Hsun HS700UTV Manual

FOREWORD
Brief introduction to maintenance handbook of HS700UTV
The handbook is edited by Chongqing Hsun Industries (Group) Ltd, and is supplied to
dealers and technicians as document of technique.
Mainly, the handbook gives methods to check, maintain and repair 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
HS700UTV.
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.
Brief introduction to maintenance handbook of HS700UTV
second version , June,2009
Published by Chongqing Hsun Industries (Group) Ltd
Chongqing Hsun Industries (Group) Ltd holds the copy right.
No publishing and reprinting without permission.

1
CONTENT
DESCRIPTION AND MACHINE IDENTIFICATION 1-1
IDENTIFICATION CODE ………………………………………………………………… 1-2
Frame No. ……………………………………………………………………………… 1-2
Engine No. ……………………………………………………………………………… 1-2
CHAPTER 1
GENERAL INFORMATION
MANUAL ORGANIZATION………………………………………………………………… 1-3
WATNINGS ,CAUTIONS AND NOTES…………………………………………………… 1-3
SAFETY ……………………………………………………………………………………… 1-3
Handing gasoline safely ……………………………………………………………… 1-4
Cleaning parts…………………………………………………………………………… 1-5
Warning labels…………………………………………………………………………… 1-5
SERIAL NUMBERS………………………………………………………………………… 1-6
FASTENERS………………………………………………………………………………… 1-6
Torque specifications…………………………………………………………………… 1-6
Self-locking fasteners………………………………………………………………… 1-6
Washers…………………………………………………………………………………… 1-7
Cotter pins………………………………………………………………………………… 1-7
Snap Rings and E-clips………………………………………………………………… 1-7
SHOP SUPPLIES 1-8
Lubricants and Fluids…………………………………………………………………… 1-8
Engine oils………………………………………………………………………………… 1-8
Greases…………………………………………………………………………………… 1-9
Brake fluid………………………………………………………………………………… 1-9
Coolant…………………………………………………………………………………… 1-9
Cleaners degreasers and solvents…………………………………………………… 1-10
Gasket sealant…………………………………………………………………………… 1-10
Applying RTV sealant…………………………………………………………………… 1-10
Gasket remover………………………………………………………………………… 1-10
Thread locking Compound……………………………………………………………… 1-10
BASIC TOOLS……………………………………………………………………………… 1-11
Screwdrivers……………………………………………………………………………… 1-11
Wrenches………………………………………………………………………………… 1-12
Adjustable wrenches…………………………………………………………………… 1-13

2
Socket wrenches, ratchets and handles…………………………………………… 1-13
Impact drivers…………………………………………………………………………… 1-14
Allen wrenches………………………………………………………………………… 1-14
Torque wrenches………………………………………………………………………… 1-14
Torque adapters………………………………………………………………………… 1-15
Pliers……………………………………………………………………………………… 1-16
Snap ring pliers………………………………………………………………………… 1-16
Hammers………………………………………………………………………………… 1-16
Ignition grounding tool………………………………………………………………… 1-17
PRECISION MEASURING TOOLS……………………………………………………… 1-17
Feeler gauge…………………………………………………………………………… 1-18
Calipers…………………………………………………………………………………… 1-18
Micrometers……………………………………………………………………………… 1-19
Adjustment……………………………………………………………………………… 1-19
Care……………………………………………………………………………………… 1-20
Metric micrometer……………………………………………………………………… 1-20
Standard inch micrometer……………………………………………………………… 1-21
Telescoping and Small Bore Gauges………………………………………………… 1-22
Dial Indicator……………………………………………………………………………… 1-22
Cylinder bore gauge…………………………………………………………………… 1-23
Compression gauge…………………………………………………………………… 1-23
Multimeter………………………………………………………………………………… 1-23
Ohmmeter(analog)calibration…………………………………………………………… 1-23
ELECTRICAL SYSTEM FUNDAMENTALS 1-23
Voltage…………………………………………………………………………………… 1-24
Resistance………………………………………………………………………………… 1-24
BADIC SERVICE METHODS……………………………………………………………… 1-24
Removing frozen fasteners…………………………………………………………… 1-26
Removing broken fasteners…………………………………………………………… 1-26
Repairing damaged threads…………………………………………………………… 1-26
Stud Removal/Installation……………………………………………………………… 1-27
Removing hoses………………………………………………………………………… 1-27
Bearings…………………………………………………………………………………… 1-27
Removal…………………………………………………………………………………… 1-28
Installation………………………………………………………………………………… 1-28
Interference fit…………………………………………………………………………… 1-29
Seal replacement……………………………………………………………………… 1-31
STORAGE 1-31
Storage area selection………………………………………………………………… 1-31

