Hisun AXIS 110 Owner'S Manual Download

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hisunmotors.com

AXIS 110 &

FORGE 110

OWNER’S MANUAL

Summary of Contents for AXIS 110

Page 1: ...hisunmotors com AXIS 110 FORGE 110 OWNER S MANUAL TM ...

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

Page 3: ...V Please call Hisun Motors Corp USA at 972 446 0760 or visit us at www hisunmotors com SAFETY NOTICE TO PARENTS This is a Category Y 10 ATV A Category Y 10 ATV is a youth model ATV that is intended for use by children age 10 or older Never allow a child to operate this ATV who is under age 10 Continually supervise any child who is under age 16 Children differ in skills physical abilities and judgm...

Page 4: ... children should take an ATV training course before operating an ATV for the first time For a training course with an authorized instructor in your area contact your dealer or call SVIA 1 800 887 2887 IMPORTANT MANUAL INFORMATION It is important this manual is read from cover to cover carefully by the ATV owner and all operators Parents should review the manual carefully with their children Never ...

Page 5: ...rticularly important information is distinguished in this manual using the following notations The Safety Alert Symbol means ATTENTION YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the machine operator a bystander or a person inspecting or repairing the machine A CAUTION indicates special precautions that must be taken to avoid damage to t...

Page 6: ...ies oil and tires This manual is based on the latest product information available at the time of publication Hisun Motors Corp USA has a policy of continually improving its products Due to improvements or other changes there may be some discrepancies We reserve the right to make product changes at any time without notice and without incurring any obligation to make the same or similar changes to ...

Page 7: ...er patterns 4 3 Clock and Fuel Levels 4 3 Master Key Switch 4 4 Control Functions 4 5 Lights Horn and On Off 4 6 Hand Controls Throttle Brakes 4 7 Shifting 4 8 Fuel Cap and Shock Adj 4 9 Chain adjustment 4 11 Seat removal 4 12 Pre Operation Checks List 5 1 Before using this ATV check the following points 5 1 Brake system 5 3 Ensure full tank of fuel 5 4 Mixed fuel alcohol gasoline 5 4 Engine oil 5...

Page 8: ... 3 Climbing uphill 7 4 Riding downhill 7 6 Obstacles 7 6 Periodic Maintenance and Adjustment Periodic maintenance chart for the emission control system 8 1 General maintenance and lubrication chart 8 2 EFI System 8 3 Throttle Valve 8 5 Idle control step motor 8 6 Fuel Injection Tap 8 6 Inlet temperature sensor 8 6 Inlet pressure sensor 8 6 Ignition signal 8 6 EFI system examination 8 7 Oil and oil...

Page 9: ...e speed adjustment 8 14 Valve clearance 8 15 Check the front brake pads 8 16 Check for the rear brake pads 8 16 Check brake fluid 8 17 Battery 8 18 Headlight Bulbs 8 20 Lubricate steering 8 23 Trouble Shooting 8 24 Cleaning and Storage 9 1 Cleaning 10 1 Specifications 10 1 10 2 Fault Codes for EFI System 11 1 12 1 YOUR WARRANTY RIGHTS AND OBLIGATIONS 9 10 11 11 11 12 ...

Page 10: ...1 1 Location of the Warning and Safety Labels LOCATION OF THE WARNING AND SPECIFICATION LABELS FOR Utility model ...

Page 11: ... understand all of the labels on your ATV 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 ...

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

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

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

Page 15: ... understand all of the labels on your ATV 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 ...

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

Page 17: ...Location of the Warning and Safety Labels 1 8 ...

Page 18: ...d follow the operating procedures described Never operate an ATV without proper training or instruction Take a Training Course Always follow the age recommendation A child under 16 years old should never operate an ATV without adult supervision Never allow a child under age 10 to operate an ATV without adult supervision and never allow continued use of an ATV by a child if he or she does not have ...

Page 19: ... both hands on the handlebars and both feet on the footboards of the ATV during operation Always go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV Never 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 e...

