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Maintenance and Adjustment

9-2

CAUTION:

To avoid personal injury and vehicle damage:



Be sure you have sufficient knowledge, experience, the proper replacement parts and

tools before you attempt any vehicle maintenance task.



If you don’t have the knowledge and equipment which are necessary to perform the

maintenance task, consult your local dealer.

SERVICE INTERVALS

ITEM

MAINTENANCE INTERVAL (WHICHEVER

COMES FIRST)

REMARKS

Hours Frequency Miles

(KM)

Pre-Ride Inspection Check

Steering

Pre-Ride

Inspect for loose hardware or abnormal wear

Front-suspension

Pre-Ride

Inspect for loose hardware or abnormal wear

Rear-suspension

Pre-Ride

Inspect for loose hardware or abnormal wear

Tires -

Pre-Ride

Proper

tire

pressure

Brake fluid level

Pre-Ride

Inspect and add if needed

Brake pedal travel

Pre-Ride

See Owner's Manual

Brake systems

Pre-Ride

Make adjustments as needed.

Lug Nuts

Pre-Ride

Ensure lug nuts are torque to spec

Frame fasteners

Pre-Ride

All fasteners are secured

Engine Oil Level

Pre-Ride

Inspect and add if needed

Coolant

Pre-Ride

Inspect and add if needed

Head / Tail / Brake Lights

Pre-Ride

Check operation

ITEM

MAINTENANCE INTERVAL (WHICHEVER

COMES FIRST)

REMARKS

Hours Frequency Miles

(KM)

Break-In Maintenance Check

Engine Oil/Filter change

First 50 (75)

Replace break-in oil & filter with proper oil

type

Transmission

First 100 (150)

Initial fluid level inspection; add lubricant if

needed

Toe adjustment

First 100 (150)

Inspect periodically; adjust when parts are

replaced

Clutches (Drive and

Driven)

First 100 (150)

Inspect; clean; replace worn parts

Содержание 450cc

Страница 1: ......

Страница 2: ...f the instructions herein will provide the knowledge needed to have safe and enjoyable UTV operation For questions regarding this UTV please call 972 446 0760 IMPORTANT SAFETY MESSAGES READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR UTV MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE UTV NEVER OPERATE THE UTV WITHOUT PROPER TRA...

Страница 3: ...al by 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 bystander or a person inspecting or repairing the machine A CAUTION indicates special precautions that must be taken to avoid damage to the machine NOTE A NOTE provides key information to make procedures ...

Страница 4: ...erature is 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 7 3 on the warming up process Follow the proper parking procedures when the temperature is higher than 100 F 38 C turn off the engine make sure the radiator fan is on for 3 minutes before turning off the power switch Starting the UTV for the firs...

Страница 5: ...rols The symbols are shown below with an indication of their meaning Safety Alert Symbol Lift Cylinder Retract Diesel Fuel Lift Cylinder Extend Engine coolant Temperature Lift Cylinder Float Parking Brake Hazard Warning Lights Battery Charging Condition High Beam Engine Oil Pressure Horn Turn Signal Hazard EPS System Error Differential Lock 2WD 4WD Position Lights ...

Страница 6: ...ehicle at full speed for the first 50 hours 8 1 Changing lubricating oil for new vehicles 8 1 Starting 8 1 Subject Page Seat belt 8 1 Head light switch 8 2 Hazard light switch 8 2 Turn signal light switch 8 2 Brake pedal 8 3 Range gear shift lever 8 3 4WD lever 8 4 Accelerator pedal 8 5 Stopping 8 5 Coolant temperature gauge 8 5 Winch operations 9 1 Transporting vehicle 9 1 Service intervals 9 2 P...

Страница 7: ...nsmission fluid 10 15 Changing front and rear axle case oil 10 15 Every 500 hours 10 15 Replacing fuel filter 10 15 Every 1500 hours 10 16 Checking injection and fuel pump 10 16 Every 1 year 10 16 Every 2 years 10 16 Flushing Cooling system and changing coolant 10 16 Anti freeze 10 17 Replacing radiator hose water pipes 10 18 Replacing fuel hose 10 18 Replacing brake master cylinder inner parts 10...

Страница 8: ...Introduction 450cc Utility 1 7 LOCATION OF PARTS Front Tire Front Tire Front Shock Absorber ...

Страница 9: ...Introduction 450cc Utility 1 8 ILLUSTRATED CONTENTS ...

Страница 10: ...Introduction 450cc Utility 1 9 ...

