Hisun 500 Utv Manual

. page 66. page 68. page 69. Published by Chongqing Huansong Industries (Group) Co., Ltd and Hisun Motors Corp USA. Chongqing Huansong Industries (Group) Co., Ltd and Hisun Motors Corp USA holds the copy right. No publishing and reprinting without permission.

READ THIS MANUAL CAREFULLY For questions regarding this. Introduction HS 500/700 INTRODUCTION Congratulations on your purchase of the HS 700 UTV. This Owner’s / Operator’s manual will provide you information regarding safe operation, operational instructions, maintenance and care. Fully understanding and following all of the instructions in this manual will provide the knowledge needed to have safe operation and longevity of the UTV. Introduction HS 500/700 IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.

Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION!. Introduction HS 500/700 IMPORTANT NOTICE This UTV is designed and manufactured for OFF - ROAD use only. It is illegal and unsafe to operate this UTV on any public street, road or highway. This UTV complies with all applicable OFF - ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture. Introduction HS 500/700 Table of Contents Subject Page Subject Page Introduction Checking the parking 11-5 Important Warnings brake 11-6 Notice Checking the tire 11-6 Table of Contents Inflation 11-7 Safe Operation 50 Hour Check 11-7 Operation Checking the engine Children Safety Instructions. Introduction HS 500/700.

SAFE OPERATION SAFE OPERATION All operators, including experienced UTV drivers or parts on the vehicle and could cause a severe passengers, should carefully read and fully injury to occur. Understand this Users Manual, and operate strictly You should always wear protective equipment, as the manual states in order to achieve the best such as helmet, boots, eye protection, ear performance and avoid accidents. SAFE OPERATION 2. Operation dams, excessive mud, or the vehicle can get stuck because of the vehicles weight.

Start the engine only in an open ventilated 11. Always close attention your area.

Carbon monoxide is colorless, odorless surroundings, and check for streets, trail and is emitted from the engine and can cause intersections or other obstacles. SAFE OPERATION 4. Driving on a slope roads or hidden obstacles. Avoid operate in the unknown depth of waters. （water depth can not exceed axle） Be cautious when riding on a slope, as this is the main reason for loss of control, and overturn, 6. SAFE OPERATION 8. Parking hydrogen and oxygen during charging and this could accelerate the risk of explosion.

To release the parking brake, depress the Read and follow the instructions before brake pedal. Replacing the battery. During maintenance, first aid kits and fire extinguishers should be placed at your fingertips. SAFE OPERATION 11. Warning and caution labels ⑴ ⑵ ⑶ ⑷ ⑸. SAFE OPERATION ⑹ ⑺ ⑻ ⑼ ⑽.

SAFE OPERATION ⑾ ⑿ ⒀ ⒁ ⒂. Servicing of the Vehicle SERVICING OF VEHICLE Your dealer is interested in your new vehicle and has the desire to help you get the most value from it.

After reading this manual thoroughly, you will find you can do some of the regular maintenance by yourself. However, when in need of parts or major service, be sure to see your dealer. SPECIFICATIONS SPECIFICATIONS SPECIFICATION TABLE Model Make Type 1 cylinder, 4-cycle, gasoline, SOHC, liquid cool Displacement L(cu.in.) 0.8（48.8） Engine Horsepower Kw(HP) 22（29.64） Rated revolution rpm 5000 Low idling revolution rpm 1350 to 1500 Fuel Capacity L(U.S.gas) 28（8.9） Transmission Wheels, Drive system 4, Rear 2WD or 4WD Differential lock Electric control: switch. SPECIFICATIONS Model Worksite/Red Worksite/Camo Width mm (in.) 1170(51.38) Length mm (in.) 900（32.88） Depth mm (in.) 280（11.4） Volume (cu.ft.) 0.29（11.35） Cargo bed Bed height mm (in.) 810（34.25） (unloaded) Cargo bed capacity kg (lbs.) 159（300） (1 row/2 row) Sound level, operator ear db (A) 86.5 Front.

