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HS 500 - Hisun Motors Corp, USA

1. Periodic Maintenance and Adjustment 8 61 Table 4 Solution of Common Problems in Electrical System S N Problems Solutions 1 Check if the headlight switch functions well 1 Lights do not work 2 Check if the wires are broken 3 Check if the lamps or bulbs are broken 1 Check if the control switch on meter board works well 2 Vehicle cannot go into 4 2 Check if the differential lock control magneto plug in rear wheel drive mode reduction gear box is damaged 3 Check if any wires are broken 3 iia diferentakndik nor 1 Check if the control switch on meter board works well work Rear differential will not 1 Check if the differential lock control magneto plug in rear 4 reduction gear box is broken work 2 Check if any wires are broken 1 Check if the sensor is damaged 5 Meter display is not 2 Check if the meter is broken normal 3 Check if the surface of speed sensor is contaminated with iron dust 1 Check if the switch is broken 6 F Siigh PTa 2 Check if any wires are broken board will not work 3 Check if the ECU is broken 8 62 Periodic Maintenance and Adjustment S N Problems Solutions EFI system 1 Check if the ECU is broken 2 Check if the nozzle is clogged or the nozzle to the ECU connection is disconnected 3 Check if the engine speed signal sensor is broken 4 Check if the engine speed signal
2. CAUTION Do not try to remove the sealing caps of the battery cells You may damage the battery 8 44 Periodic Maintenance and Adjustment A WARNING POTENTIAL HAZARD Failure to handle batteries or battery electrolyte carefully WHAT CAN HAPPEN You could be poisoned You could be severely burned by the sulfuric acid in battery electrolyte Batteries produce explosive gases HOW TO AVOID THE HAZARD Avoid contact with skin eyes or clothing Always shield eyes when working near batteries Keep out of reach of children Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Get prompt medical attention EYES Flush with water for 15 minutes and get prompt medical attention Keep batteries away from sparks flames cigarettes or other sources of ignition Ventilate when charging or using in a closed space Periodic Maintenance and Adjustment 8 45 Battery maintenance 1 When the vehicle is not used for a month or longer remove the battery and store it in acool dark place Completely recharge the battery before reinstallation CAUTION A special battery charger constant voltage ampere or constant voltage is required for recharging a sealed type battery Using a conventional battery charger may shorten the battery life i 1 Positive battery lead 2 Negative battery lead 2 Always make sure the connecti
3. Skip steps 4 6 if the oil filter cartridge is not being replaced 4 Remove the oil filter cartridge with an oil filter wrench Periodic Maintenance and Adjustment 8 15 1 Oil filter cartridge 2 Oil filter wrench 1 O ring NOTE 6 Install the new oil filter cartridge with an oil filter wrench and then tighten it to the An oil filter wrench is available at a nearby specified torque with a torque wrench service center Tightening torque Oil filter cartridge 5 Apply a light coat of engine oil to the 12 ft lbf 17Nm 1 7m kgf O ring of the new oil filter cartridge NOTE Make sure the O ring is seated properly 8 16 Periodic Maintenance and Adjustment 1 Oil filler cartridge 7 Install the engine oil drain bolt and then tighten it to the specified torque 2 Torque wrench Tightening torque Engine oil drain bolt 22 ftlbf 30Nm 3 0m kgf 8 Add the specified amount of recommended engine oil and then install engine oil filler cap and tighten Recommended engine oil See page 10 2 Oil quantity Without oil filter cartridge replacement 2 01 qt 1 9L With oil filter cartridge replacement 2 22 qt 2 1L CAUTION In order to prevent clutch slippage since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specification of CD or oils of a higher quality than specified