Страница 11: ...n be drawn into moving parts on the vehicle and could cause a severe injury to occur You should wear protective devices such as helmet boots eye protection earmuff gloves and etc 5 Only a qualified driver should operate this UTV Never operate after drinking using drugs or controlled products or while fatigued 6 Always perform the pre operation checks as following 1 Check seat belt for worn or dama...

Страница 12: ...cked DIFF LOCK is off when pressing the front rear wheels can turn at different speed Otherwise the vehicle may turnover 9 Never drive over terrain such as a ditch a hole dams excessive mud or the vehicle can get stuck because of the vehicles weight 10 Always pay close attention to your surroundings and check for streets trail intersections or other obstacles 11 Always use signals in advance of tu...

Страница 13: ...attempt to ascend the slope any further 6 Riding in mud a ditch and on slopes will increase the risk of an overturn Be more cautious when operating Drive gradually and slowly when climbing Avoid sudden changes of vehicle speed or direction 5 Driving in harsh conditions 1 Vehicle can be operated during the day or under good light conditions 2 Operate the vehicle level ground as much as possible 3 B...

Страница 14: ...d another vehicle Use a trailer or truck to transport the vehicle 2 When loading or unloading pay attention to your surroundings and others in the area 10 Maintenance Stop the vehicle and park it on level ground Pull the parking brake and remove all cargo Then place shift lever on N position stop the engine and remove the key 1 When working next to the engine exhaust or radiator work only after it...

Страница 15: ...cap Check for the coolant level in the coolant reservoir If necessary add coolant 8 Tires should be mounted on rims with special equipment by professionals 9 Keeping specified tire pressure can help to ensure driving safety 10 Elevate the vehicle and place a suitable stand under the frame when removing the wheels Be sure to tighten the wheel nuts to specified torque ...

Страница 16: ...Warning Labels 3 1 Warning and caution labels 1 2 3 4 5 6 7 8 9 ...

Страница 17: ...Warning Labels 3 2 10 11 12 13 14 15 16 ...

Страница 18: ...However when in need of parts or major service be sure to see your dealer For service contact the dealership from which you purchased your vehicle or your local dealer When in need of parts be prepared to give your dealer both the vehicle and engine serial numbers Locate the serial numbers now and record them in the space provided Type Serial No Vehicle Engine Product Identification Number Date of...

Страница 19: ...TV 4 H L range forward N R for HS450UTV Brakes Front Rear Hydraulic disk brake Parking brake Mechanical brake Steering Mechanical Suspension Front Independent Dual A arm type Rear Independent Dual A arm type Dimensions Length mm in 2720 107 09 Wide mm in 1550 61 02 Height mm in 1885 74 21 Front tread centers mm in 1350 53 15 Rear tread centers mm in 1300 46 5 Wheelbase mm in 1850 51 18 Ground Clea...

Страница 20: ...9 350 Sound level operator ear db A 85 Tire Front 25 8 12 26 9 12 6PR Rear 25 10 12 26 10 12 6PR Body color Red Black White Blue Yellow Orange Camo NOTE The values in Ground clearance and Weight are those of the machine equipped with the tires in the table above The company reserves the right to change the specifications without notice TRAVELING SPEEDS Range gear shift lever km h mph Low 13 8 High...

Страница 21: ...icle malfunction or failures with a possibility of the vehicle damage to other property and injury to the operator or others Any malfunctions or failures of the vehicle resulting from use with improper implements are not covered by the warranty Max Cargo loading weigh Cargo Bed Capacity 159kg 350lb Vehicle Total Capacity 399kg 880 lb operator one passenger opt acc weight trailer weight Max rolling...

Страница 22: ...l injury Be sure to check and service the vehicle on a level surface with the engine shut off and the parking brake set Ensure that engine temperature has cooled down prior to any work performed Check items Check Pre Ride checklist on page 9 3 prior to operating vehicle Review all warning and caution labels for compliance prior to operating vehicle ...

Страница 23: ... it a rule to set gear shift lever to NEUTRAL position before starting the engine IMPORTANT Do not use starting fluid or ether To protect the battery and the starter make sure that the starter is not continuously turned for more than 5 seconds STARTING THE ENGINE 1 Make sure the parking brake is set Parking brake NOTE The parking brake warning lamp P comes on while parking brake is applied and goe...

Страница 24: ...e brake is depressed Cold Starting When the ambient temperature is below 15 5 the engine is very cold If the engine fails to start after 5 seconds turn off the key for 30 seconds and start again STOPPING THE ENGINE 1 After slowing the engine to idle turn the key to OFF 2 Remove the key VEHICLE WARM UP CAUTION To avoid personal injury Be sure to set the parking brake during warm up Be sure to set t...