Page 20: ...r weight backward Never go down a hill at high speed Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side Go straight down the hill where possible Always follow proper procedures for crossing the side of a hill as described in this manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV Never attempt to ...

Page 21: ...l Always be careful when skidding or sliding 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 cautious in order to reduce the chance of skidding or sliding out of control Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual Remember that ...

Page 22: ...r an ATV Cargo should be properly distributed and securely attached Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer Allow greater distance for braking WARNING POTENTIAL HAZARD 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 HAZAR...

Page 23: ...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 24: ...3 1 Description and Vehicle Identification DESCRIPTION AND VEHICLE IDENTIFICATION Ignition switch Gear shift lever Meter Rear turning light Tail light comp Foot brake ...

Page 25: ...Description and Vehicle Identification 3 2 Fuel tank cap Right hand grip Head light Seat Left hand grip Front Rack Forge 110 only Rear Rack Forge 110 only ...

Page 26: ...ne identification number in the spaces provided These numbers will be needed when calling for service and or ordering parts The VIN number is also needed for registering your ATV in certain states 1 VEHICLE IDENTIFICATION NUMBER Vehicle identification number The vehicle identification number is stamped into the frame Vehicle identification number 1 NOTE The vehicle identification number is used to...

Page 27: ...Description and Vehicle Identification 3 4 Engine identification number Engine identification number 1 NOTE The engine identification number also is used to identify your machine ...

Page 28: ...ift lever to gear F forward indicator F will illuminate Moving the shift lever to gear R reverse indicator R will illuminate Park P When placing the ATV in neutral with the Park brake set the P park indicator will illuminate Coolant temp warning light Ensure the coolant temp warning light is off before restarting the ATV Never run the ATV when the coolant temperature light is on Running the engine...

Page 29: ... the coolant temperature light Multi function meter Speed Speedometer Odometer button Trip Odometer Left turn Right turn Clock Clock button Setting Trip Odometer Depress the Odometer button to access Trip A or Trip B To reset Trip A or B depress the Odometer button and hold for 3 seconds Setting Clock Depressing the clock button will Toggle between settings ...

Page 30: ...MILE button to set the hour 4 Press TRIP 000 button to set the minute 5 Press time button for 3 5 seconds then release to finish setting Fuel level gauge Fuel meter reflects the remaining volume of gasoline It will change from Green to Red while running and from RED to GREEN when filling 1 Fuel 2 Fuel gauge ...

Page 31: ...ut off button is placed in the Position and the starter button is held on When the master key switch is ON the lights can also be turned on OFF Turn Master key counterclockwise to the OFF position In this position the ATV will shut off and cannot be started All electrical functions will be turned off Always turn the master key switch to the off position when the ATV is not in use START ...

Page 32: ...Turn lights on and off with the light switch There are 3 positions High beam Off Parking Electric start button To start the engine the Electric start button needs to be depressed until engine starts Note In order for the electric start button to start the engine the Main Key switch needs to be placed in the ON position and the Emergency stop button needs to be placed in the on position 1 2 3 4 5 6...

Page 33: ... placing the turn signal switch left or right Emergency Shut Off button The ATV can be turned off at any time by depressing the Emergency shut off button to the position The Emergency Shut Off button needs to be in the ON position for the engine to start Horn The Horn is activated by depressing the horn button Hazard lights The Hazard lights are activated by depressing the Hazard button Left hand ...

Page 34: ...ATV to go forward Throttle should return to idle position when released WARNING POTENTIAL DANGERS Throttle cable not operating properly WHAT COULD HAPPEN Throttle could stick open or closed resulting in an accident HOW TO AVOID Check condition of the throttle control before each ride Make sure throttle snaps back to idle when released 2 1 ...

Page 35: ...ever Reduce the speed or stop the ATV by pressing the foot brake lever Foot Brake Lever Shift lever Once the ATV has stopped and the brake is set you can shift the ATV by using the shift lever into forward neutral or reverse Shift lever ...

Page 36: ...y turning counter clockwise Fuel cap can be installed by turning clockwise Fuel tank cap Adjustment of front and rear shocks Increase load capacity by turning adjustment ring 1 toward A Reduce load capacity by turning adjustment ring toward B Adjustment ring ...