4. When the vehicle is in 4WD the 4WD indicator will come on in the multi function meter unit display To change from 4WD to 2WD stop the vehicle be sure the select lever is set to position and then set the switch to 2WD On Command Differential Gear Lock Switch 4WD LOCK 1 On Command differential gear lock switch 4WD LOCK 2 Select lever To lock the differential gear in 4WD stop the vehicle make sure the On Command four wheel drive switch is set to 4WD move the select lever to position and then set the switch to LOCK When the differential gear is locked the differential gear lock indicator light will come on along with the differential gear lock indicatorin the multifunction meter unit display To release the differential gear lock stop the vehicle and set the switch to 4WD A WARNING POTENTIAL HAZARD Riding too fast while the vehicle is in 4WD LOCK WHAT CAN HAPPEN All wheels turn at the same speed when the differential is locked so it takes more effort to turn the vehicle The amount of effort required is greater the faster you go You may lose control and have an accident if you cannot make a sharp enough turn for the speed you are traveling Control Functions 4 13 HOW TO AVOID THE HAZARD Always ride at a slow speed when the vehicle is in 4WD LOCK and allow extra time and distance for maneuvers NOTE When the switch i
5. Meter warning fault code F00003 Motor is damaged or driving circuit in motor is damaged or power motor special fuses are blown Replace fuses to dealer for repair No electrical power connected Main fuses melted Replace fuses No meter alarm UTV can electrify ECU initialization choose pin connector with poor contact sees attached figure 2 or in the wire cable is disconnect Reinsert well connector or cables replace repair No meter alarm ECU is damaged To dealers for repair 9 21 Electric power steering system Figure 1 Fuses box K4 ECU dedicated fuse Electric power steering system 9 22 2 Open the main switch only steering left or right is power assisted Fault phenomenon Fault point Solution No meter alarm ECU damaged To dealers for repair Meter warning fault Sensor damaged sensor s code F00001_ or connector with bad contact or To dealer for repair F00002 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 Fault phenomenon Fault point Solution Steering system Steering system mecha
6. Periodic Maintenance and Adjustment Tightening torque Spark plug 12 7 ft lbf 17 5 Nm 1 75 m kgf NOTE If a torque wrench is not available when you are installing the spark plug a good estimate of the correct torque is 1 4 to 1 2 turn past finger tight Have the spark plug tightened to the specified torque as soon as possible 4 Install the spark plug cap 5 Lower the cargo bed Cleaning the engine air filter element NOTE There is a check hose at the bottom of the air filter case If dust or water collects in this hose empty the hose and clean the air filter element and air filter case 1 Air filter check hose 1 Remove the seats See pages 4 17 4 18 for seat removal and installation procedures 2 Remove the console See page 8 7 8 8 for console removal and installation procedures 3 Remove the air filter case cover by unhooking the holders Periodic Maintenance and Adjustment 8 27 Pars 1 Air filter element 1 Holder x4 2 Air filter case cover 4 Remove the air filter element 5 Remove the sponge material from its frame 1 Air filter frame 2 Sponge material 3 Element retaining plate 8 28 Periodic Maintenance and Adjustment 6 Wash the sponge material gently but thoroughly in solvent A WARNING POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the sponge material WHAT CAN HAPPEN Low flash point solvents or gasoline
7. RSUN Owner s Manual WARNING The engine exhaust from this product contains chemicals Known to the State of California to cause cancer birth defects or other reproductive harm Owner Manual INTRODUCTION Congratulations on your purchase of the HS500UTV 4 HS500UTV 3 This Owner s Operator s manual will provide you information regarding safe operation operational instructions maintenance and care Fully understanding this manual and following all of the instructions herein will provide the knowledge needed to have safe and enjoyable UTV operation If you have any questions regarding the operation or maintenance of your UTV please consult the dealer 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 AND ANY OTHER UTV OVER 90cc SHOULD NOT BE RIDDEN BY ANYONE UNDER 16 YEARS OF AGE Owner s Manual 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 A WARNING t
