Home

HS 500/700 - Hisun Motors Corp, USA

1. RAB SOME S N O Nah Sy La VN N elt nalad E y oN Introduction HS 500 700 INTRODUCTION Congratulations on your purchase of the HS 700 UTV This Owners 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 For questions regarding this UTV please call 972 446 0760 IMPORTANT SAFETY MESSAGES O 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 TRAINING OR INSTRUCTION O THIS UTV SHOULD NOT BE RIDDEN BY ANYONE UNDER 16 YEARS OF AGE 1 1 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 A 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 CAUTION A CAUTION indicates spe
2. AIR vu SEB ing dy Z SE 7 ER EE PERSOON rd y IX Ds 4 rt SAL SOVER DL an e Ro 6 Ze a nN N SU LE Y Ve E Sy j fr E jo hy 1 Oil Level 2 Dipstick IMPOTTANT If oil level is low do not run engine N Checking Coolant Level A CAUTION TO avoid personal injury e Do not remove radiator cap while coolant is hot when cool slowly rotate to the first stop and allow sufficient time for excess pressure to escape removing the cap completely li off raise the cargo bed mount the safety support 2 Check to see that the coolant level is between the FULL and LOW marks of recovery tank 3 evaporation add water only up to the full level Park the vehicle on a flat surface with engine When the coolant level drops due to In case of leakage add anti freeze and water in the specified mixing ratio up to the full level see flush cooling system and changing coolant in EVERY 2 YEARS in PERIODIC SERVICE section 11 3 PERIODIC SERVICE is EES zZ la Er Va DP 1 Recovery tank FULL A LOW IMPORTANT If the radiator cap has to be removed follow the cautions above and securely retighten the cap Use clean fresh water and anti freeze to fill the recovery tank lf water should leak consult your local HSUN Dealer N Cleaning radiator screen A CAUTION TO avoid personal injury Be sure to stop the engin
3. Every Replace 100 hrs Every 1 Clean i Air cleaner years element Every Replace 100 hrs Every 1 14 Brake pedal Check years l Every 15 Parking brake Adjust 200 hrs Brake light Every 16 Check switch 200 hrs Every 200 hrs Every 2 years Every 1 years 7 Spark arrester Clean Radiator hose and clamp Brake hose amp Every re hrs IT NET Every CPE EE Every AAA pipe Front axle case Change MAINTENANCE Every 400 hrs Engine valve Every Adjust clearance 800 hrs Every 24 Fuel injection Check 1500 hrs a Every 25 Injection Check 3900 hrs Every 2 26 Brake fluid Change years Remote Every 2 2 Replace hydraulic hose years Rear brake Every 2 28 Replace cylinder seal years Every 2 29 Front brake seal Replace years Every 2 30 Cooling system Flush years Every 2 Coolant Change years traen mes PR Service as DAS required Lightbulb Replace EN EN EN EN EN EN EN EN EN EN EN EN NOTE Engine Oil 15W 40SL gt Oil used in the engine should have an American Petroleum Institute API service classification and Knuckle case oil Change Proper SAE Engine Oil according to the ambient temperatures as shown above Brake fluid Always use DOT3 GENUINE BRAKE FLUID from a sealed container MAINTENANCE MAINTENANCE PERIODIC SERVICE PERIODIC SERVICE A CAUTION To avoid personal injury How TO OPEN THE FRONT HOOD COVE
4. Gear rack type steering gear Do not remove the membrane or replace by other UTV use gear rack type steering gear to perform parts steering function Steering gear was fixed on 15 3 ELECTRIC POWER STEERING SYSTEM frame Installation 2177 of 7 cal follows E oe us a ire ese YDS Ha Di a ES ECU with waterproof metal box 2 ECU split cable 3 Battery 4 Meter Steering torque sensor 6 Motor 7 Speed sensor Main switch 9 Fuse 7 Meter Meter is an important part of UTV Meter works together with EPS system and 15 4 monitors working condition of EPS system Fault can be displayed by fault indicator light and fault 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 At the same time fault indicator of EPS system will display the fault code for maintenance 1 Fault indicator light of EPS system 2 Fault indicator of EPS system Fault code diagram Fault style 1 fault of 00001 fault of steering torque sensor 2 tault of 00002 fault of steering ae sensor F00006 ECU overheating Fault indicator Faul a light of EPS code i F00005 ow voltage battery 00003 a motor without NS power i Foot aut lit sensor F00010 ECU non working it OPERATION AND USE OF EPS SYSTEM
5. and remind driver to take care 3 The software function forms limit position Although the mechanical structure of the EPS system has mechanical limit position it is still possible for EPS system to realize the function of decreasing steering power before reaching the mechanical limit position in form of slope curve Although the customer will feel the steering resistance increases when turned to the limited position process will become obviously more smoothly In addition it can also reduce the steering system s mechanical and electrical components load which helps in obtaining reliable function and long service life N EPS system Periodic maintenance For primary use after 50 hours adjust EPS system part of parameters according to the steering system s clearance variation and chassis changes Please go to the dealer for alignment For every 100 hours using time according to the steering system and the chassis changes adjust EPS system relevant parameters AX caution Before adjust ECU for every time please check the clearance of mechanical part and adjust four wheels fixed position of UTV EPS SYSTEM PARAMETER TABLE N EPS system basic technical parameters N EPS system working conditions 1 Working environment temperature OF ae OE N ELECTRIC POWER STEERING SYSTEM 40 C 85 C Working voltage 9 16V DC The seal type IP65 Input shaft rotation angle large than 1 25rmp Wheel rotation
6. e The fuel checked annually or every 100 service line connections should be hours whichever comes first 1 Park the vehicle on a flat surface and raise the cargo bed 2 The fuel line is made of rubber and ages regardless of service period 3 If the fuel line and clamps are found to be damaged or deteriorated replace them 4 Check the fuel filter if it is clogged by debris or contaminated with water replace it IMPORTANT When the fuel line is disconnected for maintenance or repair cover both ends of the fuel line with a piece of clean cloth or paper to prevent dust and dirt from entering Care must be taken not to admit dust and dirt into the fuel pump entrance Even a small amount of dust or dirt will cause premature wear and malfunction of the fuel pump and injector components 2 fuel line 1 fuel pump 3 Exit pipe N Checking battery condition A CAUTION To avoid personal injury Never remove the battery while the engine is running o Keep electrolyte away from eyes hands and clothes If you are spattered with it wash it away completely with water immediately and get medical attention o Wear eye protection and rubber gloves when working around the battery The factory installed battery is non refillable type if the battery is weak charge the battery is weak charge the battery or replace it with new one 4 Battery charging A CAUTION To avoid personal in
7. towing e When operating with cargo or towing a trailer always reduce speed allow more room to stop and avoid hills and rough terrain e Be sure cargo is secured since a loose load can change vehicle handling e Keep weight in the cargo bed centered and as low and far forward as possible Top heavy loads increase the risk of rollover 1 5 SAFE OPERATION Improper Use of Off Highway Vehicles Can Cause Severe Injury or Death Be Prepared e Wear an approved helmet and protective gear If you think or feel the vehicle may tip or roll reduce your risk to injury e Each rider must be able to sit with back against seat e Keep a firm grip on the steering wheel or handholds and brace yourself feet flat on floor and foot rests and hands on steering wheel or handhold s where equipped Stay e Do not put any part of your body outside of the vehicle for any reason COREENI inside Hie Ven Reguire Proper Use of Your Vehicle Do your part to prevent injuries NE Drive Responsibly e Do not allow careless or reckless driving Avoid loss of control and rollovers Q om ei oi GEE IE ON e Avoid abrupt maneuvers sideways sliding skidding x 4 fe a e Do not let people drive or ride after using alcohol or drugs or fishtailing and never do donuts 2 e Do not allow operation on public roads unless designated for e Slow down before entering a turn i Be Sure Riders Pay Attention and Plan Ahead e Fasten seat belts Cc o
8. De SS amb A ARS Leal SE BGR gt FU IEA OF al 9 RS SH 4 di r AN gt SEN _ FIN Engine serial number SPECIFICATIONS SPECIFICATIONS SPECIFICATION TABLE Mae 1 cylinder 4 cycle gasoline SOHC liquid cool Engine Displacement 0 8 48 8 22 zaw 64 Rated revolution revolution pm Low revolution 1350 to 1500 Fuel Capacity 28 2889 2889 Franson ler CC Wheels Drive system 4 Rear 2WD or 4WD Differential lock Electric control switch Front Rear Wet disk brake Brakes Parking brake Axis brake parking brake Suspension Length 2980 138 2 Front tread centers 1300 45 866 Dimensions Height 1950 76 77 Rear tread centers 1285 46 5 Wheelbase 1950 103 54 rear axle rear axle 310 13 Turning diameter 8 6 34 769 Max rolling weight Towing Capacity kg Ibs 957 2110 Payload capacity kg Ibs 159 300 Weight kg Ibs 638 1407 3 1 Clearance SPECIFICATIONS Worksite Red Worksite Camo Width 1170 51 38 Length 900 32 88 Depth 280 11 4 3 ad m cut 0 29 1135 Bed height mm in 810 34 25 unloaded Cargo bed capacity g Ibs 159 300 1 row 2 row Sound level operator ear Tire Body color ped Game NOTE e The values in Ground clearance and Weight are those of the machine equipped with the tires in the table above e The company reserves the right to change the specifications without notice TRAVE
9. E EPS system operation speed 4 ELECTRIC POWER STEERING SYSTEM Operate as the following steps Assembling your new UTV e Ensure main switch is off main switch dit RS 1 Main switch 2 OFF 3 ON START A CAUTION lf main switch is not off ECU can be destroyed by battery power in on off condition during the following connection with cables Use screw nut to connect the connecting terminals of cables firmly to and of battery N 4 N DAD E AE NN A A ET FA i ES i 4 Battery Positive Wire Of Cable 8 Positive Wire Of EPS System Q 2e amp Negative Wire Of Cable Negative Wire Of EPS System Nut Screw A CAUTION If connection terminals do not fixed power of ECU may be constantly on off during UTV driving and finally cause ECU damaged Open main switch of UTV and EPS system will automatically enter into working state Check the meter If fault indicator light of EPS system does not be lit ECU can be for regular use If fault indicator light of EPS system is lit that means EPS system find out some fault during ECU self checking process then you should consult your local dealer for maintenance in time Meter 1 Fault indicator light of EPS system 2 Fault indicator of EPS system 4h DANGER ELECTRIC POWER STEERING SYSTEM Drive UTV with faulty EPS system may cause accident severe injury or even death Never operate UTV with
10. and then start the by following the engine again N Checking Intake Air Line 1 Check to see if the hoses and hose clamps are tight and not damaged 2 If hoses and clamps are found to be worn or damaged replace or repair them at once 2 Hose joint EVERY 300 HOURS EM Checking the Tires 1 Check to see if the tires are damaged 2 If the tires are cracked bulged or cut or they are worn out replace or repair them at once Tire Tread Depth Always replace the tires when the tread depth is worn to minimum allowable 1 3mm 0 12in 11 14 PERIODIC SERVICE EVERY 400 HOURS N Changing Transmission Fluid A CAUTION To avoid personal injury eo Park the vehicle on a flat surface raise the cargo bed mount the safety support Allow engine to cool down sufficiently oil can be hot and can burn 1 Park the vehicle on a flat surface raise the cargo bed mount the safety support 2 To drain the used oil remove the drain plug at the bottom of the transmission case and drain the oil completely into the oil pan After draining reinstall the drain plug After running the engine for a few minutes stop the engine and check the oil level again add oil to prescribed level 1 Drain plug IMPORTANT e Do not operate the vehicle immediately after changing the transmission fluid e Run the engine at medium speed for a few minutes to prevent damage to the transmission EM Chan