Page 37: ... adjust both front shocks to same settings Specified spanner WARNING POTENTIAL DANGERS Front shocks adjusted to different settings WHAT COULD HAPPEN Loss of stability which could result in an accident HOW TO AVOID Make sure both left and right front shocks are adjusted to the same settings ...

Page 38: ... Control Functions Chain adjustment Chain should have to slack when pushed up in the center To adjust chain loosen Nuts 1 To tighten chain turn nuts 2 clockwise To loosen chain turn nuts 2 counter clockwise ...

Page 39: ...ng WHAT COULD HAPPEN Finger or hand could get caught between chain and sprocket which could result in severe injury HOW TO AVOID Turn off engine before attempting to inspect or adjust chain Seat removal As shown in figure seat is removed by pressing lever 2 with hand while pushing on seat at the same time ...

Page 40: ...ecessary Throttle Check the throttle cable operation and free play Wheels and tires Check the tire pressure wear and look for any damage Idle Check to see if the idle speed is normal Take it to a dealer for adjustment if necessary Lights and switches Check for proper operation of switches and that the lights all work Axle boots Check each boot for tears or leaks Instrument Panel Check and be sure ...

Page 41: ...g to inspect and maintain your ATV could be hazardous Not following the pre ride inspection procedures could result in loosing control of the ATV resulting in an accident or damage to the ATV Always perform a Pre ride inspection before each ride ...

Page 42: ...eaks If a leak is found contact your Hisun Authorized service center for repair Braking test Test brakes for proper operation at slow speeds If brakes are not working properly contact your Hisun Authorized service center for repair WARNING POTENTIAL DANGERS Brakes not working properly WHAT COULD HAPPEN Can cause an accident which could result in severe injury or death HOW TO AVOID Inspect brakes e...

Page 43: ...xed fuel alcohol gasoline Do not use gasoline mixed with over 5 methyl alcohol Over 5 methyl alcohol will damage engine components Do not use gasoline mixed with over 10 ethyl alcohol Over 10 ethyl alcohol will damage engine components WARNING POTENTIAL DANGERS Gas spilling on a hot engine WHAT COULD HAPPEN Spilling gasoline on a hot engine could result in a fire HOW TO AVOID Do not overfill fuel ...

Page 44: ...urthermore oil titled ENERGY CONSERVING 11 or higher should never be used Tires WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires on this ATV or operation of this ATV with improper or un even tire pressure may cause loss of control increasing your risk of accident Tire size Type Size Front 19 7 8 6PR Rear ...

Page 45: ...psi 0 49kgf cm2 49kpa Exceeding the recommended tire pressures could result in tire failure Fill tires slowly to the required pressures Use a low pressure tire gauge 1 Check tire pressure when tires are completely cool Tire wear limit Inspect tread wear As shown in the figure below replace tires before tread thickness a becomes less than 12in 3mm a Tread thickness ...

Page 46: ...carefully If there is a control or function you do not understand contact your dealer or your Authorized 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 smoothl...

Page 47: ...ne 2 Place the shift lever in neutral Note ATV will not start unless it is in neutral 3 Place fuel valve to the ON position 4 Place the emergency stop switch located on the handlebars to the RUN position 6 Depress the start button engaging the starter motor Note Do not push the start button more than 5 seconds at a time doing so could damage the starter motor ...

Page 48: ...V To jump the ATV please follow the instructions below 1 Open battery cover 2 Make sure the key to the ATV is turned off 4 Connect the positive red jumper cable to the positive pole on the good battery then place the other end of the positive jumper cable on the ATV positive pole on the drained battery Place the negative black jumper cable on the good battery then place the other end of the negati...

Page 49: ...minals Crossing positive to negative could result in an explosion and or damage to the ATV Warming up engine To prolong engine life always warm up the engine before starting off This allows the oil to warm up and circulate through the engine components Never start a cold engine and rev up Allow a cold engine to warm up at idle for approximately 3 to 5 minutes before driving Gear shift lever and re...