8. Record the Vehicle Identification Number and model label information in spaces provided for assistance when ordering spare parts from a service center or for reference in case the vehicle is stolen 1 VEHICLE IDENTIFICATION NUMBER 2 MODEL LABEL INFORMATION Vehicle Identification Number The Vehicle Identification Number VIN is stamped into the frame 1 Vehicle identification number NOTE The vehicle identification number VIN is used to identify your vehicle Control Functions 4 1 Functions of the respective switch positions CONTROL FUNCTIONS l are as follows ON Main switch All electrical circuits are supplied with power and the headlights and taillights illuminate when the light switch is on OFF All electrical circuits are switched off The key can be removed in this position START The electric starter is engaged by turning and holding the key in this position Release the 1 Main switch key when the engine starts 4 2 Control Functions Indicator and Warning Lights CAUTION O e Do not operate the electric starter continuously for more than 5 seconds at B a time or starter damage could occur 8G air AG Wait at least 5 seconds between each om 898888 8 ia EH Estil D start attempt P 1 m Al al fe
9. s Adjust repair damaged more difficult if no spare parts are damaged spare parts power ECU damaged or the ECU 3 No meter alarm g To dealers for repair software program has error 9 25 Electric power steering system 6 All have power assisted to turn left or right the power of steering to left and right is different Fault phenomenon Fault point Solution Two channels parameters of Replace sensor or go No meter alarm sensor changed to dealers for repair No meter alarm No power assisted the power of steering to left and right is different Mechanical steering system s Adjust repair damaged spare parts are damaged spare parts ECU damaged or the ECU No meter alarm software program has error To dealers for repair The initialization parameter of Restart initialization for ECU has error ECU No meter alarm Fault phenomenon Electric power steering system 9 26 7 Open main switch steering to the same direction automatically Fault point Solution No meter alarm Sensor is loosen To dealers for repair Maintenance and repair s supplemental description 1 Restart initialization to ECU parameter Park UTV on the flat ground and keep the front wheels to be forward always Pull out initialization selects connector See Page 9 22 Push UTV back and forth for several times and flap the wheels for several times Open the main
10. On Command four wheel drive differential gear lock indicator LED On Command differential gear lock indicator light LED High range Low range indicator light LED Main Fuse 30 0A Headlight Fuse 15 0A ECU Fuse 15 0A Auxiliary DC Jack Fuse 10 0A Signaling System Fuse 10 0A 2WD 4WD Fuse 10 0A 12 1 Fault Code of Electronic Injection System Fault Code of Electronic Injection System DTC DTC Description Related Calibration HEX DEC Number P0107 MAP Circuit Low Voltage or Open KsDGDM_MAP_ShortLow 107 263 P0108 MAP Circuit High Voltage KsDGDM_MAP_ShortHigh 108 264 P0112 IAT Circuit Low Voltage KsDGDM_IAT_ShortLow 112 274 P0113 IAT Circuit High Voltage or Open KsDGDM_IAT_ShortHigh 113 275 Coolant Oil Temperature Sensor Circuit P0117 KsDGDM_CoolantShortLow 117 279 Low Voltage Coolant Oil Temperature Sensor Circuit P0118 KsDGDM_CoolantShortHigh 118 280 High Voltage or Open P0122 TPS Circuit Low Voltage or Open KsDGDM_TPS_ShortLow 122 290 P0123 TPS Circuit High Voltage KsDGDM_TPS_ShortHigh 123 291 P0131 O2S 1 Circuit Low Voltage KsDGDM_O2_1_ShortLow 131 305 Fault Code of Electronic Injection System 12 2 P0132 O2S 1 Circuit High Voltage KsDGDM_O2_1_ShortHigh 132 306 P0031 O2S Heater Circuit High Voltage KsDGDM_O2_HeaterShortHigh 31 49 P0032 O2S Heater Circuit Low Voltage KsDGDM_O2_HeaterShortLow 32 50
11. The tripometer records distances for a specific trip and can record distances from 0 through 999 9 miles To reset a trip meter select it by pressing the left button Press left button to switch to small mileage Trip press the right button for a long time to reset The tripometer can be used to estimate the distance that can be traveled with a full tank of fuel This information will enable you to judge the fuel consumption To change the display from miles per hour to kilometers per hour press the right side button on the display This will also change the displayed mileage from miles to kilometers Clock time adjustment Press the left button and hold for three seconds and the clock goes into the hour set mode 1 Press the right button to set the hour 2 Press the left button again and the clock goes into the minute set mode 3 Press the right button to set the minutes 4 Press the left button again and the clock will exit the set mode Four wheel drive indicator tly There are two 4WD indicators on the display panel The left 4WD indicator has a blinking Control Functions 4 7 circle on the front axle when the grey and yellow 4WD selector buttons are pressed in AWD activated This position also indicates that the 4WD is NOT locked wheels on the left and right sides to rotate at indicating the function has been This allows the different speeds to accommodate turning Different
