Home

SECTOR 1000 - Hisun Motors Corp, USA

1. gt J SO Ti T Introduction HS 1000 INTRODUCTION Congratulations on your purchase of the HS 1000 UTV This Owner s Operators manual will provide you information regarding safe operation operational instructions maintenance and care Fully understanding and following all of the instructions in this manual will provide the knowledge needed to have safe operation and longevity of the UTV For questions regarding this UTV please call 972 446 0760 IMPORTANT SAFETY MESSAGES READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR UTV MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE UTV NEVER OPERATE THE UTV WITHOUT PROPER TRAINING OR INSTRUCTION THIS UTV SHOULD NOT BE RIDDEN BY ANYONE UNDER 16 YEARS OF AGE 1 1 Introduction HS 1000 IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH Particularly important information is distinguished in this manual by the following notations A The Safety Alert Symbol means ATTENTION YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the machine operator bystander or a person inspecting or repairing the machine CAUTION A CAUTION indicates special precautions that must be taken to avoid dama
2. 2 Prc a a ad ut S P Head light 27 Front Turn signal lamp 83 Tail turn signal lamp 3 Checking the brake pedal E Brake Pedal Adcaution gt To avoid personal injury 6 If the operator suddenly brakes an T accident may occur due to loss of control or shifting forward of heavy loads When driving on icy wet or loose 2 surface make sure the vehicle is correctly balanced to avoid skidding or loss of steering control Reduce the 3 speed The brake pedal is the left pedal on the foot 4 board Depress the pedal to slow or stop the vehicle 4 7 E 2 1 Brake pedal R Gear Shift Range Lever Ad caution 10 avoid personal injury Avoid changing gear shift range lever when ascending or descending a slope Before ascending or descending a slope shift to the L range to control the vehicle speed If you shift gears while ascending or descending a slope be prepared to use the brake to maintain control Vehicle must be stopped before shifting Operate in reverse at slow speeds to maintain control The gear shift range lever can only be shifted when vehicle is completely stopped and the accelerator pedal is in the NEUTRAL position To avoid transmission and shift linkage damage completely stop the vehicle using the brake pedal before shifting gears Select proper gear and engine speed depending on the type of job Before dismounting vehicle
3. Drain plug EVERY 500 HOURS B Replacing Fuel Filter Consult your local dealer for this service EVERY 600 HOURS B Adjusting Engine Valve Clearance Consult your local dealer for this service EVERY 1500 HOURS B Checking Injection and Fuel Pump Consult your local dealer for this service EVERY 1 YEAR B Replacing Air Cleaner Primary Element and Secondary Element See Cleaning Air Cleaner Primary Element in every 100 HOURS in PERIODIC SERVICE section Periodic Service EVERY 2 YEARS B Changing Brake Fluid Consult your local Dealer for this service See Checking Brake Fluid Level in DAILY CHECK in PERIODIC SERVICE section R Flushing Cooling System and Changing Coolant A CAUTION To avoid personal injury Do not remove the radiator cap while coolant is hot When cool slowly rotate cap to the first stop and allow sufficient time for excess pressure to escape before removing the cap completely 1 Stop the engine and let cool down 2 To drain the coolant open the radiator drain plug and remove radiator cap The radiator cap must be removed to completely drain the coolant 3 After all coolant is drained close the drain plug 4 Fill with clean water and flush with cooling system cleaner Follow the directions on the cleaner container After flushing fill with clean water and anti freeze until the coolant level is just below the radiator cap Install the
4. Hisun Motors Corp U S A 1434 Patton Place Ste 106 Carrollton TX 75007 Phone 972 446 0760 Fax 972 446 0765 Toll Free 877 838 6188 A WARNING The engine exhaust from this product contains chemicals Known to the State of California to cause cancer birth defects or other reproductive harm ASUN HISUN MOTORS 510 East University Dr Mckinney Texas 7 5069 PH 972 446 0760 TF 877 858 6188 hisunmotors com
5. B Before driving the UTV every time you need to do daily inspection of the EPS system 1 Check steering system s mechanical parts Check if the steering wheel is loose or not Move steering wheel and check whether it is loose or has a squeak through axis direction and horizontal direction If a defect is found repair or replace it Steering wheel s range of free clearance is O m 0 0 59in 7 lf the free clearance is over range check spare parts as below any defects found replace it Steering tie rod ball head showing signs of wear Swizzle ball of knuckle worn Gear rack on steering wheel worn Spline on steering drive shaft is loose Between input and output shafts reducer whether had idle running The steering system checking in steering process Turn the steering wheel from left to right and right to left It performed smoothly and no sticking 2 Check steering power in static condition Stop the UTV on a level surface steering wheel is placed in a straight forward position 6 Check tire inflation pressure whether meet specified requirements see tire instructions or UTV user manual If necessary refill it Check front wheel s front beam wheel offset positioning whether is correct see UTV user manual If necessary adjust it Turn on the main switch Turn the steering wheel left and right successively turning force on both sides should be equal 3 Check steering force d
6. code will be indicated on meter B Malfunction assortment During long periods of continuous fast steering especially when ambient temperature is very high it may cause the ECU to radiate a high temperature and at this time the ECU can get through detection temperature sensor s a signal to issue an ECU over heating failure warning fault code to the meter Meanwhile EPS system fault indicator light is on When ECU detected 1 steering torque sensor or 2 steering torque sensor had fault then it will indicate 1 steering torque sensor fault or 2 steering torque sensor fault code to dash board Meanwhile EPS system fault indicator light is on When ECU detected the storage battery s voltage is lower than 9VDC through sensor it will indicate the fault code of storage battery voltage low to dash board 8 7 Electric Power Steering System Meanwhile EPS system fault indicator light will be on When ECU detected motor is not working through sensor it will indicate fault code of dynamic motor without power warning to dash board Meanwhile EPS system fault indicator light is on When ECU detected the speed sensor has a fault it will indicate vehicle soeed sensor fault code to dash board Meanwhile EPS system fault indicator light is on When ECU detected its own fault and is not working normally it will indicate ECU stop working code to dash board Meanwhile EPS system fault indicator light is on
7. 2 misuse 3 repairs improperly performed or replacements improperly installed unless performed by a HISUN authorized dealer 4 use of improper replacement parts or accessories not conforming to specifications set forth by HISUN which adversely affect performance and or 5 Use in competitive racing or related events B Inspections replacement of parts and other services and adjustments required for required maintenance C Any vehicle equipped with an odometer or hour meter on which the odometer mileage or hour meter reading has been changed so that actual mileage cannot be readily determined Limited Liability A The liability of HISUN under this Emission Control System Warranty is limited solely to the remedying of defects in material or workmanship by an authorized HISUN dealer at its place of business during customary business hours This warranty does not cover inconvenience or loss of use of the vehicle or transportation of the vehicle to or from the HISUN dealer HISUN shall not be liable for any other expenses loss or damage whether direct indidental consequential or exemplary arising in connection with the sale or use of Or inability to use the vehicle for any purpose Some states do not allow the exclusion or limitation of any incidental or consequential damages so the above limitations may not apply to you d HSUN Hisun Motors Corp U S A Limited Warranty on Emission Control System B No express emission
8. The hazard light switch is operated when switch to the ON position the key switch is in the ON or OFF Push the head light switch to the OFF position position to turn off the head lights Be careful that keeping the switch ON causes the battery voltage to run down R Turn Signal Light Switch if equipped To indicate a right turn push the bottom half of the signals light switch To indicate a left turn push the upper half of the signal light switch When the left or right signal is activated the indicated turning light will flash and the other will stay on Head light switch The indicator lamp at the instrument panel also 2 Head lights OFF flashes like the above 3 Low Beam ON NOTE High Beam ON 6 The turn signal light switch is only operative 6 4WD button 2WD butt when the key switch is in the ON position utton lf the hazard light switch is pressed to the NOTE ON position while the turn signal is Turning the head light switch to the ON position activated the indicated turning light will flash causes the following lamps to light and other will stay on simultaneously Be sure to return switch to center position 1 Tail lights lamps at the rear portions of the after turning 4 6 Operating the Vehicle AA A 2 Te Sae g Fi re f Ilg ERA i 7 j NG pis H Foe H K mes 4 if l r LC aT OTT ii D SE 3 ae
9. Driving at high speed Instructions for carrier Parking Transportation Maintenance Warning and Caution Labels Identification Numbers Pre Operation Check Starting the Engine Display Warning Lamps Stopping the Engine Operating the vehicle Headlight switch Hazard switch Turn Signal switch Brake Pedal Gear Shift Lever Parking Brake Accelerator Pedal Fuel Gauge Coolant Temperature Hour Meter Speedometer Maintenance Service Intervals Periodic Service Hood Seat Cargo Bed Jack positioning Daily check Fuel Tank Engine Oil Coolant Level Parking Brake Checking CV Boots 50 Hour check Subject Wheel bolt torque Cleaning the air filter Evacuator valve Battery condition Battery Charging Storage instructions Adjusting Toe In Cleaning the Spark arrester 200 hour check Changing Engine oil Replacing engine oil filter Checking the Brake pedal stroke Radiator hoses and clamps Precautions at overheating Checking Intake air line 300 Hour check Checking the tires 500 Hour check 600 Hour Check 1500 Hour check Every year check Every 2 years check Antifreeze Every 4 years check Replacing Mini Fuses Replacing Light bulbs Specification Table Traveling Speeds Vehicle Limitations EPS System Storage Removing the vehicle from storage Troubleshooting Engine Diagnostic Trouble Codes Battery Troubleshooting Vehicle Troubleshooting Options Winch Mount Plate Emissions Warranty General Instrume
10. inner and outside gears of Replace the gears transmission shaft Transmission noise Misalignment of transmission Replace the gears gears Incorrect connection of gear Replace the gears end face Parking brake Loosen the lay up rod Hydraulic calipers for disc Contact the dealer brakes are stuck closed Less vehicle power Removing the grease for the clutch Replace CVT transmission belt Replace the clutch Less brake oil Check the braking oil level Air inside the braking system 6 Contact the dealer Brake discs abrasion 6 Contact the dealer No brakes or brake Assembling bolt of disc plate noise 6 Lock tightly loose i It f k peo mung bolt for disc brake e Lock tightly clippers loose If you have any questions consult your local dealer CVT transmission sliding 10 4 Electronic Power Steering System INTRODUCTION Our UTV is equipped with Electric Power Steering System EPS To keep reliability of EPS during operation please correctly use the descriptions and keep up with daily inspections EPS system according to following and maintenance This information to safely use the EPS system If chapter also provides important you encounter any problems during operation or maintenance please consult your local dealer ADVANTAGES OF EPS SYSTEM 1 High efficiency Traditional hydraulic power steering systems are connected by mechanical and hydraulic sy
