for b...

Page 43: ...buckle until it clicks Pull up on the latch plate to make sure it is secure 3 Place the lap portion of the belt low on your hips Push down on the buckle end of the belt as you pull up on the shoulder...

Page 44: ...or wearing the seat belt improperly WHAT CAN HAPPEN There is an increased risk of being killed or seriously injured in an accident HOW TO AVOID THE HAZARD Always wear your seat belt when riding in th...

Page 45: ...mpartment CAUTION To prevent damage to the glove compartment do not place metal products like tools or sharply edged products directly in the glove compartment If they must be stored wrap them in appr...

Page 46: ...ctions 4 24 Cargo Bed 1 Cargo bed 2 Tailgate Opening and Closing the Tailgate 1 Tailgate 2 Latch 2 To open Unhook latches and lower the tailgate To close Place tailgate in original up position then ho...

Page 47: ...bed slowly to its original position and be sure it locks into place Maximum load limit 350lb 158kg WARNING POTENTIAL HAZARD Pinch points WHAT CAN HAPPEN You or someone else could be pinched between th...

Page 48: ...limit for this cargo bed Cargo should be properly distributed and securely attached Reduce speed when carrying cargo Allow greater distance for braking WARNING POTENTIAL HAZARD Carrying a passenger in...

Page 49: ...out on rough terrain CAUTION Frequent or severe bottoming out can cause increased wear or damage to the vehicle Adjust the spring preload as follows To increase the spring preload turn the adjusting...

Page 50: ...wrench WARNING POTENTIAL HAZARD Improper shock absorber adjustment WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability which could lead to an accident HOW TO AVOID THE HAZA...

Page 51: ...high heat source This may cause the unit to explode due to excessive gas pressure Do not deform or damage the cylinders in any way Cylinder damage will result in poor damping performance Do not dispo...

Page 52: ...and thereby soften the suspension A special wrench can be obtained at a HSUN dealer to make this adjustment The spring preload setting is determined by measuring distance A shown in the illustration T...

Page 53: ...en the locknut NOTE Always tighten the locknut against the adjusting nut and then tighten it to the specified torque Rebound damping force Turn the rebound damping force adjusting screw in direction S...

Page 54: ...e damping 1 Compression damping force adjusting screw WARNING Suspension components become hot during operation Never touch the compression damping force adjusting screw the rebound damping force adju...

Page 55: ...can be obtained at a service center See pages 6 11 6 13 for precaution information 1 Trailer hitch bracket Auxiliary DC Jack The auxiliary DC jack is located at the right side of the front panel The...

Page 56: ...capacity for the auxiliary DC jack DC 12V 120W 10 A CAUTION z Do not use accessories requiring more than the above maximum capacity This may overload the circuit and cause the fuse to blow z If acces...

Page 57: ...reservoir Check coolant level Fill with coolant if necessary 5 6 8 20 8 21 Final gear oil Differential gear oil Check for leakage 5 7 Accelerator pedal Check for proper accelerator pedal operation 5 8...

Page 58: ...scribed in the Owner s Manual Brakes Always check the brake pedal travel and the brake fluid reservoir level before each use of the vehicle When applied the brake pedal should feel firm Any sponginess...

Page 59: ...e pages 8 33 8 34 Recommended brake fluid DOT 4 Brake Fluid Leakage Check to make sure there is no brake fluid leaking out of brake hoses joints or the brake fluid reservoir Apply the brakes firmly fo...

Page 60: ...find any problems with the brakes If a problem cannot be corrected by the adjustment procedures provided in this manual have the vehicle inspected by a service center Fuel Make sure there is sufficie...

Page 61: ...ohol containing ethanol can be used if ethanol content does not exceed 10 Gasohol containing methanol is not recommended because it may cause fuel system damage or vehicle performance problems WARNING...

Page 62: ...rankcase Recommended engine oil type and quantity See page 10 2 Coolant Check the coolant level in the coolant reservoir when the engine is cold The coolant level will vary with engine temperature The...

Page 63: ...radiator cap Always use a thick rag over the cap Allow any remaining pressure to escape before completely removing the cap Final Gear Oil Make sure the final gear oil is at the specified level Add oi...