3
Preparing the Motorcycle for Storage………………………………………………… 1-31
Returning the Motorcycle to Service…………………………………………………… 1-32
CHAPTER TWO TROVBLESHOOTING………………………………………………… 1-33
ENGINE PRINCIPLES AND OPERATING REQUIREMENTS………………………… 1-34
STARTING THE ENGINE ………………………………………………………………… 1-34
Engine is cold …………………………………………………………………………… 1-34
Engine is warm…………………………………………………………………………… 1-34
Starting the engine after a fall or after the engine stalls……………………………… 1-35
Flooded engine…………………………………………………………………………… 1-35
Engine cold with air temperature ……………………………………………………… 1-35
Engine cold with air temperature above 35℃（95°F）……………………………… 1-35
Cold engine with air temperature below 10℃(50°F) ………………………………… 1-35
Engine is hot……………………………………………………………………………… 1-36
Starting the engine after a fall or after the engine stalls……………………………… 1-36
Flooded engine…………………………………………………………………………… 1-36
ENGINE WILL NOT START ……………………………………………………………… 1-37
Identifying the Problem ………………………………………………………………… 1-37
Spark Test………………………………………………………………………………… 1-37
Starter Does Not Turn Over or Turns Over Slowly ………………………………… 1-39
POOR ENGINE PERFORMANCE………………………………………………………… 1-39
Engine Starts But Stalls and is Hard to Restart……………………………………… 1-39
Engine Backfires, Cuts Out or Misfires During Acceleration………………………… 1-40
Engine Backfires on Deceleration……………………………………………………… 1-41
Poor fuel mileage………………………………………………………………………… 1-41
Engine Will Not Idle or Idles Roughly ………………………………………………… 1-41
Low engine power ……………………………………………………………………… 1-41
Poor Idle or Low Speed Performance………………………………………………… 1-43
Poor high speed performance………………………………………………………… 1-43
FUEL SYSTEM……………………………………………………………………………… 1-43
Rich Mixture……………………………………………………………………………… 1-44
Lean Mixture……………………………………………………………………………… 1-44
ENGINE……………………………………………………………………………………… 1-44
Engine smoke…………………………………………………………………………… 1-44
Black smoke…………………………………………………………………………… 1-45
Blue smoke…………………………………………………………………………… 1-45
White smoke or steam…………………………………………………………………… 1-45

4
Low engine compression……………………………………………………………… 1-45
High engine compression……………………………………………………………… 1-46
Engine overheating (Cooling System) ……………………………………………… 1-46
Engine overheating (Engine) ………………………………………………………… 1-46
Preignition………………………………………………………………………………… 1-47
Detonation………………………………………………………………………………… 1-47
Power Loss Engine Noises……………………………………………………………… 1-47
ENGLNE LUBRICATION…………………………………………………………………… 1-48
High Oil Consumption or Excessive ……………………………………………………… 1-48
Exhaust smoke…………………………………………………………………………… 1-48
Low oil pressure………………………………………………………………………… 1-48
High oil pressure………………………………………………………………………… 1-49
No oil pressure…………………………………………………………………………… 1-49
Oil level too low…………………………………………………………………………… 1-49
Oil contamination………………………………………………………………………… 1-49
CYLINDER LEAKDOWN TEST…………………………………………………………… 1-49
ELECTRICAL TESTING…………………………………………………………………… 1-52
Preliminary Checks and Precautions………………………………………………… 1-52
Intermittent problems…………………………………………………………………… 1-52
Electrical component replacement…………………………………………………… 1-54
Test equipment ………………………………………………………………………… 1-54
Ammeter………………………………………………………………………………… 1-54
Self-powered test light ………………………………………………………………… 1-54
Ohmmeter ……………………………………………………………………………… 1-55
Jumper wire……………………………………………………………………………… 1-55
Test procedures………………………………………………………………………… 1-56
Voltage drop test………………………………………………………………………… 1-56
Peak voltage test………………………………………………………………………… 1-57
Continuity test…………………………………………………………………………… 1-57
Testing for a short with a self-powered test light or ohmmeter……………………… 1-58
Testing for a short with a test light or voltmeter……………………………………… 1-58
BRAKE SYSTEM…………………………………………………………………………… 1-58