11. shift the gear shift range lever to the NEUTRAL position and set parking brake Operating the Vehicle speed and engage front wheel drive L Low t baag An accident may occur if the vehicle is ig T suddenly braked with heavy loads N Neutra shifting forward causing loss of control R Reverse f oe l The braking characteristics are different between two and four wheel drive Be aware of the differences and use carefully IMPORTANT Unlock the parking brake and 1 Gear shift range lever Stale Stony L LOW Range To release the parking brake depress the brake H HIGH Range pedal push release button and push down N NEUTRAL POSITION parking brake lever Make sure that indicator in hy eee the Easy Checker TM goes off NOTE When gear shift range lever is hard to engage do not force the lever Set the parking brake slightly depress the accelerator pedal and release it to neutral position then shift the lever When the lever is hard to disengage do not force the lever Depress the brake pedal fully then shift the lever 1 Parking brake lever 2 RELEASE Damage may occur with wrong shifting Mi Accelerator Pedal operation Use the accelerator pedal when traveling Push E 4WD Lever down on it for higher speed AA caution To avoid personal injury When traveling at road speed Use only 2WD When driving on icy wet or loose surfaces make sure the vehi
12. CAUTION TO avoid personal injury Do not allow anyone near the vehicle while testing Ifthe vehicle does not pass the test do not operate the vehicle Preparation before testing 1 Place all control levers in the NEUTRAL position 2 Set the parking brake and stop the engine Test gear shift range lever safety switch 1 Sit on the operators seat 2 Shift the gear shift range lever to L H or REVERSE position 3 Turn the key to START position The engine must not crank lf it cranks consult your local dealer for this service L Low t H High t N Neutra R Reverse DY CS e i SS r aN LU Z E 0 Si A O S Y Ke 1 accelerator pedal B Checking wheel bolt torque A CAUTION To avoid personal injury Never operate vehicle with a loose wheel bolts Any time the bolts are loosened they should be retightened to the specified torque 6 Check all bolts frequently and keep them tight Check wheel bolts regularly especially when new if they are loose tighten them as follows 1 Range gear shift lever 6 7 1 Torque wheel bolts to 75 to 90 N m WE Cleaning air cleaner primary element 1 Remove the seats 2 Remove the Engine cover 10 TI 12 Air filter frame Periodic Service Remove the connecting rubber tube between air cleaner and throttle valve and the screw
13. Cause Severe Injury or Death Be Prepared A Be Sure Riders Pay Attention and Plan Ahead e Fasten seat belts e Wear an approved helmet and protective gear e Each rider must be able to sit with back against seat Keep a firm grip on the steering wheel or handholds and brace yourself feet flat on floor and foot rests and hands on steering ide of hi wheel or handhold s where equipped Stay Do not put any part of your body outside of the vehicle for any reason completely inside the vehicle Require Proper Use of Your Vehicle Do your part to prevent injuries Drive Responsibly s Do not allow careless or reckless driving Avoid loss of control and rollovers e Make sure operators are 16 or older with a valid driver s license e Do not let people drive or ride after using alcohol or drugs s Do not allow operation on public roads unless designated for off highway vehicle access collisions with cars and trucks can occur e Do nor exceed seating capacity 1 passenger If you think or feel the vehicle may tip or roll reduce your risk to injury e Avoid abrupt maneuvers sideways sliding skidding or fishtailing and never do donuts Slow down before entering a turn e Avoid hard acceleration when turning even from a stop e Plan for hills rough terrain ruts and other changes in traction and terrain Avoid Rollovers have caused paved surfaces severe injuries and death Follow All Instruction and Warnings e Avoi
14. control system warranty is given by HISUN except as specifically set forth herein Any emission control system warranty implied by law including any warranty of merchantability or fitness for a particular purpose is limited to the express emission control system warranty terms stated in this warranty The foregoing statements of warranty are exclusive and in lieu of all other remedies Some states do not allow limitations on how long an implied warranty lasts so the above limitations may not apply to yOu C No dealer is authorized to modify this Limited Emission Control System Warranty issued by HISUN IV LEGAL RIGHTS This warranty gives you specific legal rights and you may also have other rights which vary from state to state V This warranty is in addition to the limited vehicle warranty yI ADDITIONAL INFORMATION Any replacement part that is equivalent in performance and durability may be used in the performance of any maintenance or repairs by the owner However HISUN is not liable for these parts The owner is responsible for the performance of all required maintenance Such maintenance may be performed at a service establishment or by any individual The warranty period begins when the vehicle is placed into service If you have any questions regarding your warranty rights and responsibilities you should contact Hisun Motors Corp U S A or the U S Environmental Protection Agency at 2000 Traverwood Drive Ann Arbor MI 48105
15. keep himself herself safe When a fault occurs on the EPS system a fault indicator light will be on At the same time the fault indicator of EPS system will display the fault code for maintenance 1 Fault indicator light of EPS system Fault code diagram 5 00003 i motor without power 00011 Fault speed sensor 7 F00010 ECU non working i 8 2 Electric Power Steering System INTRODUCTION Our UTV is equipped with Electric Power Steering System EPS To keep the reliability of EPS during operation please correctly use the EPS system according to the following descriptions and keep up with daily inspections and maintenance This information to safely use the EPS system If chapter also provides important you encounter any problems during operation or maintenance please consult your local dealer ADVANTAGES OF EPS SYSTEM 1 High power steering systems are connected by efficiency Traditional hydraulic mechanical and hydraulic systems and are of low efficiencies usually 60 0 EPS connected by a mechanical and electric However Hisun s system is motor and it has a much higher efficiency of up to 90 2 Less energy consumption In the practical driving process of the UTV time spent steering is only about 5 of the total travelling time In a hydraulic power steering system as long as the engine is running the hydraulic pump is always working and fuel consumption will in
16. mixture percentage Never add any long life coolant of different manufacturer Different brands may have different additive components and the engine may fail to perform as specified 5 When the LLC is mixed do not employ any The LLC contains anticorrosive agent If mixed with the cleaning radiator cleaning agent agent sludge may build up adversely affecting the engine parts 6 The vehicle s genuine long life coolant has a service life of 2 years Be sure to change the coolant every 2 years NOTE The above data represent industry standards that necessitate a minimum glycol content in the concentrated antifreeze Periodic Service When evaporation add water only to keep the the coolant level drops due to antifreeze mixing ratio less than 50 In case of leakage add antifreeze and water in the specified mixing ratio before filling into the radiator B Replacing Radiator Hose Water pipes Replace the hoses and clamps See Checking Radiator Hose and Clamp in EVERY 200 HOURS in PERIODIC SERVICE section B Replacing Fuel Hose Consult your local dealer for this service R Replacing Brake Master Cylinder Inner parts Consult your local dealer for this service B Replacing Front Brake Seal Consult your local dealer for this service B Replacing Rear Brake Cylinder Seal Consult your local dealer for this service B Replacing Intake Air Line Consult your local dealer fo
17. safety devices roll over protective structure seat belts and never change the original safety devices If safety devices are damaged consult your local dealer for replacement Always use seat belts 1 Roll over protective structure Seat belts 4 Do not wear loose articles of clothing during operation as these can be drawn into moving parts on the vehicle and could cause a severe injury to occur 2 4 should 5 2 Single row vehicle s You should always wear protective equipment such as helmet boots eye protection ear protection and gloves etc Only a qualified driver with driving license should operate this UTV Never operate after drinking using drugs or controlled products or while fatigued Always perform the pre operation checks as following 1 Check seat belt for wear or damage if necessary replace it 2 Check brakes throttle brake pedal and other mechanical parts for proper operation If you discover any irregularities replace related parts as necessary Periodically check the fittings and fasteners 3 Check engine oil coolant level 4 Check that the UTV is equipped to handle the surroundings 5 Check and keep vehicle clean Sludge grease and debris can cause a fire and severe injury level and engine Passenger quantity and loading 1 Only the driver and one passenger inside cab It is suggested that children under age of 5 not be allowed as a passenger lo
18. Adjusting procedures Direction for storage 1 Loosen the lock nut and turn the tie rod to 1 When storing the vehicle for a long period adjust the rod length until the proper toe in remove the battery from level vehicle store in measurement is obtained a dry place out of direct sunlight 2 Retighten the lock nut 2 The battery will self discharge while it is IMPORTANT stored recharge it once every three months in Keep equal length of the left and right tie rod hot seasons and once every six months in cold seasons Periodic Service E Cleaning Muffler A CAUTION To avoid personal injury Before touching any part of an exhaust system be absolutely sure that it has sufficient time to cool Always wear safety goggles and face mask The particulate matter contained in the muffler contains chemicals that are harmful to people animals and marine life If you are unable to do this work have it done by your dealer Cleaning spark arrester of muffler Maintenance amp cleanout procedure The screen should be removed cleaned and inspected after every type spark arrester 100 hours of use The spark arrester is located inside of the exhaust pipe and fastened with six bolts 2 Loosen the bolts and remove the spark arrester 3 Shake loosened particles out of the screen assembly and lightly clean the screen with wire brush Soak in solvent and again clean with wire brush if necessary 4 If any bre
19. Parking 1 Set the gear shift to the N position and pull the braking brake to the top position to park the vehicle 2 Avoid stopping the vehicle on a slope If stopping on a slope make sure the vehicle is stationary before exiting 3 ged ae L e 9 SA O Parking Brake foot lever Transportation 1 Avoid dragging the vehicle behind another vehicle Use a trailer or truck to transport the vehicle 2 When loading or unloading pay attention to your surroundings and others in the area Maintenance Stop the vehicle and park it on level ground Pull the parking brake and remove all cargo Place the shift lever in the N position stop the engine and remove the key 1 When working next to the engine exhaust or radiator work only after it has cooled down 2 Wait for the engine to stop running and cool down before checking the coolant level Otherwise you could be burned by hot fluid or steam 2 6 3 No smoking when adding electrolyte or refueling Fuel tank and battery should be kept away from sparks Battery produces hydrogen and oxygen in charging and this could accelerate the risk of explosion 4 Read and follow the instructions before replacing the battery 5 During maintenance first aid kits and fire extinguishers should be placed at your fingertips 6 During maintenance you should disconnect the battery cables 7 Do not open radiator cap befor
