Huansong UTV 700 2009 User manual

HUANSONG
UTV 700
SERVICE MANUAL
2009

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