The service manual for the Hisun HS400 UTV is published by Chongqing Huansong Industries (Group) Co., Ltd and Hisun Motors Corp USA. It provides methods for checking, maintaining, and repairing the vehicle. You can find it on the UTV Board website at:
[https://www.utvboard.com/files/file/12-hisun-hs400-service-manual/](https://www.utvboard.com/files/file/12-hisun-hs400-service-manual/)

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John

April 7, 2025

Trying to remove bolt item 20 on page 103 ( camshaft timing sprocket bolt). Service manual shows bolt to be torqued at 20Nm, I have been unable to loosen this bolt, Is the bolt LH thread? What is the trick to loosen this bolt?

Summary of Contents for Hisun HS400

Page 1 Forth version , May, 2014 Published by Chongqing Huansong Industries (Group) Co., Ltd and Hisun Motors Corp USA. Chongqing Huansong Industries (Group) Co., Ltd and Hisun Motors Corp USA holds the copy right. No publishing and reprinting without permission READ THIS...
Page 2 Foreword Brief introduction to maintenance handbook of HS400UTV The handbook is edited by Technical Center of Chongqing Huansong Industries (Group) Co., Ltd., and is supplied to dealers and technicians as a document of technique. This manual gives methods to check, maintain and repair utility terrain vehicles (UTV’s), and supplies some relevant techniques and performance data.
Page 3: Wiring Diagrams
INDEX Index Chapter 1 General Chapter 2 Chapter 3 Specifications Periodic Maintenance and Adjustments Chapter 4 Chapter 5 Engine Chassis Chapter 6 Chapter 7 Electrical Engine Management System Chapter 8 Wiring Troubleshooting Diagrams...
Page 4 INDEX...
Page 5: Table Of Contents
INDEX Chapter 1 General Idle Adjustment Spark Plug, Compression test Warnings, Cautions, Notes Engine Oil Description Air filter 3-10 Identification Code, Frame Coolant level 3-11 Number, Engine Number V-Belt 3-15 Safety Spark arrester 3-16 Handling Gasoline safely Brake Pedal 3-16 Cleaning Parts, Warning Labels, Brake Pads 3-18...
Page 6 INDEX Chapter 5 Chassis Signal System Circuit Diagram, 6-27 troubleshoot Front Bumper and Hood Cooling System Circuit Diagram, 6-34 Panels and Footrest cover troubleshoot Seat Support and seat cushion 2WD/4WD Selecting System 6-37 Roll-over Protection System Circuit Diagram, troubleshoot Cargo Bed Steering System Chapter 7 EMS (Engine Brake System...
Page 7 General Warnings, Cautions, Notes Basic Tools 1-13 Description Wrenches 1-14 Identification Code, Frame Torque Wrenches 1-17 Number, Engine Number Ignition Grounding Tool 1-19 Safety Precision Measuring Tools 1-20 Handling Gasoline safely Micrometers 1-21 Cleaning Parts, Warning Labels, Serial Numbers, Fasteners Cylinder Bore Gauge, 1-26 Compression Gauge...
Page 8 General...
Page 9: Warnings, Cautions, Notes
General General Information The text provides complete information on maintenance, tune-up repair and overhaul, Hundreds of photographs and illustrations created, during the complete disassembly of four wheel all-terrain vehicles (UTV), guide the reader through every job. All procedures are in step-by-step format and designed for the reader who may be working on the UTV for the first time.
Page 10: Description
General Description 1. Headlights 2. Front shock absorber assembly 3. Brake fluid reservoir 4. Driver seat 5. Battery 6. Fuses 7. Left body protection plate 8. Driver seat belt 9. Air filter element 10. Cargo bed 11. Tail/brake lights 12. Spark arrester 13.
Page 11: Identification Code, Frame
General Identification Code Frame No. Frame No. is carved on the right side of front main frame. Engine No. Engine NO. Is carved on the right side of the engine.
Page 12: Safety
General 7. When loosening a tight fastener, Safety be guided by what would happen if the tool slips. Professional mechanics can work for years and never sustain a serious injury or mishap. Follow these guidelines and 8. When replacing fasteners, make practice common sense to safely service sure the new fasteners are the the utility terrain vehicles.
Page 13: Handling Gasoline Safely
General 15. When using compressed air to 2. When working of the fuel system, dry rotating parts, hold the part work outside or in a well-ventilated so it does not rotate. Do not allow area. the force of the air to spin the part.
Page 14: Serial Numbers, Fasteners
General 10. Use a nylon brush when cleaning Cleaning Parts parts. Metal brushes may cause a spark. Cleaning parts is one of the more tedious and difficult service jobs performed in the 11. When using a parts washer, only use home garage.
Page 15: Self Locking Fasteners, Cotter
General Warning: Washers Do not install fasteners with a strength classification lower than what was The two basic types of washers are flat originally installed by the manufacturer washers and lock washers. Flat washers doing so may cause equipment failure are simple discs with a hole to fit a screw or and or damage.
Page 16: Snap Rings And E-Clips
General Because both faces have sharp edges. Snap Rings and E-clips Stamped snap rings (Figure3) are manufactured with a sharp and a round Snap rings (Figure 1) are circular-shaped edge. When installing a stamped snap ring metal retaining clips. in a thrust application, install the sharp edge facing away from the part producing the thrust.
Page 17: Shop Supplies
General Note: SHOP SIPPLIES Refer to Engine Oil and Filter in Chapter Three for further information on API, Lubricants and Fluids SAE classifications. Periodic lubrication helps ensure a long Always use an oil with a classification service life for any type of equipment. recommended by the manufacturer, Using Using the correct type of lubricant is as an oil with a different classification can...
Page 18 General Current designations for brake fluid are Cleaners, Degreasers and DOT 3, DOT 4 and DOT 5, this Solvents classification appears on the fluid container. Each type of brake fluid has Many chemicals are available to remove oil, its own definite characteristics. Do not grease and other residue from the UTV.
Page 19: Basic Tools
General Some of the procedures in this manual Thread locking Compound specify special tools. In many cases the tool is illustrated in use. Those with a large A thread locking compound is a fluid tool kit may be able to perform procedures. applied to the threads of fasteners.
Page 20: Wrenches
General Poor quality or damaged Phillips Wrenches screwdrivers can back out (cam out) and round over the screw head. In Open-end, box-end and combination addition. Weak or soft screw materials wrenches (figure 5) are available in a can make removal difficult. The best variety of types and sizes.
Page 21 General Adjustable Wrenches An adjustable wrench or Crescent wrench (Figure 6) can fit nearly any nut or bolt head that has clear access around its entire perimeter. An adjustable wrench is best used as a backup wrench to keep a large nut or bolt from turning while the other end is being loosened or tightened with a box- end or socket wrench.
Page 22 General Impact drivers and interchangeable bits (Figure 10) are available from most tool suppliers. When using a socket with an impact driver. Make sure the socket is designed for impact use. Warning: Do not use hand sockets with air or impact tools because they may shatter and cause injury.
Page 23: Torque Wrenches
General Torque Wrenches Use a torque wrench with a socket, torque adapter or similar extension to tighten a fastener to a measured torque. Torque wrenches come in several drive sizes (1/4, 3/8, 1/2 and 3/4) and have various methods of reading the torque value.
Page 24 General TW = TA×L Diagonal cutting pliers are needed to cut wire and can be used to remove cotter pins. Use needle nose pliers to hold or bend small TW is the torque setting or dial reading objects. on the wrench. TA is the torque specification and the actual amount of torque that is applied to the fastener.
Page 25: Ignition Grounding Tool
General Use soft-faced hammers when a metal object Snap Ring Pliers must be/struck without damaging it. Never use a metal-faced hammer on engine and Snap ring pliers are specialized pliers suspension components because damage with tips that fit into the ends of snap occurs in most cases.
Page 26: Precision Measuring Tools
General PRECISION MEASURING Feeler Gauge TOOLS The ability to accurately measure Use feeler or thickness gauges (Figure19) for components is essential to perform measuring the distance between two many of the procedures described in this surfaces. manual. Equipment is manufactured to close tolerances, and obtaining consistently accurate measurements is essential to determine which...
Page 27: Micrometers
General Although not as precise as a fixed scale. In this example, the number is 10 micrometer, they allow reasonable mm. To determine the next number, note precision, typically to within 0.05 mm which of the lines on the movable scale align (0.001 in.).
Page 28 General Micrometers that cover a wider range of 3. To check a micrometer larger than 1 measurements are available. These use in. or 25mm use the standard gauge a large frame with interchangeable Supplied by the manufacturer. A anvils of various lengths. This type of standard gauge is a steel block, disc or micrometer offers a cost savings, but its rod that is machined to an exact size.
Page 29 General When reading a metric micrometer, add the Metric micrometer number of millimeters and half-millimeters on the sleeve line to the number of one one The standard metric micrometer (Figure hundredth millimeters on the thimble. Perform 24) is accurate to one one-hundredth of the following steps while referring to Figure a millimeter (0.01mm).
Page 30 General Standard Inch Micrometer 1. Read the sleeve and find the largest number visible. Each sleeve number The standard inch micrometer (Figure equals 0.100 in. 26) is accurate to one-thousandth of an inch or 2. Count the number of lines between 0.001.
Page 31 General To use a telescoping gauge, select the Dial Indicator: correct size gauge for the bore. Compress the movable post and. A dial indicator (Figure 31) is a gauge with a Carefully insert the gauge into the bore. dial face and needle used to measure Carefully move the gauge in the bore to variations in dimensions and movements.
Page 32: Cylinder Bore Gauge
General The gauge adapter is either inserted Cylinder Bore Gauge or screwed into the spark plug hole to obtain the reading. Disable the engine so it does not A cylinder bore gauge is similar to a dial start and hold the throttle in the wide-open indicator.
Page 33: Electrical System
General An ohmmeter, although useful, is not ELECTRICAL SYSTEM always a good indicator of a circuit’s actual FUNDAMENTALS ability under operating conditions. This is because of the low voltage (6-9 volts) the A thorough study of the many types of meter uses to test the circuit.