20. RAL position Stop the engine Mount the safety support Periodic Service To lower the cargo bed 1 Start the engine and then lift the bed slightly by operating the lever 2 Remove the safety support and siore it in the given location 3 Lower the lever to the DOWN position to lower the bed 4 After lowered to the lowest position lock it by making sure that the bed has the restricting plate NOTE To raise or lower the cargo bed when the engine does not start or the hydraulics are not operating shift the lever to the FLOAT position and raise or lower the bed manually Knob boit U UB D DOWN c Ulan ED S s ae Hydraulic lift cylinder level 6 2 JACK UP POINT A WARNING To avoid personal injury death or vehicle damage Do not work under the vehicle unless it is secured by safe stands or suitable blocking E Front End Jack up at the front bumper only ee Ta m IR a A Y alj MEI cali Ee S ie 7 H S GA A 1 Jack E Rear End Jack up the rear side after placing a wooden block 2 Front bumper under the right and left pipe frames for securing the engine and then supporting it Do not jack it up Supporting the steel plate portion under the engine ran Ji T Y 1 Jack 2 Front bumper Periodic Service DAILY CHECK For your own safety and maximum service life of the vehicle make a thorough daily
21. ading limit is 660lbs 300KG Reduce the loading weight according to road conditions Never exceed the weight limits for operation 3 Never allow unauthorized persons to repair this UTV This may affect vehicle performance and cause injury General 2 Operation 1 Start the engine only in an open ventilated area Carbon monoxide is colorless odorless and is emitted from the engine and can cause death in areas with poor ventilation 2 Never start the vehicle or operate the gear selector unless seated in the driver s seat 3 Never start the engine until the select lever is placed in N position and the brake is in the brake position 4 The driver and passenger shall always wear their seatbelt while the vehicle is being operated 5 Operators of the UTV should not wear earphones 6 Use the proper trailer hitch to haul cargo otherwise serious injury or death can happen W W WW K W N F I W W W SS G Trailer Hitch 7 Do not accelerate quickly when starting the engine especially driving on rough terrain as this can cause injury or death Press the accelerator pedal slowly 8 Drive at slow speeds before braking 9 With the differential unlocked DIFF LOCK is off the front rear wheels can turn at different speeds to assist in the stability of the vehicle 2 5 10 Never drive over terrain such as a ditch a hole dams excessive mud or the vehi
22. ak out onto the running engine causing a fire The fuel line connections should be checked annually or every 100 service hours whichever comes first i Park the vehicle on a flat surface and raise the cargo bed The fuel line is made of rubber and ages regardless of service period If the fuel line and clamps are found to be damaged or deteriorated replace them Check fuel filter if it is clogged by debris or contaminated with water replace it Periodic Service IMPORTANT When the fuel line is disconnected for maintenance or repair close both ends of the fuel line with a piece of clean cloth or paper to prevent dust and dirt from entering Particular care must be taken not to admit dust and dirt into the fuel pump entrance Even a small amount of dust or dirt will cause premature wear and malfunction of the fuel pump and injector components IR S 7 n s 1 fuel pump 2 fuel line 3 Exit pipe B Checking battery condition A DANGER If a battery is stored in a diminished state of charge it will become no effective and require a new battery 6 9 A CAUTION To avoid personal injury Never remove the battery while the engine is running Keep electrolyte away from eyes hands and clothes If you are spattered with it wash it away completely with water immediately and get medical attention Wear eye protection and rubber gloves when working around the battery The fac
23. aks in the screen or welds are discovered the assembly must be replaced 5 Return the spark arrester to the muffler body and refasten the bolts IMPORTANT Visually check the muffler for cracks or holes in the body welds or pipes at regular intervals USDA approval requires clearance between spark arrester sleeve and exhaust pipe to be no larger than 0 023 0 584 mm Replace the entire muffler if it is damaged 6 11 Do not operate the vehicle with a damaged muffler 1 Muffler 2 Spray fire device 3 Back cover EVERY 200 HOURS B Changing Engine Oil A CAUTION To avoid personal injury Be sure to stop the engine before replacing oil Allow engine to cool down sufficiently oil can be hot and can burn Park the vehicle on flat surface and raise the cargo bed To drain the used oil remove the drain plug at the bottom of the engine and completely drain the oil into an oil pan After draining reinstall the drain plug Fill with the new oil up to the upper notch on the dipstick See LUBRICANTS FUEL AND COOLANT in MAINTENANCE section Filter exchanged 1 8L 1 89U S qts Oil capacity Filter non exchanged 1 6L 1 68U S qts Periodic Service L s 1 at Z H U N L Yi NZ Z OA mw L a O7 4 B Checking Brake Pedal A CAUTION Stop the engine and chock the wheels before checking brake pedal If movement is outside of the specifica
24. arm Up Transmission Oil in the Low Temperature Range IMPORTANT Do not operate the vehicle under full load condition until it is sufficiently warmed up 4 4 Operating the Vehicle OPERATING NEW VEHICLE How a new vehicle is handled and maintained determines the life of vehicle A new vehicle just off the factory production line has been tested however the various parts are not mated to each other so the operator should pay more attention to the vehicle operation for the first 50 hours Drive at a slower speed and avoid excessive work or operation until the various parts become broken in How you break in the vehicle greatly affects the life of your vehicle Therefore to obtain the maximum performance and the longest life of the vehicle it is very important to properly break in your vehicle For better handling of a new vehicle the following precautions should be observed B Do not operate the vehicle at full speed for the first 50 hours Do not start quickly nor apply the brakes suddenly In winter operate the vehicle after fully warming up the engine Do not run the engine at speeds faster than prescribed On rough roads slow down to suitable speeds Do not operate the vehicle at fast speed The above precautions are not limited to new vehicles but to all vehicles It should be especially observed for new vehicles B Changing Lubricating Oil for New Vehicles The lubricating oil is especiall
25. ated power 1 70W nominal value Rated operational voltage 12V DC Rated 1050r 300r min Rated operational current S30A 3A Rated output torque 1 6N m 0 16N m motor revolving speed Options OPTIONS Consult your local dealer for further details Head rest Plastic Canopy Rear Trailer Hitch amp Pin 2 Windshield Steel Cab Motor Scan KF90121 PAR wo gt Winch Mount Plate WINCH MOUNT PLATE WINCH MOUNT PLATE Mounting the optional winch always requires you to read the instruction manual attached to the winch ee before A it Winch mount plate E Transporting Vehicle Pay attention to the following points when transporting the vehicle 1 Use a suitable truck or trailer 2 Apply the parking brake and place chocks against the front and rear tires 12 1 Hisun Motors Corp U S A Emission Control System Warranty Statement YOUR WARRANTY RIGHTS AND OBLIGATIONS The U S Environmental Protection Agency and Hisun Motors Corp U S A hereinafter HISUN are pleased to explain the emission control system warranty on your Off Road vehicle New off road motor vehicles must be designed built and equipped to meet U S EPA Federal and California anti smog standards HISUN must warrant the emission control system on your vehicle for 5 000 km or at least 30 months whichever comes first provided that there has been no abuse neglect or improper maintenance of your vehicle This off road
26. cables attached figure 2 or in the wire cable is disconnect 7 No meter alarm ECU is damaged Bring the UTV to dealer for repair Figure 1 Fuses box GG UD S L l s nme l K4 backup 15A backup 10A backup u ECU dedicated fuse ECU initialization connector 8 9 Electric Power Steering System 2 Open the main switch only steering left or right is power assisted Bring the UTV to dealer for 1 No meter alarm ECU damaged repair Sensor damaged sensor s Meter warning fault Bring the UTV to dealer for connector with bad contact or code F00001 or F00002 repair ECU damaged 3 All have auxiliary power to turn left or right when turned the steering wheel is not smooth locked backswing and other feelings S N Fault phenomenon Fault point Steering system Retighten loose bolts Steering system mechanical parts mechanical parts has the Replace damaged spare become loose or damaged big gap parts To dealers for repair Bring the UTV to dealer for repair Mechanical parts without ECU damaged or the ECU gap software program has error 4 When running all have power assisted to turn left or right when return ability is slowly or during return processing out of nimbleness S N Fault phenomenon Fault point Meter warning fault cod The speed sensor damaged or Replace speed sensor F00011 from meter to ECU transmit speed Check and repair cables signal s guide w
27. cle can get stuck because of the vehicles weight 11 Always pay close attention to your Surroundings and check for streets trail intersections or other obstacles 12 Always use signals in advance of turns 13 Do not allow entrance or exit of the vehicle while it is moving 14 Keep the floorboard free of debris that can obstruct the ability to use the brake pedal 15 Position your hands on the steering wheel Always keep your hands and feet inside passenger area of the vehicle Never try to stand while operating the vehicle 16 Do not tow passengers or attempt to jump the vehicle Children safety instructions Always watch children when they are around the vehicle Children like to imitate adults and this could lead to an accident Do not leave children alone beside the vehicle Keep children from the operating area of the vehicle Turn off the engine and remove the key when children are in the operating area Never carry children in the cargo area This is very dangerous to children Children under age of 5 should not be allowed in this vehicle Never allow children to touch or climb on the vehicle even if they are under adult supervision Always check for people or obstacles behind the vehicle before shifting the vehicle into reverse Avoid a collision with an obstacle or person Park the vehicle on a firm flat area If parking on a slope you should use hand lever parking brake remove the key General
28. cle has been used the last digit indicates The speedometer indicates the traveling speed 1 10 of an hour 1 Speedometer HOURS mile km 1 Hourmeter The speedometer indicates the traveling speed 4 10 Periodic Service A CAUTION To avoid personal injury HOW TO OPEN THE HOOD AND TILT THE SEAT A CAUTION To avoid personal injury from contact with moving parts Never open operator s seat while the engine is running Support hood with the other hand while unlocking support link Sundry Box Cover To Open Close Unhook the hood latches and then slowly tilt the sundry box cover up To close tilt cover back to closed position and fasten the latches aT 0 Hr OV Sundry box cover 1 Sundry box cover B Operator s Seat To open the seat raise the seat to the forward position 6 1 A A K Operator s seat HOW TO RAISE THE CARGO BED A CAUTION To avoid personal injury When servicing under raised bed make sure safety support is properly mounted Do not touch muffler or exhaust pipes while they are hot Otherwise severe burns could result E Raising and Lowering the Cargo Bed To raise the cargo bed 2 Apply the parking brake and start the engine 3 Release the restricting plate 4 Pull up the hydraulic lift cylinder lever to raise the cargo bed 5 When the cargo bed has been raised return the lever to the NEUT