11. assembly No meter alarm Positional parameter of steering Adjust front wheels 2 wheel front wheel error positional parameter No meter alarm EPS system s speed reducer To dealers for repair damaged 5 All have power assisted to turn left or right but steering become more heavy ECU radiator overheat ECU reduce the power of the motors Remove dirt or another Meter warning fault code F00006 output torque automatically or covering on shell of ECU ECU s inside temperature alarm To dealers for repair sensor damaged 15 10 ELECTRIC POWER STEERING SYSTEM No meter alarm steering Mechanical becomes more difficult if spare parts are damaged no power ECU damaged No meter alarm steering systems Adjust repair damaged spare parts the ECU To dealers for repair Or software program has error 6 All have power assisted to turn left or right the power of steering to left and right is different Two No meter alarm No No power assisted the power meter alarm of right is different No meter alarm No meter alarm channels sensor changed Mechanical steering to left and spare parts are damaged ECU damaged software program has error The initialization parameter of ECU Restart initialization for has error ECU Fault phenomenon Fault point parameters of Replace sensor or go to dealers for repair steering systems Adj
12. not function and tighten connection Apply grease and securely treat with anti corrosive eo Replace with a o Battery life expired new battery From beginning starter u e Battery must be e Insufficient e Charge battery does not function and serviced properly charging Insufficiently MR lights soon become dim before initial use eo Battery was used o ee e Add distilled water When viewed from the with an insufficient Regularly check the and charge the top of plates look amount of electrolyte level 2 battery whitish electrolyte Refillable type battery Battery was used e Charge battery e Charge battery only with too much N Insufficiently properly without recharging Recharging is impossible e Battery life expired e Replace battery A o Keep the terminal e Clean the terminal clean and tight Terminals are severely Poor terminal and tighten Apply grease and corroded and heat up connection securely treat with anti corrosives There is a crack or Battery electrolyte level pin holes in the Replace battery drops rapidly papa electrolytic cells Refillable type battery e Charging system Consult your local on I trouble dealer e l you have any questions consult your local dealer e The factory installed battery is non refillable type TROUBLESHOOTING MACHINE TROUBLESHOOTING eo Replace throttle cable e High idling speed of e
13. running e To avoid the danger of exhaust fume poisoning do not operate the engine in a closed building without proper ventilation When storing remove the key from the key switch to avoid unauthorized persons from operating the vehicle and getting injured VEHICLE STORAGE If you intend to store your vehicle for an extended period of time follow the procedures outlined below These procedures will insure that the vehicle is ready to operate with minimum preparation when it is removed from storage 1 Check the bolts and nuts for looseness and tighten if necessary 2 Apply grease to vehicle areas where bare metal will rust also to pivot areas 3 Unload from cargo bed Inflate the tire to a pressure a little higher than usual 5 Change 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 equipped rods with grease if 12 1 7 Remove the battery from the vehicle Store the battery following the battery storage procedures 8 Keep the vehicle in a dry place where the vehicle is sheltered from the elements Cover the vehicle 9 Keep the vehicle indoors in a dry area that is protected from sunlight and excessive heat If the vehicle must be stored outdoors cover it with a waterproof tarpaulin Put boards under the tires to keep dampness away from tire Keep the tri
14. socket Range gear shift lever Left right turning switch at N ad 9 2 INSTRUMENT PANEL AND CONTROLS Safety grab bar Tail lights RAY Sua tan Tits AE Sand RTH IMA Un Rear Tire Rear Shock Absorber 5 3 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 A 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 and implement lowered to the ground if equipped Check items Visually inspect the exterior of the vehicle Check engine oil level Check transmission oil level Check brake fluid level Check coolant level Clean radiator screen When used in a dusty place Check brake and pedal Check parking brake Check indicators gauges and meters Check lights Check seat belts and roll over protective structures Check front and rear joint boots Check tire inflation pressure Refuel See DAILY CHECK in PERIODIC SERVICE section Care of danger warning and caution labels See DANGER WARNING AND CAUTION LABELS in SAFE OPERATION section 6 1 OPERATING THE ENGINE OPERATING THE ENGINE NOTE The parking brake warning lamp P comes on A CAUTION To avoid personal injury e Read SAFE OPERATION in front of this manual while parking brake i
15. switch the hazard light flash along with the indicator on the instrument panel Press the bottom half of the hazard light switch to turn off the hazard light Note e The hazard light switch is operative when the key switch is in the ON or OFF position Be careful that keeping the switch ON causes the battery to run out N Turn Signal Light Switch if equipped To indicate a right turn push on the lower half of the turn toggle switch To indicate a left turn push on the upper half of the turn toggle switch When the left or right signal is activated the indicated turning light will flash and the other will stay on The indicator lamp at the instrument panel also flashes indicating the direction of the turn NOTE e The turn signal light switch only operates when the key switch is in the ON position lf the hazard light switch is pressed to the ON position while the turn signal is activated the indicated turning light will flash and other will stay on Be sure to return switch to center position after turning qe Wass ss Le ri nn SE AA A MAA vi y A A h AS se a o 1 Head light 8 Rear turn signal lamp 2 Front turn signal lamp 3 Checking the brake pedal N Brake Pedal Adcaution To avoid personal injury o l the operator suddenly brakes an accident may occur due to loss of control or shifting forward of heavy loads e When dr
16. warranty implied by law including any warranty of merchantability or fitness for a particular purpose is limited to the express emission control system warranty terms stated in 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 have other rights which vary from state to state V This warranty is in addition to the limited vehicle warranty 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 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 1434 Patton Place Ste 106 Carrollton TX 75007 Phone 972 446 0760 Fax
17. your warranty rights and responsibilities you should contact Hisun Motors Corp U S A 1434 Patton Place Ste 106 Carrollton TX 75007 Phone 972 446 0760 or Toll Free 877 838 6188 or the U S Environmental Protection Agency at 2000 Traverwood Drive Ann Arbor MI 48105 HSUN Hisun Motors Corp U S A Limited Warranty on Emission Control System YOUR WARRANTY RIGHTS AND OBLIGATIONS Hisun Motors Corp U S A warrants that each new 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 Protection Agency and is 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 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 applicable regulations of the United States Environmental Protection Agency Any part or parts replaced under this warranty shall become the property of HISUN Limitations This Emission Control System Warranty shall not cover any of the following A Repair or replacement as a result of 1 accident 2 misuse 3 repairs improperly performed or replacements improperly installed unless performed by a H
18. 0 700 SAFE OPERATION d SAFE OPERATION All operators including experienced UTV drivers or passengers should carefully read and fully understand this Users Manual and operate strictly as the manual states in order to achieve the best performance and avoid accidents Others who will use your UTV should be trained on how to operate the UTV and be required to read this manual before operation 1 Safety Instructions 1 Understand this UTV by reading this manual and understanding all the components of the vehicle Only start and operate the vehicle after you have finished reading this manual 2 Pay close attention to the warning and caution labels on the UTV 3 Understand completely and learn to use the safety devices roll over protective structure seat belts and never change the original safety devices If safety devices are damaged consult your local dealer for replacement Always use seat belts 1 Roll over protective structure Seat belts 4 Do not wear loose articles of clothing during operation as these can be drawn into moving parts on the vehicle and could cause a severe injury to occur You should always wear protective equipment such as helmet boots eye protection ear protection and gloves etc Only a qualified driver with driving license should operate this UTV Never operate after drinking alcohol using drugs or controlled substances or while fatigued Always perform the p
19. 972 446 0765 Toll Free 877 838 6188 OWNER S MANUAL A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm HSUN HISUN MOTORS 310 East University Dr Mckinney Texas 7 5069 PH 972 446 0760 TF 877 838 6188 hisunmotors com
20. CTRIC POWER STEERING SYSTEM ELECTRIC POWER STEERING SYSTEM INTRODUCTION Our UTV is equipped with Electric Power Steering System EPS To keep reliability of EPS during operation please correctly use EPS system according to the following descriptions and keep daily inspection and maintenance This chapter also provides important information to safely use EPS system If you encounter any problem during operation or maintenance please feel free to consult your local dealer ADVANTAGES OF EPS SYSTEM 1 High efficiency Traditional hydraulic power steering system is connected by mechanical and hydraulic and it is of low efficiency usually only 60 70 connected by mechanical and electric motor However EPS system is and it is much high efficiency with up to 90 Less energy consumption In practical driving process of UTV time in steering condition is only 5 among the total travelling time As to hydraulic power steering system as long as the engine is running the hydraulic pump is always in working condition and fuel consumption will increase 4 6 However EPS system starts the motor only when it needs steering to generate power without increasing fuel consumption The power characteristics of EPS system can be controlled by software so that UTV can be satisfied with power steering characteristics at various speeds Feeling comfortable on road Inside of EPS system we use rigid connection so under auxilia
21. ICE section 5 Turn the key to START position and release when the engine starts IMPORTANT e Because of safety devices the engine will not 1 2 start except when the gear shift lever is placed in the NEUTRAL position N Cold Starting When the 15 C ST the engine is very cold If the engine ambient temperature is below fails to start after 10 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 WARMING UP 4h CAUTION To avoid personal injury e Be sure to set the parking brake during warm up e Be sure to set the shift lever to the NEUTRAL position during warm up e Allow the engine to warm up for 5 minutes without applying any load This is to allow oil to reach every engine part If a load is applied to the engine without warm up engine damage may occur N Warm Up Transmission Oil in the Low Temperature Range IMPORTANT Do not operate the vehicle under full load until it is sufficiently warmed up OPERATING THE VEHICLE OPERATING THE VEHICLE OPERATING NEW VEHICLE How a new vehicle is handled and maintained determines the life of vehicle A new vehicle just off the factory production line has been tested however the various parts are not mated to each other so the operator should pay more attention to the vehicle operation for the first 50 ho
22. ISUN 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 required maintenance C Any vehicle equipped with an odometer or hour meter on which the odometer mileage or hour meter reading has been changed so that actual mileage cannot be readily determined Limited Liability A The liability of HISUN under this Emission Control System Warranty is limited solely to 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 in connection with the sale or use of Or inability to use the vehicle for any purpose Some states do not allow the exclusion or limitation of any incidental or consequential damages so the above limitations may not apply to you HSUN Hisun Motors Corp U S A Limited Warranty on Emission Control System B No express emission control system warranty is given by HISUN except as specifically set forth herein Any emission control system