5
Soft or Spongy Brake Lever or Pedal………………………………………………… 1-58
Brake drag……………………………………………………………………………… 1-60
Hard Brake Lever or Pedal Operation………………………………………………… 1-60
Hard Brake Lever or Pedal Operation………………………………………………… 1-60
Brake Squeal or Chatter………………………………………………………………… 1-61
Leaking brake caliper…………………………………………………………………… 1-61
Leaking master cylinder………………………………………………………………… 1-61
CHAPTER 2
SPECIFICATIONS
HOW TO USE CONVERSION TABLE OF UNIT……………………………………… 2-1
How to use conversion table ………………………………………………………… 2-1
Definition of unit ……………………………………………………………………… 2-1
GEBERAR SPECIFICATIONS…………………………………………………………… 2-2
ENGINE SPECIFICATIONS……………………………………………………………… 2-5
CHASSIS SPECIFICATIONS …………………………………………………………… 2-12
ELECTRICAL SPECIFICATIONS ……………………………………………………… 2-14
TIGHTENING TORQUES………………………………………………………………… 2-16
Engine tightening torques …………………………………………………………… 2-16
Chassis tightening torques…………………………………………………………… 2-19
GENERAL TIGHTENING TORQUE SPECIFICATIONS……………………………… 2-21
LUBRICATION PIONTS AND LUBRICANT TYPES ………………………………… 2-22
Engine…………………………………………………………………………………… 2-22
HYDROGRAPHIC CHART ……………………………………………………………… 2-23
LUBRICATION OIL WAY ………………………………………………………………… 2-24
CHAPTER 3
MAINTENCE AND ADJUSTMENT OF THE UTV
MAINTENANCE SCHEDULE………………………………………………………………… 3-1
ENGINE
ADJUSTING THE VALVE CLEARANCE………………………………………………… 3-3
IDLE ADJUSTMENT ……………………………………………………………………… 3-5
ADJUSTING THE THROTTLE CABLE…………………………………………………… 3-6

6
Adjusting the starter cable …………………………………………………………… 3-7
Checking the spark plug……………………………………………………………… 3-8
Checking the ignition timing ………………………………………………………… 3-9
Measuring the compression pressure ……………………………………………… 3-10
Checking the engine oil level ……………………………………………………… 3-11
Changing the engine oil ……………………………………………………………… 3-12
CHASSIS
Cleaning the air filter ………………………………………………………………… 3-15
Checking the coolant level …………………………………………………………… 3-16
Changing the coolant ………………………………………………………………… 3-16
Checking the coolant temperature warning light ………………………………… 3-19
Checking the v-belt ………………………………………………………………… 3-20
Cleaning the spark arrester ……………………………………………………… 3-21
Adjusting the brake pedal …………………………………………………………… 3-22
Adjusting the parking brake ………………………………………………………… 3-23
Checking the brake fluid level ……………………………………………………… 3-23
Checking the front brake pads …………………………………………………… 3-24
Checking the rear brake pads …………………………………………………… 3-24
Checking the brake hoses and brake pipes ………………………………………… 3-25
Bleeding the hydraulic brake system ……………………………………………… 3-25
Adjusting the select lever shift rod ………………………………………………… 3-26
Adjusting the brake light switch ……………………………………………………… 3-27
Checking the final gear oil level …………………………………………………… 3-27
Changing the final gear oil ………………………………………………………… 3-28
Checking the differential gear oil …………………………………………………… 3-28
Changing the differential gear oil …………………………………………………… 3-29
Checking the constant velocity joint dust boots …………………………………… 3-30
Checking the steering system …………………………………………………… 3-30
Adjusting the toe-in …………………………………………………………………… 3-31
Adjusting the front shock absorbers ……………………………………………… 3-32
Adjusting the rear shock absorbers ………………………………………………… 3-32
CHECKING THE TIRES ………………………………………………………………… 3-33
CHECKING THE WHEELS ………………………………………………………… 3-34
CHECKING AND LUBRICATING THE CABLES………………………………………… 3-35
ELECTRICAL
Checking and charging the battery ……………………………………………………… 3-36
Checking the fuses ………………………………………………………………… 3-41
Adjusting the headlight beam …………………………………………………………… 3-43

