Hisun HS 500UTV-5/HS User manual

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]
hisunmotors.com
Rev. 08071501
No one under the age of 16
should operate this vehicle.
Provincial / Municipal
governments have dierent
regulations pertaining to
owning and operating an
o-road vehicle; learn the
regulations in your area.
SECTOR 550/750
OWNER’S MANUAL
TM
GRAB SOME SUN

Introduction HS 550/750UTV
1-1
INTRODUCTION
Congratulations on your purchase of the HS 500UTV-5/HS 550UTV/HS 600UTV-3/HS
700UTV-7/HS 750UTV. This Owner’s / Operator’s manual will provide you information
regarding safe operation, operational instructions, maintenance and care. Fully
understanding this manual and following all of the instructions herein will provide the
knowledge needed to have safe and enjoyable UTV operation.
For questions regarding this UTV, please call [phone].
IMPORTANT SAFETY MESSAGES
●READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR UTV.
MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS.
●PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE UTV.
●NEVER OPERATE THE UTV WITHOUT PROPER TRAINING OR INSTRUCTION.
●THIS UTV SHOULD NOT BE RIDDEN BY ANYONE UNDER
16 YEARS OF AGE.

Introduction HS 550/750UTV
1-2
IMPORTANT MANUAL INFORMATION
FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS
INJURY OR DEATH. Particularly important information is distinguished in this manual by the
following notations:
The Safety Alert Symbol means ATTENTION!
YOUR SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to
the machine operator, bystander or a person inspecting or repairing the
machine.
A CAUTION indicates special precautions that must be taken to avoid damage
to the machine.
NOTE: A NOTE provides key information to make procedures easier clearer.

1-3
Introduction HS 550/750UTV
IMPORTANT NOTICE
This UTV is designed and manufactured for OFF - ROAD use only. It is illegal and unsafe to operate this
UTV on any public street, road or highway.
This UTV complies with all applicable OFF - ROAD noise level and spark arrester laws and regulations in
effect at the time of manufacture.
Please check your local riding laws and regulations before operating this UTV.
When the temperature is below -4°F (-20°C), park the UTV in a place where the temperature is higher
than -4°F (-20°C). Start the UTV after the UTV has warmed up. Please see page 7-3 on the warming up
process.
Follow the proper parking procedures when the temperature is higher than 100°F (38°C): turn off the
engine; make sure the radiator fan is on for 3minutes before turning off the power switch.
Starting the UTV for the first time will take longer because the fuel will need reach the fuel injectors. To
start the UTV the first time, hold the ignition key on at 5-second intervals. Allow the starter to rest 15
seconds between each start attempt.

1-4
Introduction HS 550/750UTV
NIVERSAL SYMBOLS
As a guide to the operation of your vehicle, various universal symbols have been utilized on the
instruments and controls. The symbols are shown below with an indication of their meaning.
Safety Alert Symbol Lift Cylinder-Retract
Diesel Fuel Lift Cylinder-Extend
Engine coolant-Temperature Lift Cylinder-Float
Parking Brake Hazard Warning Lights
Battery Charging Condition Master Lighting Switch
Engine Oil-Pressure Audible Warning Device
Turn Signal/Hazard Fault indicator light of EPS system
Differential Lock 2WD/ 4WD
Position light bulb