23. LEE I 1 Brake pedal 3 PEDAL STROKE 2 FREE TRAVEL NW Checking parking brake Use the parking brake to stop depress the brake pedal to release the park Make sure the parking brake warning lamp on the easy Display goes off when parking brake lever is down 1 Parking brake EM Checking gauges meter and Display lamps 1 Inspect the instrument panel for broken gauges meter and Display lamps 2 Replace if broken EM Checking head light turn signal light etc 1 Inspect lights for broken bulbs and lenses 2 Replace if broken EM Checking seat belt and ROPS 1 Always check condition of seat belt and ROPS attaching hardware before operating vehicle 2 Replace if damaged E Checking CV joint boot 1 Check to see if the joint boots are damaged 2 If the boots are cut gashed or show signs of deterioration consult your local dealer 11 5 PERIODIC SERVICE lubricate grease fittings more often ia eee gt S 1 joint boot 2 Drive shaft ns A UM jr as id Y i y a S Es BE AE IL i MES I as A Ne 1 Joint boot 2 Drive shaft 1 Parking brake 2 Parking brake pivot spray type grease EM 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 TA Front 26x9 12 70kPa 0 7kgf cm2 10psi
24. LING SPEEDS Range gear shift lever km h mph 3 2 VEHICLE LIMITATIONS VEHICLE LIMITATIONS The Vehicle has been thoroughly tested for proper performance with implements sold or approved by 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 Cargo loading weigh Rear trailer hitch a 1 ROW SEATING MODE Cargo Bed Capacity 159Kg 300 Ib Max rolling weight Cargo Load Capacity 179kg 395 Ib 957 kg 2110 lbs Max tongue weight 50 kg 110 lbs 1 Above mentioned specifications are based on level ground condition 4 1 INSTRUMENT PANEL AND CONTROLS INSTRUMENT PANEL AND CONTROLS LOCATION OF PARTS Roll Over Protection System Seat Bottom Seat Back Head Rest Front Bumper Turn Signals Headlights Front Shock Absorber 5 1 INSTRUMENT PANEL AND CONTROLS ILLUSTRATED CONTENTS 2 4 WD High low beam switch The front axle differential Steer ing wheel Light switch Emergency ight Horn Gauges Winch control Y ad GET XI ET TEG SF um e 1 A A JAS Ma di e aa EE BIN JS II ss I Parking Brake pedal Accelerator peda DC
25. R AND SEAT A CAUTION To avoid personal injury from contact with moving parts Never open operator s seat while the engine is running mM Front hood cover To open the hood turn the latch in the direction shown in the picture below and lift the hood off To close tilt cover back to closed position and fasten the latches N Operator s Seat To open the seat raise the seat to the forward position Operator s seat HOW TO RAISE THE CARGO BED 4h CAUTION To avoid personal injury e When servicing under raised cargo bed make sure safety support is properly mounted e Do not touch muffler or exhaust pipes while they are hot Otherwise severe burns could result N Raising and Lowering the Cargo Bed To raise the cargo bed 1 Apply the parking brake with the engine off 2 Pull up the cargo bed release lever 3 When the cargo bed has been raised mount the safety support To lower the cargo bed Press down the cargo bed hard untill it is locked PERIODIC SERVICE Cargo bed release Lever UP DOWN 1 Gas spring JACK UP POINT A WARNING To avoid personal injury death or vehicle damage e Do not work under the vehicle unless it is secured by safe stands or suitable blocking E Front End Jack up at the front frame tube only 1 Jack 2 Front frame tube N Rear End Jack up the rear side after placing a wooden block under the
26. Rear 26x11 12 70kPa 0 7kgf cm2 10psi EVERY 50 HOURS N Greasing Apply a small amount of multi purpose grease to the following points every 50 hours If you operated the vehicle in extremely wet and muddy conditions PERIODIC SERVICE 1 Range gear shift lever pivot spray type grease M Checking engine start system A CAUTION TO avoid personal injury e Do not allow anyone near the vehicle while testing l the vehicle does not pass the test do not operate the vehicle Preparation before testing 1 Place all control levers in the NEUTRAL position 2 Set the parking brake and stop the engine Test range gear shift lever safety switch 1 Sit on the operators seat 2 Shift the range gear shift lever to L H N or REVERSE position 3 Turn the key to START position The engine must not crank lf it cranks consult your local dealer for this service ccelerator pedal A MA W at gt 1 D N Checking wheel Lug Nut torque A CAUTION To aroid personal injury Never operate vehicle with a loose Lug Nuts Any time Lug Nuts are loosened they should be retightened to the specified torque e Check all Lug Nuts frequently and keep them tight PERIODIC SERVICE 1 Torque wheel bolts to 75to 90 N m N Cleaning air cleaner primary element 1 2 3 4 5 6 T 8 9 10 11 Open the hood cover Open the air clean
27. Your emission control system warranty covers components whose failure would increase an engine s emissions of any regulated 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 will be repaired or replaced by HISUN This is your EMISSION CONTROL SYSTEM WARRANTY NOTICE Use of this vehicle in any type of competitive event completely and absolutely voids this and all other warranties offered by HISUN OWNER S WARRANTY RESPONSIBILITIES As the vehicle owner you are responsible for the performance of the required maintenance listed in your owners 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 responsible for presenting your vehicle to the HISUN dealer as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days As the vehicle owner you should be aware that HISUN may deny your warranty coverage if your vehicle or a part has failed due to abuse neglect improper 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
28. adiator Hose and Clamp in EVERY 200 HOURS in PERIODIC SERVICE section N Replacing Fuel Hose Consult your local Hisun Dealer for this service N Replacing Brake Master Cylinder Inner parts Consult your local dealer for this service N Replacing Front Brake Seal Consult your local dealer for this service EM Replacing Rear Brake Cylinder Seal Consult your local dealer for this service N Replacing Intake Air Line Consult your local dealer for this service EVERY 4 YEARS N Replacing Brake Hose Consult your local Dealer for this service N Replacing Mini Blade Fuses The mini blade fuses are intended to protect the electrical wiring If any of them have blown out be sure to pinpoint the cause Replacing procedure 1 Disconnect the negative cable of the battery 2 Open the mini blade fuse box cover 3 Pull out the mini blade fuse 4 Insert a new mini blade fuse into the slow blow fuse box 5 Close the mini blade fuse box cover 6 Connect the negative battery cable 1 Mini Blade fuse box cover N Replacing Light Bulb e Head lights Take the bulb out of the light body and replace it with a new one e Other lights Detach the lens and replace the bulb Light Capacity Head lights 2x55W LED 0 5W Tail light Brake light LED 1W n 11 18 STORAGE STORAGE STORAGE A CAUTION To avoid personal injury e Do not clean the vehicle when the engine is
29. aise the cargo bed Turn the key switch to the ON position Step on the brake pedal to check if the brake light comes on 4 If it does not check the bulb or brake light switch MW Checking the Radiator Hoses and Clamps Park the vehicle on a flat surface and raise the cargo bed Check to see if radiator hoses are properly fixed every 200 hours of operation or six months whichever comes first 1 If hose clamps are loose or water leaks 1 2 Release the parking brake Step on the pedal and measure the pedal stroke 2 11 13 tighten bands securely Replace hoses and tighten hose clamps hoses are swollen securely if radiator PERIODIC SERVICE hardened or cracked Replace hoses and hose clamps every 2 years or earlier if checked and found that hoses are swollen hardened or cracked 1 Radiator hose 2 Clamp bands 4 Precaution at Overheating Take the following actions in the event the coolant temperature is close to or more than the boiling point which is called Overheating 1 Stop the vehicle operation in a safe place and keep the engine unloaded idling 2 Dont stop the engine suddenly but stop it after about 5 minutes of unloaded idling 3 Keep yourself well away from the vehicle for at least 10 minutes or while the steam is blowing out 4 Check to see if there is no danger such as burning get rid of the causes of overheating TROUBLESHOOTING section of the manual
30. al injury e Seat belts reduce injury Always wear your seat belts The lap style seat belts may not provide adequate protection for small children Pay special attention when carrying a child passenger A CAUTION To avoid personal injury Always use the seat belts when operating and riding the vehicle Adjust the seat belts for proper fit and connect the buckle This seat belt is an auto locking retractable type 1 Seat belt 2 Selecting light switch position WE Head Light Switch Turn on the key switch and turn the head light switch to the ON position Turn the head light switch to the OFF position to turn off the head light 1 Head light switch 2 Head lights OFF 3 High beam lights ON 4 Low beam lights ON 5 4WD button 2WD button 72 Front axle differential lock Front axle differential unlock Emergency light ON Emergency light OFF 4D Winch cable release 2 Winch cable pulled up 13 Left turning lights Right turning lights 15 Plug cover NOTE Turning the head light switch to the ON position causes the following lamps to light simultaneously 1 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 soeedometer ot ER oN Front left and right position lights N Hazard Light Switch if equipped Press the top half of the hazard light
31. anual If necessary adjust it Open the main switch e Turn the steering wheel left and right successively turning force on both sides should be equal Turn the steering wheel to rotate back and forth turning shall be smoothly no block no recoil forces which opposite of operation force If any problem found it must driven to dealer and repair it immediately 3 Steering forces checking during running conditions During running process the feeling of steering force to the left and right must be consistent During steering turning shall be smoothly no N Solutions for common fault 1 Open the main switch no auxiliary power of left and right steering S N FAULT PHENOMENON FAULT POINT SOLUTION Special fuses of ECU is blown in Meter warning fault Replace fuses To dealers fuses box see figure 1 Or ECU code F00010 for repair is damaged Sensor is damaged or sensors Meter warning fault code F000018F00002 connector with bad contact or To dealers for repair ECU is damaged ELECTRIC POWER STEERING SYSTEM Meter warning fault code Charge storage battery Low voltage in storage battery o F00005 replace it if necessary Motor is damaged or driving Meter warning fault code circuit in motor is damaged or Replace fuses to dealer FOOOO3 power motor special fuses are for repair blown No electrical power Main fuses melted Replace fuses connected ECU initialization choose pin No
32. ators of the UTV should not wear earphones 6 Use the proper trailer hitch to haul cargo Trailer Hitch 7 Do not accelerate quickly when starting the engine especially driving on rough terrain as this can cause injury or death Press the accelerator pedal slowly Drive at slow speeds before braking When the differential is unlocked DIFF LOCK is off the front rear wheels can turn at different speeds to assist in the stability of the vehicle 10 Never drive over terrain such as a ditch a hole dams excessive mud or the vehicle can get stuck because of the vehicles weight 11 Always pay close attention to your surroundings and check for streets trail intersections or other obstacles 12 Always use signals in advance of turns 13 Do not allow entrance or exit of the vehicle while it is moving 14 Keep the floorboard free of debris that can obstruct the ability to use the brake pedal 15 Position your hands on the steering wheel Always keep your hands and feet inside passenger area of the vehicle Never try to stand while operating the vehicle 16 Do not tow passengers or attempt to jump the vehicle 3 Children safety instructions Always watch children when they are around the vehicle Children like to imitate adults and this could lead to an accident Do not leave children alone beside the vehicle Keep children from the operating area of the vehicle Turn off the engine and remove the key w
