Crossfire 1000GTR Manual

FOREWORD
Brief introduction to maintenance handbook of
HS1000UTV/HS900UTV/HS800UTV-5
The handbook is edited by Technical Center of Chongqing Huansong Science And
Technology Industrial Co.,Ltd, and is supplied to dealers and technicians as document of
technique.Mainly, the handbook gives methods to check, maintain and repair utility terrain
vehicles （UTV）, and supplies some relevant technique and performance data. Some
techniques and method inside may be used to check, maintain and repair other models of
UTV, although it is mainly for HS1000UTV/HS900UTV/HS800UTV-5.
Please read the handbook through and fully understand it; otherwise, any improper
repairing and amounting would bring you problems, and accident may occur in your use.
Proper use and maintenance can guarantee UTV being driven safely, reduce its
malfunction, and help the vehicle remain its best performance.
The standards, performances and specifications mentioned in interpretation are
based on the sample in design, and they are subject to changes according to the
product’s improvement without prior notice.
First version ,October, 2014
Published by Chongqing Huansong Science And Technology Industrial Co.,Ltd
Chongqing Huansong Science And Technology Industrial Co.,Ltd holds the copy right.
No publishing and reprinting without permission.

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CONTENT
CHAPTER 1
GENERAL INFORMATION
GENERAL INFORMATION……………………………………………………………………1
WATNINGS, CAUTIONS AND NOTES……………………………………………………1
DESCRIPTION……………………………………………………………………………………2
IDENTIFICATION CODE……………………………………………………………………… 3
Frame No. ………………………………………………………………………………… 3
Engine No. ………………………………………………………………………………… 3
SAFETY ………………………………………………………………………………………… 4
Handing gasoline safely…………………………………………………………………… 4
Cleaning parts……………………………………………………………………………… 5
Warning labels……………………………………………………………………………… 5
SERIAL NUMBERS…………………………………………………………………………… 6
FASTENERS…………………………………………………………………………………… 6
Torque specifications ……………………………………………………………………… 6
Self-locking fasteners……………………………………………………………………… 6
Washers…………………………………………………………………………………… 6
Cotter pins…………………………………………………………………………………… 7
Snap rings and E-clips …………………………………………………………………… 7
SHOP SUPPLIES……………………………………………………………………………… 8
Lubricants and Fluids……………………………………………………………………… 8
Engine oils…………………………………………………………………………………… 8
Greases……………………………………………………………………………………… 8
Brake fluid…………………………………………………………………………………… 9
Coolant……………………………………………………………………………………… 9
Cleaners, Degreasers and solvents …………………………………………………… 9
Gasket sealant…………………………………………………………………………… 9
Gasket remover ………………………………………………………………………… 10
Thread locking compound……………………………………………………………… 10
BASIC TOOLS ………………………………………………………………………………… 10
Screwdrivers……………………………………………………………………………… 11

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CONTENT
CHAPTER 1
GENERAL INFORMATION
GENERAL INFORMATION……………………………………………………………………1
WATNINGS,CAUTIONS AND NOTES……………………………………………………1
DESCRIPTION……………………………………………………………………………………2
IDENTIFICATION CODE……………………………………………………………………… 3
Frame No. ………………………………………………………………………………… 3
Engine No. ………………………………………………………………………………… 3
SAFETY ………………………………………………………………………………………… 4
Handing gasoline safely…………………………………………………………………… 4
Cleaning parts……………………………………………………………………………… 5
Warning labels……………………………………………………………………………… 5
SERIAL NUMBERS…………………………………………………………………………… 6
FASTENERS…………………………………………………………………………………… 6
Torque specifications ……………………………………………………………………… 6
Self-locking fasteners……………………………………………………………………… 6
Washers…………………………………………………………………………………… 6
Cotter pins…………………………………………………………………………………… 7
Snap rings and E-clips …………………………………………………………………… 7
SHOP SUPPLIES……………………………………………………………………………… 8
Lubricants and Fluids……………………………………………………………………… 8
Engine oils…………………………………………………………………………………… 8
Greases……………………………………………………………………………………… 8
Brake fluid…………………………………………………………………………………… 9
Coolant……………………………………………………………………………………… 9
Cleaners,Degreasers and solvents …………………………………………………… 9
Gasket sealant…………………………………………………………………………… 9
Gasket remover ………………………………………………………………………… 10
Thread locking compound……………………………………………………………… 10
BASIC TOOLS ………………………………………………………………………………… 10
Screwdrivers……………………………………………………………………………… 11

