Huansong HS700UTV Reference guide

FOREWORD
Brief introduction to maintenance handbook of
HS700/600/500UTV
The handbook is edited by Technical Center of Chongqing Huansong Industries (Group)
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 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.
Third version , May, 2010
Published by Chongqing Huansong Industries (Group) Co., Ltd.
Chongqing Huansong Industries (Group) 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…………………………………………………………………… 5
Cleaning parts……………………………………………………………………………… 5
Warning labels……………………………………………………………………………… 6
SERIAL NUMBERS…………………………………………………………………………… 6
FASTENERS…………………………………………………………………………………… 6
Torque specifications ……………………………………………………………………… 6
Self-locking fasteners……………………………………………………………………… 6
Washers…………………………………………………………………………………… 7
Cotter pins…………………………………………………………………………………… 7
Snap rings and E-clips …………………………………………………………………… 7
SHOP SUPPLIES
Lubricants and Fluids……………………………………………………………………… 8
Engine oils…………………………………………………………………………………… 8
Greases……………………………………………………………………………………… 9
Brake fluid…………………………………………………………………………………… 9
Coolant……………………………………………………………………………………… 9
Cleaners, Degreasers and solvents …………………………………………………… 9
Gasket sealant…………………………………………………………………………… 10
Gasket remover ………………………………………………………………………… 10
Thread locking compound……………………………………………………………… 10
BASIC TOOLS ………………………………………………………………………………… 11
Screwdrivers……………………………………………………………………………… 11

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Wrenches ………………………………………………………………………………… 12
Adjustable wrenches …………………………………………………………………… 12
Socket wrenches, ratchets and handles ……………………………………………… 13
Impact drivers …………………………………………………………………………… 14
Allen wrenches…………………………………………………………………………… 14
Torque wrenches………………………………………………………………………… 14
Torque adapters ………………………………………………………………………… 15
Pliers……………………………………………………………………………………… 16
Snap ring pliers…………………………………………………………………………… 16
Hammers ………………………………………………………………………………… 17
Ignition grounding tool…………………………………………………………………… 17
PRECISION MEASURING TOOLS ………………………………………………………… 17
Feeler gauge ……………………………………………………………………………… 18
Calipers…………………………………………………………………………………… 18
Micrometers……………………………………………………………………………… 19
Adjustment ……………………………………………………………………………… 20
Care ……………………………………………………………………………………… 20
Metric micrometer………………………………………………………………………… 20
Standard inch micrometer……………………………………………………………… 21
Telescoping and small bore gauges…………………………………………………… 22
Dial Indicator……………………………………………………………………………… 22
Compression gauge……………………………………………………………………… 23
Multimeter………………………………………………………………………………… 23
ELECTRICAL SYSTEM FUNDAMENTALS……………………………………………… 24
Voltage …………………………………………………………………………………… 24
Resistance………………………………………………………………………………… 24
Amperage………………………………………………………………………………… 24
BASIC SERVICE METHODS……………………………………………………………… 25
Removing frozen fasteners……………………………………………………………… 26
Removing broken fasteners …………………………………………………………… 26
Repairing damaged threads …………………………………………………………… 27
Stud Removal/Installation ……………………………………………………………… 27
Removing hoses ………………………………………………………………………… 27
Bearings…………………………………………………………………………………… 28

