Hisun HS500ATV User manual

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HS500ATV Maintenance Manual

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Catalogue
General Information ……………………………...5
1 Description …………………………………………………..5
1.1 Identification code………..……………………………..6
1.1.1. Frame No. …………………………………………………6
1.1.2. Engine No.…………………………………………………7
1.2 Special tools, instruments and meters…………………7
1.3 Periodic maintenance chart……………………………….9
Engine ………………………………………………………….11
2. Inspection and adjustment of engine …………….11
2.1 Inspection of cylinder head, intake
and exhaust valve………………………………………….11
2.2 Inspection of spark Plug………………………………….12
2.3 Inspection of cylinder, piston and piston ring…….14
2.4 Inspection of crankshaft………………………………….17
2.5 Inspection of clutch……………………………………….18
2.6 Inspection of carburetor………………………………….18
2.7 Inspection of air filter………………………………….19
2.8 Inspection of oil filter………………………………….20
2.9 Inspection of lubrication system……………………….20

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2.10 Lubrication of engine…………………………………….21
2.11 Inspection of cylinder head…………………………….21
3.Disassembly of engine ……………………………………27
3.1 Cylinder head and block………………………………….27
3.2 Piston and connecting rod……………………………….31
3.3 Manual starting mechanism……………………………….32
3.4 Sensor………………………………………………….…….32
3.5 Left crankcase cover……………………………….…….33
3.6 Magneto…………………………………………………..….33
3.7 Oil pump………………………………………….……..….34
3.8 Clutch…………………………………………………...….35
3.9 Carburetor……………………………………………...….36
3.9.1 Structure of carburetor………………………...…..36
3.9.2 Inspection and adjustment of carburetor…....….37
4.Chassis
4.1 Steering operation system………………………...…..39
4.2 Brake system…………………………………………...….51
4.3 Wheels and tires……………………………………...….67
4.4 Transmission system…………………………….…...….70
4.5．gear
geargear
gearshiftmechanism……………………………………..77
4.6
Suspension…………………………..……....….。。。。。.79

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5. Electrical system ………………………..……....….84
5.1 Ignition system…………………………..……....….87
5.2 Magneto and charging system…………..……....….88
5.3 Battery……………………………………..……....….88
5.4 Lighting system…………………………..……....….90
5.5 Meterand signal system…………………………..……91
5.6 Electrical starting system…………….……..…….92
6.Appendix ………………..…………………..……....…93
6.1 Specification………..…………………..……....….93
6.2 Requirements for torque of fastener……………….99
6.3 Electrical circuits……………………………....….100

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General Information
1 Description

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1.1 Identification code
1.1.1. Frame No.
The frame No. is engraved in the right bottom of the supporting
frame. See Figure 1-1
Figure 1-1
1.1.2. Engine No.
The engine No. is engraved in the right side of the engine.
See figure 1-2

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Figure 1-2
1.2 Special tools, instruments and meters
1.2.1 Oil filter detacher
To fasten and detach the oil filter
1.2.2 Height gauge
To gauge the height of various components
1.2.3 Vernier
To measure the length of various components
1.2.4 尺 Outside micrometer
To accurately measure external
diameter of a column

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1.2.5 Inside micrometer
To accurately measure internal
diameter of a hole
1.2.6 Dial indicator
To accurately measure a small distance
1.2.7 Torque Spanner
To measure torque force
1.2.8 Feeler gauge
To measure gap-width
1.2.9 Multimeter
To check electrical circuits and parts
1.2.10 Barometer
To measure pressure of the tyre