12. air filter element maintenance is performed check the air inlet to the air filter case for obstructions Check the air filter 8 30 Periodic Maintenance and Adjustment V belt cooling duct check hose The V belt cooling duct check hose is located under the driver seat See pages 4 17 4 18 for seat removal and installation procedures If dust or water collects in the V belt cooling duct check hose remove the hose and clean it 1 V belt cooling duct check hose V belt case drain plug The V belt case drain plug is located under the driver seat See pages 4 17 4 18 for seat removal and installation procedures After riding in water deep enough to allow water to enter the V belt case remove the drain plug to drain any water from the case NOTE If water drains from the V belt case after removing the drain plug have a service center inspect the vehicle as the water may affect other engine parts Periodic Maintenance and Adjustment 8 31 1 V belt case drain plug 1 Bolt x3 2 Remove the tailpipe by pulling it out of Cleaning the spark arrester the muffler Be sure the exhaust pipe and muffler are 3 Tap the tailpipe lightly and then use a cool before cleaning the spark arrester wire brush to remove any carbon 1 Remove the bolts deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing 8 32 Periodic Maintenance and Adjustment 1 Tailpipe 4 In
13. in direction to increase the compression damping force and thereby harden the damping and in direction to decrease the compression damping force and thereby soften the damping L a Compression damping force adjusting screw 4 30 Control Functions A WARNING e Suspension components become hot during operation Never touch the compression damping force adjusting screw the rebound damping force adjusting screw or the oil reservoir with your bare hand or skin until suspension components have cooled e Always adjust the shock absorber assemblies on the left and right side to the same setting Uneven adjustment can cause poor handling and loss of stability which could lead to an accident Trailer hitch bracket This vehicle is equipped with a 1 in receiver bracket for a standard trailer hitch Trailer towing equipment can be obtained at a service center See pages 6 12 6 14 for precaution information 1 Trailer hitch bracket Auxiliary DC jack The auxiliary DC jack is located at the right side of the front panel The auxiliary DC jack can be used for suitable work lights radios etc The auxiliary DC jack should only be used when the engine is running 1 Auxiliary DC jack cap 1 Set the light switch to OFF 2 Start the engine See pages 6 1 6 3 3 Open the auxiliary DC jack cap and then insert the accessory power plug into the Control Functions 4 31 jack
14. problem yourself Control Functions 4 15 1 Brake pedal Parking brake lever The parking brake lever is located at the right side of the driver s seat It will help keep the vehicle from moving while parked To set the parking brake pull the lever up completely To release the parking brake pull up on the 4 16 Control Functions lever press the release button and then push the lever all the way down Spring pressure helps return the lever to the released position Be sure to fully release the parking brake before starting out Failure to do so may result in poor performance and premature wearing of the rear brake and V belt 2 Release button 1 Parking brake lever Drive select lever The drive select lever is used to shift you vehicle into the low high neutral and reverse positions Refer to pages 6 4 6 6 for the drive select lever operation ee ZTE 1 Drive select lever Control Functions 4 17 Fuel tank cap Seats Remove the fuel tank cap by turning it To remove a seat pull its seat lock lever counterclockwise upward lift the front of the seat and then slide the seat forward and up 1 Fuel tank cap 1 Driver seat 2 Passenger seat 3 Seat lock lever x2 4 18 Control Functions To install a seat insert the projection on the rear of the seat into the seat holders and push down on the seat at the front A WARNING POTENTIAL HAZARD A loose seat WHA