Page 64: ...the vehicle inspected by a service center WARNING Failure to check or maintain proper operation of the throttle system can result in an accident leading to serious injuries or death Never start or op...

Page 65: ...hrottle pedal freeplay Adjust the freeplay if necessary Throttle Freeplay Inspection 1 Set parking brake 2 Start the engine Allow engine to warm up a few minutes 3 Measure the distance the throttle pe...

Page 66: ...ve smoothly when pulled out and retract on its own when released The latch plate should click securely into the buckle and release when the release button is pushed firmly Wash off any dirt or mud whi...

Page 67: ...ur risk of accident HOW TO AVOID THE HAZARD 1 The tires listed below have been approved by Manufacturer for this model Other tire combinations are not recommended 2 The tires should be set to the reco...

Page 68: ...ons The following are minimums Front 9psi 63kpa 0 64kgf cm2 Rear 9psi 63kpa 0 64kgf cm2 4 Use no more than the following Pressures when seating the tire beads Front 36psi 250kpa 2 5kgf cm2 Rear 36psi...

Page 69: ...d 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 Mi...

Page 70: ...Pre Operation Checks 5 14 Tire Wear Limit When the tire groove decreases to 0 12 in 3 mm due to wear replace the tire a Tire wear limit...

Page 71: ...or function you do not understand ask your service center Starting a cold engine WARNING POTENTIAL HAZARD Freezing control cables in cold weather WHAT CAN HAPPEN You could be unable to control the veh...

Page 72: ...brake is applied However it is recommended to shift into neutral before starting the engine 3 Use the starter choke in reference to the figure Position Cold engine start ambient temperature below 41 F...

Page 73: ...ion before riding CAUTION See the Engine break in section prior 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...

Page 74: ...ecially careful not to touch the positive lead of the jumper cable to the negative lead reverse the polarity of the jumper cables when connecting to the batteries battery explosion and or serious dama...

Page 75: ...ff Drive select lever operation and reverse driving CAUTION Before shifting you must stop the vehicle and take your foot off the accelerator pedal Otherwise the transmission may be damaged Shifting Ne...

Page 76: ...ifting to reverse position 5 The brake pedal is attached to a cable that is connected to a position pin in the gearshift assembly Only when the brake pedal is depressed will the gearshift lever be abl...

Page 77: ...eed go slowly Vehicle Break in Period The break in period for your new UTV vehicle is the first 25 hours of operation or the time it takes to use the first three tanks full of gasoline No single actio...

Page 78: ...on or any condition that might result in excessive engine heating must be avoided However momentary 2 3 seconds maximum full throttle operation under load does not harm the engine Each full throttle a...

Page 79: ...reak in of the clutch and drive belt will ensure a longer life and better performance Break in the clutch and belt by operating at slower speeds during the break in period as recommended Pull only lig...

Page 80: ...apply the parking brake and block the front and rear wheels with rocks or other objects Do not park the vehicle at all on hills that are so steep you could not walk up them easily 1 Bring the vehicle...

Page 81: ...accessory or one that is equivalent in design and quality Accessories should be rigidly and securely mounted An accessory that can shift position or come off while you are operating could affect your...

Page 82: ...with a 1 in receiver See page 4 29 for more information 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 wi...

Page 83: ...id 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 vehicle WARNING POTENTIAL HAZARD Overload...

Page 84: ...2 1 2 5 Please also read all 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 p...

Page 85: ...ssenger 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...

Page 86: ...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 87: ...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 88: ...re attempting maneuvers that are more difficult Perform the Pre Operation Checks on pages 5 1 5 14 Set the parking brake shift to neutral and follow the instructions on page 6 1 to start the engine On...

Page 89: ...r or 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 you...

Page 90: ...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 91: ...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 92: ...some hills are too steep for you to climb Maximum slope angle 15 Choose carefully which hills you attempt to climb Avoid hills with slippery surfaces or ones where you will not be able to see far eno...

Page 93: ...re climbing the hill first be sure you are operating in low range 4WD or if necessary with 4WD Diff Lock To climb a hill you need traction momentum and steady throttle Travel fast enough to keep your...