Page 50: ...elease brake and accelerate gradually Gear shift lever Shifting to reverse 1 Stop vehicle and remove hand from the throttle 2 Hold the brake 3 Move gear shift lever from neutral to reverse NOTE When in reverse the reverse light on the front meter will illuminate If the reverse light does not come on please contact a service center 4 Before going in reverse look behind the ATV for obstacles or peop...

Page 51: ...etween zero and 20 hours For this reason we ask that you carefully read the following material Because the engine is brand new you must not put an excessive load on it for the first several hours of running During the first 20 hours the various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throttle operation or any condition wh...

Page 52: ...o time Do not operate it at one set throttle position 10 20 Hours Avoid prolonged operation above 3 4 throttle Rev the vehicle freely but do not use full throttle at any time Parking Stop ATV move the gear select lever to park Neutral N Set the parking brake Parking on a slope WARNING POTENTIAL HAZARD Parking the vehicle on a slope or uneven terrain WHAT CAN HAPPEN The vehicle may lose control res...

Page 53: ...Operation 6 8 1 Stop the vehicle with brakes applied 2 Shut down the engine Parking brake 3 Park the vehicle with parking brake applied Brake lever ...

Page 54: ...t 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 around on the seat or one that limits your view Use extra caution when riding an ATV with accessories The ATV may handle differently than it does without accessories Loadin...

Page 55: ... a face shield or goggles While riding an ATV you can be hit in the eyes by any of the following dust branches rocks debris from other riders bugs etc Wear protective clothing Long sleeve shirt gloves long pants and over the ankle boots Riding an ATV exposes the rider to many hazards wearing protective clothing can help protect the rider from injury WARNING POTENTIAL HAZARD Operating this ATV with...

Page 56: ...skills and techniques described in this section however are appropriate for all types of riding Riding your ATV requires special skills acquired through practice over a period of time Take the time to learn the basic techniques well before attempting more difficult maneuvers Riding your new ATV can be a very enjoyable activity providing you with hours of pleasure But it is essential to familiarize...

Page 57: ...eristics NOTE Never shift the gear into reverse until the vehicle is stopped Or it may damage the engine and transmission chain Turning Turning improperly could cause loss of traction loss of control accident or overturn Always follow proper procedures for turning as described in the owner s manual Always avoid turn at high speeds Put your weight on the footrest to the outside of the turn and lean...

Page 58: ...TV effectively on flat ground before attempting any incline Even then practice riding first on gentle slopes Try more difficult climbs only after you have developed your skills In all cases avoid inclines with slippery or loose surfaces or obstacles that might cause you to lose control Operating on excessively steep hills could cause an overturn Never operate on hills too steep for the ATV or for ...

Page 59: ...ause turn over to drive on steep uphill HOW TO AVOID HARZARD Never operate on hills too steep for the ATV or for your abilities Never operate the ATV on hills steeper than 15 degrees Never crest a hill at high speed for an obstacle a sharp drop or another vehicle or person could be on the other side of the hill If you realized that you have misjudged being able to make it to the top when climbing ...

Page 60: ... over Carefully choose your path and ride slowly 1 CVT belt box drain plug When approaching obstacles If you failed to avoid the roadblock you may stop the vehicle and check the road conditions then choose the safest path to avoid turnover WARNING POTENTIAL HAZARD incorrect driving HAZARDS MIGHT OCCUR loss control or collision might cause turnover HOW TO AVOID When you approach a new zone check wh...

Page 61: ... adjusting and lubricating the vehicle are as below WARNING POTENTIAL HAZARD Check the engine when functioning HAZARDS MIGHT OCCUR Your body parts or clothes might get stuck into the moving parts cause injury Electronic parts might cause fire HOW TO AVOID Turn the engine down when maintaining Maintaining manual aims to help you to accomplish vehicle maintaining works The tools which be provided ar...