29. cle is correctly balanced to avoid skidding and i Accelerat dal loss of steering control Reduce the S 4 8 Operating the Vehicle STOPPING B STOPPING 1 2 Release the accelerator pedal step on the brake pedal CHECK DURING DRIVING WE immediately Stop the Engine if The engine suddenly slows down or accelerates Unusual noises are suddenly heard Exhaust fumes suddenly become very white While driving check the following items to see if all parts are functioning normally 1 Fuel gauge 2 Coolant temperature gauge E Fuel Gauge Park the vehicle on a flat place When the key switch is on the fuel gauge indicates the fuel level Be careful not to empty the fuel tank Otherwise air may enter the fuel system 1 Fuel gauge B Coolant Temperature Gauge A caution To avoid personal injury Do not remove radiator cap until coolant temperature is well below its boiling point Then loosen cap slightly to relieve pressure before removing cap completely 1 With the key switch ON the temperature gauge indicates the temperature of the coolant White Zone for cold and Red zone for hot 2 If the indicator reaches the Red zone engine coolant is overheated Check the vehicle by referring to TROUBLESHOOTING section 1 Coolant temperature gauge 4 9 Operating the Vehicle The hourmeter indicates in five digits the hours the vehi
30. crease 4 6 However Hisun s EPS system starts the motor only when it needs to generate power without increasing fuel consumption 3 The power of Hisun s EPS system is controlled by software so that the UTV can be operated with power steering at 8 1 various speeds 4 Hisun s connection system so the impact of road EPS system uses a rigid conditions on steering wheel is greatly decreased For the steering 5 No pollution to environment traditional hydraulic power system the hydraulic circuit has hydraulic hose and fittings inside the system so oil leaks may occur and hydraulic hoses are not recyclable This system type can produce pollution to the environment However Hisun s EPS system does not cause pollution to the environment 6 If the engine does not start the EPS system can also work off the battery and once sufficient power is generated the power steering system is functionable IMPORTANT INFORMATION FOR SAFETY This UTV is equipped with EPS system please read this chapter carefully before operating the UTV and only when you are familiar with and master the EPS system methods and precautions Make inspections of the EPS system at regular intervals to ensure the security and reliability of your UTV Please carefully read this chapter before operating or driving and understand the correct ways to operate and drive the UTV with the EPS system and also characteristics fun
31. ctions and limits of UTV Do inspections and maintenance on Electric Power Steering System the EPS system at regular intervals Correct operation and driving skills will ensure the security and reliability of UTV To make sure your EPS system will be useful for a long time please follow the methods for maintenance in this chapter This chapter also includes detailed disassembly and maintenance information Prior to any maintenance or repairs the person performing such repairs must have qualified mechanical skills electronic maintenance skills and the special tools mentioned in this manual INTRODUCTION OF EPS SYSTEM B What is EPS system The EPS system Electric Power Steering System is a complete set of parts including a special ECU only for the EPS system hereinafter referred to as the ECU many sensors and actuators monitoring UTV speed the operating force of the steering wheel as well as temperature of the ECU and motor to provide an accurate power torque of the motor and aligning torque All of these sensors actuators and motors work together to provide easy steering with less effort by the operator W Typical parts of the EPS system In general EPS system has the following parts e Steering torque sensor e Motor to generate power torque e EPS system control unit ECU e Speed sensor e Temperature sensor e Battery voltage sensor e Mechanical reduction transmission mechanism Reducer e G
32. d clearance and Weight are those of the machine equipped with the tires in the table above The company reserves the right to change the specifications without notice TRAVELING SPEEDS Range gear shift lever km h mph 7 2 Specifications VEHICLE LIMITATIONS The Vehicle has been thoroughly tested for proper performance with implements sold or approved by Use with implements which are not sold or approved and which exceed the maximum specifications listed below or which are otherwise unfit for use vehicle may result in malfunction or failures of the vehicle damage to other property and injury to the operator or others Any malfunctions or failures of the vehicle resulting from use with improper implements are not covered by the warranty Max Cargo loading weigh Rear trailer hitch a 1 ROW SEATING MODE Cargo Bed Capacity 500Kg 1100 Ib Max rolling weight Cargo Load Capacity 730kg 1609 Ib 590 kg 1300 Ibs operator one passenger options accessories weight Max tongue weight 50 kg 110 Ibs 1 Above mentioned specifications are based on level ground condition 7 3 Storage STORAGE A CAUTION To avoid personal injury Do not clean the vehicle when the engine is running To avoid the danger of exhaust fume poisoning do not operate the engine ina closed building without proper ventilation When storing remove the key from the key switch to avoid unauthorized persons from ope
33. d repair needed 2 The Fault of closing function The main objective of research and development was that the EPS system needed to ensure that the vehicle would still be controlled by the driver when a malfunction happened Therefore the EPS system has many monitoring functions used to identify the sensors actuators and the involvement of the EPS system to check for malfunctions lf a malfunction leads to the interruption of motor control the ECU then closes the function of EPS system Shutting down the EPS system s will cause the driver to lose power steering But close tolerances are used for preventing errors in the control motor When a fault occurs power steering stoppage is EPS characteristic Although the driver may feel the a predetermined system response characteristics of loss of power steering with increased control force the driver can ensure the vehicle steering performance is not affected When a fault occurs Neither the EPS steering system nor hydraulic power steering system would have power steering When a fault occurs the two systems react similar The fault occurs the EPS system fault indicator light inside of meter will be on If above circumstance happens the EPS system will have no power steering and the the corresponding fault code and remind driver to through instrument will show take care 3 Although the mechanical structure of the EPS system has mechanical limit position i
34. d side hilling riding across slopes even on flat open areas Reserved for Reference to Other Soures of Safety Information Locate and Read Owner s Manual 12 Use only 91 Octane or higher gasoline Use Non Ethanol gasoline when possible for better performance and engine Never use E 85 gasoline in this engine as use of E 85 gasoline will void the warranty 13 e Max towing weight 800kg 1764lbs e Max tongue weight 58kg 128lbs 14 Engine exhaust from this product contains chemicals known in certain quantities to cause cancer birth defects or other reproductive harm SS EXHAUST FUMES MAY CAUSE HARM 2 8 Identification Numbers Your dealer is interested in your new vehicle and has the desire to help you get the most value from it After reading this manual thoroughly you will find you can do some of the regular maintenance by yourself However when in need of parts or major service be sure to see your dealer For service contact the dealership from which you purchased your vehicle or your local dealer When in need of parts be prepared to give your dealer both the vehicle and engine serial numbers Locate the serial numbers now and record them in the space provided Serial Number Vehicle o y O Engine Date of Purchase Name of Dealer O O o G ZA S Engine serial number 3 1 Maintenance A CAUTION To avoid personal injury and vehicle damage Be s
35. e coolant has cooled down Open the cap slowly and let the coolant pressure reduce and then open the radiator cap fully to remove Check for the coolant level in the coolant reservoir If necessary add coolant 8 Tires should be mounted on rims with special equipment only by professionals 9 Keep the specified tire pressure to ensure driving safety 10 Elevate the vehicle and place a suitable stand under the frame when removing the wheels Be sure to re tighten the wheel nuts to the specified torque General Warning and caution labels 1 2 3 Improper Operation Can Cause This Vehicle to Overturn and Lead to Serious Injury or Death e Turn speed not to exceed 18 MPH 30 KPH ro This vehicle handles differently than cars e Do not drive in the water deeper than 15 in Select gear Lon trucks or other off road vehicles In order to avoid overturns avoid sharp turns ro u g h te rra l n a n d e never turn while applying heavy throttle e turn speed less than 30km h S O p e d te rra j n x never make abrupt steering maneuvers e operate at speeds appropriate for your skills the conditions and the terrain s DO NOT do power slides donuts jumps or other driving stunts 4 5 6 Chongqing Huansong Science And Technology Industrial Co Ltd This structure meets ROPS requirements for Severe INJURY or DEATH can result if earth moving machinery under ISO 3471 you ignore the following guidelin
36. e the pedal properly fixed every 200 hours of operation or six months whichever comes first If Installation points are loose or water leaks tighten bands securely stroke Periodic Service 1 Replace hoses and tighten Installation points 1 points are tight and not damaged securely if radiator hoses are swollen 2 If hoses and Installation points are found to be hardened or cracked Replace hoses and worn or damaged replace or repair them at hose clamps every 2 years or earlier if once checked and found that hoses are swollen hardened or cracked 1 Hose 2 Hose clamp EVERY 300 HOURS B Checking Tire Precaution at Overheating 1 Check to see if tires are damaged Radiator hose _ 2 Installation points Take the following actions in the event the coolant 2 Ifthe tires are cracked bulged or cut or they temperature is close to or more than the boiling are worn out replace or repair them at once point which is called Overheating 1 Stop the vehicle operation in a safe place and Tire Tread Depth keep the engine unloaded idling Always replace the tires when the tread depth is 2 Don t stop the engine suddenly but stop it worn to minimum allowable after about 5 minutes of unloaded idling 3 Keep yourself well away from the vehicle for at least 10 minutes or while the steam is blowing out 4 Check to see if there is no danger such as burning get rid of the causes of overheating according t
37. ead SAFE OPERATION in front of this manual e Read the danger warning and caution labels located on the vehicle e To avoid the danger of exhaust fume poisoning do not operate the engine in closed buildings without proper ventilation e Start engine only from the operator s seat Never start the engine while standing on ground 6 Make it a rule to set gear shift lever to NEUTRAL position before starting the engine IMPORTANT 6 Do not use starting fluid or ether 6 To protect the battery and the starter make sure that the starter is not continuously turned for more than 5 seconds STARTING THE ENGINE 1 Make sure the parking brake is set Fa a s i Parking brake lever NOTE The parking brake warning lamp P comes on while parking brake is applied and goes off when it is released 1 Parking brake warning lamp 4 2 Operating the Vehicle 2 Set gear shift lever to the NEUTRAL position L Low t H High T N Neutra R Reverse S 1 Insert the key into the key switch and turn it 1 Gear shift range lever to START L Low Range OFF Engines stop H High Range ON Engine run or headlight on N Neutral position START Engine start R REVERSE Display Warning Lights 3 Push the accelerator pedal down about 1 2 1 When the key is turned to START lamps 1 way engine oil pressure should come on If trouble occurs at any l