Page 94: ...ive your vehicle straight downhill Avoid sharp angles that could allow the vehicle to pitch or roll over Carefully choose your path and drive no faster than you will be able to react to obstacles that...

Page 95: ...slowly and carefully If the vehicle starts to tip gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance gradually steer again in the direction...

Page 96: ...13 in 33cm Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply brakes several times to let friction dry out the linings CAUTION After ri...

Page 97: ...box and replace the filter with a new filter 3 Remove the spark plugs 4 Turn the engine over several times 5 Dry the spark plugs and reinstall them or install new plugs 6 Attempt to start the engine...

Page 98: ...Box inspection hole Front Axle Differential Lock When driving on rugged or muddy roads locking the differential case in the front axle gearbox will give you the best traction In this case the two fro...

Page 99: ...r accident Avoid jumping the vehicle as injury loss of control and damage to the vehicle could occur WARNING POTENTIAL HAZARD Failure to use extra care when operating this vehicle on unfamiliar terrai...

Page 100: ...oth sides and above the vehicle for obstacles such as branches that the vehicle might hit causing an accident or for brush that might enter the vehicle as you pass and strike the driver or passenger N...

Page 101: ...e tipping Go only fast enough to maintain your momentum but still give yourself plenty of time to react to changes in conditions If there is any question about your ability to maneuver safely over the...

Page 102: ...e 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...

Page 103: ...h 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 in...

Page 104: ...y require special tools data and technical skills INITIAL EVERY Month 1 3 6 6 12 Km miles 320 200 1 200 750 2 400 1 500 2 400 1 500 4 800 3 000 ITEM ROUTINE Whichever Comes first hours 20 75 150 150 3...

Page 105: ...ake Duct Clean Replace if necessary Every 20 40 hours More often in wet or dusty areas Engine Oil Replace Warm engine before draining Engine Oil Filter Cartridge Replace Final Differential Gear Oil Ch...

Page 106: ...ive Shaft Universal Joint Lubricate with lithium based grease Rear Upper and Lower Knuckle Pivots Lubricate with lithium based grease Fittings and Fasteners Check all chassis fittings and fasteners Ch...

Page 107: ...8 6 Periodic Maintenance and Adjustment Hood To Open Unhook the hood latches and then slowly tilt the hood up until it stops 1 Latch 2 1 Hood...

Page 108: ...re projections on the underside of the hood into slots on the back of the instrument panel Secure slots on the side of the hood around projections on the frame 1 Projection 2 2 Slot 2 CAUTION z Make s...

Page 109: ...em EFI engine was completely different from the engine which uses carburetor it consist of ECU EFI cables sensors actuators and other advanced components As the following pictures 1 Oxygen sensor 2 Ox...

Page 110: ...ltage wire 2 Ignition signal plug 3 Ignition coil 1 Fuel injector 2 Bent pipe inlet pipe 3 Intake air temperature sensor pressure sensor 4 Ducting dampers 2 Water temperature sensor 1 Air damper degre...

Page 111: ...ondition ECU will adjust the fuel injection volume according to different negative pressure and opening of air damper Adjust the engine fuel injection volume can adjust the output power and output tor...

Page 112: ...ration In addition the oil must be changed and the oil filter cartridge replaced at the intervals specified in the periodic maintenance and lubrication chart To Check Engine Oil Level 1 Place the vehi...

Page 113: ...mmended type to raise it to the correct 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 Filt...

Page 114: ...s not being replaced 4 Remove the oil filter cartridge with an oil filter wrench 1 Oil filter cartridge 2 Oil filter bolt NOTE An oil filter wrench is available at a nearby service center 5 Apply a li...

Page 115: ...orque wrench Tightening torque Oil filter cartridge 12 ft lbs 17Nm 1 7m kgf 1 Oil filler cartridge 2 Torque bolt 7 Install the engine oil drain bolt and then tighten it to the specified torque Tighten...

Page 116: ...han 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 w...

Page 117: ...ype to raise it to the correct level CAUTION Be sure no foreign material enters the final gear case 4 Install the oil filler bolt and then tighten it to the specified torque Tightening torque Final ge...