Page 34: Basic Service Methods
General 7. When a part is a press fit or BASIC SERVICE METHODS requires a special tool to remove, the information or type of tool is Most of the procedures in this manual are identified in the text. Otherwise, if a straight forward and can be performed by part is difficult to remove or install, anyone reasonably competent with tools.
Page 35 General 13. Repairs are much faster and easier 19. If using self-locking fasteners, if the UTV is clean before starting replace them with new ones. Do not work. Degrease the UTV with a install standard fasteners in place of commercial degreaser; follow the self-locking ones.
Page 36 General Removing Broken Fasteners Repairing Damaged Threads If the head breaks off a screw or bolt, Occasionally, threads are stripped through several methods are available for carelessness or impact damage. Often the removing the remaining portion. If a large threads can be repaired by using a tap (for portion of the remainder projects out, try internal threads on nuts) or a die (for gripping it with locking pliers.
Page 37 General If one is not available, thread two nuts onto Removing Hoses the stud and tighten them against each other. Remove the stud by turning the When removing stubborn hoses, do not lower nut (Figure 39). exert excessive force on the hose or fitting. Remove the hose, do not exert excessive force on the hose or fitting.
Page 38 General Note the following when removing 3. The ideal method of bearing bearings: removal is with a hydraulic press. Note the following when using a 1. When using a puller to remove a press: bearing from a shaft, take care that the shaft is not damaged.
Page 39 General Figure 45 Shows the correct way to use a Installation driver and hammer to install a bearing. 1. When installing a bearing in a housing, apply pressure to the outer bearing race (Figure 43). 3. Step 1 describes how to install a bearing in a case half or over a shaft, However, when installing a When installing a bearing on a...
Page 40 General Interference fit • As the bearing chills, it will tighten on the shaft, so install it quickly. Make sure the 1. Follow this procedure when bearing is installed installing a bearing over a shaft. completely. When a tight fit is required, the bearing inside diameter is smaller 2.
Page 41 General Improperly removing a seal can damage • Hold the housing with the bearing the housing or shaft. Improperly installing side down and tap the bearing out. the seal can damage the seat. Repeat for all bearings in the Note the following: housing.
Page 42: Storage
General STORAGE Preparing the UTV for Storage Several months of non-use can cause a The amount of preparation a UTV should general deterioration of the UTV. This is undergo before storage depends on the especially true in areas of extreme expected length of non-use, storage area temperature variations.
Page 43 General 7. Apply a protective substance to the 5. Make sure the brakes, clutch, plastic and rubber components. throttle and engine stop switch work Make sure to follow the properly before operating the UTV. manufacturer’s instructions for each Evaluate the service intervals to type of product being used.
Page 44: Specifications
Specifications Conversion table Engine Torque Specs 2-16 General Specs Chassis Torque Specs 2-19 Engine Specs General Torque Specs 2-21 Chassis Specs 2-11 Engine Lubrication Points and 2-22 type of lubricant Electrical Specs 2-14 Chassis Lubrication Points and 2-23 types of lubricant...
Page 45 Specifications...
Page 46: Conversion Table
Specifications （1）How to use conversion table All the specified documents in this manual are taken SI and Metric measurements. With the following conversion table, metric units can be converted into standard units. Sample: METRIC MULTIPLY STANDARD 0.03937 × 0.03937 0.08in Conversion table （2）Definition of unit...
Page 47: General Specs
Specifications General Specifications Item Standard Dimensions Overall length 2,680mm (105.5in) Overall width 1,320mm (52.0 in) Overall height 1,870mm (73.6in) Seat height 840mm (33.1in) Wheelbase 1,830mm (720in) Minimum ground clearance 300mm (11.8 in) Minimum turning radius 3,500mm (137.8 in) Basic Weight With oil and full fuel tank 548kg (1,208 lb)
Page 48 Specifications Item Standard Air Filter Wet type element Fuel Type Unleaded gasoline only Fuel tank capacity (5.72 lmp gal, 6.86 US gal) Carburetor Type/quantity PD36J-C / 1 Wet ,centrifugal automatic Clutch type Transmission Primary reduction system V-belt Secondary reduction system Shaft drive Transmission type V-belt automatic...
Page 49: Engine Specs
Specifications Electrical Ignition system C.D.I. (ECU) Generator system A.C. magneto Battery type U1-32 Battery capacity 12 V, 32.0Ah Headlight type Bulb wattage × quantity 12V， 35W/35V × Headlight 12V， × Front Position Light 12V， × turning light 12V， License light 12V，...
Page 50 Specifications Item Metric Standard Service Wear Limit Camshaft Drive method Cam dimensions Intake “A” 40.88 mm (1.6094in) “B” 32.30 mm (1.2717in) Exhaust “A” 40.95 mm (1.6122in) “B” 32.30 mm (1.2717in） Camshaft run out limit Cam chain No. of links 92RH2010J/126M Cam chain adjustment method Automatic...
Page 51 Specifications Valve Dimensions Head Diameter Face Width Seat Width Margin Thickness Item Metric Standard “A” head diameter 39.90 - 40.1mm (1.5709 - 1.5787 in) 33.90 - 33.98 mm (1.3346 - 1.3378 in) “B” face width 2. 5 mm (0.0984 in) 4.2 mm (0.1654 in) “C”...
Page 52 Specifications Item Metric Standard Service Wear Limit Valve spring Inner spring Free length 39.5 mm (1.56 in) 43.0 mm (1.69 in) Set length (valve closed) 32.5 mm (1.28 in) 35.0 mm (1.38 in) Compressed pressure (installed) (11.73 - 14.79 kg, 32.61 lb) (30.09 - 33.15 kg, 66.35 - 73.10 lb) Tilt limit * 2.5°/1.4mm(2.5°/.055in)
Page 53 Specifications Item Metric Standard Service Wear Limit Piston rings Top ring Type Barrel Dimensions (B×T) 1 × 3 mm (0.0394 × 0.1181in) End gap (installed) 0.30 - 0.45mm (0.0118 - 0.0177in) Side clearance (installed) 0.04 - 0.08 mm (0.0016 - 0.0031 in) 2nd ring Type Taper...
Page 54 Specifications Item Metric Standard Service Wear Limit Shifter Shifter type Shift drum and flexible shaft Air filter oil grade Engine oil Carburetor (If Equipped) Mark KINZO Type PD36J-C diffusers Ø 33mm (1.30in) Level in float chamber 29.5mm (1.16 in) Mass of float (0.35oz) Float needle Ø...
Page 55 Specifications Item Metric Standard Service Wear Limit Steering system Type Rack and pinion Front suspension Shock absorber travel 46 mm (1.811 in) Spring free length 311mm (12.24 in) Spring fitting length 265 mm (9.65in) Spring rate 19.4 N/mm(1.94 kg/mm, 108.6 lb/in) Stroke 0 - 108 mm (0 - 4.25 in)
Page 56 Specifications Item Metric Standard Service Wear Limit Front disc brake Type Dual Disc outside diameter 200mm (7.87in) thickness 3.5 mm (0.14 in) Pad thickness inner 9.0 mm (0.35 in) Pad thickness outer 9.0 mm (0.35 in) Master cylinder inside 19.0mm (0.75in) diameter Caliper cylinder inside...
Page 57: Electrical Specs
Specifications Electrical Specifications Item Metric Standard Service Wear Limit 12 V Voltage C.D.I. (ECU) Operating voltage range 8~16 V Overvoltage protection 26±2 V Stand by current ≤50mA Ignition Capacitor 2.2μF Ignition coil Minimum spark gap 6 mm (0.24in) Primary winding resistance 0.18 ~ 0.28 Ω...
Page 58 Specifications Item Metric Standard Service Wear Limit Electric starter system Type Constant mesh type Starter motor Output 0.7 kW Brush overall length 12.5 mm (0.49 in) Spring force 7.65 ~ 10.01 N (27.5 ~ 36.0 oz) 5 mm (0.20 in) Commutator diameter 28 mm (1.10 in) ----...
Page 59 Specifications Torque Specifications Engine 2-16...
Page 60 Specifications 2-17...
Page 61 Specifications 2-18...
Page 62 Specifications Chassis Torques 2-19...
Page 63 Specifications 2-20...
Page 64: General Torque Specs
Specifications General Torque Specifications This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached.
Page 65 Specifications Lubrication Points and types of Lubricant Engine 2-22...
Page 66 Specifications Chassis 2-23...
Page 67 Maintenance and Adjustment Maintenance schedule Brake Pedal 3-16 Valve Adjustment Brake Pads 3-18 Idle Adjustment Brake Lines 3-19 Spark Plug, Compression test Shift Lever Adjustment 3-20 Engine Oil Final Gear oil 3-21 Air filter 3-10 Steering system 3-23 Coolant level 3-11 Tires 3-24...
Page 68 Maintenance and Adjustment...
Page 69: Maintenance Schedule
Maintenance and Adjustment Maintenance and adjustment of the UTV Note: Correct maintenance and adjustments are necessary to ensure the vehicles safety and normal driving ability. Repair personnel should become familiar with the procedures outlined in the maintenance schedule. Maintenance Schedule...
Page 70: Maintenance And Adjustment
Maintenance and Adjustment Maintenance and Adjustment of the UTV Note: • Recommended brake fluid: DOT 4 • Brake fluid replacement: • When disassembling the master cylinder or caliper, replace the brake fluid. Normally check the brake fluid level and add fluid as required. •...
Page 71 Maintenance and Adjustment Adjusting the Valve Clearance • Fan impeller (2) • Timing inspection covers (3) Note: • The valve clearance must be adjusted when the engine is cool to the touch. • Adjust the valve clearance when the piston is at TDCC (Top Dead Center Compression).
Page 72: Idle Adjustment
Maintenance and Adjustment 4. Watch tachometer built into the • Insert a Feeler gauge (2) of the display. proper thickness between the adjuster and valve tip. Engine idle speed • Turn the Adjuster (3) clockwise or 1,400 ±100 r/min counterclockwise with a tappet adjusting tool (4) to obtain the proper clearance.
Page 73 Maintenance and Adjustment 6. Install the spark plug. 17.5 Nm (1.8 kg ·m, 12.9 lb ·ft 7. Install the spark plug cap. 8. Install the seat. Compression Test 1. Start the engine and let it warm up 6. After adjustment, check that the for several minutes.