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Removal…………………………………………………………………………………… 28
Installation………………………………………………………………………………… 29
Interference fit …………………………………………………………………………… 29
Seal replacement………………………………………………………………………… 31
STORAGE……………………………………………………………………………………… 31
Storage area selection…………………………………………………………………… 31
Preparing the motorcycle for storage …………………………………………………… 32
Returning the UTV to service…………………………………………………… 32
TROVBLESHOOTING……………………………………………………………………… 33
ENGINE PRINCIPLES AND OPERATING REQUIREMENTS………………………… 34
STARTING THE ENGINE ………………………………………………………………… 34
Engine is cold …………………………………………………………………………… 34
Engine is warm…………………………………………………………………………… 34
Starting the engine after a fall or after the engine stalls……………………………… 34
Flooded engine…………………………………………………………………………… 34
Engine cold with air temperature ……………………………………………………… 35
Engine cold with air temperature above 35℃（95°F）……………………………… 35
Cold engine with air temperature below 10℃(50°F) ……………………………… 35
Engine is hot……………………………………………………………………………… 36
Starting the engine after a fall or after the engine stalls……………………………… 36
Flooded engine…………………………………………………………………………… 36
ENGINE WILL NOT START ……………………………………………………………… 37
Identifying the problem ………………………………………………………………… 37
Spark test………………………………………………………………………………… 38
Starter does not turn over or turns over slowly ……………………………………… 39
POOR ENGINE PERFORMANCE………………………………………………………… 39
Engine starts but stalls and is hard to restart…………………………………………… 39
Engine backfires, cuts out or misfires during acceleration…………………………… 40
Engine backfires on deceleration……………………………………………………… 40
Poor fuel mileage………………………………………………………………………… 40
Engine will not idle or idles roughly …………………………………………………… 41
Low engine power ………………………………………………………………………… 41
Poor idle or low speed performance…………………………………………………… 42

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Poor high speed performance ………………………………………………………… 43
FUEL SYSTEM……………………………………………………………………………… 43
Rich mixture……………………………………………………………………………… 43
Lean mixture……………………………………………………………………………… 44
ENGINE………………………………………………………………………………………… 44
Engine smoke……………………………………………………………………………… 44
Black smoke ……………………………………………………………………………… 44
Blue smoke………………………………………………………………………………… 44
White smoke or steam…………………………………………………………………… 44
Low engine compression ………………………………………………………………… 45
High engine compression ……………………………………………………………… 45
Engine overheating (cooling system) ………………………………………………… 45
Engine overheating (engine)…………………………………………………………… 46
Preignition………………………………………………………………………………… 46
Detonation………………………………………………………………………………… 46
Power loss ……………………………………………………………………………… 46
engine noises……………………………………………………………………………… 46
ENGLNE LUBRICATION…………………………………………………………………… 47
HIGH OIL CONSUMPTION OR EXCESSIVE……………………………………………… 47
Exhaust smoke…………………………………………………………………………… 47
Low oil pressure ………………………………………………………………………… 47
High oil pressure ………………………………………………………………………… 48
No oil pressure…………………………………………………………………………… 48
Oil level too low…………………………………………………………………………… 48
Oil contamination………………………………………………………………………… 48
CYLINDER LEAK DOWN TEST…………………………………………………………… 48
ELECTRICAL TESTING…………………………………………………………………… 51
Preliminary checks and precautions …………………………………………………… 51
Intermittent problems…………………………………………………………………… 52
Electrical component replacement ……………………………………………………… 53
Test equipment …………………………………………………………………………… 53
Ammeter …………………………………………………………………………………… 53
Self-powered test light …………………………………………………………………… 53
Ohmmeter ………………………………………………………………………………… 54