38. ear rack type steering gear e Steering rod joint e Ball stud of steering knuckle e Steering shaft and universal E Construction of EPS 1 Structure chart of EPS Steering wheel Reducer Motor Steering transmission shaft Universal joint Tie rod joint Tie rod Steering knuckle Steering gear 8 2 Electric Power Steering System 2 Steering Torque Sensor Install sensor on the reducer Sensor Do not change the position of the Senor The Sensor assembly position is fixed and cannot be changed if the sensor position is found changed caused by a loose bolt please tighten the bolt and adjust the ECU at once 3 ECU The ECU is sophisticated electronic equipment and controls all the power performance of EPS so do not repair the ECU by yourself lf any problem happens on the ECU please contact your local dealer to repair it Upper housing ECU unit Seal ring Lower housing Installation position of ECU and reducer Reducer The installation location of the ECU is greatly affected by temperature changes and external humidity The housing has a membrane made of a Gortex material which regulates pressure between inside the housing and the surrounding and moisture environment also prevents buildup Do not remove the membrane or replace with other parts 8 3 Electric Power Steering System On the housing of ECU unit there are
39. ection function In order to ensure the EPS system can supply a long life of reliability a variety of detection and alarm functions are set in the ECU software program Once a fault has been checked on the EPS system the UTV can accurately shutdown the EPS system With the EPS system shut down the UTV will be able to continue to complete the steering function through the mechanical structure of the steering system However at this time the driver will feel the turning resistance increase You can continue your driving of the UTV only it will take greater force to operate the steering system A DANGER When the meter indicates a malfunction of the EPS system or when the driver finds the EPS system operation abnormal please do some steps as below Stop vehicles immediately Shut off the main switch open the front panel s repair cover and pull up the outlet which power supply for EPS system See page12 3 Drive the UTV to dealer by lower velocity and repair the EPS system EPS SYSTEM S INSPECTION MAINTENANCE REPAIR The EPS system has already been inspected by strict quality restriction before delivery so it has high reliability But if there is no inspection or maintenance as stated time period during in use of EPS it may cause the EPS system to work abnormally or Spare parts in EPS system to be damaged abnormally When the EPS system works wrong or gets a malfunction the malfunction warning and fault
40. engine does not turn over Charge the battery quick enough In cold weather 15 C always remove the battery from the vehicle charge and store it indoors install it on the vehicle only when the vehicle is going to be used Insufficient fuel 6 Check the fuel system The injector is clogged Clean or replace the injector Crankshaft position sensor is Replace crankshaft position sensor out of alignment The air cleaner is clogged Clean or replace the air cleaner Spark plug is fouled Clean or replace the spark plug Ignition coil is defective Replace the ignition coil Check with the diagnostic Engine stops suddenly instrument Motor Scan KF90121 Fill cooling system to the correct level Check radiator and hoses for loose connections or leaks Engine overheats 6 The motor driven fan does Check to see if the fuse is blown not turn Check the electric system o Dirty radiator core or grille g T screens Coolant flow route corroded Flush cooling system If you have any questions consult your local dealer Engine power is insufficient LOW coolant level 10 1 Troubleshooting Check malf code meaning by reading the below table Mt05 ECU Malf Code Table 23 Malf code in MT05 P0107 P0108 Description MAP Circuit Low Voltage or Open MAP Circuit High Voltage IAT Circuit Low Voltage IAT Circuit High Voltage or Open P0117 Coolant Oil Temperature Sensor Circuit L
41. er the vehicle after the muffler and the engine have cooled down Storage REMOVING THE VEHICLE FROM STORAGE 1 Check the tire air pressure and inflate the tires if they are low 2 Before installing the battery be sure it is fully charged Check to see if the fan works Check all fluid levels engine oil transmission oil engine coolant transmission coolant and any attached implements 5 Start the engine Observe all gauges If all gauges are functioning properly and reading normal move the vehicle outside Once outside park the vehicle and let the engine idle for at least five minutes Shut the engine off and walk around vehicle and make a visual inspection looking for evidence of oil or water leaks 6 With the engine fully warmed up Release the parking brake and test the brakes for proper adjustment as you move forward Adjust the brake as necessary 9 2 Troubleshooting ENGINE TROUBLESHOOTING If something is wrong with the engine refer to the table below for the cause and its corrective countermeasure Trouble Cause Countermeasure Check the fuel tank and fuel filter Check the electric fuel pump Check the injector 6 No fuel flow Check the ECU with Motor Scan KF90121 Replace filter electric fuel pump injector and ECU If necessary and Engine revolution is slow depending on ambient temperatures Battery becomes weak and Clean battery cables and terminals the
42. es e Maximum load in cargo bed is350Ibs 159kg e Never carry passengers in cargo bed Passengers can be thrown off causing serious injury or death e Cargo can affect handling and stability Read Owner s Manual before loading or towing When operating with cargo or towing a trailer always reduce speed allow more room to stop and avoid hills and rough terrain Be sure cargo is secured since a loose load can change vehicle handling Keep weight in the cargo bed centered and as low and far forward as possible Top heavy loads increase the risk of rollover Never carry passengers in cargo bed 7 imem ae8 Chongqing Huansong Science And Technology Industrial Co Ltd VN a or Certifies that this ROV complies with the American National Standard for Recreational Off Highway Vehicles ANSI ROHVA 1 2011 Standard TYPE OF VEHICLE D 8 9 e To avoid transmission Improper tire pressure or overloading damage shift only when can cause loss of control vehicle is stationary and at Loss of control can result in severe idle C injury or death e VV hen vehicle is stopped ce brake lever in the Front 26psi 182kPa parking Rear 26psi 182kPa e Cold tire pressure APPLY BRAKE TO START e Maximum weight capacity 2324 bs 1054kg 2 7 General 10 Change the oil when the temperature drops to 15 Celsius 5 Fahrenheit 11 Improper Use of Off Highway Vehicles Can
43. fully read this chapter before Operating or driving and understand the correct ways to operate and drive the UTV with the EPS system and also characteristics functions and limits of UTV Do inspections and maintenance on the EPS system at regular intervals Correct operation and driving skills will ensure the security and reliability of UTV To make sure your EPS system will be useful for a long time please follow the methods for maintenance in this chapter Electronic Power Steering System Typical parts of the EPS system In general parts EPS system has the following e Steering torque sensor e Motor to generate power torque e EPS system control unit ECU e Speed sensor e Temperature sensor e Battery voltage sensor e Mechanical reduction transmission mechanism Reducer e Gear rack type steering gear e Steering rod joint e Ball stud of steering knuckle e Steering shaft and universal joint B Construction of EPS 1 Structure chart of EPS Steering wheel Reducer Motor Steering transmission shaft Universal joint Tie rod joint Tie rod Steering knuckle Steering gear The Meter is an important part of the UTV The Meter works together with the EPS system and monitors working condition of the EPS system Faults can be displayed by a fault indicator light and fault indicator of EPS system so the driver can acknowledge faults of the EPS in time and take some measures to
44. ge to the machine NOTE A NOTE provides key information to make procedures easier clearer 1 2 Introduction HS 1000 IMPORTANT NOTICE This UTV is designed and manufactured for OFF ROAD use only It is illegal and unsafe to operate this UTV on any public street road or highway This UTV complies with all applicable OFF ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture Please check your local riding laws and regulations before operating this UTV When the temperature is below 4 F 20 C park the UTV in a place where the temperature is higher than 4 F 20 C Operate the UTV after the UTV has warmed up Please see page 7 3 on the warming up process Follow the proper parking procedures when the temperature is higher than 100 F 38 C turn off the engine make sure the radiator fan is on for 3 minutes before turning off the power switch Starting the UTV for the first time will take longer because the fuel will need reach the fuel injectors To start the UTV the first time hold the ignition key on at 5 second intervals Allow the starter to rest 15 seconds between each start attempt 1 3 Introduction HS 1000 Table of Contents Subject Introduction Warnings Cautions and Notes Important Notice Table of Contents Part Locations Part Locations Part Locations Safe Operation Safety Instructions Operation Children Safety Instructions Driving on a slope
45. gine from overheating B Checking brake fluid level A CAUTION TO avoid personal injury Never operate the vehicle if the brake fluid is below the minimum mark Use only DOT3 from a sealed container Other types of brake fluid may ruin synthetic resin or rubber installed in brake system components and may cause brake failure Avoid contamination of the brake fluid thoroughly clean before removing the filler cap Do not open the brake fluid reservoir cap unless absolutely necessary Use extreme care when filling the reservoir If brake fluid spills onto the power steering hose wash it off with water immediately as brake fluid quickly ruins synthetic resin or rubber hoses 1 Park the vehicle on a level surface and open the hood 2 Check to see that the brake fluid level is above the LOWER mark If it is below the LOWER mark add brake fluid Periodic Service B Checking brake pedal A CAUTION TO avoid personal injury Stop the engine and chock the wheels before checking brake pedal 1 lInspect the brake pedal for free Play and smooth operation Adjust if incorrect measurement is found see checking brake pedal in EVERY 200 HOURS in PERIODIC SERVICE section 1 Brake pedal 3 PEDAL STROKE 2 FREE TRAVEL 6 5 B Checking parking brake NOTE Make sure the parking brake warning lamp on the display goes off when parking brake lever is down 1 Parking ha
46. ine B Checking Coolant Level A CAUTION TO avoid personal injury Do not remove radiator cap while coolant is hot When cool slowly rotate to the first stop and allow sufficient time for excess pressure to escape before removing the cap completely 1 Park the vehicle on a flat surface raise the cargo bed mount the safety support and shut off the engine 2 Check to see that the coolant level is between the FULL and LOW marks of recovery tank Periodic Service When the coolant level drops due to evaporation add water only up to the full level In case of leakage add anti freeze and water in the specified mixing ratio up to the full level see flush cooling system and changing coolant in EVERY 2 YEARS in PERIODIC SERVICE section D Si if a M N 00 O A TA i E E d mE 17 Recovery tank FULL LOW IMPORTANT lf the radiator cap has to be removed follow the cautions above and securely retighten the cap Use clean fresh water and anti freeze to fill the recovery tank lf water should leak consult your local HISUN Dealer WE Cleaning radiator screen A CAUTION TO avoid personal injury Be sure to stop the engine before removing the screen Park the vehicle on a flat surface Remove the radiator cover Detach the screen and remove all foreign materials 6 4 1 Radiator screen 2 DETACH IMPORTANT Radiator screen must be clean from debris to prevent en