Page 74: Engine Oil
Maintenance and Adjustment CHECKING THE ENGINE OIL LEVEL 3. Start the engine and allow it to warm up for several minutes. 1. Remove the seat. 4. Stop the engine and recheck the oil 2. Check the engine oil level on the dip level.
Page 75 Maintenance and Adjustment 5. If the oil filter cartridge is also to be 7. Fill the engine oil to the specified replaced, perform the following level on the dipstick. procedure. Oil quantity • Remove the oil filter cartridge (1) Periodic oil change with an oil filter wrench (2).
Page 76: Air Filter
Maintenance and Adjustment 3. Remove the air filter element. (4) • c. Check the engine oil passages, the oil filter cartridge and the oil pump for damage or leaks. 4.Start the engine after solving the • problem(s) and check the engine oil pressure again.
Page 77: Coolant Level
Maintenance and Adjustment • Squeeze the excess solvent out of the element and let it dry. Note: Do not twist or wring out the element. This could damage the foam material. • Apply engine oil onto the filter element, the squeeze out the excess oil.
Page 78 Maintenance and Adjustment 6. Remove the radiator cap (1). 8. Disconnect the water pump inlet hose (2). Warning: A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause serious injury.
Page 79 Maintenance and Adjustment 13. Fill the radiator with the 14. Install the air bleed bolt. recommended antifreeze until coolant comes out of the hole for 9 Nm (0.9 m · kg, 6.5 ft · lb) the air bleed bolt. 15. Fill the coolant reservoir to between Recommended antifreeze the minimum and maximum level High-quality ethylene glycol antifreeze...
Page 80 Maintenance and Adjustment 3-14...
Page 81: V-Belt
Maintenance and Adjustment CHECKING THE V-BELT Note: Tightening the bolts (1) will push the 1. Remove: secondary sliding sheave away, causing the gap between the secondary • driver seat, passenger seat fixed and sliding • lift the cargo bed sheaves to widen . •...
Page 82: Spark Arrester
Maintenance and Adjustment CLEANING THE SPARK ARRESTER • Remove the tailpipe (2) by pulling it out of the muffler. 1. Clean: Tap the tailpipe lightly with a soft- face hammer or suitable tool, then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and the inner contact surfaces of the...
Page 83 Maintenance and Adjustment 2. Adjust the free play 1. Shift the drive select lever into neutral gear. • Loosen the locknut (2) • Turn brake rod (1) in or out 2. Lift up the hood until the correct free play is obtained.
Page 84: Brake Pads
Maintenance and Adjustment 2. Lift up the hood. 3. Check that the brake fluid level is above the minimum line on the brake fluid reservoir (1). Warning: Use Only DOT 4 Brake fluid otherwise, the rubber seals may deteriorate, causing leaks and poor brake performance.
Page 85: Brake Lines
Maintenance and Adjustment CHECKING THE BRAKE HOSES AND BRAKE BLEEDING THE HYDRAULIC LINES BRAKE SYSTEM 1. Remove the Driver’s, passenger’s seat. 2. Lift up the hood. Warning: 3. Lift up the cargo bed. Bleed the brake system if: • The system has been Inspect the Front Brake hoses (1) and the Rear disassembled.
Page 86 Maintenance and Adjustment Select Lever shift rod (4) R Rear Plastic cover (5) Both Lock Nuts (6) 4. Place the other end of the hose into a container. 5. Slowly apply the brake pedal several times. 6. Push down on the pedal and hold it. 7.
Page 87: Final Gear Oil
Maintenance and Adjustment ADJUSTING THE BRAKE LIGHT SWITCH Recommended oil SAE 80 API “GL-4” Hypoid gear Note: The brake light switch is operated by movement of the brake pedal. The brake light 4. Install the oil filler plug. switch is properly adjusted when the brake light comes on just before the Tightening torque braking effect starts.
Page 88 Maintenance and Adjustment Periodic oil change CHANGING THE DIFFERENTIAL 0.25 L (0.22 Imp qt) GEAR OIL Total amount 0.28 L (0.25 Imp qt) 1. Place the vehicle on a level Recommended oil surface. SAE 80W/90 API “L-CLE” Hypoid gear oil 2.
Page 89: Steering System
Maintenance and Adjustment CHECKING THE CONSTANT VELOCITY CHECKING THE STEERING SYSTEM JOINT DUST BOOTS Inspect the dust boots (1) for cracks or damage. 1. Inspection: Place the vehicle on a level surface. Front Inspect the steering assembly bearings, Try to move the steering wheel up and down, and back and forth.
Page 90: Tires
Maintenance and Adjustment ADJUSTING THE TOE-IN Adjustment Place the vehicle on a level surface. Warning: Be sure that both tie-rods are turned Check the tire air pressure, then measure the the same amount. If not, the vehicle toe in. will drift right or left even though the steering wheel is positioned Mark both front tire tread centers at 90 straight.
Page 91: Shock Absorbers
Maintenance and Adjustment ADJUSTING THE FRONT SHOCK ABSORBERS Warning: Always adjust both shock absorbers spring preload to the same setting. Uneven adjustment can cause poor handling and loss of stability. Adjustment Turn the spring preload adjuster (1) to increase or decrease the spring preload. Recommended tire pressure Front 70Kpa or 10 psi Rear 70KPa or 10 psi...
Page 92 Maintenance and Adjustment Note: INPECTING THE WHEELS (1) The tire pressure gauge (1) is included as standard equipment. If dust or the like is Look for Bends or damage. stuck to this gauge, it will not provide the correct readings. Therefore, take two measurements of the tire’s pressure and use the second reading.
Page 93 Maintenance and Adjustment ADJUSTING THE HEADLIGHT BEAM 4. Install a new headlight bulb into the holder. 1. Turn the headlight beam adjuster (1) in or out. Note: Avoid touching the glass part of the bulb. Keep it free from oil; otherwise, the transparency of the glass, life of the bulb, and luminous flux will be adversely affected.
Page 94 Engine Engine Notes Clutch 4-35 Engine removal Clutch Housing Assembly 4-36 Cylinder head and Cylinder Crankcase, Starter Motor and 4-39 head cover Oil Filter Rocker Arms and camshaft Crankcase 4-41 Valves and valve springs 4-13 Crankcase Bearings 4-42 Cylinder and Piston 4-18 Crankshaft and oil Pump 4-45...
Page 95 Engine...
Page 96: Engine Notes
Engine Engine Notes 6. When removing nuts and bolts take out the smallest diameter bolts first 1. Make sure the components, oils, and work in reverse of the adhesives, and sealants are from tightening method used in step 5. the motor company or recommended by the motor 7.
Page 97: Engine Removal
Engine Engine Removal Part Name Remarks Removing the carburetor and Remove the parts in the order intake manifold listed Carburetor Carburetor joint (intake manifold) For installation, reverse the order Intake Manifold listed...
Page 98: Cylinder Head And Cylinder Head
Engine Cylinder Head and Cylinder Head Cover Part Name Remarks Removing the cylinder head cover Remove the parts in the order and cylinder head listed. Cylinder head Valve Guide Check ring Intake Valve cover Exhaust Valve Cover Stud bolt M8 X 45 Cotter Pin Head Gasket...
Page 99 Engine Cylinder Head and Cylinder Head Cover Part Name Remarks Inner hex cylinder screw M8 X 50 Cam pressure plate Cam stop Seal o-ring 109×2.4 Fuel shield plate comp Exhaust pipe Clip clamp Seal o-ring 109×2.4 Cylinder head left cover For installation, reverse the order Spark plug (NGK DR8EA) listed.
Page 100 Engine Inspection Look at the cylinder head water jacket for mineral deposits or rust. Clean if Valve covers necessary. • Exhaust Valve cover (1) Installation • Intake Valve cover (2) 1. Install a new Cylinder Head Gasket. 2. Install the Cylinder Head 3.
Page 101 Engine Warning: Always use a new gasket. Note: The “UP” mark on the timing chain tensioner should face up. Timing chain tensioner bolt (10 Nm or 7 ft lbs) • Remove the screwdriver, make sure that the timing chain tensioner rod releases, and tighten the cap bolt to the specified torque.
Page 102 Engine Rocker Arms and Camshaft Part Name Remarks Removing the rocker arms and Remove the parts in the order listed. camshaft Cylinder head cylinder head gasket Hex bolt M6×16 Pressure plate Shaft, swing arm Swing arm comp, valve wave washer Adjusting screw, valve Adjusting nut, valve Shaft, swing arm...
Page 103 Engine Rocker Arms and Camshaft Part Name Remarks Bearing 6005 Timing chain Driven sprocket, timing pin 4×10 Shield plate, driven sprocket Washer 10.5×22×3 Hex flange bolt M6×25 For installation, reverse the order Guide plate listed. 4-10...
Page 104 Engine Inspection Rocker Arms • Rocker arm Lobes (1) • Valve Adjusters (2) Rocker arm shaft outside diameter Service Wear Limit Φ11.96mm Calculate the clearance by subtracting the shaft outside diameter from the rocker arm Look for discoloration, pitting or scratches. hole inside diameter.
Page 105 Engine Look at the camshaft sprocket for wear or Install the camshaft and camshaft damage. If necessary replace the sprocket. camshaft sprocket and cam chain as a set. • Turn the crankshaft counterclockwise with a breaker Follow the diagram for proper cam chain to bar.
Page 106: Valves And Valve Springs
Engine Valves and Valve Springs Part Name Remarks Removing the valves and valve Remove the parts in the order springs listed. Cylinder Head Intake Valve Exhaust Valve Valve spring seat Valve spring (outer) Valve spring (inner) Valve seal Valve spring cap For installation, reverse the order Valve Keeper listed.
Page 107 Engine Inspection Measure the stem to guide clearance. Stem-to-guide clearance = valve guide Check for valve sealing. inside diameter – valve stem diameter. • Pour a clean solvent (1) into the intake and exhaust ports. Note: • Check that the valve seals properly. If the mating surface is coarse, There should be no leakage at the corroded or does not contact with valve...
Page 108 Engine Note: Valve spring free length When installing a new valve always valve outer spring：42.5mm replace the guide. If the valve is valve inner spring：39mm removed or replaced always replace the oil seal. Valve spring squareness valve outer spring：0.10 mm Measure the valve seat surface width.