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1.2.11 Magneto drawing device
To detach the magneto
1.2.12 Snap ring clampTo install
and detach snap rings
1.3 Pe riodic maintenance chart
EVERY INITAL
month
1 3 6 6 12
km 320 1,200 2,400
2,400 4,800
(mi) (200) (750) (1,500)
(1,500) (3,000)
ITEM
ROUTINE
Whicheve
comes first
hours 20 75 150 150 300
Valves ● Check valve clearance.
●Adjust if necessary. ○ ○ ○ ○
Sparkplug
●Check condition.
●Adjust gap and clean.
●Rep;ace if necessary.
○ ○ ○ ○ ○
Air fiter element
● clean.
●Replace if necessary.
Every20-40hours
（More often in wet of dusty areas.）
Carburetor* ● Checkandadjustidlespeed/starteroperation.
● Adjust if necessary.
○ ○ ○ ○
Crankcase
breathersystem*
● Check breather hose for cracks of
damage.
● Replace if necessary.
○ ○ ○
Exhaust system*
● Check for lecakage.
● Tighten if necessany.
● Replace gasket(s) if necessary.
○ ○ ○
Spark arrester ● Clean.
○ ○ ○
Fuel line* ● Check fuel hose for cracks or damage.
● Replace if necessaly.
○ ○ ○
Engine oil ●Replace.(Wamenginebefore draining.)
○ ○ ○ ○

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Engine oil filter
cartridge ●Replace.
○ ○ ○ ○
Engine oil strainer*
●Clean.
○ ○ ○ ○
Final gear oil
Differential gear oil
● Check for oil leakage.
● Replace eveny 12 months.
○ ○
Front brake*
● Check operation/fuid leakage.(See NOTE
page 8).
● Correct if necessary.
○○○○ ○
Rear brake* ● Check operation.
● Adjust if necessary.
○○○○ ○
Select lever safety
system cable
● Check operation.
● Adjust if necessary.
○○ ○
V-belt* ● Check operation.
● Check for cracks or damage.
○○○ ○
Wheel ● Check balance/damage/
● Repair if necessary.
○○○○
Wheel bearing*
● Check bearing assemblies for lossenss/
damage.
● Replace if necessary.
○○○○
Front and rear
suspendion*
● Check operation.
● Correct if necessary.
○○
Steering system* ● Checkoperation./Replace if damaged
● Check toe-in./Adjust if necessaly.
○○○○○
Drive shaft universal
joint*
● Lubricate with lithium–soap–bassed
grease.
○○○
Axle boots* ● Check operation.
● Replace if damaged.
○○○○○
Fittings and
fasteners*
● Check all chassis fittings and fastenrs.
● Correct if necessary.
○○○○○
Lights and
switches*
● Check operation.
● Adijust headinght beams.
○○○○○
engine
2. Inspection and adjustment of engine
2.1.1
2.1.1 2.1.1
2.1.1 Inspection cylinder head, intake and exhaust system
check the pressure of cylinder

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Preheat the engine, then misfire and unplug the spark
plug.Fix pressure gauge into the hole.
Note: Giving a leakage check to the pressure gauge.
Rotate the engine until the pressure gauge stop rising.
The maximum reading would be greater than0.7- 0.9Mpa
after starting for 4-6 times. See figure 2-1.
Figure 2-1
Check the valve clearance
Note:when adjust valve clearance,the engine must be
cooled.(The tempreture should be less than 35℃ )
Remove the seat cushion and fuel tank,unplug the vision hole
cover ,round the flywheel of magneto anti-clockwise to aim “T”
at the signal of fore cover on the left.
Note: The piston must be fixed to the top dead enter .
(Figure 2-2)

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Remove cylinder valve cover,check the clearance between the
valve stem by feeler gauge .
Valve clearance:inlet and exhaust valve: 0.05～0.08mm.
See figure 2-3.
Figure 2-3
Loose the lock nut,rotate the adjusting screw until it
appears that the feeler gauge be pulled .Then fasten the
adjusting screw by valve adjuster,tighten the lock nut and
check the valve clearance .After installing the cylinder
valve cover , vision hole cover,the fuel tank and cushion.See
figure 2-4.