7
Changing the headlight bulb …………………………………………………………… 3-43
Changing the tail/brake light bulb ………………………………………………………… 3-44
CHAPTER 4
ENGINE
ENGINE NOTE …………………………………………………………………………… 4-1
ENGINE REMOVAL………………………………………………………………………… 4-2
CYLINDER HEAD AND CYLINDER HEAD COVER ………………………………… 4-4
ROCKER ARMS AND CAMSHAFT …………………………………………………… 4-10
VALVES AND VALVE SPRINGS ……………………………………………………… 4-16
CYLINDER AND PISTON………………………………………………………………… 4-22
ENGINE COOLING FAN AND A.C. MAGNETO ……………………………………… 4-26
BALANCER GEARS AND OIL PUMP GEARS ……………………………………… 4-31
PRIMARY AND SECONDARY SHEAVES
Primary and secondary sheaves …………………………………………………… 4-34
Primary sheave………………………………………………………………………… 4-35
Secondary sheave …………………………………………………………………… 4-36
CLUTCH …………………………………………………………………………………… 4-41
CRANKCASE
Starter motorand oil filter …………………………………………………………… 4-45
Crankcase ……………………………………………………………………………… 4-47
Crankcase bearings…………………………………………………………………… 4-48
CRANKSHAFT AND OIL PUMP
Crankshaft and oil pump ……………………………………………………………… 4-52
Oil pump………………………………………………………………………………… 4-53
TRANSMISSION
Transmission……………………………………………………………………………… 4-56
Drive axle assembly……………………………………………………………………… 4-57
MIDDLE GEAR
Middle drive shaft………………………………………………………………………… 4-62
Middle driven shaft ……………………………………………………………………… 4-63
CARBURETOR……………………………………………………………………………… 4-70
CHAPTER 5
CHASSIS
MALFUNCTION INSPECTION…………………………………………………………… 5-1

8
DIRECTION SYSTEM
The structure of the steering…………………………………………………………… 5-4
The structure of steering wheel part…………………………………………………… 5-6
Diassembling the parts of the steering wheel ………………………………………… 5-7
The structure of steering wheel part …………………………………………………… 5-8
Diassembling the steering column parts……………………………………………… 5-9
Checking and service the steering column parts …………………………………… 5-10
Steering drive axle ……………………………………………………………………… 5-11
Steering machine parts………………………………………………………………… 5-12
BRAKE SYSTEM…………………………………………………………………………… 5-16
Front disk brake components ………………………………………………………… 5-17
Front brake discs ……………………………………………………………………… 5-18
Checking the front brake disc ………………………………………………………… 5-19
Front brake pads………………………………………………………………………… 5-20
Replacing the front brake pads………………………………………………………… 5-21
Front brake caliper……………………………………………………………………… 5-21
Disassembling the front brake calipers ……………………………………………… 5-24
Assembling the front brake calipers…………………………………………………… 5-25
Installing the front brake calipers …………………………………………………… 5-26
Rear brake disc ………………………………………………………………………… 5-27
Checking the rear brake disc…………………………………………………………… 5-28
Rear brake caliper and brake pads…………………………………………………… 5-29
Replacing the rear brake pads………………………………………………………… 5-32
Disassembling the rear brake caliper ………………………………………………… 5-33
Assembling the rear brake caliper …………………………………………………… 5-34
Installing the rear brake caliper………………………………………………………… 5-37
Brake master cylinder ………………………………………………………………… 5-38
Checking the master cylinder………………………………………………………… 5-39
Installing the brake master cylinder…………………………………………………… 5-40
FOOTREST ASSEMBLY……………………………………………………………………… 5-41
WHEEL AND TYRE PARTS ……………………………………………………… 5-44
Front wheels …………………………………………………………………………… 5-44
Rear wheels……………………………………………………………………………… 5-45
Checking the wheel tyre and wheel hub……………………………………………… 5-46
Installing the wheel hub and wheel tyre ……………………………………………… 5-47
Specification of wheel and tyre………………………………………………………… 5-48
TRANSMISSION SYSTEM ……………………………………………………………… 5-49
Front bridge……………………………………………………………………………… 5-49
Disassembling the front bridge………………………………………………………… 5-54