Page 109 Engine Apply a fine lapping compound to the If the valve seat is to wide or narrow or valve face and repeat the above steps. cracked, grind it to ensure it’s sealing ability Note: After every lapping operation be sure to Note: clean off all of the compound from the After reface the valve seat or replacing...
Page 110 Engine Using a valve spring compressor (1) install the valve retainers (2). To secure the valve keepers onto the valve stem, lightly tap the valve tip with a soft faced dead blow hammer. Caution; Hitting the valve tip with excessive force could damage the valve.
Page 111: Cylinder And Piston
Engine Cylinder and Piston Part Name Remarks Removing the cylinder and piston Remove the parts in the order listed. Water Pump outlet hose Cylinder Cylinder base gasket Dowel Pin 14 X 16 Dowel Pin 18 X 10 O-ring Piston pin clip Piston pin Piston For installation, reverse the order...
Page 112 Engine Inspection Service Wear Limit Out of roundness:0.005mm Taper:0.005mm Look at the cylinder and piston walls for vertical scratches. If scored bore the cylinder and replace the piston and rings. Measure the external diameter of the piston at 10mm above the piston skirt. Remove the piston rings from the piston, and inspect the ring groove for cracks or wear.
Page 113 Engine Measure the piston pin outside diameter. Installation Install the Piston rings onto the piston. Note: Be sure to install the piston rings so that the manufacturer’s marks or numbers are located on the upper side of the rings. Lubricate the piston and piston rings liberally with engine oil.
Page 114 Engine Install the cylinder • Cylinder • O-ring (base gasket) • Bolts (M10, torque to 42 Nm or 30 ft lbs). • Bolts (M6, torque to 10 Nm or 7 ft lbs). Note: Install the cylinder with one hand while compressing the piston rings with the other hand.
Page 115: Engine Cooling Fan And A.c
Engine Engine Cooling Fan and A.C. Magneto Part Name Remarks Removing the engine cooling fan Remove the parts in the order and A.C. magneto listed. Drive belt cover Engine oil Coolant Water pump assembly Engine cooling fan air duct assembly Air shroud 1 Engine cooling fan Air shroud 2...
Page 116 Engine Engine Cooling Fan and A.C. Magneto Part Name Remarks Wire clip Hex Flange bolt M6 X 30 Generator stator Washer B6 Pickup coil Stator lead holder Generator rotor Starter wheel gear Washer Woodruff key Starter idle gear shaft Bearing For installation, reverse the order Starter idle gear listed.
Page 117 Engine Inspection Install the starter wheel gear, (with the groove (a) facing the A.C. magneto rotor), A.C. Magneto onto the starter clutch, and hold the starter clutch. • Stator coil • Pickup coil Look for damage, signs of burnt discoloration or fraying wires. Turn the starter wheel gear counterclockwise (1) to check that the starter clutch and wheel gear engage...
Page 118 Engine Inspect the starter idle gear teeth (1) and Install the dowel pins a new gasket and the starter wheel gear teeth (2) for the A.C. magneto cover. damage, chips, roughness, pitting or wear. 10 Nm or 7 ft lbs Note: When installing the A.C.
Page 119 Engine Install the engine cooling fan to the pulley. 7 Nm or 5 ft lbs Install the air shroud. 10 Nm or 7 ft lbs Install the engine cooling fan air duct assembly (1) with the arrow mark (a) towards the air shroud. 4-26...
Page 120 Engine Balancer Gears and Oil Pump Gears Part Name Remarks Removing the balancer gears and Remove the parts in the order listed. oil pump gears Nut/lock washer Balancer driven/oil pump drive gear Chain Straight key Oil pump driven gear Plate Balancer drive gear Spring For installation, reverse the order...
Page 121 Engine Inspection Install the balancer driven gear. Inspect the Timing Chain. Look for cracks Note: or stiffness. If replacement is necessary, Align the punch mark (a) on the replace the timing chain and the camshaft balancer drive gear with the punch sprocket as a set.
Page 122 Engine Primary and Secondary Sheaves Part Name Remarks Removing the primary and Remove the parts in the order listed. secondary sheaves Engine assembly Drive belt cover Rubber gasket Bearing housing Dowel pin Primary sheave assembly V-belt Primary fixed sheave Secondary sheave assembly Drive belt case For installation, reverse the order Rubber gasket...
Page 123: Primary Sheave
Engine Primary Sheave Part Name Remarks Disassembling the primary sheave Remove the parts in the order listed. Primary pulley sheave cap Primary pulley slider Spacer Primary pulley cam Primary pulley weight Collar Oil seal Primary sliding sheave For installation, reverse the order O-ring listed.
Page 124: Secondary Sheave
Engine Secondary Sheave Part Name Remarks Disassembling the secondary Sheave Remove the parts in the order listed. Spring seat Compression spring Spring seat Guide pin Secondary sliding sheave O-ring Secondary fixed sheave Oil seal For installation, reverse the Oil seal order listed.
Page 125 Engine Inspection Secondary Sheave Primary Sheave Inspect the torque cam grooves (1) and the guide pins (2) for wear or damage. Measure the weights outside diameter. Check for smooth operation. Service Wear Limit 29.5 mm Inspect the secondary sheave spring for damage or fatigue.
Page 126 Engine Installation Assembling the secondary sheave Install the weights (1). Apply assembly lube to the secondary sliding sheave inner surface (1) and the Note: bearings, oil seals and inner surface of the Apply grease (90g) to the whole outer secondary fixed sheave (2). surface of the weights and install.
Page 127 Engine Tighten the primary sheave nut (1). 120 Nm or 85 ft lbs Tighten the secondary sheave nut (2). 100 Nm or 72 ft lbs Note: Use the sheave holder (3) to hold the primary sheave. First, tighten the primary sheave nut (1), then tighten the secondary sheave nut (2).
Page 128: Clutch
Engine Clutch Part Name Remarks Removing the clutch Remove the parts in the order listed. Primary and secondary sheaves Clutch housing assembly Gasket/dowel pin ½ One-way clutch bearing For installation, reverse the Clutch carrier assembly order listed. 4-35...
Page 129: Clutch Housing Assembly
Engine Clutch Housing Assembly Part Name Remarks Disassembling the clutch housing Remove the parts in the order listed. Oil seal Circlip Bearing Housing Circlip Bearing Circlip Bearing For installation, reverse the order Clutch Housing listed. 4-36...
Page 130 Engine Inspection Inspect the clutch shoe for heat damage. Inspect the clutch housing (1) for heat Measure the clutch shoe thickness. damage, wear or grooves. Service Wear Limit Inspect the one way clutch bearing (2) for (a) 1.0 mm chafing, wear or damage. Installation Note: Replace the one-way clutch assembly...
Page 131 Engine Install the dowel pins, gasket and clutch housing assembly. 10 Nm or 7 ft lbs Note: Tighten the bolts in stages, using a crisscross pattern. After tightening the bolts, check that the clutch housing assembly rotates counterclockwise smoothly. 4-38...
Page 132: Crankcase, Starter Motor And Oil
Engine Crankcase, Starter Motor and Oil Filter Part Name Remarks Remove the starter motor, and oil Remove the parts in the order filter listed A.C magneto rotor Primary and secondary sheaves Clutch carrier assembly Starter motor Check Ball SR8 Spring Pressure plate Filter mount Oil Filter...
Page 133 Engine Crankcase, Starter Motor and Oil Filter Part Name Remarks Hex flange bolt M6×20 Cable shield Shock absorber sheath, suspension For installation, reverse the Suspension collar sheath order listed. 4-40...
Page 134 Engine Crankcase Part Name Remarks Separating the crankcase Remove the parts in the order listed. Left crankcase Dowel pin Press plate,bearing Press plate,bearing Fuel seal MV036A1 For installation, reverse the Gear switch order listed. 4-41...
Page 135: Crankcase Bearings
Engine Crankcase bearings Part Name Remarks Removing the crankcase bearings Remove the parts in the order listed. Crankshaft and oil pump Transmission Middle drive/driven shaft O-ring/collar Oil seal Bearing retainer For installation, reverse the Bearing order listed. 4-42...
Page 136 Engine Inspection Caution: Before tightening the crankcase holding bolts, be sure to check whether Thoroughly wash the case halves in a mild solvent. the transmission is functioning properly by manually rotating the shift Clean all the gasket mating surfaces and drum in both directions.
Page 137 Engine B Right crankcase Note: Tighten the bolts in stages, using a crisscross pattern. Apply sealant (Quick Gasket) (4) to the thread of the bolt (2) shown in the illustration. Apply 4-stroke engine oil (to the crank pin, bearing and oil delivery hole). 4-44...
Page 138: Crankshaft And Oil Pump
Engine Crankshaft and Oil Pump Part Name Remarks Removing the crankshaft and oil pump Remove the parts in the order listed. Crankcase separation Oil Pump Gasket Oil pump assembly Hex flange bolt M6×25 Cover, oil pump Balancer For installation, reverse the Crankshaft order listed.
Page 139: Oil Pump
Engine Oil Pump Part Name Remarks Disassembling the oil pump Remove the parts in the order listed. Oil pump housing Outer rotor Inner rotor Rotor cover For installation, reverse the Shaft order listed. 4-46...
Page 140 Engine Inspection Tip clearance Limit: 0.23 mm Side clearance Limit: 0.17 mm Body clearance Limit: 0.24 mm Inspect the oil pump rotor housing and rotor cover for cracks wear or damage. Measure the crankshaft width (A). Crank width 58.9 ~ 59.1mm Measure the side clearance (D).
Page 141 Engine Installation Assemble the oil pump with the recommended lubricant. • inner rotor • outer rotor • oil pump shaft Install the crankshaft and balancer. Note: Hold the connecting rod at the Top Dead Center (TDC) with one hand while turning the nut of the installation tool with the other.
Page 142: Transmission
Engine Transmission Part Name Remarks Removing the transmission Remove the parts in the order listed. Crankcase separation Middle driven gear Low wheel gear Shift drum Shift fork assembly Short spring Shift fork 1 Long spring Shift fork 2 Guide bar Secondary shaft Drive axle assembly For installation, reverse the...