33. below table MtO5 ECU Malf Code Table 23 Malf code in MT05 P0107 P0108 Description MAP Circuit Low Voltage or Open MAP Circuit High Voltage IAT Circuit Low Voltage IAT Circuit High Voltage or Open P0117 Coolant Oil Temperature Sensor Circuit Low Voltage P0118 Coolant Oil Temperature Sensor Circuit High Voltage or Open TPS Circuit Low Voltage or Open TPS Circuit High Voltage O2A Circuit Low Voltage O2A Circuit High Voltage O2A Heater Circuit High Voltage O2A Heater Circuit Low Voltage Injector 1 Circuit Malfunction Injector 2 Circuit Malfunction FPR Coil Circuit Low Voltage or Open FPR Coil Circuit High Voltage CKP Sensor Noisy Signal CKP Sensor No Signal Cylinder 1 Ignition Coil Malfunction P0337 Cylinder 2 Ignition Coil Malfunction ldle Speed Control Error System Voltage Low system Voltage High P0650 MIL Circuit Malfunction Tachometer Circuit Low Voltage P1694 Tachometer Circuit High Voltage O Cc gt D Q lt D Q 2 lt O Cc D dy E O gt dp O O gt dy Cc lt O Cc ox O O v O D A D ma J 13 2 TROUBLESHOOTING BATTERY TROUBLESHOOTING Trouble Cause Countermeasure Preventive measure eo Battery overused until lights are dim e Charge the battery e Charge the battery eo Battery has not sufficiently properly been recharged o Keep the terminal e Clean the terminal e Poor terminal clean and tight Starter does
34. cial precautions that must be taken to avoid damage to the machine NOTE A NOTE provides key information to make procedures easier clearer 1 2 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 Please check your local riding laws and regulations before operating this UTV When the temperature is below 4 F 20 C park the UTV in a place where the temperature is higher than 4 F 20 C Operate 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 first time will take longer because the fuel will need reach the fuel injectors To start the UTV the first time hold the ignition key on at 5 second intervals Allow the starter to rest 15 seconds between each start attempt 1 3 Introduction HS 500 700 Table of Contents Subject Introduction Important Warnings Notice Table of Contents Safe Operation Operation Children Safety Instructions Driving on a slope Driving in Harsh Conditions Dri
35. e ECU software program Once fault has been checked on EPS system UTV can accurate shutdown the EPS sysiem Shut off the EPS system UTV will be able to continue to complete the steering function through the mechanical structure of the steering system However at this time the driver will feel the turning resistance increases you can continue your driving of UTV only throw a greater force to operate the steering system A DANGER When meter indicated malfunction of EPS system or when the driver found EPS system operation abnormally please do some steps as below Stop vehicles immediately close the main switch open the front panel s repair cover and pull up the outlet which power supply for EPS system See page12 3 e Driving UTV to dealer by lower velocity and repair EPS system EPS SYSTEM S INSPECTION MAINTENANCE REPAIR EPS system had already inspected by strict quality restriction before delivery so it has high reliability ELECTRIC POWER STEERING SYSTEM But if there is no inspection or maintenance as stated time period during in use of EPS it may cause EPS system work abnormally or spare parts in EPS system are damaged abnormally When EPS system work wrong or get malfunction the malfunction warning and fault code can be indicated on meter N Malfunction assortment e During long time continuous fast steering especially when ambient temperature is very high it may cause ECU radiator
36. e before removing the screen Park the vehicle on a flat surface Remove the radiator cover Detach the screen and remove all foreign materials 1 Radiator screen IMPORTANT Radiator screen must be clean from debris to prevent engine trom overheating NW Checking brake fluid level A CAUTION TO avoid personal injury Never operate the vehicle if the brake fluid is below the minimum mark Use only DOT3 from a sealed container Other types of Brake fluid may ruin synthetic resin or rubber installed in brake system components and may cause brake failure Avoid contamination of the brake fluid thoroughly clean before removing the filler cap Do not open the brake fluid reservoir cap unless absolutely necessary Use extreme care when filling the reservoir If brake fluid spills on power steering hose wash off with water immediately as brake fluid quickly ruins synthetic resin or rubber hoses Check to see that the brake fluid level is the LOWER mark If it is below the LOWER mark add brake fluid PERIODIC SERVICE GN 4 J om 12 l orm 1 OIL CUP N Checking brake pedal 2 LOWER A CAUTION TO avoid personal injury e Stop the engine and chock the wheels before checking brake pedal 1 Inspect the brake pedals for free clearance and smooth operation Adjust if incorrect measurement is found see checking brake pedal in EVERY 200 HOURS in PERIODIC SERVICE section S
37. e nennen nenne 3 1 TRAVELING SPEEDS O E VEHICLE LIMITATIONS see see see ees ese ese see see see ees ees see see ees oes see see see ees con ano cos 4 1 INSTRUMENT PANEL AND CONTROLS IA AE AA O AE Oe eee 5 1 LOCATION OF PARTS a u 5 1 LE USTRATED CONTENTS ee a u le ee eo Ge seny 5 2 PRE OPERATION CHECK ae rue 6 1 DAILY CHECK ee aa 6 1 OPERATING THE ENGINE ses sse ese sessse ees see ese ees see ese see ese ees see ees see ese see see see STARTING THE ENGINE see ese cee eee EER ORE EE EE EE EE RE EE EE EER OER EER en nen A Cold Starting deu cuc ene coe cee cee coe wee cee coe wee ves nen wee nen nen wee nen nen cee nen nen cee cee ces A STOPPING THE ENGINE RAR RRA RARE 7 2 WARMING UP A A Warm Up Transmission Oil in the Low Temperature Range een 7 2 OPERATING NEW VEHICLE ss ssssssesssss ses ese es es ses ese ses ses ese ses see ese see see ese see ees 8 1 Do not operate the Vehicle at Full Speed for the First 50 Hours een 8 1 Changing Lubricating Oil for New Vehicles sesse nennen sa EER n nennen nennen nn nn nee 8 1 Head Light Switch r sense ennnnneennnneneeennnennnnnnnneennnnene en nsn es snsss seen ssnnne 8 2 Hazard Light Switch sesse ees es ee EER EE GE EE SEE nenn nn ER Gee en EE sense ss Gee en ee es 8 2 Turn Signal Light Switch srrrrsssssssersssceeeeeeeeeeeessceeeeeeeeceeessceenssceeeeeeeeseeensceeens 8 2 Brake Pedal ETES TEE TEST rrr rrrrrrrrr rrr rrr rrr rrr rrr rrr rrr rrr rrr rrr err rrr rrr r
38. eck steering wheel is loosened or not Move steering wheel and Check whether is loosen or with squeak through axis direction and horizontal direction If defection found repair or replace it eo Steering wheel s 0 15mm 0 0 59in If the free clearance is over range check spare range of free clearance is parts as below any defection found replace it Any defection found replace it Steering tie rod ball head is whether to wear down Swizzle ball of Knuckle wear out or not Gear rack on steering wheel wear out or not Spline on steering drive shaft is loosen or not Between input and output shafts reducer whether had idle running The steering system checking in steering process Turn the steering wheel from left to right and right to left it required smoothly and no blocking allowed 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 e Check tire inflation pressure whether meet to the velocity at both left and right directions specified requirements see tire instructions or lf any problem occurs it must driven to dealer and UTV user manual repair it immediately If necessary refill it e Check front wheels front beam wheel offset positioning whether is correct see UTV user m
39. ee EE ee Ee ee Ee ee se Cleaning radiator screen sere EE EE EE ER EE EER EE EE EE ee EE Gee ER ee EER Ee sense ee se Checking brake fluid level AS AAA EEE E OSS OOO ER VI AA UIE AA cec tes 8 5 8 5 8 5 8 5 8 5 8 5 Checking brake pedal TE EE CE EES DES E TOT OE EE NS NN S ETT 11 5 Checking parking brake ee ee ee ee ee ee ee ee RNA 11 5 Checking gauges meter and easy checker lamps coros 11 5 Checking head light turn signal light OIC sesse esse EER EE EER EE EER EER EER EER ORE ER EE ee 11 5 Checking seat belt and ROPS EET TT TE ET rr rere rrr errr rr rrr err ere eee eee ee ee ee ee nn 11 5 Checking joint boot ET TA AA ee 11 5 Checking tire inflation pressure PIPrrerrerrerrerrrrrrrrrrerrrrrr rrr rrr err err errr rrr rrr rr err eee 0 11 6 EVERY 50 HOURS PrrrrTerrerrerrerrrrrrrrrrrrrrrrrrrrr rrr rrr rrr rrr rrr rrr rrr rrr rrr rrr rrr rrr rr rr see ee 11 6 Greasing EE ER EE N 11 6 Checking engine start system tetssereerrerrerrereeeereereereesseesseseeseeeneeeeeeseeseeeeesee 11 7 Checking wheel bolt torque trees see see Ee ee EER EER Ee Re ee ee ER Ee ee ee ee ees ees ees 11 7 Cleaning air cleaner primary element stres sesse ER EE EE ER EE EE EE EE ER EE ee ee ee ee 11 8 Checking battery condition reer ees ee EER EER eee ona eee EER EER EER EER nennen ees es ees ees 11 9 Adjusting toe in see ee ee EER ER ER EE Ke EE EE EER EER ee Re ee ee ER ona ere ee wee see ees ees ees 11 10 Cleaning Muffler PrrrrTerrrrrrrrrrrrrrrrrrrr
40. er case cover Remove the air filter element Remove the sponge material from its frame Wash the sponge material gently but thoroughly in solvent Squeeze the excess solvent out of the sponge material and let it dry Inspect the sponge material and replace it if damaged Thoroughly apply foam air filter oil or other quality liquid foam air filter oil not spray type to the sponge material Pull the sponge material over its frame Install the air filter element Install the air filter case cover and be sure the crankcase breather hose is connected 1 Air filter element 1 Air filter frame 2 Air filter element 3 Element retaining plate IMPORTANT O 11 8 Do not run the engine with filter element removed Be sure to refit the cover with the arrow on the rear of cover upright if the cover is improperly fitted evacuator valve will not function and dust will adhere to the element Evacuator Valve Open the air cleaner cover once a week under ordinary conditions or daily when used in a dusty place to get rid of large particles of dust and dirt Check fuel line and fuel filter PERIODIC SERVICE A 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 to check the fuel lines periodically the fuel lines are subject to wear and aging fuel may leak out onto the running engine causing a fire
41. es out of direct sunlight and extreme heat IMPORTANT When washing the vehicle be sure to stop the engine Allow sufficient time for the engine to cool before washing e Do not wash with a pressure washer Cover the vehicle after the muffler and the engine have cooled down REMOVING THE VEHICLE FROM STORAGE 1 Check the tire air pressure and inflate the tires if they are low 2 Before installing the battery Be sure it is fully charged Check to see if the fan works Check all fluid levels engine oil transmission oil engine coolant transmission coolant and any attached implements 5 Start the engine Observe all gauges If all gauges are functioning properly and reading 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 6 With the engine fully warmed up Release the parking brake and test the brakes for proper adjustment as you move forward Adjust the brake as necessary 12 2 TROUBLESHOOTING TROUBLESHOOTING ENGINE TROUBLESHOOTING lf something is wrong with the engine refer to the table below for the cause and its corrective countermeasure Trouble Cause Countermeasure e Check the fuel tank and fuel filter e Check the electric fuel pump e Check the injector No fuel flow e Check the ECU with Motor Scan KF90121 e
42. ese ss sees see ese ses see ees see see see ese see see ee ee see see ese see ee Adjusting Engine Valve Clearance sesse nennen nn nennen nn nn nn nen RE Ee Checking Injection and Fuel Pump TEE TT EO TO Te ee EVERY 1 YEAR sesse sssessesssses see ses ees ese see see see ses ese see see see ses ees see see see see 0 ee Replacing Air Cleaner Primary Element and Secondary Element EVERY 2 YEARS sesse sesse ese sss ses ese ses see ese see see see see ese see nenn se see nen nn nee Changing Brake Fluid re rss nenn nennen nennen nn nen nen nn nee Flushing Cooling System and Changing Coolant sesse ses EER EER nen nenne nenne Replacing Radiator Hose Water pipes Cee cere ec cesses OT ET EE N TENTE Replacing Fuel HOSE ss ssssssssss ses ses ese ses ese ses ese nenn nn nn nen nen nn nee Replacing Brake Master Cylinder Inner parts Cee cece ccc ccc ccc ccc nennen nennen ernennen nee Replacing Front Brake Seal er ses nenne nennen ernennen nennen nn nennen nn nn nee Replacing Rear Brake Cylinder Seal ss EER EER nennen nennen nn nennen nn nn nen Replacing Intake Air Line sesse nennen nen nenn nen nn nenne EVERY 4 YEARS sesse sesse ese sss ses ese ses see css see see nennen nen nen nn nee Replacing Brake Hose ss sssssssss ese ses ss ee EER EE EER EE ne EER EER ORE nn nn nen nen nee Replacing SIOW BIOW FUSES sesse ss ss EER EE EER EER RE EE EER EER nn EER PER nen nn nn nee STORAGE esse ses