Page 118: ...ing torque Final gear oil drain bolt 14 ft lbs 20 Nm 2 0 m kgf 5 Add the recommended final gear oil up to the brim of the filler hole Recommended oil SAE 80 API GL 4Hypoid gear oil Oil quantity 0 42 q...

Page 119: ...Level 1 Place the vehicle on a level surface 2 Remove the differential 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 oi...

Page 120: ...lbs 23Nm 2 3 m kgf Changing the Differential Gear Oil 1 Place the vehicle on a level surface 2 Place a container under the differential gear case to collect the used oil 3 Remove the differential gea...

Page 121: ...5 Hypoid gear oil Oil quantity 0 3 qt 0 28L 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 t...

Page 122: ...one can easily break the oil cooler and cause oil leak CAUTION If the oil cooler is blocked it will make the oil temperature overheated and damage the engine Coolant The coolant level should be checke...

Page 123: ...oir capacity up to the maximum level mark 0 663 qt 0 627L CAUTION Mix anti freeze with distilled water only However if distilled water is not available soft water can be used for refilling Changing th...

Page 124: ...content of the coolant If water is used instead of coolant have a service center check the antifreeze content of the coolant as soon as possible The radiator fan is automatically switched on or off ac...

Page 125: ...tment 1 Rear axle boot 2 each side Spark Plug Inspection Removal 1 Remove hood See pages 8 6 2 Remove the spark plug cap 3 Use the spark plug wrench in the tool kit to remove the spark plug as shown 1...

Page 126: ...ot 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...

Page 127: ...17 5 Nm 1 75 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 tight...

Page 128: ...Remove the Engine cover See page 8 16 8 17 for Engine cover removal and installation procedure 3 Remove the connecting rubber tube between air cleaner and throttle valve and the screws fixing the air...

Page 129: ...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 130: ...al NOTE The sponge material should be wet but not dripping 10 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 b...

Page 131: ...moved This will allow unfiltered air to enter causing rapid engine wear and possible engine damage Additionally operation without the air filter element will affect throttle valve jetting with subsequ...

Page 132: ...que Tightening torque Tailpipe bolt 8 5 ft lbs 12 Nm 1 2 m kgf WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester Hot exhaust system WHAT CAN HAPPEN Could injure the eyes Could cause bur...

Page 133: ...k Each brake pad is provided with wear indicator grooves which allow you to check the brake pad wear without having to disassemble the brake system To check the brake pad wear check the wear indicator...

Page 134: ...r grooves If a brake pad has worn to the point that the wear indicator grooves have almost disappeared have a service center replace the brake pads as a set 1 Brake pad wear indicator groove Checking...

Page 135: ...nly the recommended quality brake fluid Otherwise the rubber seals may deteriorate causing leakage and poor braking performance Recommended brake fluid DOT 4 z Refill with the same type of brake fluid...

Page 136: ...il seals every two years z Replace the brake hoses every four years Checking the Brake Pedal Have a service center check the brakes at the intervals specified in the periodic maintenance and lubricati...

Page 137: ...components requires professional knowledge These procedures should be performed by a service center Brake Light Switch Adjustment The brake light switch which is activated by the brake pedal is prope...

Page 138: ...TIAL HAZARD Damaged control cables WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged Cables can also become frayed or kinked Operation of controls could be...

Page 139: ...he cable ends If the cables do not operate smoothly ask a service center to replace them Recommended lubricant Engine oil see page 10 2 Brake Pedal and Accelerator Pedal Lubrication Lubricate the pivo...

Page 140: ...ication Lubricate the knuckle upper and lower pivots with a grease gun Recommended lubricant Lithium based grease Steering Shaft Lubrication Lubricate the pivot points Recommended lubricant Lithium ba...

Page 141: ...8 40 Periodic Maintenance and Adjustment Lower universal joint steering transmission shaft Front balance rod...

Page 142: ...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 Inst...

Page 143: ...cle 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 center...

Page 144: ...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 145: ...ttery lead CAUTION A special battery charger constant voltage ampere or constant voltage is required for recharging a sealed type battery Using a conventional battery charger may shorten the battery l...

Page 146: ...n off the ignition switch when checking or replacing a fuse WARNING POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead...