Page 62: ... HAZARD Driving nonstandard modified vehicle HAZARDS MIGHT OCCUR If you assemble and modify the vehicle incorrectly it might cause hazards under some circumstances HOW TO AVOID Any inappropriate vehicle modifying is strictly prohibited ...

Page 63: ...nless otherwise specified Have a dealer perform service if you are not familiar with servicing an ATV 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 can result in an accident HOW TO AVOID THE HAZARD Never modify this ATV using improper installation or us...

Page 64: ... data and technical skills ITEM ROUTINE Whichever Comes first INITIAL EVERY Month 1 3 6 6 12 Km Miles 320 198 1 200 745 2 400 1450 2 400 1450 4 800 2900 Hours 20 75 150 150 300 Valves Check valve clearances Adjust if necessary Spark plug Check the plug condition Adjust the gap and clean Replace if necessary Air filter element Clean Replace if necessary Every 20 40 hours More often in wet or dusty ...

Page 65: ...atalyzer Check the exhaust Replace the muffler if necessary oil filter Check for leaks around the seal Replace it if necessary Engine filter element Clean Replace if necessary Engine oil strainer Clean Brakes Check operation fluid leaks See NOTE Correct if necessary Clutch Check operation Adjust if necessary Wheels Check balance damage run out Replace if necessary Wheels bearings Check bearing ass...

Page 66: ...Correct if necessary Lights and a witches Check operation Adjust headlight beams EFI Use EFI diagnostic apparatus for inspection Since this may require special tools data and technical skills have a dealer perform this service NOTE Brake fluid replacement Recommended brake fluid DOT 4 When disassembling the master cylinders or calipers replace the brake fluid Periodically check the brake fluid lev...

Page 67: ...stem is different from a carbureted engine An EFI engine is composed of advanced parts such as an ECU EFI wires and sensors Parts are shown below Oxygen sensor Exhaust pipe High voltage wire Ignition signal plug Ignition coil Fuel injector Elbow pipe inlet pipe ...

Page 68: ...according to the temperature Inlet pressure sensor Monitors the inner pressure of the inlet line the operation of the engine is determined both by the throttle valve s angle and the inlet line pressure The ECU adjusts the injectors based on the inner pressure and the angle of the throttle valve The output power and torque are adjusted by changing the injection quantity Ignition signal The generato...

Page 69: ...d less emissions EFI system examination If the EFI system fails the associated fault code is shown on the display panel You can diagnose the system using an EFI scanner purchased from your dealer This scanner provides detailed fault code information An owner s manual for the fault code is available Diagnostic apparatus EFI cables ...

Page 70: ...he Maintenance chart Checking oil level 1 Place ATV on a flat surface 2 Remove oil cap 4 3 Check oil level on the dipstick 3 4 If oil is below the minimum oil level 2 add oil until the maximum oil level is reached 1 Note Do not fill above maximum oil level 1 Oil type SAE10W 30 or SAE10W 40 The maximum oil level The minimum oil level Dipstick Oil cap ...

Page 71: ...tall the oil drain bolt 1 and tighten to the proper torque Torque spec Oil drain bolt 22ft lbf 3 0m kgf 30Nm NOTE In order to avoid clutch slippage because the oil also lubricates the clutch do not mix any other chemicals with the oil Do not use CD standard oil or any other standard higher than the specified oil Do not use ENERGY CONVERSING II oil or other oils higher than this standard Oil capaci...

Page 72: ... Remove the plug cap 1 from the spark plug Spark plug cap 3 Remove the spark plug with the spark plug wrench supplied in the tool kit Spark plug Inspection Inspect the plug for carbon deposits and clean if necessary If plug shows excessive carbon replace the plug Specified spark plug CR7HSA ...

Page 73: ...ll the inspected plug or new plug until finger tight Finish tightening plug with a wrench If the plug is a new plug tighten approximately 1 2 turn more with the wrench If plug is an old plug tighten approximately 1 8 turn more with a wrench Spark Plug Torque 12 7 ft lbf 1 75 m kgf 17 5Nm Air Filter Removal and Cleaning 1 Locate the Air Filter housing under the seat 2 Remove screws 1 holding the ai...