43. faulty EPS system N Function of EPS system e EPS system requires enough power to supply correct power torque e Supply steering power according to speed UTV s steering power can change as different various speeds and steering angle EPS systems can supply different power torque depending on the speed and steering angle T1 steering power sensor steering resistant torque which is checked by 2 T2 power torque on steering gear which is supplied by EPS system 3 Power Torque In Static Condition 4 Power Torque At Middle Speed 5 Power Torque At The Highest Speed Stationary the maximum power torque can make UTV U turn or stop into place as much as possible to ease the steering operation With increased speed reduce power torque can make UTV at high speed to make ii easier to maintain driving direction As shown power auxiliary effect depends not only on speed but also steering torque exerted by the driver If the driver is to impose a smaller steering 15 6 torque power torque of the EPS system will be relatively small This can be achieved outstanding auto centering effect that means when UTV is in straight line steering system will be not sensitive the steering wheel does not move from side to side e Fault alarm and protection function In order to ensure EPS system can supply a long term reliable working a variety of detection and alarm functions are set in th
44. ff highway vehicle access collisions with cars and trucks can occur S e Avoid hard acceleration when turning even e Do nor exceed seating capacity 1 passenger from a stop e Plan for hills rough terrain ruts and other changes in traction and terrain Avoid Rollovers have caused osse sod DANI OBEN TANN paved surfaces severe injuries and death Follow All Instruction and Warnings e Avoid side hilling riding across slopes even on flat open areas Reserved for Reference to Other Soures of Safety Information Chongqing Huansong Science And Technology Industrial Co Ltd certifies that this ROV complies with the American National Standard for Recreational Off Highway Vehicles ANSI ROHVA 1 2011 Standard DO NOT USE GAS MIXED WITH ETHANOL USE 100 GAS ONLY Never carry USE WITH ETHANOL MIXED GAS WILL passengers CAUSE DAMAGE TO THE MACHINE AND WILL VOID YOUR WARRANTY in cargo bed Use NON ETHANOL gasoline if possible IF ETHANOL gasoline is not available then use 91 octane or higher gasoline e Max towing weight 544kg 1200Ibs e Max tongue weight 50kg 110lbs 1 6 SAFE OPERATION Improper tire pressure or overloading can cause loss of control Change the oil when the Loss of control can result in severe temperature drops to 15 injury or death Celsius 5 Fahrenheit e Cold tire pressure Front 10psi 70kPa Rear 10psi 70kPa e Maximum weight capacity 1898lbs 861kg eKeep
45. freeze throw up at once and seek medical attention When antifreeze comes in contact with the skin or clothing wash it off immediately e Do not mix different types of Antifreeze The mixture can produce chemical reaction causing harmful substances e Antifreeze is extremely flammable and explosive under certain conditions Keep fire and children away from antifreeze e When draining fluids from the engine place some container underneath the engine body Do not pour waste onto the grounds down a drain or into any water source Also observe the relevant environmental protection regulations when disposing of antifreeze If it freezes coolant can damage the cylinders and radiator If the ambient temperature falls below 00132 F or before a long term storage let out cooling water completely or mix fresh water with long life coolant and fill the radiator and recovery tank with the mixture 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 Mixing the LLC The procedure for the mixing of water and antifreeze differs according to the make of the antifreeze and the ambient temperature Refer to SEA J1034 standard more specifically also to SAE J814c IMPORTANT When the antifreeze is mixed with wa
46. ging 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 the oil completely into the oil pan 3 Fill with the new oil up to the upper notch on the dipstick See LUBRICANTS FUEL AND COOLANT in MAINTENANCE section 4 After filling reinstall the filling plug Oil capacity for front axle 0 6L 0 6U S gals Oil capacity for A rear axle case Fa fl SAH Front axle case drain plug Rear axle case drain plug EVERY 500 HOURS N Replacing Fuel Filter Consult your local dealer for this service EVERY 600 HOURS 11 15 PERIODIC SERVICE mM Adjusting Engine Valve Clearance Consult your local dealer for this service EVERY 1500 HOURS N Checking Injection and Fuel Pump Consult your local dealer for this service EVERY 1 YEAR N Replacing Air Cleaner Primary Element and Secondary Element See Cleaning Air Cleaner Primary Element in every 100 HOURS in PERIODIC SERVICE section EVERY 2 YEARS EM Changing Brake Fluid Consult your local Dealer for this service See Checking Brake Fluid Level in DAILY CHECK in PERIODIC SERVICE section mM Flushing Cooling System and Changing Coolant A CAUTION To avoid personal injury e Do not remove the radiator cap while coolant is hot When cool slowly rotate cap to the first stop and allow sufficient time for excess pressure to esca
47. hands and body safely UES away when closing bed eNEVER operate the vehicle with the bed up Improperly loading a trailer and failure to use extra care when pulling trailer can cause an accident or injury Never load more than 110lbs 50kg tongue weight on the towing bracket Do not tow more than Select gear LON 1200lbs 544kg rolling weight trailer plus cargo Operate rough terrain and in low range gears only allow for increased braking distance sloped terra In and use extreme caution when operating on inclines Read carefully the loading information and trailer hitch sections in the owners manual 1 7 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 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 Jie Seria we o eww BE BE Pr econ Number Date of Purchase N MEE Name of Dealer o N R vn Ta N sms
48. height Rotate the tires 180 degrees and measure at the rear of the front tires 5 Front distance should be shorter than rear distance if not adjust tie rod length 1 Wheel to wheel distance at front FRONT Adjusting procedures 1 Loosen the lock nut and turn the tie rod to adjust the rod length until the proper toe in measurement is obtained 2 Retighten the lock nut IMPORTANT Keep the equal length of the left and right tie rod 11 10 PERIODIC SERVICE M Cleaning Muffler A CAUTION To avoid personal injury o Before touching any part of an exhaust system be absolutely sure that it has sufficient time to cool Always wear safety goggles and face mask e The particulate matter contained in the muffler contains chemicals that are harmful to people animals and marine life If you are unable to do this work have it done by your dealer e Cleaning spark arrester of muffler Maintenance amp cleanout procedure The screen type spark arrester should be removed cleaned and inspected after every 100 hours of use 1 The spark arrester is located inside of the exhaust pipe and fastened with six bolts 2 Loosen the bolts and remove the spark arrester 3 Shake loosened particles out of the screen assembly and lightly clean the screen with wire brush Soak in solvent and again clean with wire brush if necessary 4 If any breaks in the screen or welds are discovered the assemb
49. hen children are in the operating area Never carry children in the cargo area This is very dangerous to children Children under age of 5 should not be allowed in this vehicle Never allow children to touch or climb on the vehicle even if they are under adult supervision Always check for people or obstacles behind the vehicle before shifting the vehicle into reverse Avoid a collision with an obstacle or person Park the vehicle in a firm flat area If parking on a slope you should use the parking brake then remove the key SAFE OPERATION 4 Driving on a slope Be cautious when riding on a slope as this is the main reason for loss of control and overturn leading to severe injury or even death 1 Drive in a straight line on a slope at a low speed Reduce weight when riding on a slope or rough terrain Avoid the sudden application of the brakes when you go uphill or downhill Be more careful when vehicle turns on a slope If you start to lose momentum or need to park when climbing use the hand lever brakes to come to a stop Release the brake and begin to coast down the hill If do not believe you can operate the UTV safely in reverse do not attempt to ascend the slope any further Riding in mud a ditch and on slopes will increase the risk of an overturn Be more cautious when operating in 4WD vehicle traction will increase and it is easy to misjudge for vehicle s ability to climb a grade Drive gradua
50. iving on icy wet or loose surface 8 3 make sure the vehicle is correctly loaded to avoid skidding or loss of steering control Reduce the speed The brake pedal is the left pedal on the foot board Depress the pedal to slow or stop the vehicle 1 Brake pedal 4 Selecting the travel speed N Gear Shift Lever Ad caution To avoid personal injury e Avoid changing range gear shift lever when ascending or descending a slope o Before ascending or descending a slope shift to the L range to control the vehicle speed e Operate in reverse at slow speeds to maintain control 1 The gear shift lever can only be shifted when the vehicle is completely stopped and the brake pedal is pressed 2 To avoid transmission and shift linkage damage completely stop the vehicle using the brake pedal before shifting gears 3 Select depending on the type of job proper gear and engine speed Range gear shift lever L LOW Range H HIGH Range N NEUTRAL POSITION R REVEREE NOTE When gear shift lever is hard to engage do not force the lever Set the parking brake slightly depress the accelerator pedal and release it to neutral position then shift the lever When the lever is hard to disengage do not force the lever Depress the brake pedal fully then shift the lever An accident may occur if the brakes are applied suddenly while towing heavy loads The load can shift f
51. jury When the battery hydrogen and oxygen gases in the battery is being activated are extremely explosive Keep open sparks and flames away from the battery at all times especially when charging the battery PERIODIC SERVICE eo When disconnecting the cable from the battery start with the negative terminal first when connecting the cables to the battery start with the positive terminal first Always use a voltmeter to check a battery s charge 1 Battery 1 To slow charge the battery connect the battery positive terminal to the charger positive terminal and the negative to the negative Then recharge in the standard fashion 2 A boost charge is only for emergencies it will partially charge the battery as early as possible 3 When exchanging an old battery for a new one use battery of equal specification shown in table 1 Battery type 12V32Ah Direction for storage 1 When storing the vehicle for a long period remove the battery from level vehicle store in a dry place out of direct sunlight 2 The battery will self discharge while it is stored recharge it once every three months in hot seasons and once every six months in cold seasons N Adjusting toe in 1 Park vehicle on flat place 2 Turn steering wheel so front wheels are in the straight ahead position 3 Lock the park brake and stop the engine Measure distance between front tires center to center of tire at hub