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Jumper wire……………………………………………………………………………… 54
TEST PROCEDURES………………………………………………………………………… 55
Voltage test……………………………………………………………………………… 55
Voltage drop test………………………………………………………………………… 55
Peak voltage test………………………………………………………………………… 56
Continuity test……………………………………………………………………………… 56
Testing for a short with a self-powered test light or ohmmeter……………………… 56
Testing for a short with a test light or voltmeter………………………………………… 57
BRAKE SYSTEM……………………………………………………………………………… 57
Soft or spongy brake lever or pedal…………………………………………………… 57
Brake drag………………………………………………………………………………… 58
Hard brake lever or pedal operation…………………………………………………… 59
Brake Grabs……………………………………………………………………………… 59
Brake squeal or chatter ………………………………………………………………… 59
Leaking brake caliper …………………………………………………………………… 60
Leaking master cylinder………………………………………………………………… 60
CHAPTER 2
SPECIFICATIONS
HOW TO USE CONVERSION TABLE OF UNIT…………………………………………… 61
How to use conversion table…………………………………………………………… 61
Definition of unit ………………………………………………………………………… 61
GEBERAR SPECIFICATIONS ……………………………………………………………… 62
ENGINE SPECIFICATIONS ………………………………………………………………… 65
CHASSIS SPECIFICATIONS………………………………………………………………… 71
ELECTRICAL SPECIFICATIONS…………………………………………………………… 73
TIGHTENING TORQUES …………………………………………………………………… 75
Engine tightening torques………………………………………………………………… 75
Chassis tightening torques ……………………………………………………………… 78
GENERAL TIGHTENING TORQUE SPECIFICATIONS ………………………………… 81
LUBRICATION PIONTS AND LUBRICANT TYPES……………………………………… 82
Engine……………………………………………………………………………………… 82
Chassis……………………………………………………………………………………… 83

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HYDROGRAPHIC CHART…………………………………………………………………… 84
LUBRICATION OIL WAY…………………………………………………………………… 85
CHAPTER 3
MAINTENCE AND ADJUSTMENT OF THE UTV
MAINTENANCE SCHEDULE……………………………………………………………… 86
ENGINE
Adjusting the valve clearance…………………………………………………………… 88
Idle adjustment …………………………………………………………………………… 91
Adjusting the throttle cable……………………………………………………………… 91
Adjusting the starter cable……………………………………………………………… 92
Checking the spark plug ………………………………………………………………… 93
Checking the ignition timing……………………………………………………………… 94
Measuring the compression pressure………………………………………………… 95
Checking the engine oil level …………………………………………………………… 97
Changing the engine oil ………………………………………………………………… 98
CHASSIS
Cleaning the air filter………………………………………………………………… 101
Checking the coolant level …………………………………………………………… 102
Changing the coolant…………………………………………………………………… 103
Checking the coolant temperature warning light …………………………………… 106
Checking the v-belt……………………………………………………………………… 107
Cleaning the spark arrester …………………………………………………………… 108
Adjusting the brake pedal……………………………………………………………… 109
Adjusting the parking brake…………………………………………………………… 110
Checking the brake fluid level ………………………………………………………… 111
Checking the front brake pads………………………………………………………… 111
Checking the rear brake pads………………………………………………………… 112
Checking the brake hoses and brake pipes ………………………………………… 113
Bleeding the hydraulic brake system ………………………………………………… 113
Adjusting the select lever shift rod …………………………………………………… 115
Adjusting the brake light switch ……………………………………………………… 115
Checking the final gear oil level ……………………………………………………… 116

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Changing the final gear oil……………………………………………………………… 116
Checking the differential gear oil……………………………………………………… 117
Changing the differential gear oil……………………………………………………… 117
Checking the constant velocity joint dust boots……………………………………… 118
Checking the steering system………………………………………………………… 119
Adjusting the toe-in …………………………………………………………………… 120
Adjusting the front shock absorbers………………………………………………… 121
Adjusting the rear shock absorbers …………………………………………………… 121
Checking the tires ……………………………………………………………………… 122
Checking the wheels…………………………………………………………………… 124
Checking and lubricating the cables ………………………………………………… 124
ELECTRICAL
Checking and charging the battery…………………………………………………… 125
Checking the fuses …………………………………………………………………… 130
Adjusting the headlight beam ………………………………………………………… 131
Changing the headlight bulb ………………………………………………………… 132
Changing the tail/brake light bulb …………………………………………………… 133
CHAPTER 4
ENGINE
ENGINE NOTE……………………………………………………………………………… 134
ENGINE REMOVAL………………………………………………………………………… 135
CYLINDER HEAD AND CYLINDER HEAD COVER…………………………………… 137
ROCKER ARMS AND CAMSHAFT……………………………………………………… 142
VALVES AND VALVE SPRINGS………………………………………………………… 148
CYLINDER AND PISTON………………………………………………………………… 154
ENGINE COOLING FAN AND A.C. MAGNETO ……………………………………… 158
BALANCER GEARS AND OIL PUMP GEARS………………………………………… 163
PRIMARY AND SECONDARY SHEAVES
Primary and secondary sheaves ……………………………………………………… 166
Primary sheave………………………………………………………………………… 167
Secondary sheave ……………………………………………………………………… 168
CLUTCH ……………………………………………………………………………………… 173