47. inspection before operating the vehicle to start the engine A CAUTION To avoid personal injury Be sure to check and service the vehicle on a flat surface with the engine off and the parking brake ON Visual Inspection Look around and under the vehicle for such items as loose bolts trash build up oil or coolant leaks broken or worn parts B Checking and Refueling A CAUTION To avoid personal injury Do not smoke while refueling Be sure to stop the engine before refueling 1 Turn the key switch to ON check the amount of fuel by fuel gauge 2 Fill fuel tank when fuel gauge shows1 4 or less fuel in tank x I i LN p ZO l b a P i m WN l fr 21 UA W be me S Oita RIS l NS Fuel tank cap Fuel tank capacity 34L 8 9 U S GALS 6 3 IMPORTANT If the oil level is low do not run the engine Checking the engine oil level 1 Park the vehicle on a flat surface raise the cargo bed mount the safety support and shut off the engine 2 To check the oil level draw out the dipstick wipe it clean replace it and draw it out again check to see if the level is too low add new oil to the prescribed level at the oil inlet ZSI NN 4G Je VO L ag _ 4 L HT ee H ls s kn b a L__44 B K gt eg A GS V vz U CZAR K S Up K SOF OKS D aa y H A X D gt T IMPORTANT If oil level is low do not run the eng
48. ire broken circuits Replace connector or ECU connectors is loose assembly No meter alarm Positional parameter of steering Adjust front wheels 2 wheel front wheel error positional parameter r No meter alarm EPS system s speed reducer Bring the UTV to dealer damaged for repair Electric Power Steering System 5 All have power assisted to turn left or right but steering becomes heavy Meter fault code F00006 warning No meter alarm steering becomes more difficult if no power No meter alarm No meter alarm No power assisted the power of steering to left and right is different No meter alarm No meter alarm ECU reduce the power of the motors radiator overheat output torque automatically or ECU s inside temperature alarm sensor damaged Mechanical steering system s spare parts are damaged ECU damaged or the ECU software program has error Two channels parameters of sensor changed Mechanical steering system s spare parts are damaged ECU damaged or the ECU software program has error The initialization parameter ECU has error 7 Open main switch steering to the same direction automatically S N 1 Fault phenomenon No meter alarm No meter alarm Sensor no loosening Fault point Sensor is loosen The initialization parameter of ECU has error 8 11 Remove dirt or another covering on shell of ECU Bring the UTV to dealer fo
49. nd bar B Checking gauges meter and easy checker lamps for broken the instrument warning lamps 1 Inspect panel 2 Replace if broken B Checking head light turn signal light etc 1 Inspect lights for broken bulbs and lenses 2 Replace if broken B Checking seat belt and ROPS 1 Always check condition of seat belt and ROPS attaching hardware before operating vehicle 2 Replace if damaged Periodic Service E Checking CV boots EVERY 50 HOURS 1 Check to see if the CV boots are damaged or W Greasing not Apply a small amount of multi purpose grease to 2 If the boots are cut gashed or show signs of the following points every 50 hours If you operated deterioration consult your local dealer the vehicle in extremely wet and muddy conditions Front L JYOTI S V ate ad Pa L a t TODA HZ Hp lubricate grease fittings more often 1 CV boot 2 Drive shaft VINT N j f Pres WSF K a a CL ee 1 Parking hand bar 2 Parking brake pivot spray type grease 1 CV boot 2 Drive shaft B Checking tire inflation pressure Though the tire pressure is factory set to the prescribed level it naturally drops slowly in the course of time thus check it everyday and inflate as necessary tire sizes inflation pressure Front 27x9 14 179kPa Rear 27x11 14 0 7kgf cm2 26psi Range gear shift lever pivot spray type grease Periodic Service B Checking engine start system A
50. ng some measures to keep him her safe When a fault terminals of cables firmly to G and of occurs on the EPS system a fault indicator light battery will be on At the same time the fault indicator of a EPS system will display the fault code for N s E maintenance NX SK Fault indicator light of EPS system Fault code diagram Nee Se Fault sty i ie a nas code eves garo 2 Positive Wire Of Cable system S 1 fault of steering 3 Positive Wire Of EPS System 1 F00001 irate sencor lit 4 Negative Wire Of Cable 2 fault of steerin Negative Wire Of EPS System torque sensor Nut F00006 ECU overheating ey ee F 00005 ow voltage battery alarm Dynamic motor without power alarm paus Fault of speed m If connection terminals are not connected sensor power of ECU may be constantly on off F00010 ECU non working during UTV driving and finally cause ECU damage Turning On the main switch of UTV and EPS system will automatically enter into working state 8 5 Electric Power Steering System Check the meter If fault indicator light of EPS system is not lit ECU is ready for regular use lf fault indicator light of EPS system is lit that means EPS system found a fault during the ECU self checking process then you should consult your local dealer for maintenance Meter 1 Fault indicator light of EPS system 2 Fault indicator of EPS system A DANGER Driving the UTV
51. nt Panel and Controls LOCATION OF PARTS Roll Over Protection System Headrest Safety Hand Rail Headlights Front Tires l k LOT l Z i L w t eU 9 C Seat Back W X l if X Fi Seat Turn Signals E Front Panel Front Bumper Front Shock Absorber 2 1 General LOCATION OF PARTS Cargo Bed Taillights Tailgate ee al l Fuel Cap Rear Tires Muffler Rear Shock Absorber ILLUSTRATED CONTENTS High low beam lights Steering wheel Lig Horn D oa L C 7 Parking Brake peda Accelerator pedal Range gear shift lever switch General Emer ge ight Turn Signals 4WD button Front axle differential De e Se ae SIT Z A v a DC socket Rear axle differential 2 3 All General AX SAFE OPERATION operators including experienced carefully read and fully understand this Users Manual Operation as directed in this manual should be strictly adhered to in order to achieve the best performance and avoid accidents Others who use your UTV should be trained on how to operate the UTV and read this manual before operation Safety Instructions Understand this UTV by reading this manual and understanding all the components of the vehicle Only start and operate the vehicle after finishing reading this manual Pay close attention to the warning and caution labels on the UTV Understand completely and learn to use the
52. o the TROUBLESHOOTING section of the manual and then start the engine again 3mm 0 12in B Checking Intake Air Line Check to see if the hoses and Installation Periodic Service EVERY 400 HOURS E Changing Transmission Fluid A CAUTION To avoid personal injury Park the vehicle on a flat surface raise the cargo bed mount the safety support Allow engine to cool down sufficiently oil can be hot and can burn To drain the used oil remove the drain plug at the bottom of the transmission case and drain the oil completely into the oil pan After draining reinstall the drain plug After running the engine for a few minutes stop the engine and check the oil level again add oil to prescribed level 3 CV NA ka fe AAA LAAL Na NLS SS ma SLAN Drain plug IMPORTANT Do not operate the vehicle immediately after changing the transmission fluid Run the engine at medium speed for a few minutes to prevent damage to the transmission WE Changing Front and Rear Axle Case Oil 1 Park the vehicle on a firm flat and level surface To drain the used oil remove the drain the oil 2 completely into the oil pan 3 Fill with the new oil up to the upper notch on the dipstick See LUBRICANTS FUEL AND COOLANT in MAINTENANCE section d After filling reinstall the filling plug Oil capacity 0 6L 0 6U S gals Q p SLAN Z f d aA y
53. ocation with engine running the warning lamp corresponding to that location comes on The parking brake warning lamp 2 parking brake comes on while parking brake is applied and goes off when it is released H anr Accelerator pedal INCREASE 3 DECREASE 4 3 Operating the Vehicle IMPORTANT Relying on the engine warning lights is never enough Never fail to conduct daily checks carefully by referring to Pre Operation Check in the PERIODIC SERVICE section 3 Turn the key to START position and release when the engine starts IMPORTANT e Because of safety devices the engine will not start except when the gear shift lever is placed in the NEUTRAL position and the brake is depressed E Cold Starting When the ambient temperature is below 15 C 5F the engine is very cold If the engine fails to start after 5 seconds turn off the key for 30 seconds and start again STOPPING THE ENGINE 1 After slowing the engine to idle turn the key to OFF 2 Remove the key WARMING UP A CAUTION To avoid personal injury e Be sure to set the parking brake during warm up Be sure to set the shift lever to the NEUTRAL position during warm up Allow the engine to warm up for 5 minutes without applying any load This is to allow oil to reach every engine part If a load is applied to the engine without warm up engine damage may occur E W
54. ow Voltage P0118 Coolant Oil Temperature Sensor Circuit High Voltage or Open TPS Circuit Low Voltage or Open TPS Circuit High Voltage O2A Circuit Low Voltage O2A Circuit High Voltage O2A Heater Circuit High Voltage O2A Heater Circuit Low Voltage Injector 1 Circuit Malfunction Injector 2 Circuit Malfunction FPR Coil Circuit Low Voltage or Open FPR Coil Circuit High Voltage CKP Sensor Noisy Signal CKP Sensor No Signal Cylinder 1 Ignition Coil Malfunction P0337 Cylinder 2 Ignition Coil Malfunction Idle Speed Control Error system Voltage Low system Voltage High P0650 MIL Circuit Malfunction Tachometer Circuit Low Voltage P1694 If you have any questions consult your local dealer Tachometer Circuit High Voltage 10 2 Troubleshooting BATTERY TROUBLESHOOTING Trouble Cause Countermeasure Preventive measure until lights are dim Charge the battery Charge the battery sufficiently properly been recharged Keep the terminal Starter does not function Clean the terminal clean and tight Poor terminal and tighten connection Apply grease and securely treat with anti corrosive Replace new Battery life expired battery From beginning starter E Battery must be Insufficient Charge battery does not function and a serviced properly charging Insufficiently Es lights soon become dim before initial use 6 Battery was used Saag o Add distilled wa
55. r repair Adjust repair damaged spare parts Bring the UTV to dealer for repair Replace sensor or go to dealer for repair Adjust spare parts repair damaged Bring the UTV to dealer for repair of Restart initialization for ECU Solution Bring the UTV to dealer for repair Restart initialization for ECU Electric Power Steering System E Maintenance and repair s supplemental description 1 Restart initialization to ECU parameter Park UTV on the flat ground and keep the front wheels pointed forward always Pull out initialization selects connector See Page 12 9 Push UTV back and forth for several times and turn the wheels several times Turn on the main switch and wait for 5 seconds Reinsert pin connector to finish the ECU parameter initialization process Then turn on the main switch check whether the fault is removed If it is not removed follow the previous steps of initialization process again Because the different mechanical settings of the UTV it may require 3 5 times to be repeated in order to get the correct initialization parameters If a customer complaint is vehicle deviation you should take into account the fault causes not only includes the EPS system but also includes a chassis mechanical failure customers may use Deviation to describe a specific situation So four wheel alignment need to be adjusted first then ECU replacement an
56. r this service EVERY 4 YEARS B Replacing Brake Hose Consult your local dealer for this service B Replacing Mini Fuses The mini fuses are intended to protect the electrical cabling If any of them have blown out be sure to pinpoint the cause Replacing procedure 1 Disconnect the negative cable of the battery 2 Open the mini fuse box cover 3 Pull out the mini fuse 4 Insert a new mini fuse into the mini fuse box 5 Close the mini fuse box cover 6 Connect the negative battery cable 2 Slow blow fuse box cover B Replacing Light Bulb 6 Head lights Take the bulb out of the light body and replace it with a new one 6 Other lights Detach the lens and replace the bulb Ain Tail light Specifications SPECIFICATION TABLE Specifications Make 2 cylinders 4 cycle gasoline OHV liquid cool Engine Displacement 1 0 998 9 E E Rated revolution revolution mm 700 Kee idling revolution 1350 to 1500 Fuel Capacity L U S gal 34 8 34 BD amen S o S O Wheels Drive system 4 Rear 2WD or 4WD Differential lock Electric control switch Front Rear Hydraulic disk brake Brakes Parking brake Rear wheel Foot Pedal Suspension Length m in 3111 122 5 Height 1974 77 75 Ground SE e 7 1 3 Clearance Specifications 3 Bed height mm in 914 36 0 unloaded Cargo bed capacit Sound level operator ear Tire Body color NOTE The values in Groun