Introduction HS 550/750UTV
1-5
Table of Contents
Subject Page
Introduction 1-1
Important manual information 1-2
Important notice 1-3
Universal symbols 1-4
Location of parts 1-7
Illustrated contents 1-11
Safe operation 2-1
Safety instructions 2-1
Operation 2-2
Children safety instructions 2-3
Driving on a slope 2-3
Driving in harsh conditions 2-3
Driving at high speed 2-3
Instructions for carrier 2-4
Parking 2-4
Transportation 2-4
Maintenance 2-4
Warning and caution labels 3-1
Servicing of vehicle 4-1
Specifications table 5-1
Vehicle limitations 5-4
Pre-operation 6-1
Operating the engine 7-1
Starting the engine 7-1
Cold starting 7-2
Stopping the engine 7-2
Warming up 7-2
Warm-up transmission oil in the low
temperature range
7-3
Operating the vehicle 8-1
Operating new vehicle 8-1
Do not operate the vehicle at full
speed for the first 50 hours
8-1
Changing lubricating oil for new vehicles 8-1
Subject Page
Starting 8-1
Seat belt 8-1
Head light switch 8-2
Emergency light switch 8-2
Turn signal light switch 8-2
Brake pedal 8-3
Range gear shift lever 8-4
4WD lever 8-5
Accelerator pedal 8-5
Stopping 8-5
Fuel gauge 8-6
Winch mount plate 9-1
Transporting vehicle 9-1
Service intervals 9-2
Periodic service 10-1
How to open the front hood and seat 10-1
Front hood cover 10-1
Operator’s sea 10-1
How to raise the cargo bed 10-1
Raising and Lowering the Cargo Bed 10-1
Jack-up point 10-2
Front end 10-2
Rear end 10-2
Daily check 10-2
Walk around inspection 10-3
Checking and Refueling 10-3
Checking coolant level 10-3
Cleaning radiator screen 10-4
Checking brake fluid level 10-4
Checking brake pedal 10-5
Checking parking brake 10-5
Checking gauges meter and easy
checker lamps
10-5
Checking head light turn signal light etc 10-5

Introduction HS 550/750UTV
1-6
Checking seat belt and ROPS 10-5
Checking joint boot 10-5
Checking tire inflation pressure 10-6
Every 50 hours 10-6
Greasing 10-6
Checking engine start system 10-7
Checking wheel bolt torque 10-7
Cleaning air cleaner primary element 10-8
Checking battery condition 10-9
Adjusting toe-in 10-10
Cleaning muffler 10-11
Every 200 hour 10-11
Changing engine oil 10-11
Replacing engine oil filter 10-12
Replacing transmission oil 10-12
Checking brake pedal 10-13
Checking brake hose and pipe 10-13
Checking brake light switch 10-13
Checking radiator hose and clamp 10-13
Checking intake air line 10-14
Every 300 hours 10-14
Checking tire 10-14
Every 400 hours 10-15
Changing transmission fluid 10-15
Changing front and rear axle case oil 10-15
Every 500 hours 10-15
Replacing fuel filter 10-15
Every 600 hours 10-15
Adjusting engine valve clearance 10-16
Every 1500 hours 10-16
Checking injection and fuel pump 10-16
Every 1 year 10-16
Replacing air cleaner primary element
and secondary element
10-16
Every 2 years 10-16
Changing brake fluid 10-16
Flushing Cooling system and changing
coolant
10-16
Anti-freeze 10-16
Replacing radiator hose (water pipes) 10-18
Replacing fuel hose 10-18
Replacing brake master cylinder (inner
parts)
10-18
Replacing front brake seal 10-18
Replacing rear brake cylinder seal 10-18
Replacing intake air line 10-18
Every 4 years 10-18
Replacing brake hose 10-18
Replacing slow-blow fuses 10-18
Storage 10-19
Vehicle storage 10-19
Removing the vehicle from storage 10-20
Troubleshooting 11-1
Engine troubleshooting 11-1
Diagnostic trouble code table 11-2
Battery troubleshooting 11-3
Machine troubleshooting 11-4
Options 12-1
Emissions warranty 13-1