Page 147: ...Fuse Main Fuse Headlight Fuse Ignition Fuse Auxiliary DC Jack Fuse Signaling System Fuse Carburetor Warmer Fuse 2WD 4WD Fuse Backup Fuse 30 0A 15 0A 10 0A 10 0A 10 0A 10 0A 3 0A 10 0A 4 Turn the key t...

Page 148: ...s 2 Remove the cover at the rear of the headlight by pulling it off 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 Remo...

Page 149: ...OID THE HAZARD Wait for the bulb to cool before touching or removing it CAUTION Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the l...

Page 150: ...beam if necessary Tail Brake Light Bulb Replacement If a tail brake light bulb burns out replace it as follows 1 Take down the tail light from carrier 1 Rear tail light 2 Remove the bulb holder togeth...

Page 151: ...y trouble may occur during operation Any problem in the fuel compression or ignition systems can cause poor starting and loss of power The troubleshooting chart describes a quick easy procedure for ma...

Page 152: ...le 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...

Page 153: ...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 Re paste th...

Page 154: ...orn or contaminated by stuffs that can reduce friction 3 Check if there is any leakage in brake system s oil lines or conjunctions 4 Check if the post rod in brake master cylinder is deformed 5 Check...

Page 155: ...front brake goes down which causes the rear wheels to lock up before the front wheels when braked 3 Check if spring force deviation of shock absorbers in front left and right suspension are within sp...

Page 156: ...hicle cannot go into 4 wheel drive mode 3 Check if the wire is broken 3 Rear differential will not work 1 Check if the control switch on meter board works well 1 Check if the differential lock control...

Page 157: ...1 Check the bearings in knuckles if they are broken 1 Check the main ball pins to find out if they are broken 2 Check the lock screws of front wheels and axles to find out if they are loose or broken...

Page 158: ...bent 5 Wheels jump during use 3 Check if the tires are worn or deformed 1 Check if overloaded 2 Check if the springs are two soft after long time running 6 Shock absorbers become soft and not comforta...

Page 159: ...e 2 Check if the CDI s faulty 1 Check if the carburetor is blocked 2 Check and clean core of air cleaner 3 Power performance is falling 3 Check muffler for partly block and clean spark arrestor 1 Chec...

Page 160: ...coolant loop for mixed with air 1 Check the battery which with low electricity may cause the motor failure 2 Check the starting motor for damage 3 Check if the carburetor is in regular situation 4 Che...

Page 161: ...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 162: ...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 163: ...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 164: ...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 165: ...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 166: ...for HS400UTV 2 1550mm 61 0 in for HS400UTV 3 1870mm 73 6 in 840mm 33 1 in 1830mm 72 0 in 300mm 11 8 in 3500mm 137 8 in Basic weight with oil and full fuel tank 543kg 1197 lb Engine Engine type Cylinde...

Page 167: ...ge replacement 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 o...

Page 168: ...fferential gear case oil Type Quantity SAE80 API GL 5 Hypoid gear oil 0 28L 0 3 qt Radiator capacity including all routes 1 5 L 1 59 qt Air filter Wet element Fuel Type Fuel tank capacity Unleaded gas...

Page 169: ...on Primary reduction system Secondary reduction system CVT reduction ratio Transmission type Operation V belt Shaft drive 1 75 35 20 V belt automatic Right hand operation Chassis Frame type Caster ang...

Page 170: ...brake Right hand operation Dual disc brake Left hand and right foot operation Suspension Front suspension Rear suspension Double wishbone Double wishbone Shock absorber Front shock absorber Rear shoc...

Page 171: ...age quantity Headlight Tail brake light Front Rear turning light License light 12V35 0W 35 0W 2 12V5 0W 21 0W 2 12V10 0W 10 0W 2 12V3 0W Indicator lights Neutral indicator light Reverse indicator ligh...

Page 172: ...Specifications 10 7 Model HS400UTV 2 HS400UTV 3 Main Fuse Headlight Fuse Ignition Fuse Auxiliary DC Jack Fuse Signaling System Fuse 2WD 4WD Fuse 30 0A 15 0A 10 0A 10 0A 10 0A 3 0A...

Page 173: ...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 174: ...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 175: ...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 176: ...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 177: ...ach new 2013 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 178: ...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 179: ...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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