Page 143: Drive Axle Assembly
Engine Drive Axle Assembly Part Name Remarks Disassembling the drive axle Remove the parts in the order listed. Driven gear , gear R DR adapter sleeve Intermediate axle Driven gear , gear D For installation, reverse the Bush 26x42x14.7 order listed. 4-50...
Page 144 Engine Inspection Inspect the springs for cracks or damage. Inspect the shift fork follower (1) and the shift fork pawl (2). Look for scoring, bends, wear or damage. Inspect the dog and slot engagement. Look for wear or damage. Inspect the guide bar for bends. Inspect the high wheel gear and middle drive gear teeth.
Page 145 Engine Inspect the secondary shaft and driven sprocket. Look at the gear teeth for discoloration, pitting or wear. Check the gear movement on the shaft. It should move smoothly. Replace the circlip with a new one. Inspect the chain for cracks of stiffness. If replacement is necessary replace the chain, secondary shaft and driven sprocket as a set.
Page 146: Middle Drive Shaft
Engine Middle Drive Shaft Part Name Remarks Removing the middle drive shaft Remove the parts in the order listed. Crankcase separation Bearing housing Middle drive gear Middle drive pinion gear Shim Middle drive shaft For installation, reverse the Bearing retainer order listed.
Page 147: Middle Driven Shaft
Engine Middle Driven Shaft Part Name Remarks Removing the middle drive shaft Remove the parts in the order listed. Crankcase separation Drive shaft coupling Circlip Bearing Universal joint Universal joint yoke Bearing housing/O-ring Shim Middle driven pinion gear Bearing retainer Bearing retainer For installation, reverse the Middle driven shaft...
Page 148 Engine Inspection Measure the gear lash. Middle gear lash Inspect the gear teeth of the drive pinion gear (1) and the driven pinion gear (2). 0.1 ~ 0.3 mm Look for pitting, galling, wear or damage. • Temporarily install the left crankcase.
Page 149 Engine Installation Install the universal joint yoke, washer and nut (1). Install the middle driven shaft bearing retainer (1) Note: Bearing retainer Use the universal joint holder (2) to 80 Nm hold the yoke. Attach the ring nut wrench (2) and turn it Universal joint yoke nut counterclockwise to tighten the retainer, (it 150 Nm...
Page 150 Engine Press each bearing into the universal joint, using a suitable socket, far enough to allow installation of the circlip (2). Install the drive shaft coupling, washer and nut (1) using the coupling gear/middle shaft tool (2) and torque to 97 Nm or 70 ft lbs.
Page 151: Intake Manifold Assembly
Engine Intake Manifold Assembly Part Name Part Name Remarks Remarks Intake Assembly Intake Pipe joint Nut M8 Inner Hex screw M6 X 20 Inner Hex screw M6 X 20 Fuel injector mounting base Fuel injector mounting base Fuel injector Inlet Temp/ pressure sensor Inlet Temp/ pressure sensor Phillips panhead screw Phillips panhead screw...
Page 152 Engine Intake Assembly Part Name Part Name Remarks Remarks Clamp Damper (D42) Water temp Sensor Clamp 4-59...
Page 153 CHASSIS Front Bumper and Hood Front Bridge 5-30 Panels and Footrest cover Rear Bridge 5-38 Seat Support and seat cushion Gearshift, Parking Brake 5-41 Roll-over Protection System Pedal Assembly 5-46 Cargo Bed Front Suspension 5-48 Steering System Front Arm 5-50 Brake System 5-15 Rear Suspension...
Page 154 CHASSIS Front Bumper and Hood...
Page 155: Front Bumper And Hood
CHASSIS Part Name Remarks Remove the parts in the order Removing the front bumper and Hood listed. Front Bumper Assembly Bumper Support Front headlight grille Right Mounting Lug, Front Panel Left Mounting Lug, Front Panel For installation, reverse the order Hood listed.
Page 156: Panels And Footrest Cover
CHASSIS Part Name Remarks Removing the panels and footrest covers Left Side Board Right Side Board Center Protective Board Left Footrest Pedal Right Footrest Pedal Seat Front Protection Board Rear Lateral Cover, Left Rear Lateral Cover, Right Rear Left Mud-guard Board Rear Right Mud-guard Board Seat Support and Seat Cushion...
Page 157: Seat Support And Seat Cushion
CHASSIS Part Name Remarks Removing the seat support and seat cushion Seat Support Plate Assembly Seat Support Seat Cushion Front lower Protective Plate Middle lower Protective Plate Roll Over Protection System and Back Rest...
Page 158 CHASSIS Part Name Remarks Removing the ROPS and Back Rest Top Horizontal Tube Assembly II, Shed Top Horizontal Tube Assembly I Left Rear Shed Assembly Right Rear Shed Assembly Left Front Shed Assembly Right Front Shed Assembly Rear Lower Connecting rod Seat Cushion Cargo Bed...
Page 159: Cargo Bed
CHASSIS Part Name Remarks Removing the cargo bed Cargo Bed Assembly T Gas Spring Assembly Cargo Bed Assembly...
Page 160 CHASSIS Part Name Remarks Removing the cargo bed assembly Front Panel Assembly, Carrier Left Side board Assembly, Carrier Right Side board Assembly, Carrier Bottom Board Assembly, Carrier Carrier Door Assembly Dump bracket Assembly Steering System...
Page 161: Steering System
CHASSIS Part Name Remarks Removing the steering system Plastic Cover Steering Wheel Hex Flange Self-locked Nut M12×1.25 Gasket Steering Column Hex Flange Bolt M10×1.25×20 Steering Wheel Component Steering Transmission Shaft Assembly Hex Flange Bolt M8×25 Circlip Φ8 Washer Φ8 Steering System...
Page 162 CHASSIS Part Name Remarks Steering Gear Hex Flange Bolt M10×1.25×30 Adjuster Cap Spring Washer Clamp L=300 Right Rubber Boot Clamp L=120 Tie Rod End, Steering Machine Hex Flange Nut M10×1.25 Cotter pin Φ3.5×20 Hex Nut M10×1.25 Rack and Pinion assembly 5-10...
Page 163 CHASSIS Inspection Inspect the internal splines of the steering wheel and the external splines of the Check for excessive movement of the steering shaft. steering column. Check the, up and down, side to side, movement. Check the rotating Service Wear Limit movement.
Page 164 CHASSIS Inspect the steering column Inspect the steering joint (1) for turning movement (2). • Steering column tube (1) • Bearing (2) • Steering Shaft (3) • Spline (4) Inspect the dust boots for cracks, splits, damage or wear. If replacement is necessary, be sure to fill approximately ½...
Page 165 CHASSIS Inspect the drive gear (1) and the spline gear for ease of movement. If roughness is found disassemble and look for wear in the splines. Warning Never attempt to repair a steering joint by welding. Note: When replacing parts in the steering system, clean them and lubricate the moving parts with lithium grease.
Page 166 CHASSIS Brake system The Brake system is crucial to the life safety of the operator and passengers therefore, it must be periodically inspected and maintained. This vehicle uses the double return route hydraulic pressure disc brake system. Please follow the tips of inspection as below.
Page 167: Brake System
CHASSIS Brake system Part Name Remarks Removing the brake components Master cylinder Six-Angle Flange Bolt M6×20 Belt 3 L=150 Belt 4 L=200 Belt 3 L=150 Hex Flange Bolt M6×30 Hex Flange Bolt M6×20 Oil Pipe Clip 1, Front Disc Brake Hex Flange Bolt M6×20 Oil Pipe Clip Ⅱ, Front Disc Brake Brake assembly (3 IN 1)
Page 168: Front Brake Discs
CHASSIS Front Brake Discs Part Name Remarks Removing front brake caliper Brake caliper assembly Bolt Brake disc Brake caliper assembly Brake caliper, piston assembly Brake caliper piston Dust seal Caliper piston seal Bleed screw Brake, pad Pad spring Brake pad holding bolt Bolt, flange 5-16...
Page 169 CHASSIS Inspection 1. Connect a suitable hose (1) to the caliper bleed screw (2). Put the Inspect the brake disc for galling or other end into a suitable brake fluid damage. catch container. Measure the brake disc deflection. Brake disc maximum deflection 0.10 mm (0.004 in) Measure the brake disc thickness (1).
Page 170 CHASSIS Disassembling the front brake calipers Inspect the brake caliper pistons (1) for scratches, rust, pitting or wear. Remove the brake line from the caliper and remove the caliper from the UTV. Inspect the cylinders (2) for scratches or wear. Remove the bleed screw and place a rag in the caliper to catch the pistons as you Inspect the caliper body (3) for cracks or...
Page 171 CHASSIS Warning: Warning: All internal brake components should Proper brake hose routing is essential be cleaned and lubricated with new to insure safe vehicle operation. brake fluid only before installation. Install the bleed screw into the caliper but do not fully tighten. Install clear hose onto Must use DOT4 Brake Fluid the bleed screw and the other end into a Install the brake caliper pistons (1).
Page 172: Rear Brake Caliper
CHASSIS Rear Brake Caliper Part Name Remarks Removing the rear brake caliper Brake caliper assembly Bolt Brake disc Bolt, flange Brake pad holding bolt Brake caliper assembly Brake, pad Brake pad (piston side) Insulator/pad shim Pad spring 5-20...
Page 173 CHASSIS Rear Brake Caliper Part Name Remarks Parking brake arm nut Set bolt Parking brake arm Parking brake arm shaft Spring Parking brake case bolt Parking brake case Gasket Bleed screw Brake caliper bracket Caliper piston seal Dust seal Brake caliper piston 5-21...
Page 174 CHASSIS Inspection Inspect the brake disc for galling or damage. Measure the disc deflection. Brake disc maximum deflection 0.10 mm (0.004 in) Measure the brake disc thickness (2). Must use DOT4 Brake Fluid DISASSEMBLING THE REAR BRAKE CALIPER 1. Remove: •...
Page 175 CHASSIS Warning: Installation All internal brake components should 1. Install: be cleaned in new brake fluid only. Do not use solvents as they will cause seals to swell and • caliper piston seal (1) distort. • dust seal (2) Inspect the brake caliper piston(1) for scratches, rust, corrosion or wear.