9
Checking the joints……………………………………………………………………… 5-55
Checking the differential gear ………………………………………………………… 5-56
Installing the front bridge parts………………………………………………………… 5-57
Rear bridge ……………………………………………………………………………… 5-58
REVERSE MECHANISM PARTS ……………………………………………………… 5-64
Adjusting reverse mechanism parts ………………………………………………… 5-67
Checking and service of reverse mechanism………………………………………… 5-67
SUSPENSION……………………………………………………………………………… 5-68
Front Suspension and arm …………………………………………………………… 5-68
Disassembling, service and assembly the supporting rocker parts………………… 5-70
Checking the front arms and shock absorber………………………………………… 5-72
Installing the front arms and front shock absorber ………………………………… 5-73
Rear suspension ……………………………………………………………………… 5-74
Rear arm shaft…………………………………………………………………………… 5-75
Checking and service of rear suspension …………………………………………… 5-76
Checking the stabilizer and shock absorber ………………………………………… 5-77
Installing the rear arms and rear shock absorber …………………………………… 5-78
COOLING SYSTEM……………………………………………………………………… 5-79
Radiator ………………………………………………………………………………… 5-79
Checking the radiator…………………………………………………………………… 5-82
Installing the radiator…………………………………………………………………… 5-83
Checking the oil cooler ………………………………………………………………… 5-84
Water pump……………………………………………………………………………… 5-85
Disassembling the water pump ……………………………………………………… 5-87
Checking the water pump……………………………………………………………… 5-88
Assembling the water pump…………………………………………………………… 5-89
SEAT ………………………………………………………………………………………… 5-92
FUEL TANK………………………………………………………………………………… 5-93
Checking the fuel pump operation …………………………………………………… 5-95
Disassembling and checking ,service oil cooling system…………………………… 5-96
Installing oil cooling system…………………………………………………………… 5-97
CHAPTER 6
ELECTRICAL COMPONENTS
Electrical System Malfunction Inspection ………………………………………… 6-1
ELECTRICAL ……………………………………………………………………………… 6-2
ELECTRICALCOMPONENTS ………………………………………………………… 6-2

10
CHECKING THE SWITCH ……………………………………………………………… 6-4
Checking the switch…………………………………………………………………… 6-4
Checking the switch continuity ……………………………………………………… 6-5
CHECKING THE BULBS AND BULB SOCKETS …………………………………… 6-6
IGNITION SYSTEM ……………………………………………………………………… 6-7
TROUBLESHOOTING …………………………………………………………………… 6-7
ELECTRIC STARTING SYSTEM ……………………………………………………… 6-11
CIRCUIT DIAGRAM ……………………………………………………………………… 6-11
TROUBLESHOOTING …………………………………………………………………… 6-12
STARTER MOTOR ……………………………………………………………………… 6-15
Checking the starter motor …………………………………………………………… 6-16
Assembling the starter motor ………………………………………………………… 6-17
CHARGING SYSTEM …………………………………………………………………… 6-18
CIRCUIT DIAGRAM ……………………………………………………………………… 6-18
TROUBLESHOOTING …………………………………………………………………… 6-19
LIGHTING SYSTEM ……………………………………………………………………… 6-21
CIRCUIT DIAGRAM ……………………………………………………………………… 6-21
TROUBLESHOOTING …………………………………………………………………… 6-22
CHECKING THE LIGHTING SYSTEM ………………………………………………… 6-23
If the headlights fail to come on ……………………………………………………… 6-23
If the headlights fail to come on ……………………………………………………… 6-24
SIGNALING SYSTEM …………………………………………………………………… 6-25
CIRCUIT DIAGRAM ……………………………………………………………………… 6-25
TROUBLESHOOTING …………………………………………………………………… 6-26
CHECKING THE SIGNAL SYSTEM …………………………………………………… 6-27
If the brake lights fail to come on …………………………………………………… 6-27
If the neutral lights fail to come on ………………………………………………… 6-28
If the parking brake indicator light fails to come on ………………………………… 6-29
If the reverse indicator light fails to come on ……………………………………… 6-30
If the coolant temperature warning ………………………………………………… 6-31
If the differential gear lock indicator light fails to come on ………………………… 6-33
If the four-wheel drive indicator light fails to come on …………………………… 6-35
COOLING SYSTEM ……………………………………………………………………… 6-36
CIRCUIT DIAGRAM ……………………………………………………………………… 6-36
TROUBLESHOOTING …………………………………………………………………… 6-37
2WD/4WD SELECTING SYSTEM ……………………………………………………… 6-40
CIRCUIT DIAGRAM ……………………………………………………………………… 6-40
TROUBLESHOOTING …………………………………………………………………… 6-41

11
CHAPTER 7
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING………………………………………………… 7-1
Fuel system ……………………………………………………………………………… 7-1
Electrical system ………………………………………………………………………… 7-1
Compression system …………………………………………………………………… 7-2
POOR IDLE SPEED PERFORMANCE ………………………………………………… 7-3
Poor idle speed performance…………………………………………………………… 7-3
POOR MEDIUM AND HIGH-SPEED PERFORMANCE ……………………………… 7-3
Poor medium and high-speed performance…………………………………………… 7-3
FAULTY GEAR SHIFTING………………………………………………………………… 7-3
Shift lever does not move ……………………………………………………………… 7-3
Jumps out of gear………………………………………………………………………… 7-4
OVERHEATING…………………………………………………………………………… 7-4
Overheating……………………………………………………………………………… 7-4
FAULTY BRAKE…………………………………………………………………………… 7-4
Poor braking effect……………………………………………………………………… 7-4
SHOCK ABSORBER MALFUNCTION………………………………………………… 7-5
Malfunction ……………………………………………………………………………… 7-5
UNSTABLE HANDLING…………………………………………………………………… 7-5
Unstable handling ……………………………………………………………………… 7-5
LIGHTING SYSTEM………………………………………………………………………… 7-6
Head light is out of work………………………………………………………………… 7-6
Bulb burnt out…………………………………………………………………………… 7-6