57. radiator cap securely 7 Fill with fresh water up to the FULL mark on the recovery tank Start and operate the engine for few minutes Stop the engine and let cool 10 Check coolant level of recovery tank and add coolant if necessary Coolant capacity 4 0L 4 2U S qts wi d 10 S yh ae ST 9 Q FULL 1 Recovery tank IMPORTANT Do not start the engine without coolant Use clean fresh water and anti freeze to fill the radiator and recovery tank When the anti freeze is mixed with water the antifreeze mixing ratio must be less than 50 Securely tighten radiator cap If the cap is loose or improperly fitted water may leak out and the engine could overheat E Anti Freeze A CAUTION To avoid personal injury When using antifreeze put on some protection such as rubber gloves Antifreeze contains poison 6 f you ingest antifreeze follow the emergency instructions on the antifreeze container and seek medical attention When antifreeze comes in contact with the skin or clothing wash it off immediately Periodic Service Do not mix different types of Antifreeze The mixture can produce chemical reaction causing harmful substances Antifreeze is extremely flammable and explosive under certain conditions Keep fire and children away from antifreeze When draining fluids from the engine place a container underneath the engine body Do not pour was
58. rating the vehicle and getting injured VEHICLE STORAGE lf you intend to store your vehicle for an extended period of time follow the procedures outlined below These procedures will insure the vehicle is ready to operate with minimum preparation when it is removed from storage 1 Check the bolts and nuts for looseness and tighten if necessary Apply grease to vehicle areas where bare metal will rust also to pivot areas Unload the cargo bed Inflate the tires to a pressure a little higher than usual Change the engine oil and run the engine to circulate oil throughout the engine block and internal moving parts for about 5 minutes With all implements lowered to the ground coat any exposed rods with grease if equipped Remove the battery from the vehicle Store the battery following the battery storage procedures Keep the vehicle in a dry place where the vehicle is sheltered from the elements Cover the vehicle Keep the vehicle indoors in a dry area that is protected from sunlight and excessive heat If the vehicle must be stored outdoors Cover it with a waterproof tarpaulin Put the dampness away from tires boards under tires to keep Keep the tires out of direct sunlight and extreme heat IMPORTANT 9 1 When washing the vehicle be sure to stop the engine Allow sufficient time for the engine to cool before washing Do not wash with a high pressure car washing machine Cov
59. repe ff tf Bier required NOTE Engine Oil 15W 40SL Oil used in the engine should have an American Petroleum Institute API service classification and Proper SAE Engine Oil according to the ambient temperatures as shown above Brake fluid Always use DOT3 GENUINE BRAKE FLUID from a sealed container 5 3 Operating the Vehicle Pre Operation Check DAILY CHECK To better prevent troubles it is important to Know the condition of the vehicle before operating Check it before starting A CAUTION To avoid personal injury Be sure to check and service the vehicle on a level surface with the engine shut off the parking brake ON and implements lowered to the ground if equipped Check items Visually inspect the exterior of the vehicle Check engine oil level Check transmission oil level Check brake fluid level Check coolant level Clean radiator screen When used in dusty areas Check brake and pedal Check parking brake Check indicators gauges and meters Check lights Check seat belts and roll over protective structures Check front and rear joint boots Check tire inflation pressure Check backup beeper if equipped Refuel See PRE OPERATION CHECK in PERIODIC SERVICE section Check danger warning and caution labels See DANGER WARNING AND CAUTION LABELS in SAFE OPERATION section 4 1 Operating the Vehicle A CAUTION To avoid personal injury e R
60. s attaching the air cleaner and then remove the air cleaner Remove the air filter element Remove the sponge material from its frame Wash the sponge material gently but thoroughly in solvent Squeeze the excess solvent out of the sponge material and let it dry Inspect the sponge material and replace it if damaged Thoroughly apply foam air filter oil or other quality liquid foam air filter oil not spray type to the sponge material Pull the sponge material over its frame Install the air filter element Install the air filter case cover and be sure the crankcase breather hose is connected 2 Air filter element 2 Element retaining plate 6 8 The air cleaner uses a dry element never apply oil Do not run the engine with filter element removed Be sure to refit the cover with the arrow on the rear of cover upright if the cover is improperly fitted evacuator valve will not function and dust will adhere to the element Evacuator Valve Open the air cleaner cover once a week under ordinary conditions or daily when used in a dusty place to get rid of large particles of dust and dirt Check fuel line and fuel filter A CAUTION To avoid personal injury Be sure to stop the engine and remove the key when attempting to make the following checks and changes lines the fuel periodically The fuel lines are subject to Never fail to check wear and aging and fuel may le
61. sets of 5 Gear rack type steering gear electric plugs which function as follows UTV use gear rack type steering gear to perform e P1 positive pole pole for EPS motor steering function Steering gear was fixed on e P2 negative pole pole for EPS motor frame e P3 connected with a cable and transfers Installation position of steering as follows signals to the ECU i e P4 connected with the steering torque sensor and supplies power to steering torque sensor and accepts signals for torque e P5 connected with motor 6 Electronic connectivity diagram of EPS system 4 Reducer The reducer is installed on the frame of UTV A motor and steering torque sensor is also installed on the reducer Outside view of reducer 1 ECU with waterproof metal box 2 ECU split cable Battery 4 Meter Steering torque sensor Motor Speed sensor Main switch Fuse 8 4 Electric Power Steering System 7 Meter A The Meter is an important part of the UTV CAUTION The Meter works together with the EPS system f main switch is not turned off the ECU can and monitors working condition of the EPS system be destroyed by battery power in on off Faults can be displayed by a fault indicator light condition during the following connection with and fault indicator of EPS system so the driver can cables acknowledge faults of the EPS in time and take Use screw nut to connect the connecti
62. stems and are usually 60 0 EPS connected by a mechanical and electric of low efficiencies However Hisun s system iS motor and it has a much higher efficiency of up to 90 Hisun s EPS system starts the motor only when it needs to generate power without increasing fuel consumption The power of Hisun s EPS system is controlled by software so that the UTV can be operated with power steering at various speeds Hisun s EPS connection system so the impact of road system uses a rigid conditions on steering wheel is greatly decreased the traditional hydraulic power steering system No pollution to environment For the hydraulic circuit has hydraulic hose and fittings inside the system so oil leaks may occur and hydraulic hoses are not recyclable This system type can produce pollution to the environment However Hisun s EPS system does not cause pollution to the environment 6 If the engine does not start the EPS system can also work off the battery and once sufficient power is generated the power steering system Is functionable IMPORTANT INFORMATION FOR SAFETY This UTV is equipped with EPS system please read this chapter carefully before operating the UTV and only when you are familiar with and master the EPS system methods and precautions Make inspections of the EPS system at regular intervals to ensure the security and reliability of your UTV 8 1 Please care
63. t eel el Pe ae 5 1 Maintenance Indication of After 5o co 0 e aso so llla 7s Every rane e fel feo fel fo Tel fel e som element Benes Every p 100 hrs Every wam E el fet tel fe Tel fel fel soms Fuel line Replace Fery 100 hrs A own al T Air cleaner ears element Baas 6 Every p 100 hrs prakepecal Jone o fol to fet fen years Parking brake l Every aa of tet iiel T lef arm Brake light Every emen ox ol to fel tel ams Every padiatornose e ef fo tel zs maoa feee tt L ears Every me EE sot rence f et eme years Every rake ers TTT 20 ms fomeck fT TT TT ery yeas Every C ea ea k Front axle case Every fetes oe L Knuckle case Every ae TTT Engine valve Every wa TT TT l l sot x Every rana fore TT tt S lon x Every afen e a aiin Jl EE EE e years tee hydraulic hose p years Rear brake Every 2 Replace cylinder seal years Front brake Every 2 Replace seal years P k N S Z _ k co CO NI O O1 oo NO k h D k Intake air line LO 5 2 Maintenance Indication of After 50 100 150 200 250 300 350 400 450 500 550 600 e50 700 70 hrs E 2 cooingaystem Fush E ears E 2 jar eoa onae E ears naagin ores Ser required fue hanas tf Sr required nk
64. t is still possible for the EPS system to realize the function of decreasing steering power before reaching the mechanical limit position in the form of a slope curve Although the customer will feel the steering resistance increase when turned to the limited position the process will become obviously more smooth Electric Power Steering System In addition it can also reduce the steering system s mechanical and electrical components load which helps in obtaining reliable function and long service life B EPS system Periodic maintenance For primary use after 50 hours adjust EPS system part of parameters according to the steering system s clearance variation and chassis changes Please go to the dealer for alignment For every 100 hours using time according to the steering system and the chassis changes adjust EPS system relevant parameters AX caution Before adjusting ECU the clearance of mechanical parts first and adjust please check four wheels position of UTV EPS TABLE B EPS system basic technical parameters SYSTEM PARAMETER E EPS system working conditions 1 Working environment temperature 40 C 85 C 2 Working voltage 9 16V DC 3 The seal type IP65 4 Input shaft rotation angle 1 25rmp large than 5 Wheel rotation speed 10round min 15round min B Motor assy basic parameters Type DC permanent magnet control motor Rated working time 3 min per time R
65. te onto the grounds down a drain or into any water source Also observe the relevant environmental protection regulations when disposing of antifreeze If it freezes coolant can damage the cylinders and radiator If the ambient temperature falls below 0 q32 F or before a long term storage let out cooling water completely or mix fresh water with long life coolant and fill the radiator and recovery tank with the mixture 1 Long life coolant hereafter LLC comes in several types Use ethylene glycol EG type for this engine 2 Before employing LLC mixed cooling water fill the radiator with fresh water and empty it again Repeat this procedure 2 or 3 times to clean up the inside 3 The procedure for the mixing of water and antifreeze differs according to the make of the antifreeze and the ambient temperature Refer to SEA J1034 standard more specifically also to SAE J814c IMPORTANT When the antifreeze is mixed with water the antifreeze mixing ratio must be less than 50 Freezing Boiling ue point point SESE aa 108 226 Anti freeze At 1 013x10 Pa 760mmHg pressure atmospheric A higher boiling point is obtained by using a radiator pressure cap which permits the development of pressure within the cooling system 4 Adding the LLC 1 Add only water if the mixture reduces in amount by evaporation 2 If there is a mixture leak add the LLC of the same manufacturer and type in the same