Page 176 CHASSIS 3. Install: Note: The hole for the parking brake arm shaft • gasket (1) has multiple threads. If the punch mark • parking brake case (2) (a) on the parking brake arm shaft is not • parking brake case bolts (3) between the alignment marks (b) when the parking brake arm shaft is screwed in 22Nm (2.2 m ·...
Page 177 CHASSIS INSTALLING THE REAR BRAKE 3. Air bleed the brake system CALIPER 4. Check the brake fluid level. If 1. Install: theBrake fluid level is below the “MIN” level line Add the recommended • brake caliper assembly brake fluid to the proper level. •...
Page 178: Front Wheel
CHASSIS Front Wheel Part Name Remarks Removing the front wheel Warning: Securely support the vehicle so Front wheel rim There is no danger of it falling over. Front tire Valve Stem Lug Nut M10×1.25 Center cap Hub Nut M20×1.5 Soleplate, front wheel hub Bolt 5-26...
Page 179: Rear Wheel
CHASSIS Rear Wheels Part Name Remarks Removing the rear wheel Warning: Securely support the vehicle so Rear wheel rim There is no danger of it falling Rear tire over. Valve stem Lug Nut M10 X 1.25 Center cap Hub Nut M20×1.5 Soleplate, rear wheel hub Bolt 5-27...
Page 180 CHASSIS Inspection Inspect the wheel hub (1) for cracks or damage. Look at the splines (2) inside the Measure the rim run out and check the hub for wear or damage. Look at the hub balance. nut for looseness or signs of distortion. Wheel runout limit Installation Radial (2): 2.0 mm (0.08 in)
Page 181 CHASSIS Tighten the lug nuts. Therefore, please ensure the tire pressure strictly complies with figures shown in the chart above. Before operating the vehicle 55 Nm or 40 ft lbs each time, please check if profile depth of Warning: the tire is over worn, which might result in spinning, instability, loss of control and Tapered wheel nuts (1) are used for both the front and rear wheels.
Page 182: Front Bridge
CHASSIS Front Bridge Part Name Remarks Removing the front bridge (L.&R.) Circlip Double off-set joint assembly Circlip Ball bearing Circlip Boot band Dust band Boot band Joint shaft assembly C.V. Axle, front Bridge 5-30...
Page 183 CHASSIS Front Bridge Part Name Remarks Removing the front bridge Transmission shaft part, front bridge Differential gear case Differential gear case cover Drive pinion gear Universal joint yoke Nut M14×1.25 O- ring Φ14×d=Φ7 Oil seal,Φ48×Φ65×9 Oil seal, front box input shaft Shim(0.1T) Shim(0.2T) Shim(0.5T)
Page 184 CHASSIS Front Bridge Part Name Remarks Bolt M8×25 Differential gear assembly Bolt M8×25 Bolt M8×10 Oil change bolt M10×16 Circlip Column pin Φ5×80 Gear motor Coulping shaft device Rack O- ring, divide moved=Φ2×Φ81 O- ring, front box cover d=Φ2.4×Φ140 Bearing 6007 RΦ35×Φ62×14 Bearing 6912Φ60×Φ85×13 Bearing 16007 Φ35×Φ62×9 Bearing HK152112 Φ15×Φ21×12...
Page 185 CHASSIS Front Bridge Part Name Remarks Nut M10 Washer Φ10 Shaft fork 4 Universal joint Bolt M14X15 Block ring Hose Φ4.5×L=710 Clip pipe 1 Clamp Intermediate shaft Circlip Cushion piece Spring D=Φ25×Φ2.3×28 Dustproof rubber Dustproof rubber Bolt M10×25 Washer Screw 5-33...
Page 186 CHASSIS Disassembly of the front bridge. 4. Repeat the steps for the opposite bearing. Remove the left and right front wheels. 5. Remove the yoke. Remove the front disc brake clip, cotter pin, castle nut, washer and wheel hub. Note: Remove the left and right rocker arm and It may be necessary to lightly tap the cross steering knuckle.
Page 187 CHASSIS Inspect the double offset joint. Look at Replace the oil seals and O-rings with new the splines of both the ball joint and the ones. shaft for wear or damage. Look at the balls and ball races for pitting, wear or Inspect the drive shaft splines, universal damage.
Page 188 CHASSIS ASSEMBLING THE UNIVERSAL JOINT Install the circlips (2) into the groove of each bearing. Install the opposite yoke into the universal joint. ASSEMBLING THE DIFFERENTIAL Apply wheel bearing grease to the GEAR bearings. 1. Measure the gear lash Install the bearing (1) onto the yoke. 2.
Page 189 CHASSIS Install the front bridge differential onto the • Insert bolts (5) into the gear motor frame with two hexagon bolts M10×110,two (6) and use them as a guide to set nuts M10 and two flat gaskets. the motor on the differential gear assembly (7) so that the shift fork Fastening Torque of the Bolt sliding gear (8) does not move.
Page 190: Rear Bridge
CHASSIS Rear Bridge Part Name Remarks Removing the rear bridge(L.&R.) Circlip Boot band Boot band Dust band Circlip Double off-set joint assembly Double off-set joint assembly Circlip Ball bearing Joint shaft assembly C.V. Axle, rear bridge Nut M12×1.25 Housing, pinion bearing Rear adjustment gasket I (0.1T) 5-38...
Page 191 CHASSIS Rear Bridge Part Name Remarks Rear adjustment gasket I(0.2T) Rear adjustment gasket I(0.5T) Rear adjustment gasket II Sensor, speed O-ring Φ19.4×Φ2.3 Bolt M8×35 Washer, plate Φ8 Bolt M8×25 Washer, plate Φ8 Zinc alloy flowing bean Housing, bearing Ring gear stopper Washer, plate Nut, flange M8 Bolt, flange M8×12...
Page 192 CHASSIS Rear Bridge Part Name Remarks Rear adjustment gasket III (0.1T) Rear adjustment gasket III (0.2T) Bolt, flange Plug, straight screw Gasket Φ14×1.5 Spring, compression Φ14×Φ1.8×46 Shaft, drive Circlip Φ17.5×1 Coupling Circlip Front dust cover Φ46×Φ23.5×35 Rear dust cover Φ40.7×Φ19×30 Clip Hose Φ4.5×800 Driven gear...
Page 193: Gearshift, Parking Brake
CHASSIS Gearshift, Parking Brake Part Name Remarks Parking system Parking Cable Assembly Parking Return cable Gearshift component Steel ball Φ9.5 5-41...
Page 194 CHASSIS Gearshift and Parking system Components Part Name Remarks Handle cover Screw M6×12 Washer Φ6 Handle sheath Gearshift rod Screw M4×8 Dust sleeve, Gearshift Burring bush Split Washer Φ12 Steel ball Φ9.5 Gearshift cable assembly Washer Φ8 Cotter pin φ3.5×20 Locked handle sheath, Handrail Parking Return Switch 5-42...
Page 195 CHASSIS Gearshift and Parking system Components Part Name Remarks Mounting Feet, Return Switch Return spring, Parking handle Hex Flange Bolt M6×12 Split Washer Φ13 Dust sleeve, Parking Return Switch Hex Flange Self-locked Nut M6 Parking Cable Assembly Parking Pedal Hex Flange Bolt M8×35 Bush Φ12×Φ8.5×20 Hex Flange Self-locked Nut M6 Return Spring, Parking Pedal...
Page 196 CHASSIS Gearshift and Parking system Components Part Name Remarks Mounting Plate, Parking Pedal Hex Flange Bolt M8×25 Spacing Bush I, Parking Pin Hex Flange Nut M8 Parking sensor Parking Torsion Spring parking lock plate Hex Flange Nut M8 Hex Flange Bolt M8×30 Spacing Bush II, Parking Pin Hex Flange Bolt M8×35 Parking Cable Assembly...
Page 197 CHASSIS Checking and Servicing of the reverse Adjusting the Gear shift lever mechanism. (1) Forward 1. Check the mobility of gear shift (2) Neutral handle. If it is not working properly, (3) Reverse remove the gear shift mechanism to (4) Steel ball Φ9.5 check if the fork , ball or spring is (5) Select lever shift rod stuck, in which case replace the...
Page 198: Pedal Assembly
CHASSIS Pedal Assembly Part Name Remarks Rear brake pedal assembly Ignition Switch assembly Accelerator pedal assembly 5-46...
Page 199 CHASSIS Brake Pedal Assembly Part Name Remarks Rear brake pedal Washer Φ15 Split Washer Φ13 Return spring, rear brake pedal Dust sleeve, Braking Pedal Return spring, rear brake pedal Rear brake pump bracket assembly Hex Flange Bolt M8×20 Hex Flange Self-locked Nut M8 Hex Flange Bolt M8×16 Accelerator pedal assembly Return Spring, Accelerator Pedal...
Page 200: Front Suspension
CHASSIS Front Suspension Part Name Remarks Shock Absorber Canister (Black) Hex Flange Self-locked Nut M10×1.25 Hex Flange Bolt M10×1.25×52 Hex Flange Self-locked Nut M10×1.25 Front Anti-roller Lever Assembly Shock Absorber Rubber, Anti-roller Lever Press Board, Anti-roller Lever Six-Angle Flange Bolt M8×16 Tie Rod, Anti-roller Lever Hex Flange Bolt M10×1.25×45 5-48...
Page 201 CHASSIS Front Suspension Part Name Remarks Hex Flange Self-locked Nut M10×1.25 Hex Flange Bolt M10×1.25×95 Tie Rod Collar, Anti-roller Lever Ball Joint Assembly 1 (Left Rotation) Tie rod, Front Balance Lever Ball Joint Assembly 1 (Right Rotation) Ball Joint Sleeve(Balance Lever) 5-49...
Page 202: Front Arm
CHASSIS Front Arm Part Name Remarks Front Upper Right Swing Arm Front Upper Left Swing Arm Front Lower Right Swing Arm Front Lower Left Swing Arm Hex Flange Bolt M10×1.25×70 Washer, Swing Arm Six-Angle Flange Self-locked Nut M10×1.25 Middle Rubber Tube, Swing Arm Circlip D=30 Front Ball Joint Assembly 5-50...