Introduction HS 550/750UTV
1-7
LOCATION OF PARTS
Bench seat

Introduction HS 550/750UTV
1-8
Bucket seat

1-9
Introduction HS 550/750UTV
ILLUSTRATED CONTENTS
Bench seat

Introduction HS 550/750UTV
1-10
Bucket seat

Introduction HS 550/750UTV
1-11
Bench seat

Introduction HS 550/750UTV
1-12
Bucket seat

Safe Operation
2-1
All operators, including experienced UTV drivers
or passengers, should carefully read and fully
understand this Users Manual, and operate
strictly as the manual states in order to achieve
the best performance and avoid accidents.
Others who will use you UTV should be trained
how to operate the UTV and be required to read
this manual before operation.
1. Safety Instructions:
1. Understand this UTV by reading this manual
and understanding all the components of the
vehicle. Only start and operate the vehicle
after finishing reading this manual.
2. Pay close attention to the warning and
caution labels on the UTV.
3. Understand completely and learn to use the
safety devices (roll-over protective structure,
seat belts), and never change original safety
devices. If safety devices are damaged,
consult your local dealer for replacement.
Always use seat belts.
Bench Seat
①Roll-over protective structure；
②Seat belts
Bucket seat
①Roll-over protective structure；
②Seat belts
4. Do not wear loosen articles of clothing
during operation, as these can be drawn into
moving parts on the vehicle and could cause
a severe injury to occur.
You should always wear protective equipment,
such as helmet, boots, eye protection, ear
protection, and gloves etc.
5. Only a qualified driver should operate this
UTV. Never operate after drinking, using
drugs or controlled products, or while
fatigued.
6. Always perform the pre-operation checks as
following:
1) Check seat belt for worn or damaged, if
necessary, replace it.
2) Check brakes, throttle, brake pedal and
other mechanical parts for proper operation.
If you discover any irregularities, replace
related parts as necessary. Periodically check
the fittings and fasteners.
3) Check engine oil level and engine coolant
level.
4) Check that the UTV is equipped to handle

Safe Operation
2-2
the surroundings.
5) Check and keep vehicle clean. Sludge,
grease and debris can cause a fire and
severe injury.
7. Passenger quantity and loading:
1) Only the driver and one passenger inside
cab. It is suggested that children under
age of 5 not be allowed as a passenger.
2) Single-row vehicle’s loading limit is 350lbs
(159KG). Reduce the loading weight
according to road conditions. Never
exceed the weight limits for operation.
8. Never allow unauthorized persons to repair
this UTV. This may affect vehicle
performance and cause injury.
9. This UTV is designed and manufactured for
off-road use only, so never drive on paved
roadways.
2. Operation
1. Start the engine only in an open ventilated
area. Carbon monoxide is colorless, odorless
and is emitted from the engine and can
cause death in areas with poor ventilation.
2. Never start the vehicle or operate the gear
selector unless seated in the driver’s seat.
3. Never start the vehicle or operate the gear
selector unless seated in the driver’s seat.
4. The driver and passenger shall always wear
their seatbelt while the vehicle is being
operated.
5. Operators of the UTV should not wear
earphones.
6. Use trailer hitch to trail cargo, otherwise,
serious injury or death will happen.
①Trailer Hitch
7. Do not accelerate quickly when starting the
engine, especially driving on rough terrain as
this can cause injury or death. Press the
accelerator pedal slowly.
8. Drive at slow speed before braking.
9. When press the differential unlocked button
(DIFF.LOCK is off), the front/rear wheels can
turn at different speed. Otherwise, the
vehicle may turnover.
10. Never drive over terrain such as a ditch, a
hole, dams, excessive mud, or the vehicle
can get stuck because of the vehicles
weight.
11.
Always pay close attention to your
surroundings, and check for streets, trail
intersections or other obstacles.
12. Always use signals in advance of turns.
13. Do not allow entrance or exit of the vehicle
while it is moving.
14. Clean dash board and Keep the floorboard
free of debris that can obstruct the ability to
use the brake pedal.
15. Position your hands on the steering wheel.
Always keep your hands and feet inside
passenger area of the vehicle. Never try to
stand while operating the vehicle.
16. Do not tow passengers, or attempt to jump
the vehicle.