Страница 25: ...faster than prescribed On rough roads slow down to suitable speeds Do not operate the vehicle at fast speed The above precautions are not limited to new vehicles However they should be especially observed for new vehicles Changing Lubricating Oil for New Vehicles The lubricating oil is especially important for a new vehicle Various parts need time to wear and polish themselves to the correct opera...

Страница 26: ...ipped Press the hazard switch to the up position to turn on the hazard lights This will turn on the blinking turn signals and audible alarm will sound Note The emergency light switch will operate when the key switch is in the ON position Be careful that keeping the switch ON causes the battery to run out Turn Signal Light Switch if equipped To indicate a right turn push on the lower half of the tu...

Страница 27: ...The brake pedal is the left pedal on the foot board Depress the pedal to slow or stop the vehicle Brake pedal 4 Selecting the travel speed Range Gear Shift Lever CAUTION To avoid personal injury Avoid changing gears when ascending or descending a slope Before ascending or descending a slope shift to the L range to control the vehicle speed If you shift gears while ascending or descending a slope b...

Страница 28: ...l fully then shift the lever Damage may occur with wrong shifting operation 4WD Lever CAUTION To avoid personal injury when traveling at road speed Use only 2WD When driving on icy wet or loose surfaces make sure the vehicle is correctly loaded to avoid skidding and loss of steering control Reduce the speed and engage front wheel drive Accident may occur if the vehicle is suddenly braked such as h...

Страница 29: ...ly become very white While driving check the following items to see if all parts are functioning normally Fuel gauge Coolant Temperature Gauge CAUTION To avoid personal injury Do not remove radiator cap until coolant temperature is well below its boiling point Then loosen cap slightly to relieve pressure before removing cap completely 1 With the key switch ON the temperature gauge indicates the te...

Страница 30: ...icle 8 6 Coolant temperature gauge The hourmeter indicates in five digits the hours the vehicle has been used the last digit indicates 1 10 of an hour Hourmeter The speedometer indicates the traveling speed Speedometer ...

Страница 31: ...tions in the winch owner s manual before attempting to install or use a winch Winch mount plate Transporting Vehicle Pay attention to the following points when transporting the vehicle 1 Use a suitable truck and trailer 2 Apply the parking brake and properly secure vehicle to trailer ...

Страница 32: ...res Pre Ride Proper tire pressure Brake fluid level Pre Ride Inspect and add if needed Brake pedal travel Pre Ride See Owner s Manual Brake systems Pre Ride Make adjustments as needed Lug Nuts Pre Ride Ensure lug nuts are torque to spec Frame fasteners Pre Ride All fasteners are secured Engine Oil Level Pre Ride Inspect and add if needed Coolant Pre Ride Inspect and add if needed Head Tail Brake L...

Страница 33: ...ct replace as needed Antifreeze Coolant 50 H 6 M 500 800 Pressure Test Add Fluid Tranmission Fluid 50 H 6 M 500 800 Replace Engine mounts 100 H 12 M 1000 1600 Inspect replace as needed Cooling Hoses 100 H 12 M 1000 1600 Inspect for cracks and leaks Drive Shafts 100H 12M 1000 1600 Remove and grease Spark plug 100 H 12 M 1000 1600 inspect replace as needed Clutches Drive and Driven 100 H 12 M 1000 1...

Страница 34: ...90 Fill to bottom of fill plug or 0 455L or 14 oz Front Differential Dextron 3 ATF Fill to bottom of fill plug or volume of oil Drive Shaft U Joint Grease Locate fittings and grease ENGINE OIL Always check and change the oil at the intervals outlined in the Service Interval Chart above Always use the recommended engine oil Always change the oil filter whenever changing oil Vehicle operation with i...

Страница 35: ...atches Turn switch Front hood cover Operator s Seat To open the seat raise the seat to the forward position Operator s seat HOW TO RAISE THE CARGO BED CAUTION To avoid personal injury When servicing under raised bed make sure safety support is properly mounted Do not touch muffler or exhaust pipes while they are hot Otherwise severe burns could result Raising and Lowering the Cargo Bed To raise th...

Страница 36: ...s or suitable blocking Front End Jack up at the front frame tube only Jack Front frame tube Rear End Jack the rear only after placing a wooden block under the right and left frame tubes for securing the engine and then supporting it Do not apply jack pressure on the steel plate directly under the engine Jack Rear frame tube DAILY CHECK For your own safety and maximum service life of the vehicle ma...