Page 203 CHASSIS Front Arm Part Name Remarks Hex Flange Bolt M10×1.25×70 Hex Flange Self-locked Nut M10×1.25 Hex Flange Nut M10×1.25 Cotter pin Φ3.5×20 Left Front Lower Rocker Protection Board Right Front Lower Rocker Protection Board Cross tape head Bolt M6×12 5-51...
Page 204 CHASSIS Inspection Caution: These components should be greased 1. When disassembling and servicing with lithium based grease before the suspension components look for installation. Be sure there are no apparent problems with bushings, cracks in rubber components before cotter pins and shock absorbers. installation.
Page 205 CHASSIS Installation of the front arms and shock absorbers Install the front upper arm (1) and the front lower arm (2). Lubricate the bolts (3) with lithium based grease and position them so that the bolt head faces outward. Temporarily tighten the nuts (4). Install the shock absorbers (5) and tighten nut (6).
Page 206: Rear Suspension
CHASSIS Rear Suspension Part Name Remarks Shock Absorber Canister (Black) Hex Flange Bolt M12×1.25×70 Hex Flange Self-locked Nut M12×1.25 Hex Flange Bolt M12×1.25×65 Rear Anti-roller Lever Assembly Shock Absorber Rubber, Anti-roller Lever Press Board, Anti-roller Lever Hex Flange Bolt M8×16 Tie rod assembly, Balance Lever Flange bolt Flange nut...
Page 207 CHASSIS Rear Swing Arm Assembly Part Name Remarks Rear Right Upper Swing Arm Rear Left Upper Swing Arm Rear Right Lower Swing Arm Rear Left Lower Swing Arm Hex Flange Bolt M10×1.25×105 Hex Flange Self-locked Nut M10×1.25 Middle Rubber Tube, Swing Arm Washer, Swing Arm Hex Flange Bolt M10×1.25×70 Hex Flange Self-locked Nut M10×1.25...
Page 208 CHASSIS Inspection Installation The rear suspension components are checked in the same manner as the front. Refer back to the front inspection. Inspect the stabilizer for bends, cracks or damage. Inspect the steering knuckles for pitting or damage. Inspect the rear arms for bends or damage. Look at the middle bushing for wear or damage.
Page 209: Cooling System
CHASSIS Cooling System Part Name Remarks Radiator and fan assembly Hex Flange Bolt M6×16 Hex Flange Nut M6 Rubber Cushion Radiator Radiator Cap Radiator guard Fan Assembly Bolt M6×20 Washer Φ6 Spring washer Φ6 Flange Nut M6 Temperature Sensor Pipe Clip Φ20-Φ30 5-57...
Page 210 CHASSIS Cooling System Part Name Remarks Pipe Clip Φ14-Φ25 Left Front Rubber Pipe(Water Inlet) Right Front Rubber Pipe(Water Inlet) Left Metal Pipe Right Metal Pipe Left Rear Rubber Pipe( Engine) Right Rear Rubber Pipe( Engine) Pipe Clip(Rubber covered) Six-Angle Flange Bolt M6×12 Standby Water Bottle Six-Angle Flange Bolt M6×16 Standby Water Tank Cover Assy...
Page 211 CHASSIS Inspection Installation Inspect the radiator fins for obstructions. After installing the cooling system fill the Use compressed air to the rear to blow out radiator with the proper coolant mixture any debris. 50/50 coolant and water. Loosen the bleed screw on the thermostat housing and allow the air to vent out of the system.
Page 212 CHASSIS Water Pump Part Name Remarks Removing the water pump Thermostat cover hex flange bolt M6×20 washer 6×13×1.5 hex flange bolt M6×14 water temperature sensor clip II water pipe I Gear, Water pump washer 10×1 bearing 1010 cylinder inlet water joint 5-60...
Page 213: Water Pump
CHASSIS Water Pump Part Name Remarks O-ring 33.4×2.4 bearing 6000 Gear, Water pump water pipe-400UTV-1 water pipe clip water pipe-400UTV-3 Pin Φ8×11.8 water pipe-400UTV-2 Cover, Water Pump O-ring 50×2.5 Water Seal Vane Wheel Oil Seal 10×20×5 5-61...
Page 214 CHASSIS Disassembly of the Water Pump Note: Tap out the bearing and oil seal from the Remove the rubber damper holder (1) outside of the water pump housing. and Rubber damper (2). Before installation apply lithium based grease to the oil seal and engine oil to the bearing.
Page 215 CHASSIS Assembling the water pump Install the rubber damper (1) and rubber damper holder (2). Install the oil seal (1) into the water pump housing (2) using a socket (3) that Note: matches the seals outside diameter. Use Before installing the rubber damper, coolant or tap water as a lubricant for the apply tap water or coolant onto its seals outer surface to aid in installation.
Page 216: Seat
CHASSIS Seat Part Name Remarks Removing the seat Seat Cushion fixing rubber sleeve, seat Back Rest Bolt M6×16 Safety belt buckle Right Safety Belt Assembly (Tri-Point Fixing Style) Hex Flange Bolt M10×1.25×20 Safety Belt Component Left Safety Belt Assembly (Tri-Point Fixing Style) Safety Belt Buckle Cover Six-Angle Flange Bolt M10×1.25×25-Φ14×5 Safety Belt Bushing...
Page 217: Roll-Over Protection System
CHASSIS Removing the seat To remove the seat grab the front of the seat bottom and lift it out of the grommets. Pull it forward and remove the seat bottom. To remove the back rest, remove the fasteners (8) that attach it to the roll-over protection system.
Page 218 CHASSIS Fuel Tank Part Name Remarks Removing the fuel tank Fuel tank Fuel tank lid Hold-down plate Foam strip Fuel tank rubber cushion Clip Φ10 Fuel Tank Ventilation Pipe Φ7×Φ11×480 Outlet vent pipe holder Screw M5×10 Washer Φ5 Cushion Fuel sensor Screw M5×12 Washer Φ5 Small fuel tank 1...
Page 219: Fuel Tank
CHASSIS Fuel Tank Part Name Remarks Cap, small fuel tank One Way Valve Ventilate tube, Small fuel tank Φ4.5×Φ8×380 Pump holder Hex Flange Bolt M6×8 Fuel Return Pipe, small oiler Clip Φ9 Outlet Fuel Pipe, Small Oiler Clip Φ9 Oil filter assembly Vacuum tube, Vacuum pump Long foam cover Clip Φ10...
Page 220 CHASSIS Fuel Tank Part Name Remarks Oil filter assembly Fuel Outlet Pipe, Fuel Tank Clip Φ9 Hex Flange Bolt M8×25 Fuel Outlet Pipe, Vacuum pump Clip Φ9 Vacuum tube, Vacuum pump Long foam cover Clip Φ Reflux pipe Seal ring, reserve oil tank Small fuel tank 2 Screw M4×12 Screw M4×16...
Page 221 CHASSIS Checking the operation of the fuel Drain out the oil and perform a pressure pump test of the oil cooling system. The pressure should be 0.3 MPA. Remove the seat bottom and right protector. Use compressed air through the oil cooler, oil line and rubber hoses at 0.03 MPA for 3 Place a fuel can under the end of Hose minutes.
Page 222: Battery Basics
Electrical Electrical Components Charging System Circuit 6-21 Diagram, troubleshoot Battery Basics Lighting System Circuit Diagram, 6-23 Charging a Lead Acid Battery troubleshoot Charging a Maintenance Free Signal System Circuit Diagram, 6-27 Battery troubleshoot Testing a Switch Cooling System Circuit Diagram, 6-34 troubleshoot Switch Continuity...
Page 223 Electrical...
Page 224 Electrical Electrical Components 1. Gear motor 7. Thermo switch 1 2. Thermo switch 2 8. Ignition coil 3. Radiator fan 9. Gear position switch 4. Brake light switch 10. Reverse switch 5. Parking brake switch 11. Speed sensor 6. Circuit breaker(radiator fan 12.
Page 225 Electrical Electrical Components 1. Four-wheel drive relay 1 9. Battery 2. Four-wheel drive relay 2 10. Rectifier/regulator 3. Starter relay 11. Indicator light assembly 1 4. Four-wheel drive relay 3 12. Indicator light assembly 2 5. Differential gear lock indicator light 13.
Page 226 Electrical Whenever performing any type of electrical test it is very important to start off with a known good Battery! Check the charge State of the Battery. It needs to be fully charged. There are 2 types of Batteries commonly used on UTV’s. •...
Page 227 Electrical Warnings: Batteries generate explosive gas and contain electrolyte, which is made of sulfuric acid, a highly poisonous and caustic chemical. Whenever working with batteries always follow these preventative measures: • Wear eye protection, Eye shield or safety glasses with side shields. •...
Page 228 Electrical...
Page 229 Electrical...
Page 230 Electrical Testing the switch Use a pocket tester to check the terminals for continuity. If the continuity is faulty at any point, replace the switch. The example chart shows that: (1)There is continuity between the “Brown/Blue and Red” leads when the switch is set to “ON”.
Page 231 Electrical Checking the switch continuity 1. Fuse 5. Light switch 2. Brake light switch 6. Parking brake switch 3. Main switch 7. Reverse switch 4. On-Command four-wheel drive 8. Four-wheel drive switch switch and differential gear lock switch 6-10...
Page 232 Electrical Checking the Bulbs and Bulb Sockets Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. If damage wear or corrosion is found replace the bulb, bulb socket or both. Check the continuity of the socket and the bulb.
Page 233: Ignition System
Electrical IGNITION SYSTEM CIRCUIT DIAGRAM Troubleshooting IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK): Check the following: 1. Fuses (main, ignition) 2. Battery 3. Spark plug 4. Ignition spark gap 5. Spark plug cap resistance 6. Ignition coil resistance 7.
Page 234 Electrical 6-13...
Page 235 Electrical 6-14...
Page 236 Electrical 6-15...
Page 237 Electrical ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 6-16...
Page 238 Electrical Troubleshooting IF THE STARTER MOTOR FAILS TO OPERATE: Check the following: 1. Fuses (main, ignition, signaling system) 2. Battery 3. Starter motor 4. Starter relay 5. Main switch 6. Gear position switch 7. Brake light switch 8. Diode 1 9.
Page 239 Electrical 6-18...
Page 240 Electrical 6-19...