Safe Operation
2-3
3. Children safety instructions
Always watch children when they are around the
vehicle. Children like to imitate adults and this
could lead to an accident.
Do not leave children alone beside the vehicle.
Keep children from the operating area of the
vehicle.
Turn off the engine and remove the key when
children are in the operating area. Never carry
children in the cargo bed. This is very dangerous
to children. Children under age of 5 are not be
allowed in this vehicle.
Never allow children to touch or climb the vehicle
even if they are under adult supervision, or
climbing on vehicle.
Always check for people or obstacles behind the
vehicle before shifting the vehicle into reverse.
Avoid a collision with an obstacle or person.
Park the vehicle on a firm, flat area. If parking on
a slope, you should use parking brake, remove
the key, and get tires stuck in the tire wedge.
4. Driving on a slope
Be cautious when riding on a slope, as this is the
main reason result for loss of control, overturn,
leading to severe injury or even death.
1. Drive in a straight line on a slope at a low-
speed.
2. Reduce weight when ride on a slope or
rough terrain.
3. Avoid the sudden application of the brakes
when you go uphill or downhill. Be more
careful when vehicle turns on a slope.
If you start to lose momentum or need to park
when climbing, use the parking brake to come to
a stop. Release the brake and begin to
4. coast down the hill.
5. If do not believe you can operate the UTV
safely in reverse do not attempt to ascend
the slope any further.
6. Riding in mud, a ditch, and on slopes will
increase the risk of an overturn. Be more
cautious when operating. Drive gradually and
slowly when climbing. Avoid sudden changes
of vehicle speed or direction.
5. Driving in harsh conditions
1. Vehicle can be operated during the day or
under good light conditions.
2. Operate the vehicle in open, smooth
pavement.
3. Under all conditions, both operator and
passengers should wear helmet and
protective equipment.
4. Driver should slow down according to road
conditions, terrain, visibility conditions.
5. Be cautious when driving over a ditch, stone
road or hidden obstacles.
6. Avoid operating in any unknown depth of
water.（water depth should not exceed axle
height）
6. Driving at high speed
1. Check for front/rear wheels conditions. Pay
attention to the differences of braking
performances between two and four-wheel
drive.
2. Slow down when turning. Turning at high
speed may result in overturn or even death.
3. Turn on your headlights at high speeds.
4. Only drive at a speed that can be controlled.
Do not use DIFF.LOCK when driving at high

Safe Operation
2-4
5. speed. Otherwise, this may cause vehicle
loss of control.
6. When driving at high speed, suddenly turning
the steering wheel will reduce vehicle
stability. Never sharply turn the steering
wheel at high speeds.
7. Instructions for carrier
1. Never carry a passenger in the cargo area.
2. Evenly distribute the cargo to maintain
proper stability. Avoid overloading the carrier.
Cargo should be securely attached.
3. Reduce loaded weight when driving on poor
road conditions or steep inclines.
4. Do not put your hands and you body under
the cargo bed when it is raised. Once
lowered, lock the cargo bed in place before
operating the vehicle. Never driving before
securing and locking the cargo bed.
8. Parking
1. Set the gear shift to the “N” position and To
release the parking brake, depress the brake
pedal.
①Parking brake.
2. Avoid stopping the vehicle on a slope. If
stopping on a slope make sure the vehicle is
stationary before exiting.
9. Transportation
1. Avoid dragging the vehicle behind another
vehicle. Use a trailer or truck to transport the
vehicle.
2. When loading or unloading, pay attention to
your surroundings and others in the area.
10. Maintenance
Stop the vehicle and park it on level ground. Pull
the parking brake and remove all cargo. Then
place shift lever on “N” position, stop the engine
and remove the key.
1. When working next to the engine, exhaust or
radiator, work only after it has cooled down.
2. Wait for the engine to stop running and cool
down before checking the coolant level.
Otherwise, you could be burned by hot fluid
or steam blown out.
3. No smoking when adding electrolyte or
refueling. Fuel tank and battery should be
kept away from sparks. Battery produces
hydrogen and oxygen during charging and
this could accelerate the risk of explosion.
4. Read and follow the instructions before
replacing the battery.
5. During maintenance, first aid kits and fire
extinguishers should be placed at your
fingertips.
6. During maintenance, you should disconnect
the battery cables.

Safe Operation
2-5
①Battery
7. Do not open radiator cap before coolant has
cooled down. When the coolant is cold, open
slowly and let the coolant pressure reduced,
and then open water cooler cap. Check for
the coolant level in the coolant reservoir. If
necessary, add coolant.
8. Tires should be mounted on rims with special
equipment by professionals.
9. Keeping specified tire pressure can help to
ensure driving safety.
10. Elevate the vehicle and place a suitable
stand under the frame when removing the
wheels. Be sure to tighten the wheel nuts to
specified torque.

Warning Labels
3-1
Warning and caution labels
（1）（2）（3）
（4）（5）（6）
（7）
（8）（9）

Warning Labels
3-2
（10）（11）
(12）(13)
(14) (15)
(16)