Страница 37: ...ount of fuel by the fuel gauge 2 Fill fuel tank when fuel gauge shows1 4 or less fuel in tank Fuel tank cap Fuel tank capacity 28L 7 4 0 1U S GALS IMPORTANT If oil level is low do not run engine Checking engine oil level 1 Park the vehicle on a flat surface with engine off raise the cargo bed mount the safety support 2 To check the oil level draw out the dipstick wipe it clean replace it and draw ...

Страница 38: ...llow the cautions above and securely retighten the cap Use clean fresh water and anti freeze to fill the recovery tank If water should leak consult your local HSUN Dealer Cleaning radiator screen CAUTION TO avoid personal injury Be sure to stop the engine before removing the screen 1 Park the vehicle on a flat surface Remove the radiator cover 2 Remove the radiator cover 3 Detach the screen and re...

Страница 39: ...king brake pedal CAUTION TO avoid personal injury Stop the engine and chock the wheels before checking brake pedal 1 Inspect the brake pedals for free play and smooth operation Adjust if incorrect measurement is found see checking brake pedal in EVERY 200 HOURS in PERIODIC SERVICE section Brake pedal FREE TRAVEL PEDAL STROKE Checking parking brake Pull the parking brake to apply the brakes with th...

Страница 40: ...f deterioration consult your local dealer Joint boot Drive shaft Checking tire inflation pressure Though the tire pressure is factory set to the prescribed level it naturally drops slowly in the course of time thus check it every day and inflate as necessary tire sizes inflation pressure Front 25x8 12 100kPa 1 0kgf cm2 14psi 26x9 12 Rear 25x10 12 110kPa 1 1kgf cm2 16psi 26x10 12 EVERY 50 HOURS Gre...

Страница 41: ...hift lever to F N or REVERSE position for HS400UTV 4 Shift the range gear shift lever to L H N or REVERSE position for HS450UTV 3 Turn the key to START position 4 The engine must not crank 5 If it cranks consult your local dealer for this service Range gear shift lever Checking wheel bolt torque CAUTION To avoid personal injury Never operate vehicle with loose wheel bolts Any time these bolts are ...

Страница 42: ... filter element Locating pad Mounting point Air filter cover IMPORTANT The air filter uses a dry element Never apply oil Do not run the engine with air filter removed Be sure to install cover properly prior to operation Improper secured cover will allow dirt and air into engine causing idle issues and potentially damage engine Air Filter Cover Open the air filter cover once a week under ordinary c...

Страница 43: ...t cause premature wear and malfunction of the fuel pump and injector components Fuel pump Fuel line Exit pipe 5 To remove the in line fuel filter clamps b slide the clamps b away from the in line fuel filter a Twist and pull the fuel lines off of the in line fuel filter a 6 Check the in line filter a for debris and or water contamination Replace as necessary Checking battery condition DANGER If yo...

Страница 44: ...le 3 When exchanging an old battery for a new one use battery of equal specification shown in table 1 Battery type Volts 12volt 300CCA 12 Direction for storage 1 When storing the vehicle for a long period remove the battery from the vehicle store in a dry place out of direct sunlight The battery shall self self discharge while it is shored recharge it once every three months in hot seasons and onc...

Страница 45: ... in solvent and again clean with wire brush if necessary 4 If any breaks in the screen or welds are discovered the assembly must be replaced 5 Return the spark arrester to the muffler body and refasten the bolts IMPORTANT Visually check the muffler for cracks or holes in the body weldment or pipes at regular intervals USDA approval requires clearance between spark arrester sleeve and muffler body ...

Страница 46: ...placed the engine oil normally decreases a little Make sure that the engine oil does not leak through the seal and check the oil level on the dipstick Then replenish the engine oil up to the prescribed level Bolt Cover O seal ring Engine oil filter IMPORANT To prevent serious damage to the engine use only a genuine filter Replacing Transmission Oil CAUTION To avoid personal injury Be sure to stop ...

Страница 47: ...arking brake 2 Step on the pedal and measure the pedal stroke 3 If brake pedal stroke is outside of the specifications contact your local dealer for adjusting the brake Brake pedal FREE TRAVEL PEDAL STROKE Checking Brake Hose and Pipe 1 Check to see that brake hose and lines are not swollen hardened or cracked 2 Check the brake hose and pipe joints for oil leaks 3 If there is any abnormality consu...

Страница 48: ...fter about 5 minutes of idling 3 Do not open radiator cap until engine has sufficiently cooled down 4 Inspect radiator for debris in screen clogged radiator fins coolant level in radiator and proper coolant fan operation Correct any of these findings and restart engine Allow it to get to normal operation temperature to ensure issue has been corrected Checking Intake Air Tube 1 Check to see if the ...