52. lly and slowly when climbing Avoid suddenly changes of vehicle speed or direction 5 Driving in harsh conditions Vehicle can be operated during the day or under good light conditions Under passengers all conditions both operator and should wear helmet and protective equipment The Driver should slow down according to road conditions terrain visibility conditions Be cautious when driving over a ditch stone 1 3 roads or hidden obstacles Avoid operate in the unknown depth of waters water depth can not exceed axle Driving at high speed Check the condition of the front and rear wheels Be cautious when driving over a ditch stone roads or hidden obstacles Pay attention to the difference of braking performances between two and four wheel drive Slow down when turning Turning at high speeds may result in overturn or even death Turn on your headlights at high speeds Drive only when the vehicle speed can be controlled Do not use DIFF LOCK when driving at high speeds This may cause loss of control of the vehicle When driving at high speeds sudden turning of the steering wheel will reduce vehicle stability Never sharply turn the steering wheel at high speeds 7 Instructions for carrier Never carry a passenger in the cargo area Evenly distribute the cargo to maintain proper Stability Avoid overloading the carrier Cargo should be securely attached Reduce loaded weight when d
53. lt of closing function The main objective to research and develop EPS system is needed to ensure that the vehicle is still controlled by driver when malfunction happened Therefore we will not allow any directions clockwise or counterclockwise suddenly appear bigger undesirable steering torque Therefore the EPS system has many monitoring function used to identify the sensor actuator and the involvement of the EPS system function whether is malfunctioning All cannot continue to reliable accurate control motor malfunction will lead to the interruption of motor control ECU then closed function of EPS system Close the EPS systems bad results will also cause the driver can not obtain power steering But close measure is mainly used for preventing error control motor When fault occurs power steering disappear is a EPS characteristic Although the driver may feel the predetermined system response characteristics of some accidents but increases the control force can ensure the vehicle steering performance is not affected Neither the EPS steering system nor hydraulic power steering system when fault occurs power steering will disappear When a fault occurs the two systems reaction will be similar This fault occurs EPS system fault indicator light inside of meter will be lighten If above circumstances happened EPS 15 12 system will be no power steering and through the instrument to show the corresponding fault code
54. ly 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 e USDA approval requires clearance between spark arrester sleeve and exhaust pipe to be no larger than 0 023 0 584 mm eo Replace the entire muffler if it is damaged e Do not operate the vehicle with a damaged muffler 1 Muffler 4 Back cover 2 Spark arrester EVERY 200 HOURS E Changing Engine Oil A CAUTION To avoid personal injury Be sure to stop the engine before replacing oil Allow engine to cool down sufficiently oil can be hot and can burn 1 Park the vehicle on flat surface and raise the cargo bed 2 To drain the used oil remove the drain plug at the bottom of the engine and completely drain the oil into an oil pan 3 After draining reinstall the drain plug Fill with the new oil up to the upper notch on the dipstick See LUBRICANTS FUEL AND COOLANT in MAINTENANCE section Filter exchanged 1 8L 1 89U S ats Oil capacity Filter non exchanged 1 6L 1 68U S ats 11 11 PERIODIC SERVICE KO E Al AY os Or 1 y ca lig 4 T oa w ETNI p N 3 0177 SS Lay E IE om A AE a B ZI SGG gt va is da ST DS ESA a Ja Oil Level 6 Dipstick N Replacing Engine Oil Filter A CAUTION To a
55. meter alarm UTV can Per connector with poor contact sees Reinsert well replace electri attached figure 2 or in the wire connector or repair cables cable is disconnect ECU is damaged To dealers for repair Figure 1 Fuses box We ECU initialization connector s Peston ER We GER Le NG CAN 4 ECU dedicated fuse ECU initialization connector 2 Open the main switch only steering left or right is power assisted ese To dealers for repair sensor damaged sensor s Meter warning fault code F00001 or F00002 connector with bad contact or To dealer for repair ECU damaged 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 Steering system Retighten loose bolts Steering system mechanical parts mechanical parts has the Replace damaged spare become loose or damaged big gap parts Mechanical parts without ECU damaged or the ECU To dealers for repair gap software program has error 4 When running all have power assisted to turn left or right when return ability is slowly or during return processing out of nimbleness Meter warning fault cod The speed sensor damaged or Replace speed sensor F00011 from meter to ECU transmit speed Check and repair cables signal s guide wire broken circuits Replace connector or ECU connectors is loose
56. ngine e Replace throttle petal eo Replace he throttle connection Replace the primary clutch eo Put the gearshift rod into the position of N e Not good adjustment for e Put the gearshift arm of engine gearshift stay wire into N Adjust the stay wire and the bolt e Lock tightly Replace the gears e Big matching clearance for the Non agility for Gearshift inner and outside gears of Replace the gears transmission shaft Transmission noise e Big clearance of transmission o Replace the gears gears e Not good connection of gear eo Replace the gears end face eo Parking brake e Loosen the lay up rod r ing for di Not full Uncoupling for disc Contact the distributor brake Less vehicle power e Removing the grease for the clutch Replace CVT transmission belt Replace the clutch Less brake oil e Check the braking oil level e Air inside the braking system e Contact the distributor eo Brake discs abrasion Contact the distributor No good brake or noise e A li It of di g ren bolt of disc plate e Lock tightly 6 i lt f k ASS MDIRS bolt for disc brake e Lock tightly clippers loose If you have any questions consult your local dealer e CVT transmission sliding OPTIONS OPTIONS Consult your local dealer for further details Head rest Plastic Canopy Rear Trailer Hitch amp Pin 2 Windshield Steel Cab Motor Scan KF90121 EPS NOOR ODN N 14 1 ELE
57. o Replace filter electric fuel pump injector and ECU If necessary Engine is difficult to start or is tight and Engine revolution is slow depending on ambient temperatures eo Battery becomes weak and e Clean battery cables and terminals the engine does not turn over Charge the battery quick enough e in cold weather 15 0 always remove the battery from the vehicle charge and store it indoors install it on the vehicle only when the vehicle is going to be used Insufficient fuel e Check the fuel system The injector is clogged e Clean or replace the injector Crankshaft position sensor is Replace crankshaft position sensor Spoiled The air cleaner is clogged e Clean or replace the air cleaner Spark plug is dirty or spoiled Clean or replace the spark plug Ignition coil is spoiled Replace the ignition coil Check with the diagnostic Engine stops suddenly instrument Motor Scan KF90121 Fill cooling system to the correct level e Check radiator and hoses for loose connections or leaks Engine overheats e The motor driven fan does not Check to see if the fuse is not blown turn e Check the electric system 5 Dirty radiator core or grille reeds screens e Coolant flow route corroded Flush cooling system If you have any questions consult your local dealer 13 1 Engine power insufficient e Low coolant level TROUBLESHOOTING Check malf code meaning by reading the
58. of high temperature and at this time ECU can get through detection temperature sensors signal to issue ECU over heating failure warning s fault code to meter Meanwhile EPS system fault indicator light is lighten When ECU detected 1 steering torque sensor or 2 steering torque sensor had fault then it will indicate 1 steering torque sensor fault or 2 steering torque sensor fault code to dash board Meanwhile EPS system fault indicator light is lighten When ECU detected the storage batter s voltage is lower than 9VDC through sensor it will indicate the fault code of storage battery voltage low to dash board Meanwhile EPS system fault indicator light will be lighten When ECU detected motor is out of work through sensor it will indicate fault code of dynamic motor without power warning to dash board Meanwhile EPS system fault indicator light is lighten When ECU detected the speed sensor had fault it will indicate vehicle speed sensor fault code to dash board Meanwhile EPS system fault indicator light is lighten When ECU detected its own fault and can not be work normally it will indicate EUC stop working code to dash board Meanwhile EPS system fault indicator light is lighten N To drive UTV at every time need to do daily inspection of EPS system Before drive UTV at every time need to do daily inspection as following steps 1 Check steering system s mechanical part of each parts interval e Ch
59. orward causing loss of control The braking characteristics are different between two and four wheel drive Be aware of the differences and practice the differences at slower speeds first IMPORTANT 5 Release the parking brake and start slowly To release the parking brake depress the brake pedal Make sure that indicator in the Instrument Panel goes off 8 4 1 Parking brake M Accelerator Pedal The Accelerator pedal is used to increase the engine and vehicle speed Push down on it for higher speed Accelerator pedal STOPPING N STOPPING 1 Release the Accelerator pedal 2 Step on the brake pedal CHECK DURING DRIVING M Immediately Stop the Engine if The engine suddenly slows down or accelerates Unusual noises are suddenly heard Exhaust fumes suddenly become very white While driving check the following items to see if all parts are functioning normally 1 Coolant temperature gauge 2 Fuel gauge NW Fuel Gauge Park the vehicle on a flat place When the key switch is START the fuel gauge indicates the fuel level Be careful not to empty the fuel tank Otherwise air may enter the fuel system 1 Fuel gauge EM Coolant Temperature Gauge Ad caution To avoid personal injury e Do not remove radiator cap until coolant temperature is well below its boiling point Then loosen cap slightly to relieve 8 5 pressure before removing cap completely 1 Wi
60. pe before removing the cap completely 1 Stop the engine and let cool down 2 To drain the coolant open the radiator drain plug and remove radiator cap The radiator cap must be removed to completely drain the coolant 3 After all coolant is drained close the drain plug 4 Fill with clean water and cooling system cleaner Follow directions of the cleaner instruction After flushing fill with clean water and anti freeze until the coolant level is just below the radiator cap Install the radiator cap securely 7 Fill with fresh water up to the FULL mark on the recovery tank Start and operate the engine for few minutes Stop the engine and let cool 10 Check coolant level of recovery tank and coolant if necessary Coolant capacity 4 0L 4 2U S ats 2 FULL 1 Recovery tank 3 LOW IMPORTANT e Do not start engine without coolant Use clean fresh water and anti freeze to fill the radiator and recovery tank When the anti freeze is mixed with water the antifreeze mixing ratio must be less than 50 e Securely tighten radiator cap If the cap is loose or improperly fitted water may leak out and the engine could overheat N Anti Freeze AX caution To avoid personal injury eo When using antifreeze put on some 11 16 PERIODIC SERVICE protection such as rubber gloves Antifreeze contains poison e l you should drink anti
61. pter e This includes detailed disassembly and maintenance information chapter also User wants to repair by themselves must have qualified mechanical skills electronic maintenance skills and the special tools mentioned in the manual INTRODUCTION OF EPS SYSTEM M What is EPS system The EPS system Electric Power Steering System is a complete set of parts including a special ECU only for EPS system hereinafter referred to as ECU many sensors and actuators by signal such as monitoring UTV speed the operating force of the steering wheel as well as temperature of ECU and motor to provide an accurate power torque of the motor and aligning torque As a result it will have easy steering function and soft effect of steering wheel aligning N Typical parts of EPS system In general EPS system has the following parts e Steering torque sensor e Motor to generate power torque e EPS system control unit ECU e Speed sensor e Temperature sensor e Battery voltage sensor e Mechanical reduction transmission mechanism Reducer e Gear rack type steering gear e Steering rod joint e Ball stud of steering knuckle e Steering shaft and universal joint N Construction of EPS 1 Structure chart of EPS Steering wheel Reducer 8 Motor Steering transmission shaft 6 Universal joint 6 Tie rod joint Tie rod Steering knuckle 9 Steering gear 2 Steering Torque Sensor Install sensor on the red