Page 74: ... Be careful not to tear the element while cleaning 6 If air filter element is damaged replace 7 Apply Air filter oil to the sponge element then squeeze out excess oil 8 Re install air filter element in air filter housing NOTE The air filter element should be cleaned once every 20 40 hours If ATV is ridden in wet muddy or dusty conditions the air filter element should be cleaned more often Each tim...

Page 75: ...or bolts 2 Remove spark arrestor 2 from muffler 3 Gently tap the spark arrestor on a hard surface to remove sediment 4 Use a wire brush to loosen and remove any additional sediment 2 Exhaust Outlet Spark arrestor 4 Re install the spark arrestor 5 Re installl the 3 bolts 1 that hold the spark arrestor in place Torque spec Spark Arrestor bolts 6 9 ft lbf 0 95 m kgf 9 5N m ...

Page 76: ... sure muffler is cool before cleaning Spark Arrestor Idle Adjustment To adjust idle speed 1 Locate the idle adjustment screw 1 2 Allow the engine to warm up approximately five minutes 3 With the engine running turn the idle adjustment screw in or out a b at small increments until the correct idle is achieved NOTE A service center can perform this adjustment A diagnostic tachometer is required for ...

Page 77: ...es should be done by an authorized service center or comparable servicing dealer Proper valve gap will help ATV to run at peak performance Follow the valve gap adjustment intervals listed in the maintenance chart Proper Valve Clearance Intake 0 08 0 12 mm Exhaust 0 13 0 17 mm ...

Page 78: ...ark on the caliper assembly the brake pads will need to be replaced Wear marks CAUTION Remove wheels before checking brake pads Check rear brake pads To inspect rear brake pad wear locate the wear marks located on the brake pad assembly scale If the wear marks are not visible on the caliper assembly the brake pads will need to be replaced Brake pad wear indicators Check brake fluid level ...

Page 79: ...luid could cause air to enter the braking system which could cause a loss of braking ability If brake fluid is low check the brake system for leaks or brake pads for wear Adding or changing brake fluid Fill with recommended brake fluid Recommended brake fluid DOT 4 Mixed brake fluids can produce chemical reactions and affect braking function Always use the same type of brake fluid when adding Neve...

Page 80: ...THE HAZARD 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 milk Follow with milk of magnesia beaten egg or vegetable oil Get prompt medical attention EYES Flush with water for 15 minutes and get prompt medical attention Keep batteries away from sparks...

Page 81: ...ut off the main switch Follow the steps below to inspect fuses 1 Make sure key is in the OFF position CAUTION To avoid short circuits make sure the key is in the OFF position 2 Open fuse box and locate bad fuse fuse is bad if amperage bar in fuse is melted If unsure if fuse is bad check fuse with a fuse tester 3 Replace fuse with a new one 4 Once fuse is replaced test new fuse under load by turnin...

Page 82: ...ective materials Changing headlight bulb If a headlight bulb burns out replace it as follows 1 Pull off bulb holder cover 1 at the rear of the headlight Note Depending on your model the headlight bulb cover on back of the headlight may just pull straight off or need to be pushed in and turned counter clockwise 2 Remove bulb holder 2 form headlight housing by pushing in bulb holder and turning coun...

Page 83: ... Touching the glass with your fingers will allow oil from your skin to affect the transparency of the glass light bulb luminosity and will shorten the life of the bulb If you do touch the bulb or the bulb comes in contact with oil or gasoline clean bulb with alcohol and a clean rag 5 Install new bulb into bulb holder by pressing in retainer and turning clockwise 6 Reinstall the bulb and bulb holde...

Page 84: ...ssary reconnect lights to wire harness Headlight beam adjustment To raise the beam turn the adjusting screw in direction a To lower the beam turn the adjusting screw in direction b CAUTION It is advisable to have a dealer make this adjustment 1 Headlight beam adjusting screw ...