VEHICLE LIMITATIONS VEHICLE LIMITATIONS The Vehicle has been thoroughly tested for proper performance with implements sold or approved. Use with implements which are not sold or approved and which exceed the maximum specifications listed below, or which are otherwise unfit for use, vehicle may result in malfunction or failures 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. INSTRUMENT PANEL AND CONTROLS INSTRUMENT PANEL AND CONTROLS LOCATION OF PARTS. INSTRUMENT PANEL AND CONTROLS ILLUSTRATED CONTENTS. INSTRUMENT PANEL AND CONTROLS. PRE-OPERATION CHECK PRE-OPERATION CHECK DAILY CHECK To better prevent troubles, it is important to know condition of the vehicle well. Check it before starting.

CAUTION： To avoid personal injury： Be sure to check and service the vehicle on a level surface with the engine shut off and the parking brake “ON”. OPERATING THE ENGINE OPERATING THE ENGINE NOTE： CAUTION： The parking brake warning lamp (P) comes on To avoid personal injury： while parking brake is applied and goes off when it  Read 'SAFE OPERATION' in front of this is released. OPERATING THE VEHICLE start except when the gear shift lever is placed in the “NEUTRAL” position. ■ Cold Starting When ambient temperature below -15℃( 5℉), the engine is very cold. If the engine fails to start after 10 seconds, turn off the key for 30 seconds and start again.

OPERATING THE VEHICLE OPERATING THE VEHICLE OPERATING NEW VEHICLE ■ Changing Lubricating Oil for New Vehicles How a new vehicle is handled and maintained The lubricating oil is especially important for a new vehicle. Various parts are not “broken-in” determines the life of vehicle.

A new vehicle just off the factory production line and are not accustomed to each other. ⑮ Plug cover NOTE： Turning the head light switch to the “ON” position causes the following lamps to light simultaneously. Tail lights (lamps at the rear portions of the vehicle) Lamp built in the coolant temperature gauge Lamp built in the fuel gauge Lamp built in the speedometer Front left and right position lights ①. when the key switch is in the “ON” position. Make sure the vehicle is correctly loaded to If the hazard light switch is pressed to the avoid skidding or loss of steering control.

“ON” position while the turn signal is activated, Reduce the speed. ① Range gear shift lever ① Parking brake (L) LOW Range (H) HIGH Range ■ Accelerator Pedal (N) NEUTRAL” POSITION The Accelerator pedal is used to increase the (R) “REVEREE” engine and vehicle speed. Push down on it for NOTE: higher speed. While driving, check the following items to see if all pressure before removing cap completely. With the key switch “ON” the temperature parts are functioning normally. Gauge indicates the temperature of the coolant. White Zone for “cold” and Red zone for “hot”.

If the indicator reaches the Red zone, engine coolant is overheated. The speedometer indicates the traveling speed. ① Speedometer. WINCH MOUNT PLATE WINCH MOUNT PLATE WINCH MOUNT PLATE Always read and follow the instructions in the winch owner’s manual before attempting to install or use a winch. ① Winch mount plate ■ Transporting Vehicle Pay attention to the following points when transporting the vehicle. MAINTENANCE MAINTENANCE AND ADJUSTMENT 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. MAINTENANCE Every ○ ○ ○ ○ ○ ○ ○ Spark arrester Clean 100 hrs Wheel bolt Every ○ ○ ○ ○ ○ ○ ○ ◎ Check torque 100 hrs Every ○ ○ ○ ○ ○ ○ ○ Battery condition Check 100 hrs Every ○. MAINTENANCE Every ○ Knuckle case oil Change 400 hrs Engine valve Every Adjust clearance 800 hrs Every Fuel injection Check 1500 hrs Every Injection Check 3900 hrs Every 2 Brake fluid Change years Remote Every 2 Replace hydraulic hose years Rear brake Every 2 Replace. MAINTENANCE. MAINTENANCE.

PERIODIC SERVICE PERIODIC SERVICE ■ Operator’s Seat CAUTION: To open the seat, raise the seat to the forward To avoid personal injury: position. How TO OPEN THE FRONT HOOD COVER AND SEAT CAUTION To avoid personal injury from contact with moving parts: . PERIODIC SERVICE ① Cargo bed release Lever Front frame tube ① Jack ② ② ■ Rear End ③ DOWN Jack up the rear side after placing a wooden block under the right and left pipe frames for securing the engine and then supporting it.

