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

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Checking the gear motor………………………………………………………………… 256
Assembling the universal joint……………………………………………………………257
Adjusting the differential gear lash……………………………………………………… 257
Assembling the differential gear …………………………………………………………258
Installing the front bridge parts………………………………………………………… 259
Rear bridge ……………………………………………………………………………… 260
REVERSE MECHANISM PARTS ……………………………………………………… 266
Adjusting reverse mechanism parts ………………………………………………… 268
Checking and service of reverse mechanism………………………………………… 268
SUSPENSION……………………………………………………………………………… 270
Front Suspension and arm …………………………………………………………… 270
Disassembling, service and assembly the supporting rocker parts………………… 272
Checking the front arms ………………………………………………………………… 273
Checking the front shock absorber…………………………………………………… 273
Installing the front arms and front shock absorber ………………………………… 274
Rear suspension ……………………………………………………………………… 275
Rear arm shaft…………………………………………………………………………… 276
Checking and service of rear suspension …………………………………………… 277
Checking the stabilizer…………………………………………………………………… 277
Checking the rear arms………………………………………………………………… 277
Checking the stabilizer and shock absorber ………………………………………… 277
Installing the rear arms and rear shock absorber …………………………………… 278
COOLING SYSTEM………………………………………………………………………… 279
Radiator ………………………………………………………………………………… 279
Checking the radiator…………………………………………………………………… 282
Installing the radiator…………………………………………………………………… 282
Checking the oil cooler ………………………………………………………………… 283
Water pump……………………………………………………………………………… 284
Disassembling the water pump ……………………………………………………… 286
Checking the water pump……………………………………………………………… 286
Assembling the water pump…………………………………………………………… 287
SEAT ………………………………………………………………………………………… 289
FUEL TANK………………………………………………………………………………… 291
Checking the fuel pump operation …………………………………………………… 294

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Disassembling and checking ,service oil cooling system…………………………… 294
Installing oil cooling system…………………………………………………………… 295
CHAPTER 6
ELECTRICAL COMPONENTS
ELECTRICAL SYSTEM MALFUNCTION INSPECTION ……………………………… 296
ELECTRICAL ……………………………………………………………………………… 297
ELECTRICAL COMPONENTS…………………………………………………………… 297
Checking the switch…………………………………………………………………… 299
Checking the switch continuity ……………………………………………………… 300
Checking the bulbs and bulb sockets …………………………………… 301
IGNITION SYSTEM ……………………………………………………………………… 302
CIRCUIT DIAGRAM ……………………………………………………………………… 302
Troubleshooting …………………………………………………………………… 303
ELECTRIC STARTING SYSTEM ……………………………………………………… 307
CIRCUIT DIAGRAM ……………………………………………………………………… 307
Troubleshooting …………………………………………………………………… 308
STARTER MOTOR ……………………………………………………………………… 311
Checking the starter motor …………………………………………………………… 312
Assembling the starter motor ………………………………………………………… 313
CHARGING SYSTEM …………………………………………………………………… 314
CIRCUIT DIAGRAM ……………………………………………………………………… 314
Troubleshooting …………………………………………………………………… 315
LIGHTING SYSTEM ……………………………………………………………………… 317
CIRCUIT DIAGRAM ……………………………………………………………………… 317
Troubleshooting …………………………………………………………………… 318
Checking the lighting system ………………………………………………… 319
If the headlights fail to come on ……………………………………………………… 319
If the taillights fail to come on ……………………………………………………… 320
SIGNALING SYSTEM …………………………………………………………………… 321
CIRCUIT DIAGRAM ……………………………………………………………………… 321
Troubleshooting …………………………………………………………………… 322
Checking the signal system …………………………………………………… 323