Page 85: ...ght bulb holder socket by turning counter clockwise 2 Remove bulb from socket assembly by pushing in gently and turning bulb counter clockwise 3 Insert new bulb by pushing in socket assembly and turning clockwise 4 Reinstall tail light bulb holder into the tail light assembly by pushing in and turning clockwise Taillight socket ...

Page 86: ...ch you cannot solve please contact a 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 ...

Page 87: ...tall warning placards with rivets 2 Skid plate is damaged 1 Inspect bottom frame for damage and repair if needed 2 Inspect bottom of engine for damage make sure there are no leaks repair if needed 3 Replace with new skid plate as necessary Sheet 2 Brake system troubleshooting S N Problems Solutions 1 Brake system seizing 1 Check if parking brake releases when returned to off position 2 Check brake...

Page 88: ...deformed 5 Check if brake lines have any air If they do use special brake bleeding tools to remove air 6 Check to see if there is sufficient brake fluid in brake reservoir Brake fluid should be above the minimum mark 3 When driving front or rear brakes make sound or brake discs or rotors turn red because of heat 1 Check if brake discs are deformed Replace if needed 2 Check hydraulic cylinder on br...

Page 89: ... to see if the ECU or the EFI systems is damaged Have a service center repair if needed Sheet 4 Operational troubleshooting S N Problems Solutions 1 Steering is loose 1 Check to see if the nuts on the steering column steering knuckles and steering stem are loose Tighten if necessary 2 Check steering column for damage 3 Inspect tie rods for looseness or damage Replace if needed 2 Front wheels shake...

Page 90: ...el hub if needed 5 Check all rubber bushings for damage in rear end assembly Replace if needed Sheet 5 Engine troubleshooting S N Problems Solutions 1 Engine will not start 1 Make sure key and emergency shut off switch are at the ON position 2 Check fuel level 3 Check to make sure spark plug is secure and that the spark plug cap is attached 4 Inspect electrical circuits A service center can perfor...

Page 91: ...can perform this diagnosis 4 Engine backfires 1 Check for air leaks in the air filter or air inlet pipe Replace if needed 2 Check to see if the connection between the exhaust pipe and engine or the exhaust pipe and muffler has an air leak Replace or repair if needed 3 Check grade of gasoline if too low engine may backfire 5 Engine is hard to start at lower temperatures 1 Check battery voltage in c...

Page 92: ...ap and water 3 Rinse with low pressure clean fresh water 1CAUTION If a pressure washer system is used for cleaning not recommended exercise extreme caution High pressure water can damage components and can remove paint and decals Avoid directing the high pressure water stream at the following items Wheel bearings brake components transmission seals engine radiator etc 4 Dry surfaces with a clean s...

Page 93: ...h fresh gasoline and fuel stabilizer fuel stabilizer can be purchased at your dealer or any motorcycle small engine or car parts store Start engine and allow to run for 5 minutes so the stabilizer can disperse through the fuel tank and carburetor Fuel Stabilizer To get the correct ratio of fuel stabilizer to gasoline follow the manufacture instructions on the fuel stabilizer 2 Change engine oil 3 ...

Page 94: ...ATV should be stored with the wheels off the ground 7 Cover the exhaust port with a plastic bag and rubber band to keep any moisture from entering 8 Apply a thin coat of oil to all metal part surfaces Do not apply oil to any plastic vinyl or rubber parts 9 Remove battery from the ATV Fully charge battery and store out of the sun in a cool dry place Check battery voltage each month during storage a...

Page 95: ...ap and water 3 Rinse with low pressure clean fresh water 1CAUTION If a pressure washer system is used for cleaning not recommended exercise extreme caution High pressure water can damage components and can remove paint and decals Avoid directing the high pressure water stream at the following items Wheel bearings brake components transmission seals engine radiator etc 4 Dry surfaces with a clean s...

Page 96: ...h fresh gasoline and fuel stabilizer fuel stabilizer can be purchased at your dealer or any motorcycle small engine or car parts store Start engine and allow to run for 5 minutes so the stabilizer can disperse through the fuel tank and carburetor Fuel Stabilizer To get the correct ratio of fuel stabilizer to gasoline follow the manufacture instructions on the fuel stabilizer 2 Change engine oil 3 ...