Do not jack it up supporting the steel plate portion under the engine directly. PERIODIC SERVICE ■ Visual Inspection Look around and under the vehicle for such items as loose bolts, trash build-up, oil or coolant leaks, broken or worn parts. ■ Checking and Refueling CAUTION To avoid personal injury:  Do not smoke while refueling. PERIODIC SERVICE ① Radiator screen ① Recovery tank ② FULL ③ LOW IMPORTANT  Radiator screen must be clean from debris to IMPORTANT prevent engine from overheating  If the radiator cap has to be removed, follow the cautions above and securely retighten the ■. PERIODIC SERVICE ① OIL CUP ② LOWER ① Parking brake ■ Checking brake pedal ■ Checking gauges,meter and Display lamps Inspect the instrument panel for broken CAUTION gauges, meter and Display lamps. TO avoid personal injury: Replace if broken.

PERIODIC SERVICE lubricate grease fittings more often. ① joint boot ② Drive shaft ① Joint boot ② Drive shaft ① Parking brake ② Parking brake pivot（spray type grease） ■ Checking tire inflation pressure Though the tire pressure is factory-set to the prescribed level, it naturally drops slowly in the course of time, check it everyday and inflate as necessary. PERIODIC SERVICE ① Range gear shift lever ① Range gear shift lever pivot (spray type grease ) ■ Checking engine start system CAUTION TO avoid personal injury  Do not allow anyone near the vehicle while testing.  If the vehicle does not pass the test, do not operate the vehicle. PERIODIC SERVICE ① Torque wheel bolts to 75to 90 N.m ① Air filter frame ② Air filter element ③ Element retaining plate ■ Cleaning air cleaner primary element Open the hood cover.

Open the air cleaner case cover. Remove the air filter element. Remove the sponge material from its frame.

PERIODIC SERVICE CAUTION To avoid personal injury:  Be sure to stop the engine and remove the key when attempting to make the following checks and changes.  Never fail check fuel lines periodically the fuel lines are subject to wear and aging fuel may leak out onto the running engine causing a fire. PERIODIC SERVICE  When disconnecting the cable from the battery start with the negative terminal first; ■ Adjusting toe-in when connecting the cables to the battery start with the positive terminal first. Proper toe-in 0 to12 mm (0 to 0.47 in) .

PERIODIC SERVICE  ■ Cleaning Muffler Replace the entire muffler if it is damaged.  Do not operate the vehicle with a damaged CAUTION muffler.

To avoid personal injury:  Before touching any part of an exhaust system, be absolutely sure that it has sufficient time to cool!. PERIODIC SERVICE ① Oil Level ① Bolt; ② Cover ② Dipstick ③ “O” seal ring; ④ Engine oil filter ■ Replacing Engine Oil Filter IMPORANT:  To prevent serious damage to the engine, use CAUTION only a genuine filter. To avoid personal injury: . PERIODIC SERVICE If brake pedal stroke is outside of the specifications, contact your local dealer for adjusting the brake. ① Oil Level ② Dipstick ① Brake pedal ② “FREE TRAVEL” ③ “PEDAL STROKE” ■ Checking Brake Pedal ■ Checking Brake Hose and Pipe Check to see that brake hoses and lines are CAUTION not swollen, hardened or cracked. PERIODIC SERVICE hardened or cracked. Replace hoses and engine again.

Hose clamps every 2 years or earlier, if ■ Checking Intake Air Line checked and found that hoses are swollen, hardened or cracked. Check to see if the hoses and hose clamps are tight and not damaged.

PERIODIC SERVICE EVERY 400 HOURS To drain the used oil, remove the drain the oil ■ Changing Transmission Fluid completely into the oil pan. Fill with the new oil up to the upper notch on CAUTION the dipstick. To avoid personal injury: (See “LUBRICANTS, FUEL AND COOLANT”.

PERIODIC SERVICE ■ Adjusting Engine Valve Clearance anti-freeze until the coolant level is just below Consult your local dealer for this service. The radiator cap. Install the radiator cap securely.

EVERY 1500 HOURS Fill with fresh water up to the “FULL” mark on ■. PERIODIC SERVICE protection such as rubber gloves. (Antifreeze IMPORTANT:  contains poison.) When the antifreeze is mixed with water, the  If you should drink antifreeze, throw up at antifreeze mixing ratio must be less than 50%.