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CRANKCASE
Starter motorand oil filter……………………………………………………………… 177
Crankcase……………………………………………………………………………… 179
Crankcase bearings…………………………………………………………………… 180
CRANKSHAFT AND OIL PUMP
Crankshaft and oil pump ……………………………………………………………184
Oil pump…………………………………………………………………………………185
TRANSMISSION
Transmission…………………………………………………………………………… 188
Drive axle assembly…………………………………………………………………… 189
MIDDLE GEAR
Middle drive shaft………………………………………………………………………… 193
Middle driven shaft ……………………………………………………………………… 194
CARBURETOR……………………………………………………………………………… 200
CHAPTER 5
CHASSIS
MALFUNCTION INSPECTION…………………………………………………………… 205
DIRECTION SYSTEM
The structure of the steering…………………………………………………………… 208
The structure of steering wheel part…………………………………………………… 210
Diassembling the parts of the steering wheel ………………………………………… 211
Checking the parts of the steering wheel……………………………………………… 211
Diassembling the steering column parts……………………………………………… 212
Checking and service the steering column parts……………………………………… 213
Diassembling the steering drive axle ………………………………………………… 213
Checking and service the steering drive axle………………………………………… 214
Diassembling the steering machine part……………………………………………… 215
The structure of the steering………………………………………………………… 215
Reinstalls the steering system parts…………………………………………………… 216
BRAKE SYSTEM…………………………………………………………………………… 217
Front disk brake components ………………………………………………………… 219
Front brake discs ……………………………………………………………………… 220

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Checking the front brake disc ………………………………………………………… 221
Front brake pads………………………………………………………………………… 222
Replacing the front brake pads………………………………………………………… 223
Front brake caliper……………………………………………………………………… 224
Disassembling the front brake calipers ……………………………………………… 226
Assembling the front brake calipers…………………………………………………… 227
Installing the front brake calipers …………………………………………………… 227
Rear brake disc ………………………………………………………………………… 229
Checking the rear brake disc…………………………………………………………… 230
Rear brake caliper and brake pads…………………………………………………… 231
Replacing the rear brake pads………………………………………………………… 234
Disassembling the rear brake caliper ………………………………………………… 234
Assembling the rear brake caliper …………………………………………………… 235
Installing the rear brake caliper………………………………………………………… 237
Brake master cylinder…………………………………………………………………… 239
Checking the master cylinder ………………………………………………………… 240
Assembling the brake master cylinder………………………………………………… 240
Installing the brake master cylinder…………………………………………………… 240
FOOTREST ASSEMBLY ………………………………………………………………… 242
WHEEL AND TYRE PARTS ……………………………………………………………… 245
Front wheels……………………………………………………………………………… 245
Rear wheels……………………………………………………………………………… 246
Checking the wheel tyre………………………………………………………………… 247
Checking the wheel hub………………………………………………………………… 247
Installing the wheel hub………………………………………………………………… 247
Installing the wheel tyre………………………………………………………………… 248
Specification of wheel and tyre………………………………………………………… 248
TRANSMISSION SYSTEM ………………………………………………………………… 249
Front bridge……………………………………………………………………………… 249
Disassembling the front bridge………………………………………………………… 254
Disassembling the universal joint …………………………………………………… 254
Removing the differential gear assembly…………………………………………… 254
Checking the joints……………………………………………………………………… 255
Checking the differential gear…………………………………………………………… 255