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If the brake lights fail to come on …………………………………………………… 323
If the neutral lights fail to come on ………………………………………………… 324
If the parking brake indicator light fails to come on ………………………………… 325
If the reverse indicator light fails to come on ……………………………………… 326
If the coolant temperature warning ………………………………………………… 327
If the differential gear lock indicator light fails to come on ………………………… 329
If the four-wheel drive indicator light fails to come on …………………………… 331
COOLING SYSTEM ……………………………………………………………………… 333
Circuit diagram ……………………………………………………………………… 333
Troubleshooting …………………………………………………………………… 334
2WD/4WD SELECTING SYSTEM ……………………………………………………… 337
Circuit diagram ……………………………………………………………………… 337
Troubleshooting …………………………………………………………………… 338
CHAPTER 7
ENGINE MANAGEMENT SYSTEM
INTRODUCTION
Ems (engine management system) …………………………………………………… 342
Typical components of EMS………………………………………………………………342
Layout of EMS components………………………………………………………………343
COMPONENTS OF EMS
Electronic control unit …………………………………………………………………… 343
Multec 3.5 injectors ……………………………………………………………………… 344
Throttle body assembly(with stepper motor) …………………………………………348
Engine coolant temperature sensor …………………………………………………… 350
Intake air pressure and temperature sensor ……………………………………………350
Oxygen sensor …………………………………………………………………………… 351
Ignition coil………………………………………………………………………………… 351
Fuel pump module…………………………………………………………………………355
EMS FAULT DIAGNOSIS
EME fault diagnosis ………………………………………………………………………361
Fault code list………………………………………………………………………………361

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CHAPTER 8
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING………………………………………………… 363
Fuel system ……………………………………………………………………………… 363
Electrical system ………………………………………………………………………… 363
Compression system …………………………………………………………………… 364
POOR IDLE SPEED PERFORMANCE ………………………………………………… 365
Poor idle speed performance…………………………………………………………… 365
POOR MEDIUM AND HIGH-SPEED PERFORMANCE ……………………………… 365
Poor medium and high-speed performance………………………………………… 365
FAULTY GEAR SHIFTING………………………………………………………………… 365
Shift lever does not move ……………………………………………………………… 365
Jumps out of gear……………………………………………………………………… 366
OVERHEATING……………………………………………………………………………… 366
Overheating……………………………………………………………………………… 366
FAULTY BRAKE…………………………………………………………………………… 367
Poor braking effect……………………………………………………………………… 367
SHOCK ABSORBER MALFUNCTION………………………………………………… 367
Malfunction ……………………………………………………………………………… 367
UNSTABLE HANDLING…………………………………………………………………… 367
Unstable handling ……………………………………………………………………… 367
LIGHTING SYSTEM………………………………………………………………………… 368
Head light is out of work………………………………………………………………… 368
Bulb burnt out…………………………………………………………………………… 368
CHAPTER 9
HS600UTV SERVICE MANUAL
HS600UTV SUPPLEMENTARY…………………………………………………………… 369
SPECIFICATIONS…………………………………………………………………………… 370
Geberar specifications …………………………………………………………… 370
Engine specifications ……………………………………………………………… 370

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CHAPTER 10
HS500UTV SERVICE MANUAL
HS500UTV SUPPLEMENTARY…………………………………………………………… 372
SPECIFICATIONS…………………………………………………………………………… 373
Geberar specifications ………………………………………………………………… 373
Engine specifications ……………………………………………………………… 373
ENGINE REMOVAL………………………………………………………………………… 379
CYLINDER HEAD AND CYLINDER HEAD COVER…………………………………… 381
ROCKER ARMS AND CAMSHAFT……………………………………………………… 384
VALVES AND VALVE SPRINGS………………………………………………………… 388
CYLINDER AND PISTON………………………………………………………………… 393
HS700UTV/HS600UTV/HS500UTV WIRING DIAGRAM……………………………… 397

GENERALINFORMATION
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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 utility terrain vehicles (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.
WARNINGS, CAUTIONS AND NOTES
The terms WARNING, CAUTION and NOTE have specific meaning in this manual.
WARNING: emphasizes areas where injury or even death could result from negligence.
Mechanical damage may also occur. WARNINGS are to be taken seriously
CAUTION: emphasizes areas where equipment damage could result. Disregarding a
CAUTION could cause permanent mechanical damage. though injury is unlikely.
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.

GENERALINFORMATION
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DESCRIPTION
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
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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
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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
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.

GENERALINFORMATION
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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,
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.