GENERALINFORMATION
1-1
DESCRIPTION AND MACHINE IDENTIFICATION
1. Headlights
2. Front shock absorber assembly
adjusting ring
3. Brake fluid reservoir
4. Air filter element
(engine and air intake duct)
5. V-belt case
6. Driver seat
7. Driver seat belt
8. Spark plug
9. Cargo bed
10. Tail/brake lights
11. Rear shock absorber assembly
adjusting ring
12. Cargo bed release levers
13. Spark arrester
14. Passenger seat belt
15. Passenger seat
16. Oil filter cartridge
17. Engine oil dipstick
18. Battery
19. Fuses
20. Coolant reservoir
21. Radiator cap
22. Fuel tank cap
23. Light switch
24. Steering wheel
25. Starter (choke)
26. Main switch
27. On-Command four-wheel-drive
and differential lock switches
28. Multi-function meter unit
29. Auxiliary DC jack
30. Drive select lever
31. Parking brake lever
32. Accelerator pedal
33. Brake pedal
NOTE:
The vehicle you have purchased may
differ slightly from those in the figures
of this manual.

GENERALINFORMATION
1-2
IDENTIFICATION CODE
Frame No.
Frame No. is carved in the lower right side of
Figure.
Engine No.
Engine NO. is carved on the right side of the
engine, Figure.

GENERALINFORMATION
1-3
CHAPTER ONE
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 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
MANUAL ORGANIZATION
A shop manual is a tool and, as in all Clymer manuals, the chapters are thump tabbed for easy
reference, main heads are listed in the table of contents and the index, Frequently used specifications
and capacities from the tables at the end of each individual chapter are listed in the UTV, Quick
reference data section at the front of the manual specifications and capacities are provided in U.S
standard and metric units of measure
During some of the procedures, there will be reference to heading in other chapters or sections of
manual, when a specific heading is called out in a step it will be italicized as it indicated as being “in
this section”, it is located within the same main heading, For example, the sub-heading handling
Gasoline safely is located within the main heading SAFETY
This chapter provides general information on shop safety, tools and their usage, service
fundamentals and shop supplies.
WARNINGS, CAUTIONS AND NOTES
The terms WARNING, CAUTION and NOTE have specific meaning in this manual.
A WARNING emphasizes areas where injury or even death could result from negligence.
Mechanical damage may also occur. WARNINGS are to be taken seriously
A CAUTION emphasizes areas where equipment damage could result. Disregarding a CAUTION
could cause permanent mechanical damage. though injury is unlikely.
A NOTE provides additional information to make a step or procedure easier or clearer.
Disregarding a NOTE could cause inconvenience. but would not cause equipment damage or injury.
SAFETY
Professional mechanics can work for years and never sustain a serous injury or mishap. Follow
these guidelines and practice common sense to safely service the utility terrain venires