2
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Wrenches ………………………………………………………………………………… 11
Adjustable wrenches …………………………………………………………………… 12
Socket wrenches, ratchets and handles ……………………………………………… 12
Impact drivers …………………………………………………………………………… 13
Allen wrenches…………………………………………………………………………… 13
Torque wrenches………………………………………………………………………… 13
Torque adapters ………………………………………………………………………… 14
Pliers……………………………………………………………………………………… 15
Snap ring pliers…………………………………………………………………………… 15
Hammers ………………………………………………………………………………… 16
Ignition grounding tool…………………………………………………………………… 16
PRECISION MEASURING TOOLS ………………………………………………………… 16
Feeler gauge ……………………………………………………………………………… 16
Calipers…………………………………………………………………………………… 17
Micrometers……………………………………………………………………………… 18
Adjustment ……………………………………………………………………………… 18
Care ……………………………………………………………………………………… 19
Metric micrometer………………………………………………………………………… 19
Standard inch micrometer……………………………………………………………… 20
Telescoping and small bore gauges…………………………………………………… 21
Dial Indicator……………………………………………………………………………… 21
Compression gauge……………………………………………………………………… 22
Multimeter………………………………………………………………………………… 22
Cltp-on ammeter………………………………………………………………………… 22
Magneto puller………………………………………………………………………………23
ELECTRICAL SYSTEM FUNDAMENTALS……………………………………………… 23
Voltage …………………………………………………………………………………… 23
Resistance………………………………………………………………………………… 23
Amperage………………………………………………………………………………… 23
BASIC SERVICE METHODS……………………………………………………………… 24
Removing frozen fasteners……………………………………………………………… 25
Removing broken fasteners …………………………………………………………… 25
Repairing damaged threads …………………………………………………………… 26
Stud Removal/Installation ……………………………………………………………… 26
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Removing hoses ………………………………………………………………………… 26
Bearings…………………………………………………………………………………… 27
Removal…………………………………………………………………………………… 27
Installation………………………………………………………………………………… 28
Interference fit …………………………………………………………………………… 28
Seal replacement………………………………………………………………………… 30
STORAGE……………………………………………………………………………………… 30
Storage area selection…………………………………………………………………… 30
Preparing the motorcycle for storage …………………………………………………… 30
Returning the UTV to service…………………………………………………… 31
TROVBLESHOOTING……………………………………………………………………… 31
ENGINE PRINCIPLES AND OPERATING REQUIREMENTS………………………… 32
STARTING THE ENGINE ………………………………………………………………… 32
Engine is cold …………………………………………………………………………… 33
Engine is warm…………………………………………………………………………… 33
Flooded engine……………………………………………………………………………33
ENGINE WILL NOT START ……………………………………………………………… 34
Identifying the problem ………………………………………………………………… 34
Spark test………………………………………………………………………………… 35
The starter cannot work repeatedly or can only work slowly………………… 36
POOR ENGINE PERFORMANCE………………………………………………………… 36
The engine starts slowly or difficultly…………………………………………… 36
Engine backfires, cuts out or misfires during acceleration…………………………… 36
The engine is not idling or cannot idle stably…………………………………………… 37
Poor fuel mileage………………………………………………………………………… 37
Engine will not idle or idles roughly …………………………………………………… 37
Low engine power ………………………………………………………………………… 37
Poor idle or low speed performance…………………………………………………… 39
Poor high speed performance ………………………………………………………… 39
FUEL SYSTEM……………………………………………………………………………… 39
Rich mixture……………………………………………………………………………… 40
Lean mixture……………………………………………………………………………… 40
ENGINE………………………………………………………………………………………… 40
Engine smoke……………………………………………………………………………… 40

3
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Removing hoses ………………………………………………………………………… 26
Bearings…………………………………………………………………………………… 27
Removal…………………………………………………………………………………… 27
Installation………………………………………………………………………………… 28
Interference fit …………………………………………………………………………… 28
Seal replacement………………………………………………………………………… 30
STORAGE……………………………………………………………………………………… 30
Storage area selection…………………………………………………………………… 30
Preparing the motorcycle for storage …………………………………………………… 30
Returning the UTV to service…………………………………………………… 31
TROVBLESHOOTING……………………………………………………………………… 31
ENGINE PRINCIPLES AND OPERATING REQUIREMENTS………………………… 32
STARTING THE ENGINE ………………………………………………………………… 32
Engine is cold …………………………………………………………………………… 33
Engine is warm…………………………………………………………………………… 33
Flooded engine……………………………………………………………………………33
ENGINE WILL NOT START ……………………………………………………………… 34
Identifying the problem ………………………………………………………………… 34
Spark test………………………………………………………………………………… 35
The starter cannot work repeatedly or can only work slowly………………… 36
POOR ENGINE PERFORMANCE………………………………………………………… 36
The engine starts slowly or difficultly…………………………………………… 36
Engine backfires, cuts out or misfires during acceleration…………………………… 36
The engine is not idling or cannot idle stably…………………………………………… 37
Poor fuel mileage………………………………………………………………………… 37
Engine will not idle or idles roughly …………………………………………………… 37
Low engine power ………………………………………………………………………… 37
Poor idle or low speed performance…………………………………………………… 39
Poor high speed performance ………………………………………………………… 39
FUEL SYSTEM……………………………………………………………………………… 39
Rich mixture……………………………………………………………………………… 40
Lean mixture……………………………………………………………………………… 40
ENGINE………………………………………………………………………………………… 40
Engine smoke……………………………………………………………………………… 40