62. r cap before coolant has cooled down When the coolant is cold open slowly and let the coolant pressure reduce and then open radiator cap Check for the coolant level in the coolant reservoir If necessary add coolant Tires should be mounted on rims with special equipment only by professionals Keep the specified tire pressure to ensure driving safety Elevate the vehicle and place a suitable stand under the frame when removing the wheels Be sure to re tighten the wheel nuts to the specified torque SAFE OPERATION 11 Warning and caution labels Operation takes more effort while the vehicle e Turn speed not to exceed 18 MPH 30 KPH SONE A 3 When in 4VVD LOCR operate at a slow speed e Do not drive in the water deeper than 400mm and allow extra time and distance for turns to avoid loss of control Chongqing Huansong Science And Technology Industrial Co Ltd This structure meets ROPS requirements for earth moving machinery under ISO 3471 EXHAUST FUMES MAY CAUSE HARM Engine exhaust from this product contains chemicals known in certain quantities to cause cancer birth defects or other reproductive harm Severe INJURY or DEATH can result if you ignore the following guidelines e Maximum load in cargo bed is350lbs 159kg e Never carry passengers in cargo bed Passengers can be thrown off causing serious injury or death Cargo can affect handling and stability Read Owner s Manual before loading or
63. r perform inspection items which are marked 4 in the chart below SERVICE INTERVALS IMPORTANT The jobs indicated by must be done after the first 50 hours of operation 1 Air cleaner should be cleaned more often in dusty conditions than in normal conditions 2 Every year or every 6 times of cleaning 3 Replace only if necessary 4 Consult your local dealer for this service n When the battery is used for less than 100 hours per year check the battery condition by reading the indicator annually The items listed below marked are registered as emission related critical parts by DEALER in the U S EPA non road emission regulation As the engine owner you are responsible for the performance of the required maintenance on the engine according to the below instruction Please see Warranty Statement in detail Indication of After 0 co zone oso ann es on as Jon are ro 700 wes Every 1 Engine oil Change 200 hrs Every 2 Engine oil filter Replace 200 hrs Transmission Every 3 Change fluid 400 hrs Engine start Every 4 Check system 50 hrs 5 G Appl ep reasin da 50 hrs Every Muffler Clean 100 hrs 10 1 MAINTENANCE Every 100 hrs Wheel bolt Every Check torque 100 hrs me Every Battery condition Check 100 hrs l l Every 10 Ton in Adjust 100 hrs Indication of After EIE on EI EE Every Check m Fuel filter 100 hrs element Every Pepco 100 hrs Every Check 500 hrs Fuel line
64. re operation checks as following Check seat belt for wear or damage if necessary replace it Check brakes throttle brake pedal and other mechanical parts for proper operation If you discover any irregularities replace related parts as necessary Periodically check the fittings and fasteners Check engine oil level and engine coolant level Check that the UTV is equipped to handle the surroundings Check and keep vehicle clean Sludge grease and debris can cause a fire and severe injury Passenger quantity and loading Only the driver and one passenger inside cab It is suggested that children under age of 5 not be allowed as a passenger Single row vehicle s loading limit is 660lbs 300KG Reduce the loading weight according to road conditions Never exceed the weight limits for operation Never allow unauthorized persons to repair this UTV This may affect vehicle performance and cause injury SAFE OPERATION N Operation 1 Start the engine only in an open ventilated area Carbon monoxide is colorless odorless and is emitted from the engine and can cause death in areas with poor ventilation 2 Never start the vehicle or operate the gear selector unless seated in the driver s seat 3 Never start the engine until the select lever is placed in N position and the brake is in the brake position 4 The driver and passenger shall always wear their seatbelt while the vehicle is being operated 5 Oper
65. 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 1 Jack 2 Rear frame tube DAILY CHECK For your own safety and maximum service life of the vehicle make a thorough daily inspection before operating the vehicle AX caution To avoid personal injury e Be sure to park the vehicle on a flat surface with the engine off and the parking brake ON PERIODIC SERVICE mM 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 N Checking and Refueling A CAUTION To avoid personal injury e Do not smoke while refueling e Be sure to stop the engine before refueling 1 Turn the key switch to ON check the amount of fuel by fuel gauge 2 Fill fuel tank when fuel gauge shows1 4 or less fuel in tank 1 Fuel tank cap Fuel tank capacity IMPORTANT If oil level is low do not run engine 28L 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 it out again check to see if the level id too low add new oil to the prescribed level at the oil inlet f h DR y 7 I 2 RR Ber SI LORNE PERS gt DER FEN DU add SEN e SN ela BSE SEN
66. riving on poor road conditions or on steep inclines Do not put your hands or your body under the carrier when the carrier is up Avoid driving before securing and locking the cargo bed SAFE OPERATION 8 Parking 1 To release the parking brake depress the brake pedal 1 Parking brake 9 Transportation Avoid dragging the vehicle behind another vehicle Use a trailer or truck to transport the vehicle When loading or unloading pay attention to your surroundings and others in the area Maintenance Stop the vehicle and park it on level ground Pull the parking brake and remove all cargo Place the shift lever in the N position stop the engine and remove the key 1 When working next to the engine exhaust or radiator work only after it has cooled down Wait for the engine to stop running and cool down before checking the coolant level Otherwise you could be burned by hot fluid or steam No smoking when adding electrolyte or refueling The fuel tank and battery should be kept away from sparks The battery produces 1 4 hydrogen and oxygen during charging and this could accelerate the risk of explosion Read and follow the instructions before replacing the battery During maintenance first aid kits and fire extinguishers should be placed at your fingertips During maintenance you should disconnect the battery cables 1 Battery T 10 Do not open the radiato
67. rr err eer eee ee eee ee Range Gear Shift Lever POTrrrrrrrerrrrerrrerrrrrrrrerrrrrrrrerrrrr rrr rrr rrr rrr rrr rrr rrr rrr OOG OE ede AND EVER ae een Speed Control Pedal reses ee ER ER RE RE EE EE EER ER RE Ee EE EER EER EER ee Re ee PEER re STOPPING TIOTTCTTTTTrrrerrerrerrerrerrrrrrrrrrrrrrrrrrrrerr rrr rrr Oe rrr rrr rrr rrr rrr errr rr rrr errr 000 STOPPING corro rro rro ETE EE TT TT rrr rrr rrr rrr rrr rrr rrr rrr rrr rrr rrr rrr rrr errr rrr rrr er re CHECK DURING DRIVING Tee Torre eee Tee ee ee Te Tee ee ee Te ee E cus ee EI Pee een Immediately Stop the Engine ee Fuel Gauge EE TE ET A ET OO OT TOE EE ET OE ERTS TES Coolant Temperature Gauge PRERE ERE CCE EERE CCRT Salsa CERT CR CREE Te EK WINCH MOUNT PLATE ae ran WINCH MOUNT PLATE DISEASES AAA ER EE OR EE OE OE OE N EE OE SERVICE INTERVALS RE ES EE EE OE RS RE EEE TE SEER T T PERIODIC SERVICE a Se oe Dee Ge ed RS HOW TO OPEN THE FRONT HOOD AND SEAT sesse ees sesses see ese ese ses see see ee Front Hood cover A AAA elena GE led AA ANA AA ef oe AT AR ees HOW TO RAISE TEE CARGO BED ea Ede es Se oes ee Ge Ge a pe eed Raising and Lowering the Cargo Bed esse EE ER EE EE EE EE EE Ge EE ee Ee ee Ee DAILY CHECK DEE ero Ge OE OE Er Walk Around Inspection stress ee ER EE EE EE ER EE EER EE GER EE Ge Ee Gee Ee ee ee ee ees Checking and Refueling esse ee EE EE EE ER EE EER EE EER EE Ge EE ee Ee ee ee nenn Checking Coolant Level sterre sees EE EER EE EER EE EE EE ER EE Ge EE
68. rrrrrrerrerrerrerrrrrerrerr rrr rrr rrr rrr rrr rrr err rrr err er 11 11 EVERY 200 HOURS TOET IS ETE TE ET ETE ET EET OT cas ces ces ces TO rrr TOT ES 11 11 Changing Engine Oil TIPeTerTerrerrerrerrerrrrerrrerrrrerrrrrerrrrrrrrr rrr rrr rrr err err err err err ere 11 11 Replacing Engine Oil Filter er AAA ee ee ee NE 11 12 Replacing Transmission Oil PIPPTPrrerrerrerrerrerrerrrrrrrrrrrrrrrrr rrr rrr err rrr rrr err err eer ere 11 12 Checking Brake Pedal Prerrrrrrrrrrrrrrrrrrrrrrr rrr rrr rrr rrr rrr rrr rrr rrr rrr rrr rrr reer rr ese 11 13 Checking Brake Hose and Pipe von sn sn rrr rrr err rrr rrr err rrr rrr err rrr ere eee ET eee ee ee ee ee 11 13 Checking Brake Light Switch een 11 13 Checking Radiator Hose and Clamp TEE EET ETE ET rrr nn ES 11 13 Checking Intake Air Line POOTTerrTerrerrerrerrerrerrerrerrrrrrrrrrrrrrrrr rrr rrr rrr rrr rrr errr eee 11 14 EVERY 300 HOURS EE ARA CEC ER SOOO CEE EES 11 14 Checking Tire TT ES EE OE EE AAA 11 14 EVERY 400 HOURS ETE TEE IS EET rrr rrr rrr rrr rrr err rr rr rr rr ET ET OE ET ET EE er irr 11 15 Changing Transmission Fluid corro rro rrr rrr rrr rrr rrr rrr rrr rrr rrr rrr rrr rrr rrr rrr rrr rere rere ee 11 15 Changing Front and Rear Axle Case Oil PIOVErrrrrrerrerrerrerrerrrrrrrrrrrrrrrrr rrr rrr rere ee 11 15 EVERY 500 HOURS ETE TEST IS EET TE ET ET ET rrr rrr err rrr errr rrr ET ET OE ET ET sssso 11 15 Replacing Fuel Filter err ee ee Tee eT ee ee CE EE EE TE EO cens ee 11 15 EVERY 600 HOURS sssssssssssss
69. ry of start motor the impact of road barriers on steering wheel can be greatly decreased No pollution to environment For the traditional hydraulic power steering system the hydraulic circuit has hydraulic hose and fittings inside so oil leaks may occur and hydraulic hose is not recycled so this is produce pollution to environment However EPS system has not pollution to environment When engine does not start EPS system can also work as battery and once sufficient power generate steering power can be workable IMPORTANT INFORMATION FOR SAFETY UTV you buy is equipped with EPS system please read this chapter carefully before operating UTV and only you are familiar with and master enough of EPS system about using methods and precautions information can you start to drive your UTV Make inspection and maintenance on EPS system on regular and ensure the security and reliability when you use your UTV O Please carefully read this chapter before operation or driving to acknowledge completely about correct way to operate and drive the UTV with EPS system and also characteristics functions and limits of UTV Doing inspection and maintenance on EPS system on regular correct operation and driving skills will ensure the security and reliability of UTV ELECTRIC POWER STEERING SYSTEM e To make sure your EPS system will be useful for a long time and no problem please follow the method for maintenance in this cha
70. s applied and goes off when it IS released e Read the danger warning and caution labels located on the vehicle e To avoid the danger of exhaust fume poisoning do not operate the engine in closed buildings without proper ventilation e Start engine only from operator s seat Never start engine while standing on ground D Parking brake warning lamp e Make it a rule to set gear shift lever to NEUTRAL position before starting the 2 Set gear shift lever to the NEUTRAL position engine IMPORTANT e Do not use starting fluid or ether e To protect the battery and the starter make sure that the starter is not continuously turned for more than 10 seconds STARTING THE ENGINE 1 Make sure the parking brake is set 1 Range gear shift lever L Low Range H High Range Low Range Ls N Neutral position R REVERSE 3 Push the speed control pedal down about 1 2 way 1 Parking brake OPERATING THE VEHICLE 1 Accelerator pedal gt INCREASE gt DECREASE 4 Push the accelerator pedal down about 1 2 way AW ttn di P ew DRS Insert the key into the key switch and turn it START 1 OFF Engines stop ON Engine run or headlight on START Engine start IMPORTANT Relying on the engine warning lights is never enough Never fail to conduct daily checks carefully by referring to Pre Operation Check in PERIODIC SERV