GENERALINFORMATION
1-4
1. Do not operate the utility terrain venires in an enclosed area venires The exhaust gasses contain
carbon monoxide. an odorless, colorless and tasteless poisonous gas. Carbon monoxide levels
build quickly in small enclosed areas and can cause unconsciousness and death in a short time.
Make sure to properly ventilate the work area or operate the UTV side
2. Never use gasoline or any extremely flammable liquid to clean parts. Refer to cleaning parts and
handling Gasoline Safely in this section
3. Never smoke or use a torch in the vicinity of flammable liquids, such as gasoline or cleaning
solvent.
4. If welding or brazing on the UTV the fuel tank to a safe distance at least 50ft.(15m) away.
5. Use the correct type and size of tools to avoid damaging fasteners.
6. Keep tools clean and in good condition. Replace or repair worn or damaged equipment.
7. When loosening a tight fastener, be guided by what would happen if the tool slips.
8. When replacing fasteners, make sure the new fasteners are the same size and strength as the
original ones.
9. Keep the work area clean and organized.
10. Wear eye protection anytime the safety of the eyes is in question. This includes procedures that
involve drilling, grinding, hammering, compressed air and chemicals.
11. Wear the correct clothing for the job. Tie up or cover long hair so it does not get caught in moving
equipment.
12. Do not carry sharp tools in clothing pockets.
13. Always have an approved fire extinguisher available. Make sure it is rated for gasoline (Class B)
and electrical (Class C) fires.
14. Do not use compressed air to clean clothes, the UTV or the work area. Debris may be blown into
the eyes or skin. Never direct compressed air at anyone. Do not allow children to use or play with
any compressed air equipment.
15. When using compressed air to dry rotating parts, hold the part so it does not rotate. Do not allow
the force of the air to spin the part. The air jet is capable of rotating parts at extreme speed. The
part may disintegrate of become damaged, causing serious injury.
16. Do not inhale the dust created by brake pad and clutch wear. These particles may contain
asbestos. In addition, some types of insulating materials and gaskets may contain asbestos.
Inhaling asbestos particles is hazardous to one’s health.
17. Never work on the UTV while someone is working under it.
Handling Gasoline Safely
Gasoline is a volatile flammable liquid and is one of the most dangerous items in the shop.
Because gasoline is used so often, many people forget it is hazardous. Only use gasoline as fuel
for gasoline internal combustion engines. Keep in mind when working on the machine, gasoline is
always present in the fuel tank, fuel line and carburetor. To avoid a disastrous accident when
working around the fuel system, carefully observe the following precautions:
1. Never use gasoline to clean parts. Refer to Cleaning Parts in this section.
2. When working of the fuel system, work outside or in a well-ventilated area.
3. Do not add fuel to the fuel tank or service the fuel system while the UTV is near open flames,

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sparks or where someone is smoking .Gasoline vapor is heavier than air, it collects in low areas
and is more easily ignited than liquid gasoline.
4. Allow the engine to cool completely before working on any fuel system component.
5. Do not store gasoline in glass containers. If the glass breaks, a serious explosion of fire may
occur.
6. Immediately wipe up spilled gasoline with rags. Store the rags in a metal container with a lid until
they can be properly disposed of, or place them outside in a safe place for the fuel to evaporate.
7. Do not pour water onto a gasoline fire. Water spreads the fire and makes it more difficult to put out.
Use a class B, BC or ABC fire extinguisher to extinguish the fire.
8. Always turn off the engine before refueling. Do not spill fuel onto the engine or exhaust system.
Do not overfill the fuel tank. Leave an air space at the top of the tank to allow room for the fuel to
expand due to temperature fluctuations.
Cleaning Parts
Cleaning parts is one of the more tedious and difficult service jobs performed in the home garage.
Many types of chemical cleaners and solvents are available for shop use. Most are poisonous and
extremely flammable. To prevent chemical exposure, vapor buildup, fire and serious injury, observe
each product warning label and note the following:
1. Read and observe the entire product label before using any chemical. Always know what type of
chemical is being used and whether it is poisonous and/or flammable.
2. Do not use more than one type of cleaning solvent at a time. If mixing chemicals is required,
measure the proper amounts according to the manufacturer.
3. Work in a well-ventilated area.
4. Wear chemical-resistant gloves.
5. Wear safety glasses.
6. Wear a vapor respirator if the instructions call for it.
7. Wash hands and arms thoroughly after cleaning parts.
8. Keep chemical products away from children and pets.
9. Thoroughly clean all oil, grease and cleaner residue from any part that must be heated.
10. Use a nylon brush when cleaning parts. Metal brushes may cause a spark.
11. When using a parts washer, only use the solvent recommended by the manufacturer. Make sure
the parts washer is equipped with a metal lid that will lower in case of fire.
Warning Labels
Most manufacturers attach information and warning labels to the UTV. These labels contain
instructions that are important to personal safety when operating, servicing, transporting and storing
the UTV. Refer to the owner’s manual for the description and location of labels. Order replacement
labels from the manufacturer if they are missing or damaged.