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Figure 2-4
2.1.2
2.1.22.1.2
2.1.2 Spark Plug checking
1.Unplug the Spark-Plug cap:remove the spark plug by
spanner,look over whether the spark-plug insulator and
electrode is damaged or sooting. If so ,see figure 2-5.
Figure 2-5
1． Check the spark clearance by feeler gauge whether it is
between 0.6～0.7mm.Or adjust the gap,clean incrustation with
spark-plug cleaner and steel wire brush and check if the spark
plug sealing washer(Figure 2-6).

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Figure 2-6
3.Swirl the spark plug and tighten to 18 ～ 20N.m by
spanner ,then fix the spark plug cap when assembling.
2.1.3 cylinder,piston,piston ring
Specification

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diagnosing and eliminating of malfunction:
● Emission of black smoke for abrasion of cylinder or piston,
1. Cylinder , piston of piston ring is worn out.
2.The piston ring is not properly assembled.
3. The piston or cylinder wall is scraped.
●
●●
● overhea
overheaoverhea
overheated
tedted
ted
1 Excessive incrustation of piston.
2 Blast and abnormal noise.
项目item
标准值 mm
standard value: mm
维修极限值 mm
limit value:mm
气缸内径 Inner
diameter of
cylinder
φ84.503～φ84.527
φ84.6
taper 0.0040 0.005
out of roundness 0.0035 0.005
cylinder
degree of warp 0.04 0.10
Outside diameter of piston φ84.47～φ84.45 φ84.35～φ84.25
Inner diameter of piston pin
hole
φ20.002～φ20.01
φ20.05～φ20.1
gap between piston pin and
piston pin hole
0.002～0.019 0.03
Piston ring
end
clearance
Top ring/the
second ring
0.2～0.4 0.5～0.7
oil ring 0.03～0.15 0.3～0.5
top ring 0.03～0.07 0.10～0.15
gap between
piston ring
and piston
groove second ring 0.02～0.06 0.09～0.14
gap between cylinder and
piston
0.033～0.062 0.07～0.10
Piston,piston
ring and
piston pin
outside diameter of piston
pin
φ19.991～φ20 φ19.95～φ19.97
Inner diameter φ 20.016 ～ φ
20.027
φ20.05
Crank shaft
Gap between small end of
connecting rod and piston
pin
φ0.018～φ0.036 0.05

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3 Abrasion of cylinder or piston.
Inspection of cylinder.
1.Check whether the cylinder is damaged.
2.Measure the bore diameter of cylinder at three spots.
3.At the top,the middle and the bottom of the piston
stroke .And measure the bore diameter at directions of
right-angle intersection
repairing limit value:
out of roundness: 0.005 mm
taper ：0.005mm
Inspection of piston and piston ring
1. Measure the gap between piston ring and piston groove.
2. The first ring
3. The second ring
Note:It is forbidden to damaging the piston ring when
assembling.Check whether the piston and the piston
groove is cracked and abraded .See figure 2-9.

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Figure 2-9
：0.5mm。
Insert piston ring into cylinder,and measure the end gap.
repairing limit value:the first ring/the second ring: 0.5mm
See figure 2-10 .
Figure 2-10
Measure the bore diameter of piston pin hole.
repairing limit value: see figure 2-11.

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Figure 2-11
Measure the external diameter 10mm above the bottom of the
piston skirt.
Extreme position :the gap between cylinder and piston
repairing limit value: 0.1mm
See figure 2-12.
1、
Figure 2-12
7． Measure the external diameter of piston pin:
the gap between piston and piston pin:
0.02mm
repairing limit value: 0.02mm .See figure 2-13.

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Figure 2-13
2.1.4 Inspection of crank and connecting rod
Check that whether crank and connecting rod can rotate without
stuck and whether the clearance between crank and connecting
rod is 0.5～0.6mm.The hop of crank shaft should be 0.05mm.If
not so,replace it. See figure 2-14-1, figure 2-14-2.
Figure 2-14-1 Figure 2-14-2