Page 241 Electrical Starter Motor Part Name Remarks Removing the starter motor Starter motor lead Starter motor/O-ring 6-20...
Page 242 Electrical CHARGING SYSTEM CIRCUIT DIAGRAM Troubleshooting If the Battery is not Charging: Check the following: 1. Fuse (main) 2. Battery 3. Charging voltage 4. Charging coil resistance 5. Wiring connections (the entire charging system) 6-21...
Page 243 Electrical 6-22...
Page 244 Electrical Lighting System Circuit Diagram 6-23...
Page 245 Electrical Troubleshooting If the headlight or taillight fail to come on: Check the following: 1. Fuses (main, lighting system) 2. Battery 3. Main switch 4. Light switch 5. Wiring connections (the entire lighting system) Fuses (main, lighting system) 6-24...
Page 246 Electrical Checking the Lighting System 1. If the headlights fail to come on: 6-25...
Page 247 Electrical 6-26...
Page 248 Electrical Signaling System Circuit Diagram 6-27...
Page 249 Electrical Troubleshooting If the Brake light and indicator light, or the warning light fails to come on: Check the following: 1. Fuses (main, signaling system) 2. Battery 3. Main switch 4. Wiring connections (the entire signal system) 6-28...
Page 250 Electrical Checking the Signal System 1. If the brake light fails to come on: 6-29...
Page 251 Electrical 2. If the neutral light or reverse light fails to come on: 6-30...
Page 252 Electrical 3. If the parking brake indicator light fails to come on: 6-31...
Page 253 Electrical 4. If the coolant warning light does not come on when the main switch is turned to “On”, or if the coolant temperature warning light does not come on when the temperature is high (more than 117 – 123 ⁰ C (242.6 – 253.4⁰ 6-32...
Page 254 Electrical 5. If 4WD light or differential lock light does not come on： 6-33...
Page 255 Electrical Cooling System Circuit Diagram 6-34...
Page 256 Electrical Troubleshooting: The Fan Motor does not move. Check the following: 1. Fuse (main) 2. Battery 3. Main switch 4. Radiator fan motor 5. Thermo switch 3 6. Wiring connections (the entire cooling system) 6-35...
Page 257 Electrical 6-36...
Page 258 Electrical 2WD/4WD Selecting System Circuit Diagram 6-37...
Page 259 Electrical Troubleshooting: The 4WD indicator fails to come on: Check the following: 1. Fuses (main, four-wheel drive) 2. Battery 3. Main switch 4. Four-wheel drive relay 1 5. Four-wheel drive relay 2 6. Four-wheel drive relay 3 7. On-Command four-wheel drive switch and differential gear lock switch 8.
Page 260 Electrical 6-39...
Page 261 Electrical 6-40...
Page 262 Electrical TROUBLESHOOTING 1. Check if the 2/4WD switch is working. • Turn on the switch, put the gear to position N; keep front and rear wheel off the ground , and then roll the front wheel to see if the rear wheel moves together with it or if it turns alone..
Page 263: Ems Introduction, Components
Engine Management System EMS Introduction, Throttle Body assembly Components Engine coolant temperature Layout sensor, Oxygen sensor Fuel Pump Module Fault Codes 7-12 Multec 3.5 Injectors...
Page 264 Engine Management System...
Page 265: Engine Management System
Engine Management System Introduction EMS (Engine Management System) EMS is a self contained set of components including a custom built computer, sensors, and actuators which control the operation of an engine by monitoring the engine speed, load and temperature. While doing that it also provides the ignition spark at the right time for the prevailing conditions and metering the fuel to the engine in the exact quantity required.
Page 266: Layout
Engine Management System Layout of EMS Components Components of EMS Electronic Control Unit The ECU continuously monitors the operating conditions of the engine through the system sensors. It also provides the necessary computation, adaptability, and output control in order to minimize the tailpipe emissions and fuel consumption, while optimizing vehicle drivability for all operating conditions.
Page 267: Multec 3.5 Injectors
Engine Management System Maintenance service and Repair Multec 3.5 Injectors ECU is a non-serviceable part. Once there The Multec 3.5 Fuel Injector is an are problems, it’s important to first electromechanical device. A magnetic field determine if the problem is caused by is generated as voltage is applied to the software/calibration.
Page 268 Engine Management System Installation Relieve fuel pressure. Follow these guidelines to prevent damage Remove the retaining clip from the fuel to the injector and its electrical interface injector. during the replacement or re-installation process. Remove the fuel line connection from the injector.
Page 269: Throttle Body Assembly
Engine Management System Plugging Disconnect the injector-cleaning tank from the system and install the fuel pump Fuel deposits cause plugging. connections. Connect the fuel feed line to injector. Plugging can cause flow restrictions, frictional changes and the collection of Start and idle the vehicle for an additional other particles attracted by the tacky 2 minutes to ensure the residual injector surface.
Page 270: Engine Coolant Temperature
Engine Management System Throttle Body Installation Intake Air Pressure and Temperature Sensor Reverse the procedure for installation noting the following: This sensor has two functions. The first is the intake manifold air temperature, it Adjust accelerator cable play. provides a resistance that varies as a function of temperature within prescribed Check to ensure that all removed parts are tolerance limits.
Page 271 Engine Management System Keep a Min distance of 150 mm (around Disconnect negative cable at battery. 6”) between coil and any VR sensor DO NOT smoke, and place ‘No device. SMOKING” sign near work area. Never route the coil C- wire with the same Make sure to have fire extinguisher handy.
Page 272 Engine Management System Fuel System Diagnosis Step Action Switch on Ignition If fuel pump running If fuel pump running key. Fuel Pump noise can be heard, noise can not be primes for 3 go to step 4. heard, go to step 2. seconds when the ignition key is ON.
Page 273 Engine Management System Fuel Module Removal: Fuel Leakage Check Procedure: Relieve fuel pressure in fuel lines referring After performing any service on fuel to the ‘Fuel Pressure Relief Procedure’ system, check to make sure that there are provided in this section. no fuel leaks as below.
Page 274: Fault Codes
Engine Management System EMS FAULT DIAGNOSIS When fault codes are triggered, the odometer's clock will turn into a number， which is a fault code, find out the cause with this number, press clock button then it will turn back to clock mode, and five seconds later, the fault code will show again. Fault Code List 7-12...
Page 275 Engine Management System Fault Code List (Con’t) 7-13...
Page 276: Mechanical Problems Spark Test
Troubleshooting ? ? ? Diagnosing electrical or Cylinder Leak Down Test mechanical problems Electrical Testing, Preliminary 8-10 Spark test checks and precautions Fuel System Intermittent Problems 8-11 Preignition, Detonation and 8-12 engine noises...
Page 277 Troubleshooting...
Page 278: Troubleshooting
Troubleshooting Diagnose electrical and Mechanical problems by using a systematic approach and remembering basic operating requirements. Define the Problem Symptoms Determine Which areas could exhibit these symptoms? Test and Analyze The Suspect Areas Verify Data The Problem By following a systematic approach, the possibility of unnecessary parts replacement can be avoided, always start with the simple and most obvious checks when troubleshooting, This would include the engine stop switch, fuel quantity and condition, fuel vale position and spark plug cap tightness.
Page 279: Spark Test
Troubleshooting When Troubleshooting or diagnosing a problem on a UTV, it is always good to use a systematic approach to solving the issue. There are 3 main things to look for to have a running motor. • A Fuel air mixture being delivered to the cylinder. •...
Page 280: Fuel System
Troubleshooting 5. Turn the engine over using the Key switch. A fat blue spark must be evident between the spark tester or spark plug terminals 6. If there is a strong, blue spark, the ignition system is functioning properly, Check for one or more of the following possible malfunctions: •...
Page 281 Troubleshooting 2. Cylinder head: • Loose spark plug or damaged spark plug hole. • Damaged cylinder head gasket. • Warped or cracked cylinder head. • Damaged decompression assembly. See Maintenance and Adjustment section for procedure. Standard 188.31 Psi Minimum 163.57 Psi Maximum 210.50 Psi Upon completion of these 3 tests you should know which system is in question and the direction of further testing or repair.
Page 282: Engine Noises
Troubleshooting Preignition Preignition is the premature burning of fuel and is caused by hot spots in the combustion chamber. Glowing deposits in the combustion chamber, inadequate Cooling or an overheated spark plug can all cause preignition. This is first noticed as a power loss but eventually causes damage to the internal parts of the engine because of the high combustion chamber temperature.
Page 283: Cylinder Leak Down Test
Troubleshooting • Valve train noise—Check for the following: 1) Excessive valve clearance. 2) Worn or damaged camshaft. 3) Damaged camshaft. 4) Worn or damaged valve train components. 5) Damaged valve lifter bore(s). 6) Valve sticking in guide. 7) Broken valve spring. 8) Low oil pressure.
Page 284 Troubleshooting Note: Because the following test is performed with the cylinder head cover installed on the engine, the camshaft lobes cannot be viewed to ensure that the engine is positioned at TDC on its compression stroke. To determine when the engine is approaching TDC on its compression stroke, or whether it is 360°off.
Page 285: Electrical Testing, Preliminary
Troubleshooting Note: Because of play in the transmission gears, it is unlikely the engine will stay at TDC on the first try If the crankshaft turns, reposition the countershaft slightly and then relock it in position with the holding tool. After several attempts, you will get a feel of the transmission play and know what direction the countershaft should be turned and locked.
Page 286: Intermittent Problems
Troubleshooting • Disconnect each electrical connector in the suspect circuit and make sure there are no bent terminals in the electrical connector. • Make sure the terminals on the end of each wire are pushed all the way into the connector.
Page 287: Ecu
Troubleshooting Caution: A heat gun or hair dryer will quickly raise the heat of the component being tested. ℃ ℃ ℃ ℃ ℉ ℉ ℉ ℉ Do not apply heat directly to the ECM or use heat in excess of 60 (140 ) on any electrical component.
Page 293 HISUN MOTORS 1434 Patton Place Suite 106 Carrollton, Texas 75007 (972) 446-0760 (877) 838-6188 www.hisunmotors.com...

Hisun HS400 Service Manual

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Chapter 2 Specifications

Chapter 5 Chassis

Chapter 6 Electrical

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