71. se s sesse sesse see ese see EER ses ER EER EER RE EER RE PRE see RE EER EER RE EER EER see EER EER aes STORAGE sesse ese ernennen ses see see see oe nennen nen cesses REMOVING THE VEHICLE FROM STORAGE ss ssssssesssss nn nennen nenne ese ese ee TROUBLESHOOTING ss sesse ses cnn ses ses see see see see see con esses ees esses nes nn sn nn ees se ENGINE TROUBLESHOOTING sesse ssessssssse see see see see see see see see see see ees ees ees ee Check malf code meaning by reading the below table sr EE settee EER EE ees BATTERY TROUBLESHOOTING Seren MACHINE TROUBLESHOOTING ERRE RARA RAR ER OPTIONS cor rro rro TEE ETES rrr rrr rrr rrr rrr rr rrr oo ET roo TOT OT rr rr TE rr ET ces ET IT Tee Hisun Motors Corp U S A Emission Control System Warranty Statement YOUR WARRANTY RIGHTS AND OBLIGATIONS The U S Environmental Protection Agency and Hisun Motors Corp U S A hereinafter HISUN are pleased to explain the emission control system warranty on your Off Road vehicle New off road motor vehicles must be designed built and equipped to meet U S EPA Federal and California anti smog 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
72. speed 10round min 15round min Motor assy basic parameters Type DC permanent magnet control motor Rated working time 3 min per time Rated power 1 70W nominal value Rated operational voltage 12V DC Rated motor revolving speed 1050r 300r min Rated operational current 30A 3A Rated output torque 1 6N m40 16N m 15 13 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 or Bl ly HEF Safety Alert Symbol Fuel Engine coolant Temperature Parking Brake Battery Charging Condition Engine Oil Pressure Turn Signal Hazard Differential Lock Position light bulb della Lift Cylinder Retract O IO ddiN Lift Cylinder Extend g QTPo ddim Lift Cylinder Float O IO Hazard Warning Lights Master Lighting Switch be Audible Warning Device Ol Fault indicator light of EPS system 2WD AND CONTENTS AASAFETY OPERATION ee see ens cee cee cee cee ses cee ARE HER ARE ces EE SEE ces cesses ces ee see ese see ees see 1 1 SERVICING OF VEHICLE esse ccc sssessessees see see see see see ees ees ees ees see see see see ees ees ees D SPECIFICATIONS corro rr orcos EET err rrr err rrr rrr rrr errr rr rrr err rrr rrr err rrr rrr err ere eee eee ee eee ee ee 3 1 SPECIFICATION TABLE cecccsccsccscescccccccccccccccccc ccc see cesses cesses cesses nn nenn
73. ter the antifreeze mixing ratio must be less than 50 Freezing point Boiling point VOL At 1 013x10 Pa 760mmHg pressure atmospheric A higher boiling point is obtained by using a radiator pressure cap which permits the development of pressure within the cooling system 5 Adding the LLC 1 Add only water if the mixture reduces in amount by evaporation 2 If there is a mixture leak add the LLC of the same manufacturer and type in the same mixture percentage Never add any long life coolant of different manufacturer Different brands may have different additive components and the engine may fail to perform as specified 6 When the LLC is mixed do not employ any radiator cleaning agent The LLC contains anticorrosive agent If mixed with the cleaning agent sludge may build up adversely affecting the engine parts 7 The vehicles genuine long life coolant has a service life of 2 years Be sure to change the coolant every 2 years NOTE The above data represent industry standards that require a minimum glycol content in the concentrated antifreeze o When evaporation add water only to keep the the coolant level drops due to 11 17 PERIODIC SERVICE antifreeze mixing ratio less than 50 In case of leakage add antifreeze and water in the specified mixing ratio before filling into the radiator N Replacing Radiator Hose Water pipes Replace the hoses and clamps See Checking R
74. th the key switch ON the temperature gauge indicates the temperature of the coolant White Zone for cold and Red zone for hof 2 If the indicator reaches the Red zone engine coolant is overheated Check the vehicle by referring to TROUBLESHOOTING section 1 Coolant temperature gauge The hour meter indicates in five digits the hours the vehicle has been used the last digit indicates 1 10 of an hour ODO HOURS mile km 1 Hour meter The speedometer indicates the traveling speed 1 Speedometer 8 6 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 N Transporting Vehicle Pay attention to the following points when transporting the vehicle 1 Use a suitable truck or trailer Apply the parking brake and place chocks against the front and rear tires 2 Tie the vehicle to the sides of the trailer or truck using suitable tie downs 9 1 MAINTENANCE MAINTENANCE AND ADJUSTMENT A CAUTION To avoid personal injury and vehicle damage e Be sure you have sufficient knowledge experience the proper replacement parts and tools before you attempt any vehicle maintenance task e If you don t have the knowledge and equipment which are necessary to perform the maintenance task consult your local dealer eo Have your local deale
75. ty Filter exchanged 1L 1 05U S ats 11 12 PERIODIC SERVICE EN CA f er a N TE A LS D SA IT TT ETS exp W Ci q J S AA E 4 AoW Vi UNG aA P i ak u NE N N 7 e S LIS Ned es BRS SON MT 4 Q NA MES fs En a gt Bie 7 AR SL gt Dr x 4 de N Oil Level 0 Dipstick EM Checking Brake Pedal A CAUTION Stop the engine and chock the wheels before checking brake pedal If movement is outside of the specifications contact your local dealer for adjusting the brake Checking the brake pedal free travel 7 to 14mm 0 3 to in On the pedal Proper brake pedal free travel Release the parking brake 2 Slightly depress the brake pedal and measure free travel at the top of the pedal stroke 3 If brake pedal free travel is outside of the specifications contact your local dealer for adjusting the brake Checking the brake pedal stroke Less than 120mm 4 7in Pedal stroke On the pedal 3 If brake pedal specifications contact your local dealer for stroke is outside of the 1 Brake pedal 2 FREE TRAVEL N Checking Brake Hose and Pipe 3 PEDAL STROKE 1 Check to see that brake hoses and lines are not swollen hardened or cracked Check the brake hoses and fittings for oil leaks lf there is any abnormality consult your local dealer for this service N Checking Brake Light Switch 1 Park the vehicle on a flat surface and r
76. ucer D Sensor No change after the sensor fixed Sensor assembly position is certained and can not make any change if found sensor postion was changed caused by bolt looseness please tighten the bolt and initialize the ECU at once See Page12 12 3 ECU ECU is sophisticated electronic equipment and 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 lf any problem happens on ECU please contact e P1 positive pole pole for EPS motor your local dealer to repair it e P2 negative pole pole for EPS motor e P3 connect with cable of UTV and transfer single that ECU required e P4 connect with steering torque sensor supply power to steering torque sensor and accept single of torque e P5 connect with motor Upper housing 2 ECU unit 3 Seal ring 4 Lower housing Installation position of ECU and reducer 4 Reducer Install reducer on the frame of UTV Install motor and steering torque sensor on reducer Outside view of reducer 2 Reducer The installation location of the ECU will be greatly effected by temperature changes and external humidity Housing has a membrane made of Goretex material for pressure balance between inside the shell and the surrounding environment but also to prevent the parts from moisture intrusion 5
77. urs Drive at a slower speed and avoid excessive work or operation until the various parts become broken in How you break in the vehicle greatly affects the life of your vehicle Therefore to obtain the maximum performance and the longest life of the vehicle it is very important to properly break in your vehicle For better handling of a new vehicle the following precautions should be observed N Do not operate the vehicle at full speed for the first 50 hours Do not start quickly nor apply the brakes suddenly e In winter operate the vehicle after fully warming up the engine Do not run the engine at speeds faster than prescribed e On rough roads slow down to suitable speeds Do not operate the vehicle at fast soeed The above precautions are not limited to new vehicles but to all vehicles It should be especially observed for new vehicles 8 1 N Changing Lubricating Oil for New Vehicles The lubricating oil is especially important for a new vehicle Various parts are not broken in and are not accustomed to each other Small pieces of metal grit may develop during the operation of the vehicle and this may wear out or damage the parts Therefore take care to change the lubricating oil a little earlier than would ordinarily be required For further details of change interval hours see MAINTENANCE section STARTING 1 Fasten the seat belt E Seat Belt ANWARNING To avoid person
78. ust repair damaged spare parts the ECU To dealers for repair Or 7 Open main switch steering to the same direction automatically Fault phenomenon Fault point To dealers for repair r No meter alarm The initialization parameter of ECU Restart initialization for Sensor no loosening has error ECU and flap the wheels for several times N Maintenance and repair s supplemental description Restart initialization to ECU parameter Park UTV on the flat ground and keep the front wheels to be forward always e Pull out initialization selects connector See Page 12 9 Push UTV back and forth for several times 15 11 e Open the main switch and wait for 5 seconds eo Reinsert pin connector to finish the ECU parameter initialization process Then open the main switch check whether the fault is removed If it is not removed follow the previous steps of initialization process Because the different mechanical clearance of UTV it may require 3 5 times to be repeated in order to get the correct initialization parameters ELECTRIC POWER STEERING SYSTEM lf a customer complaint vehicle deviation it should take into account the fault causes not only includes the EPS system fault also includes a chassis mechanical failure customers may use Deviation to describe a specific situation So four wheel alignment need to be adjusted at first time then ECU replacement and repair needed 2 The Fau
79. ving at High speed Instructions for Carrier Parking Transportation Maintenance Warning and Caution Labels Servicing of Vehicle Specifications Traveling Speeds Vehicle Limitations Part Locations Pre Operation Check Starting the engine Stopping the engine Operating the vehicle Lights Checking the brake pedal Selecting a gear Stopping Fuel gauge Coolant Temperature Gauge Speedometer Winch Mount Plate Transporting the vehicle Maintenance Intervals Periodic Service Front Hood cover Operator s seat Raise the Cargo bed Jack Positions Checking and refueling Checking the Oil level Checking the coolant level Cleaning the radiator screen Checking the Brake Fluid level Checking the brake pedal Subject Checking the parking brake Checking the tire Inflation 50 Hour Check Checking the engine start system Testing the gear shift lever safety switch Wheel Lug nut torque Cleaning the air filter Checking the Battery Directions for storage Adjusting the Toe In Cleaning the Muffler 200 Hour Changing Engine oil Changing engine oil filter Checking the brake pedal Precautions at overheating 300 hour 400 hour Flushing cooling system Light Bulbs Replacing Mini blade fuses Storage Removing the vehicle from storage Engine Troubleshooting Trouble Codes Battery Troubleshooting Vehicle Troubleshooting Options Electric Power Steering System EPS Trouble Codes Universal Symbols Introduction HS 50
80. void personal injury e Be sure to stop the engine before changing the oil filter cartridge Allow engine to cool down sufficiently oil can be hot and can burn 1 Park the vehicle on a flat surface remove the seat and open the adjustment hatch cover 2 Remove the oil filter 3 Put a film of clean engine oil on the rubber seal of the new filter 4 Tighten the filter quickly until it contacts the mounting surface Tighten filter by hand an additional 1 2 turn only 5 After the new filter has been replaced 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 1 Bolt 2 Cover 3 O seal ring 4 Engine oil filter IMPORANT To prevent serious damage to the engine use only a genuine filter N Replacing Transmission Oil A CAUTION To avoid personal injury e Be sure to stop the engine before changing oil Allow engine to cool down sufficiently oil can be hot and can burn 1 Park the vehicle on a flat surface raise the cargo bed and mount the safety support Put a film of clean transmission oll Quickly tighten the filter until it contacts the mounting surface tighten it an additional 1 turn only 4 After running the engine for a few minutes stop the engine and check the oil level again Add oil to the prescribed level Oil capaci

HS 500/700 - Hisun Motors Corp, USA

Contents

Download Pdf Manuals

Related Search

Related Contents