Page 97: ...ATV should be stored with the wheels off the ground 7 Cover the exhaust port with a plastic bag and rubber band to keep any moisture from entering 8 Apply a thin coat of oil to all metal part surfaces Do not apply oil to any plastic vinyl or rubber parts 9 Remove battery from the ATV Fully charge battery and store out of the sun in a cool dry place Check battery voltage each month during storage a...

Page 98: ...ce Minimum turning radius 66 3 in 1683 mm 40 9 in 1039 mm 40 6 in 1033mm 25 2 in 640 mm 44 1 in 1120 mm 4 7 in 120 mm 122 in 3100 mm Basic weight With oil and full fuel tank 375 lbs 170kg Engine Engine type Cylinder arrangement Displacement Bore stroke 4 stroke Air cooled SOHC Single cylinder 108cm3for HS110ATV 52 4 50 mm 2 06 1 97 in ...

Page 99: ...ump Engine oil Type Recommended engine oil classification API Service SE SF SG type or higher 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 with a diesel specification of CD or oils of a higher quality than specified In addition do ...

Page 100: ...67 Imp qt 2 L 2 11 US qt 1 76 Imp qt 2 0 L Final gear case oil Type Quantity SAE80 API GL 4 Hypoid gear oil 0 84 US qt 0 7 Imp qt 0 8L Air filter Wet filter element type Fuel Type Fuel tank capacity UNLEADED GASOLINE ONLY 1 85US gal 1 54 lmp gal 7 L Throttle valve Type quantity D26 1 Spark plug Type manufacturer Spark plug gap CR7HSA 0 023 0 028 in 0 6 0 7 mm Clutch type Wet centrifugal automatic ...

Page 101: ...n 3 72 67 18 1 88 32 17 2 12 36 17 2 62 34 13 CVT belt automatic Right hand operation Tire Type Size front rear Tubeless 19 7 8 18 9 5 8 Brake Front brake type operation Rear brake type operation Dual disc brake right hand operation single disc brake right foot operation Suspension Front suspension Rear suspension Double swing arm Single swing arm ...

Page 102: ...n Damper Disc Spring Oil Hydraulic Vibration Damper Disc Spring Oil Hydraulic Vibration Damper Wheel travel Front wheel travel Rear wheel travel 10 7in 273mm 11 4in 290mm Electrical Ignition system Generator system Battery type Battery capacity ECU A C magneto YTX5L BS 12V4 2 Ah Headlight type HS1 ...

Page 103: ...brake light Front turning lights Rear turning lights 12 V 35 W 0 5 W 2 12 V 55W 2 12 V 55W 2 LED 0 6W 2 2V 5 0W 21 0W LED 0 7W 2W LED 0 85 2W Indicator light Neutral indicator Forward indicator Reverse indicator Parking indicator Full beam indicator Turning indicator LED LED LED LED LED LED Fuses Main fuse Backup fuse 30A 30A ...

Page 104: ...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 105: ...jector 2 Circuit Malfunction 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 P0...

Page 106: ...2S 2 Circuit Low Voltage KsDGDM_O2_2_ShortLow 137 311 P0138 O2S 2 Circuit High Voltage KsDGDM_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 Ks...

Page 107: ...11 4 Fault Code of Electronic Injection System P0172 BLM Min Adapt Kohler Special KsFDIAG_BLM_MinAdapt 172 370 P0174 PE System Lean Kohler Special KsFDIAG_PESystLean 174 372 ...

Page 108: ...mog standards HISUN must warrant the emission 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 fa...

Page 109: ...d by HISUN OWNER S WARRANTY RESPONSIBILITIES As the vehicle owner you are responsible for the 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 respons...

Page 110: ...per maintenance or unapproved modifications If you 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 ...

Page 111: ... 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 112: ...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 113: ...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 114: ... 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 115: ...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 116: ...y 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 07021501 AXIS 110 FORGE 110 OWNER S MANUAL ...

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Hisun AXIS 110, Owner'S Manual

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