66. ter When viewed from the with an insufficient Regularly check the and charge the top of plates look amount of electrolyte level E battery whitish electrolyte Refillable type battery Battery was used Charge battery Charge battery only with too much E Insufficiently properly without recharging Recharging is impossible Battery life expired Replace battery a Keep the terminal Clean the terminal clean and tight Terminals are severely Poor terminal and tighten Apply grease and corroded and heat up connection l securely treat with anti corrosives There is a crack or Battery electrolyte level pin holes in the Replace battery drops rapidly pa tapiay electrolytic cells Refillable type battery Charging system 6 Consult your local on N trouble dealer Ifyou have any questions consult your local dealer The factory installed battery is non refillable type 10 3 Troubleshooting MACHINE TROUBLESHOOTING Replace throttle cable High idling speed of engine Replace throttle petal Replace the throttle connection Replace the primary clutch Put the gearshift rod into the position of N 6 Gear shift connection is not Put the gearshift arm of engine adjusted properly into N Adjust the stay wire and the bolt Lock tightly Replace the gears Misaligned clearance for the Gear Shift will not shift into gear
67. tions contact your local dealer for adjusting the brake 3 If brake pedal stroke is outside of the specifications contact your local dealer for adjusting the brake ihe f 1 Brake pedal 2 FREE TRAVEL 3 PEDAL STROKE B Checking Brake Hose and Lines 1 Check to see that brake hose and lines are not swollen hardened or cracked 2 Check the brake hose and pipe joints for oil Checking the brake pedal free travel leaks 3 If there is any abnormality consult your local dealer for this service B Checking Brake Light Switch 1 Park the vehicle on a flat surface and raise the Proper brake pedal 7 to 14mm free travel 0 3 to in On the pedal 1 Release the parking brake 2 Slightly depress the brake pedal and measure cargo bed free travel at the top of the pedal stroke Turn the key switch to the ON position If brak f i ide of th i 3 brake pedal free travel is outside of the Step on the brake pedal to check if the brake specifications contact your local dealer for light comes on 4 If it does not check the bulb or brake light switch adjusting the brake Checking the brake pedal stroke Less than 120mm 4 7in R Checking Radiator Hose and Clamp On the pedal Park the vehicle on a flat surface and raise the Pedal stroke 1 Release the parking brake cargo bed Check to see if radiator hoses are 2 Step on the pedal and measur
68. tory installed battery is non refillable type if the battery is weak charge the battery or replace it with new one Battery charging A CAUTION To avoid personal injury When the battery hydrogen and oxygen gases in the battery is being activated are extremely explosive Keep open sparks and flames away from the battery at all times especially when charging the battery When disconnecting the cable from the battery start with the negative terminal first when connecting the cable to the battery start with the positive terminal first Always check battery charge by using a voltmeter Periodic Service Fa aK Vy 7 B Adjusting toe in 1 Park vehicle on flat place 2 Turn steering wheel so front wheels are in the straight ahead position Lock the park brake and stop the engine Measure distance between tire beads at rear of tire at hub height 5 Front distance should be shorter than rear 1 Battery 1 To slow charge the battery connect the SS ice O AGUSE EET battery positive terminal to the charger positive terminal and the negative to the negative then recharge in the standard fashion 2 A boost charge is only for emergencies it will partially charge the battery as early as possible 3 When exchanging an old battery for a new aa w AAT RN AAJ one use battery of equal specification shown in table 1 Battery type 1 Wheel to wheel distance at front 2 FRONT
69. ure you have sufficient knowledge experience the proper replacement parts and tools before you attempt any vehicle maintenance task If you don t have the knowledge and equipment which are necessary to perform the maintenance task consult your local dealer Have your local dealer perform inspection items which are marked 4 in the chart below SERVICE INTERVALS IMPORTANT The jobs indicated by must be done after the first 50 hours of operation 1 Air cleaner should be cleaned more often in dusty conditions than in normal conditions 2 Every year or every 6 times of cleaning 3 Replace only if necessary 4 Consult your local dealer for this service 5 When the battery is used for less than 100 hours per year check the battery condition by reading the indicator annually The items listed below marked are registered as emission related critical parts by DEALER in the U S EPA non road emission regulation As the engine owner you are responsible for the performance of the required maintenance on the engine according to the below instruction Please see Warranty Statement in detail 5 co aw e T H 7280999999999991 7 eoan roe oT T fT fo fol 1 fat re Tg foe TT se P e fo EEE EEE EEE Se Ps emn rer oof e e feel e e e 9 re une foen foot fof tel tel et el e 2 rr samara own fet fof fe l f E gt 2 Gr ow fof A tell et tel 7 9 o msn owe fo gt t gt l f gt gt 2 Polen doe Pe
70. uring running conditions During running process the feeling of steering force to the left and right must be consistent During steering turning shall be smooth no blockage no recoil force that is opposite of operation force During the return process the return force is equal to the velocity at both left and right directions If any problem occurs the UTV must be driven to dealer and repaired immediately 8 8 Electric Power Steering System E Solutions for common fault 1 Open the main switch no auxiliary power of left and right steering FAULT PHENOMENON FAULT POINT SOLUTION 1 Meter warning fault Special fuses of ECU is blown in Replace fuses Bring the code F00010 fuses box see figure 1 Or ECU is UTV to dealer for repair damaged 2 Meter warning fault code Sensor is damaged or sensors Bring the UTV to dealer for F00001 amp F00002 connector with bad contact or ECU repair is damaged 3 Meter warning fault code Low voltage in storage battery Charge storage battery F00005 replace it if necessary 4 Meter warning fault code Motor is damaged or driving circuit Replace fuses Bring the F00003 in motor is damaged or power UTV to dealer for repair motor special fuses are blown 5 No electrical power Main fuses melted Replace fuses connected No meter alarm UTV can ECU initialization choose pin Reinsert well replace electrify connector with poor contact sees connector or repair
71. vehicle was designed to meet the emission standards for 10 000 km or five years whichever comes first Your emission control system warranty covers components whose failure would increase an engine s emissions of any regulated pollutant Where a warrantable condition exists HISUN will repair your vehicle at no cost to you including diagnosis parts and labor lf an emission related part on your vehicle is defective the part will be repaired or replaced by HISUN This is your EMISSION CONTROL SYSTEM WARRANTY NOTICE Use of this vehicle in any type of competitive event completely and absolutely voids this and all other warranties offered by HISUN OWNER S WARRANTY RESPONSIBILITIES As the vehicle owner you are responsible for the performance of the required maintenance listed in your owner s manual HISUN recommends that you retain all receipts covering maintenance on your vehicle but HISUN cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance You are responsible for presenting your vehicle to the HISUN dealer as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days As the vehicle owner you should be aware that HISUN may deny your warranty coverage if your vehicle or a part has failed due to abuse neglect improper maintenance or unapproved modifications If you use your vehicle in any t
72. with faulty EPS system may cause an accident severe injury or even death Never operate UTV with faulty EPS system B Function of EPS system EPS system requires enough power to supply correct power torque Supply Power steering according to speed UTV S power steering can change at different speeds and steering angles 8 6 The EPS systems can supply different power torque depending on the speed and steering angle T1 steering resistant torque which is checked by steering power sensor T2 power torque on steering gear which is supplied by EPS system 3 Power Torque In Static Condition 4 Power Torque At Middle Speed Power Torque At The Highest Speed Stationary the maximum power torque can assist a turn while stopped in place as much as possible to ease the steering operation With increased speed reduce power torque can assist steering at high speed to make ii easier to maintain driving direction As shown power auxiliary effect depends not only on speed but also steering torque exerted by the driver If the driver is to impose a smaller steering torque power torque of the EPS system will be relatively small This can be achieved outstanding auto centering effect that means when the UTV is in a straight line the steering system will not be as sensitive the steering wheel does not move from side to side Electric Power Steering System Fault alarm and prot
73. y important for a new vehicle Various parts are not broken in and are not mated to each other Small pieces of metal grit may develop during the operation of the vehicle and this may wear out or damage the parts Therefore take care to change the lubricating oil a little earlier than would ordinarily be required For further hours details of interval MAINTENANCE section change see STARTING 1 Fasten the seat belt E Seat Belt AQwarnine To avoid personal injury 6 Seat belts reduce injury Always wear your seat belts The lap style seat belts may not provide adequate protection for small children Pay special attention when carrying a child passenger A CAUTION To avoid personal injury Always use the seat belts when operating and riding the vehicle Adjust the seat belts for proper fit and connect the buckle This seat belt is an auto locking retractable type 4 5 Operating the Vehicle vehicle 2 Lamp built in the coolant temperature gauge 3 Lamp built in the fuel gauge 4 Lamp built in the soeedometer E Hazard Light Switch if equipped Press the top half of the hazard light switch the 1 Buckle 2 Latch plate hazard lights flash along with the indicator on the 2 Selecting light switch position instrument panel Press the bottom half of the hazard light switch to turn off the hazard lights R Head Light Switch Note Turn on the key switch and push the head light
74. ype of competitive event this warranty is immediately and completely void If you have any questions regarding your warranty rights and responsibilities you should contact Hisun Motors Corp U S A 1434 Patton Place Ste 106 Carrollton TX 75007 Phone 972 446 0760 or Toll Free 877 838 6188 or the U S Environmental Protection Agency at 2000 Traverwood Drive Ann Arbor MI 48105 d HSUN Hisun Motors Corp U S A Limited Warranty on Emission Control System YOUR WARRANTY RIGHTS AND OBLIGATIONS Hisun Motors Corp U S A warrants that each new off road vehicle A is designed built and equipped so as to conform at the time of initial retail purchase with all applicable regulations of the United States Environmental Protection Agency and is free from defects in material and workmanship which cause such vehicle to fail to conform to applicable regulations of the United States Environmental Protection Agency for the periods specified above Coverage Warranty defects shall be remedied during customary business hours at any authorized HISUN dealer located within the United States of America in compliance with the Clean Air Act and applicable regulations of the United States Environmental Protection Agency Any part or parts replaced under this warranty shall become the property of HISUN Limitations This Emission Control System Warranty shall not cover any of the following A Repair or replacement as a result of 1 accident

SECTOR 1000 - Hisun Motors Corp, USA

Contents

Download Pdf Manuals

Related Search

Related Contents