Once and seek medical attention. Freezing point Boiling point VOL%. (See “Checking Radiator Hose and Clamp” in “EVERY 200 HOURS” in “PERIODIC SERVICE” section.) ■ Replacing Fuel Hose Consult your local Hisun Dealer for this service.

■ Replacing Brake Master Cylinder (Inner ① Mini Blade fuse box cover parts) Consult your local dealer for this service. STORAGE STORAGE Remove the battery from the vehicle. Store the STORAGE battery following battery storage procedures. CAUTION Keep the vehicle in a dry place where the To avoid personal injury: vehicle is sheltered from the elements. Cover  Do not clean the vehicle when the engine is the vehicle. STORAGE 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 do a visual inspection looking for evidence of oil or water leaks. With the engine fully warmed up. Release the parking brake and test the brakes for proper adjustment as you move forward. TROUBLESHOOTING TROUBLESHOOTING ENGINE TROUBLESHOOTING If something is wrong with the engine, refer to the table below for the cause and its corrective countermeasure. Trouble Cause Countermeasure  Check the fuel tank and fuel filter。  Check the electric fuel pump.

TROUBLESHOOTING Check malf code meaning by reading the below table. Mt05 Malf Code Table:23 Malf code in MT05 Description P0107 MAP Circuit Low Voltage or Open P0108 MAP Circuit High Voltage P0112 IAT Circuit Low Voltage P0113 IAT Circuit High Voltage or Open P0117 Coolant/Oil Temperature Sensor Circuit Low Voltage P0118. TROUBLESHOOTING BATTERY TROUBLESHOOTING Trouble Cause Countermeasure Preventive measure  Battery overused   until lights are dim. Charge the battery Charge the battery  Battery sufficiently.

Been recharged.  Keep the terminal  Starter does not function Clean the terminal . TROUBLESHOOTING MACHINE TROUBLESHOOTING Trouble Cause Countermeasure  Replace throttle cable;   High idling speed of engine Replace throttle petal  Replace he throttle   High rotary speed for clutch Replace he junior clutch spring;  connection. Replace the primary clutch. OPTIONS OPTIONS Consult your local dealer for further details. Head rest； Plastic Canopy； Rear Trailer Hitch & Pin(2〞)； Windshield； Steel Cab； Motor Scan KF90121; 14-1. ELECTRIC POWER STEERING SYSTEM ELECTRIC POWER STEERING SYSTEM INTRODUCTION barriers on steering wheel can be greatly Our UTV is equipped with Electric Power Steering decreased.

System (EPS). To keep reliability of EPS during 5) No pollution to environment. For the traditional operation, please correctly use EPS system hydraulic power steering system, the hydraulic according to the following descriptions and keep.

ELECTRIC POWER STEERING SYSTEM  ■ Construction of EPS To make sure your EPS system will be useful for a long time and no problem, please follow 1. Structure chart of EPS the method for maintenance in this chapter.  This chapter also. ELECTRIC POWER STEERING SYSTEM controls all the power performance of EPS, so do On the shell of ECU unit, there are sets of electric not repair ECU by yourself.

Plugs by cables and function as follows: ○. P1：positive pole ( If any problem happens on ECU, please contact + pole) for EPS motor ○. ELECTRIC POWER STEERING SYSTEM frame.

Monitors working condition of EPS system. Fault can be displayed by fault indicator light and Installation position of steering as follows: fault indicator of EPS system, so the driver can acknowledge fault of EPS in time and take some measures to keep himself/herself safe. ELECTRIC POWER STEERING SYSTEM Operate as the following steps: ④ Negative Wire Of Cable  Assembling your new UTV.

⑤ Negative Wire Of EPS System  Ensure main switch is off. ⑥ ⑦ Screw main switch CAUTION If connection terminals do not fixed, power of ECU may be constantly on-off during UTV driving, and finally cause ECU damaged. ELECTRIC POWER STEERING SYSTEM torque, power torque of the EPS system will be Drive UTV with faulty EPS system may cause relatively small. This can be achieved outstanding accident, severe injury or even death. Auto-centering effect, that means when UTV is in Never operate UTV with faulty EPS system. ELECTRIC POWER STEERING SYSTEM  But if there is no inspection or maintenance as When ECU detected its own fault and can not stated time period during in use of EPS, it may be work normally, it will indicate EUC stop cause EPS system work abnormally or spare parts working code to dash board.