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SERIALNUMBERS
Serial and identification numbers are stamped on various locations on the frame, engine and
carburetor body. Record these numbers in the Quick Reference Data section in the front of the manual.
Have these numbers available when ordering parts.
FASTENERS
Proper fastener selection and installation is important to ensure the motorcycle operates as
designed and can be serviced efficiently. The choice of original equipment fasteners is not arrived at
by chance. Make sure replacement fasteners meet all the same requirements as the originals
Many screws. Bolts and studs are combined with nuts to secure particular components. to indicate
the size of a nut. Manufactures specify the internal diameter and the thread pitch
The measurement across two flats on a nut or bolt indicates the wrench size
WARNING
Do not install fasteners with a strength classification
lower than what was originally installed by the
manufacturer doing so may cause equipment failure
and or damage
Torque Specifications
The material used in the manufacturing of the UTV may be subjected to uneven stresses if the
fasteners of the various subassemblies are not installed and tightened correctly. Fasteners that are
improperly installed or work loose can cause extensive damage. it is essential to use an accurate
torque wrench as described in this chapter
Self-Locking Fasteners
Several types of bolts. Screws and nuts incorporate a system that creates interference between
the two fasteners. Interference is achieved in various ways. The most common types are the nylon
insert nut and a dry adhesive coating on the threads of a blot.
Self-locking fasteners offer greater holding strength than standard fasteners, which improves their
resistance to vibration.All self-locking fasteners cannot be reused. The materials used to from the lock
become distorted after the initial installation and removal. Discard and replace self-locking fasteners
after removing them. Do not replace self-locking fasteners with standard fasteners.

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1-7
Washers
The two basic types of washers are flat washers and lock washers. Flat washers are simple discs
with a hole to fit a screw or bolt. Lock washers are used to prevent a fastener from working loose.
Washers can be used as spacers and seals. Or can help distribute fastener load and prevent the
fastener from damaging the component
As with fasteners. When replacing washers make sure the replacement washers are of the same
design and quality
Cotter Pins
A cotter pin is a split metal pin inserted into a hole or slot to prevent a fastener from loosening. In
certain applications, such as the rear axle on an UTV or motorcycle, the fastener must be secured in
this way. For these applications. A cotter pin and castellated (slotted) nut is used.
To use a cotter pin, first make sure the diameter is correct for the hole in the fastener. Aster
correctly tightening the fastener and aligning the holes, insert the cotter pin through the hole and bend
the ends over the fastener, Unless instructed to do so, never loosen a tightened fastener to align the
holes. If the holes do not align. Tighten the fastener enough to achieve alignment
Cotter pins are available in various diameters and lengths. Measure the length from the bottom of
the head to the tip of the shortest pin
Snap Rings and E-clips
Snap rings (Figure 1) are circular-shaped metal
retaining clips. They secure parts in place on parts such
as shafts. External type snap rings are used to retain
items on shafts. Internal type snap rings secure parts
within housing bores. In some applications. in addition to
securing the component(s). snap rings of varying
thicknesses also determine endplay. These are usually
called selective snap rings.
The two basic types of snap rings are machined and
stamped snap rings. Machined snap rings (Figure 2) can
be installed in either direction. Because both faces have
sharp edges. Stamped snap rings (Figure 3) are
manufactured with a sharp and a round edge. When
installing a stamped snap ring in a thrust application,
install the sharp edge facing away from the part
producing the thrust.
E-clips are used when it is not practical to use a
snap ring. Remove E-clips with a flat blade screwdriver
by prying between the shaft and E-clip. To install an
E-clip. Center it over the shaft groove and push or tap it

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1-8
into place
Observe the following when installing snap rings:
1. Remove and install snap rings with snap rings
pliers. Refer to Basic Tools in this chapter
2. In some applications. it may be necessary to
replace snap rings after removing them
3. Compress or expand snap rings only enough to
install them. If overly expanded. Lose their
retaining ability
4. After installing a snap ring. Make sure it seats
completely
5. Wear eye protection when removing and
installing snap rings
SHOP SIPPLIES
Lubricants and Fluids
Periodic lubrication help ensure a long service life for any type of equipment. Using the correct
type of lubricant is as important as performing the lubrication service. Although in an emergency the
wrong type is better than not using one, The following section describes the types of lubricants most
often required. Make sure to follow the manufacturer’s recommendations for lubricant types
Engine oils
Engine oil for four-stroke motorcycle UTV engine use is classified by three standards: the
American Petroleum Institute (API) service classification. The Society of Automotive Engineers (SAF)
viscosity rating Standard classification
The API and SAE information is on all oil container labels. Two letters indicate the API service
classification. The number or sequence of numbers and letter (10W-40 for example) is the oil’s
viscosity rating. The API service classification and the SAE viscosity index are not indications of oil
quality.
The APL service classification standards, The first letter in the classification S indicates that the oil
is for gasoline engines. The second letter indicates the standard the oil satisfies .
The classifications are: MA (high friction applications) and MB( low frication applications).
NOTE
Refer to Engine Oil and Filter in
Chapter Three for further information
on API, SAE classifications.
Always use an oil with a classification recommended by the manufacturer, Using an oil with a
different classification can cause engine damage.