Hisun HS 400 User manual

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
MANUAL
CAREFULLY
For questions regarding
this UTV, please
contact HISUN at:
[phone]
www.hisunmotors.com
REV. 06051401
SERVICE
MANUAL
HS400

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 docu ent of technique.
This anual gives ethods to check, aintain and repair utility terrain vehicles (UTV’s),
and supplies so e relevant techniques and perfor ance data. So e
techniques and ethods inside ay be used to check, aintain and repair other odels
of UTV, although it is ainly for the HS400UTV.
Please read the handbook through and fully understand it; otherwise, any i proper
repairing could bring you proble s, and or an accident ay occur.
Proper use and aintenance can guarantee the UTV being driven safely, reduce its
alfunctions, and help the vehicle re ain at its best perfor ance level.
The standards, procedures and specifications entioned in this anual are based on
the sa ple in design, and they are subject to changes according to the product’s
i prove ent without prior notice.
Second version , May, 2014
Published by Chongqing Huansong Industries (Group) Co., Ltd.
Chongqing Huansong Industries (Group) Co., Ltd holds the copy right.
No publishing and reprinting without per ission.

INDEX
Chapter 2
Specifications
Chapter 3
Periodic
Maintenance and
Adjustments
Chapter 4
Engine
Chapter 5
Chassis
Chapter 6
Electrical
Chapter 7
Engine
Management
S stem
Chapter 8
Troubleshooting
???
Wiring
Diagrams
Index
1.
2.
3.
Chapter 1
General

INDEX

INDEX
Chapter 1 General
Warnings, Cautions, Notes
Description
Identification Code, Frame
Number, Engine Number
Safet
Handling Gasoline safel
Cleaning Parts, Warning Labels,
Serial Numbers, Fasteners
Self locking Fasteners, Cotter
Pins
Snap Rings and E-clips
Shop Supplies
Basic Tools
Wrenches
Torque Wrenches
Ignition Grounding Tool
Precision Measuring Tools
Micrometers
C linder Bore Gauge,
Compression Gauge
Electrical S stem Fundamentals
Basic Service Methods
Storage
Chapter 2 Specifications
Conversion table
General Specs
Engine Specs
Chassis Specs
Electrical Specs
Engine Torque Specs
Chassis Torque Specs
General Torque Specs
Engine Lubrication Points and
t pe of lubricant
Chassis Lubrication Points and
t pes of lubricant
Chapter 3
Maintenance schedule
Valve Adjustment
1-3
1-4
1-5
1-6
1-7
1-8
1-9
1-10
1-11
1-13
1-14
1-17
1-19
1-20
1-21
1-26
1-27
1-27
1-36
2-3
2-4
2-6
2-11
2-14
2-16
2-19
2-21
2-22
2-23
3-3
3-5
Idle
Adjustment
Spark Plug, Compression test
Engine Oil
Air filter
Coolant level
V-Belt
Spark arrester
Brake Pedal
Brake Pads
Brake Lines
Shift Lever Adjustment
Final Gear oil
Steering s stem
Tires
Shock Absorbers
Headlight adjustment
Chapter 4 Engine
Engine Notes
Engine removal
C linder head and C linder head
cover
Rocker Arms and camshaft
Valves and valve springs
C linder and Piston
Engine cooling fan and A.C.
magneto
Balancer Gears and Oil Pump
Gears
Primar and Secondar Sheaves
Primar Sheave
Secondar Sheave
Clutch
Clutch Housing Assembl
Crankcase, Starter Motor and Oil
Filter
Crankcase
Crankcase Bearings
Crankshaft and oil Pump
Oil Pump
Transmission
Drive Axle Assembl
Middle Drive shaft
Middle Driven shaft
Intake Manifold Assembl
3
-
6
3-7
3-8
3-10
3-11
3-15
3-16
3-16
3-18
3-19
3-20
3-21
3-23
3-24
3-25
3-27
4-3
4-4
4-5
4-9
4-13
4-18
4-22
4-27
4-29
4-30
4-31
4-35
4-36
4-39
4-41
4-42
4-45
4-46
4-49
4-50
4-53
4-54
4-58