Hisun 500 Utv Parts Manual

ELECTRIC POWER STEERING SYSTEM 2. Check steering power in static condition block, no recoil force which opposite of Let UTV stop on the level road, steering wheel is operation force.  placed in a straight forward position. During return process, the return force is equal . ELECTRIC POWER STEERING SYSTEM Meter warning fault code： Charge storage battery, Low voltage in storage battery F00005 replace it if necessary. Motor is damaged or driving Meter warning fault code： circuit in motor is damaged or Replace fuses, to dealer F00003 power motor special fuses are for repair. ELECTRIC POWER STEERING SYSTEM 3.

All have auxiliary power to turn left or right, when turned the steering wheel is not smooth, locked, backswing and other feelings. Fault phenomenon Fault point Solution Steering system Retighten loose bolts. Steering system mechanical parts mechanical parts has the Replace damaged spare become loose or damaged. ELECTRIC POWER STEERING SYSTEM No meter alarm, steering Mechanical steering system’s Adjust、repair damaged becomes more difficult if spare parts are damaged. Damaged, No meter alarm To dealers for repair. Software program has error.

All have power-assisted to turn left or right，the power of steering to left and right is different. Fault phenomenon Fault point Solution. ELECTRIC POWER STEERING SYSTEM If a customer complaint' vehicle deviation', it system will be no power steering, and through the should take into account the fault causes not only instrument to show the corresponding fault code includes the EPS system fault, also includes a and remind driver to take care. ELECTRIC POWER STEERING SYSTEM -40℃～＋85℃ 2. Working voltage：(9～16V) DC 3. The seal type：IP65 4.

Input shaft rotation angle：large than ±1.25rmp 5. Wheel rotation speed： 10round/min～15round/min ■ Motor assy basic parameters  Type: DC permanent magnet control motor  Rated working time: 3 min/per time . UNIVERSAL SYMBOLS As a guide to the operation of your vehicle, various universal symbols have been utilized on the instruments and controls. The symbols are shown below with an indication of their meaning.

Safety Alert Symbol Lift Cylinder-Retract Fuel Lift Cylinder-Extend Engine coolant-Temperature Lift Cylinder-Float Parking Brake. CONTENTS SAFETY OPERATION 1-1 SERVICING OF VEHICLE 2-1 SPECIFICATIONS 3-1 SPECIFICATION TABLE 3-1 TRAVELING SPEEDS 3-2 VEHICLE LIMITATIONS 4-1 INSTRUMENT PANEL AND CONTROLS 5-1 LOCATION OF PARTS 5-1 ILLUSTRATED CONTENTS 5-2 PRE-OPERATION CHECK. Brake Pedal 8-3 Range Gear Shift Lever 8-3 4WD Lever 8-4 Speed Control Pedal 8-4 STOPPING 8-5 STOPPING 8-5 CHECK DURING DRIVING 8-5 Immediately Stop the Engine if： 8-5 Fuel Gauge 8-5 Coolant Temperature Gauge. Checking brake pedal 11-5 Checking parking brake 11-5 Checking gauges meter and easy checker™ lamps 11-5 Checking head light turn signal light etc 11-5 Checking seat belt and ROPS 11-5 Checking joint boot 11-5 Checking tire inflation pressure 11-6 EVERY 50 HOURS. EVERY 600 HOURS 11-15 Adjusting Engine Valve Clearance 11-16 EVERY 1500 HOURS 11-16 Checking Injection and Fuel Pump 11-16 EVERY 1 YEAR 11-16 Replacing Air Cleaner Primary Element and Secondary Element 11-16 EVERY 2 YEARS 11-16 Changing Brake Fluid. 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 will be repaired or replaced by HISUN.

This is your EMISSION CONTROL SYSTEM WARRANTY. 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 applicable regulations of the United States Environmental Protection Agency. Any part or parts replaced under this warranty shall become the property of HISUN. 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. OWNER’S MANUAL WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. HISUN MOTORS 310 East University Dr McKinney, Texas 75069 PH (972) 446-0760 TF (877) 838-6188 hisunmotors.com.