Страница 49: ...ew minutes stop the engine and check the oil level again add oil to prescribed level Drain plug IMPORTANT Do not operate the vehicle immediately after changing the transmission fluid Run the engine at medium speed for a few minutes to prevent damage to the transmission Changing Front and Rear Axle Case Oil 1 Park the vehicle on a firm flat and level surface 2 To drain the used oil remove the drain...

Страница 50: ...e coolant 3 After all coolant is drained close the drain plug 4 Fill with clean water and cooling system cleaner 5 Follow directions of the cleaner instruction 6 After flushing fill with clean water and anti freeze until the coolant level is just below the radiator cap Fill with fresh water up to the FULL mark on the recovery tank 7 Start and operate the engine for few minutes 8 Stop the engine an...

Страница 51: ...e 1 Long life coolant hereafter LLC comes in several types Use ethylene glycol EG type for this engine 2 Before employing LLC mixed cooling water fill the radiator with fresh water and empty it again Repeat this procedure 2 or 3 times to clean up the inside 3 Mixing the LLC 4 The procedure for the mixing of water and antifreeze differs according to the make of the antifreeze and the ambient temper...

Страница 52: ...S in PERIODIC SERVICE section Replacing Fuel Hose Consult your local HUANSONG Dealer for this service Replacing Brake Master Cylinder Inner parts Consult your local dealer for this service Replacing Front Brake Seal Consult your local dealer for this service Replacing Rear Brake Cylinder Seal Consult your local dealer for this service Replacing Intake Air Line Consult your local dealer for this se...

Страница 53: ...sary 2 Apply grease to vehicle areas where bare metal will rust also to pivot areas 3 Unload from cargo bed 4 Inflate the tire to a pressure a little higher than usual 5 Charge the engine oil and run the engine to circulate oil throughout the engine block and internal moving parts for about 5 minutes 6 With all implements lowered to the ground coat any exposed rods with grease if equipped 7 Remove...

Страница 54: ...ission coolant and any attached implements 5 Start the engine Observe all gauges If all gauges are functioning properly and reading normal move the vehicle outside Once outside park the vehicle and let the engine idle for at least five minutes Shut the engine off and work around vehicle and make a visual inspection looking for evidence of oil or water leaks 6 With the engine fully warm up Release ...

Страница 55: ...tery from the vehicle charge and store it indoors install it on the vehicle only when the vehicle is going to be used Engine power is insufficient Insufficient fuel The injector is clogged Crankshaft position sensor is bad The air cleaner is clogged Spark plug is dirty or fouled Ignition coil is bad Check the fuel system Clean or replace the injector Replace crankshaft position sensor Clean or rep...

Страница 56: ...it Low Voltage P0132 O2A Circuit High Voltage P0031 O2A Heater Circuit High Voltage P0032 O2A Heater Circuit Low Voltage P0201 Injector 1 Circuit Malfunction P0202 Injector 2 Circuit Malfunction P0230 FPR Coil Circuit Low Voltage or Open P0232 FPR Coil Circuit High Voltage P0336 CKP Sensor Noisy Signal P0337 CKP Sensor No Signal P0351 Cylinder 1 Ignition Coil Malfunction P0352 Cylinder 2 Ignition ...

Страница 57: ...ates look whitish Refillable type battery only Battery was used with an insufficient amount of electrolyte Add distilled water and charge the battery Regularly check the electrolyte level Battery was used with too much without recharging Charge battery Insufficiently Charge battery properly Recharging is impossible Battery life expired Replace battery Terminals are severely corroded and heat up Po...

Страница 58: ... the position of N Put the gearshift arm of engine into N Adjust the cable and the bolt Lock tightly Gear abrasion Replace the gears Transmission noise Tolerance between inner outer gears out of tolerance Replace the gears Low vehicle speed or power Parking brake engaged Adjust cable CVT belt slipping Replace CVT transmission belt Replace the clutch Soft No Brakes Low brake fluid Check the brake f...

Страница 59: ...1 Consult your local dealer for additional accessories to add to your vehicle 1 Heavy Duty Front and Rear Bumpers 2 Front Basket 3 Hard Cab Enclosure 4 Soft Cab Enclosure 5 Snow Plow 6 LED Lights 7 Spare Tire Carrier ...

Страница 60: ...IGHTS AND OBLIGATIONS Your emission control system warranty covers components whose failure would increase an engine s emissions of any regulated pollutant 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 A...

Страница 61: ... the remedying of defects in material 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 i...

Страница 62: ...w long an implied warranty lasts so the above limitations may not apply to you VI ADDITIONAL INFORMATION Any replacement part that is equivalent in performance and durability may be used in the performance of any maintenance or repairs 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 ...

Страница 63: ......

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