15. 2 Check the starting motor for damage 3 Check if the spark plug is fouled or burned 4 Check if the air cleaner is blocked 8 64 Periodic Maintenance and Adjustment S N Problems Solutions Engine cannot start Check if the oil circuit is working properly Check if the exhaust system is blocked Cylinder and cylinder head Check if the spark plug is loose Check if the cylinder head or cylinder body is loose Check if the cylinder head gasket is broken Check if the cylinder gasket is broken Check if the cylinder body is worn damaged or seized Piston and piston rings Check for an improperly installed piston ring Check if the piston ring is worn or broken Check if the piston ring is seized Check if the piston is seized or damaged Valve camshaft and crankshaft Check for an Improperly sealed valve Check for improperly connected valve and valve seat Check if the valve timing is improper Check if the valve spring is broken A R WIM HRIW IM A ALHR OLY A IOJ Check if the camshaft is seized Periodic Maintenance and Adjustment 8 65 S N Problems Solutions 9 Crankcase and 1 Check if the crankcase installed improperly crankshaft 2 Check if the crankshaft is seized 1 Check for improperly adjusted valve clearance 2 Check for improperly
16. High R 5 Press the accelerator pedal gradually N Neutral and continue to watch to the rear while F backing up R Reverse 1 Drive select lever NOTE e When in reverse the reverse indicator light should be on If the light does not come on ask a service center to inspect the reverse indicator light electrical circuit e Due to the synchronizing mechanism in the engine the light may not come on 6 7 Operation A WARNING POTENTIAL HAZARD Parking on a hill or other incline WHAT CAN HAPPEN The vehicle could roll out of control increasing the chance of an accident HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines If you must park on an incline apply the parking brake and block the front and rear wheels with rocks or other objects Never park the vehicle on hills that are too steep A WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN You could hit an obstacle or person behind you resulting in serious injury HOW TO AVOID THE HAZARD When you shift into reverse make sure there are no obstacles or people behind you When it is safe to proceed go slowly Operation 6 8 Parking Parking on a Slope a When parking stop the engine and shift the drive select lever into the neutral position b Push the brake pedal down and pull the parking brake to top position to park the vehicle 1 Bring the vehicle to a stop by applyi
17. In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign material enters the crankcase 9 Start the engine and then let it idle for Periodic Maintenance and Adjustment 8 17 several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause 10 Turn the engine off wait at least ten minutes and then check the oil level and correct it if necessary 11 Install the console Final gear oil Checking the final gear oil level 1 Place the vehicle on a level surface 2 Remove the oil filler bolt and then check the oil level in the final gear case 1 Speedometer sensor 2 final gear oil 3 Correct oil level NOTE The oil level should be at the brim of the filler hole 3 If the oil is below the brim of the filler hole add sufficient oil of the recommended type to raise it to the correct level 8 18 Periodic Maintenance and Adjustment CAUTION 1 Be sure no foreign material enters the final gear case 2 Please clean the sensor every 320 mile period 3 Install the oil filler bolt and then tighten it to the specified torque Tightening torque Final gear oil filler bolt 17 ft lbf 23 Nm 2 3 m kgf Changing the final gear oil 1 Place the vehicle on a level surface 2 Place a container under the final gear case to collect the used oil 3 Remove the oil fille
18. 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 Gear rack type steering gear e Steering rod joint e Ball stud of steering knuckle e Steering shaft and universal joint Electric power steering system 9 4 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 9 5 Electric power steering system 2 Steering Torque Sensor Install sensor on the reducer Sensor No change after the sensor fixed Sensor assembly position is certained and can not make any change if found sensor postion was changed caused by bolt looseness please tighten the bolt and initialize the ECU at once See Page 9 27 3 ECU ECU is sophisticated electronic equipment and controls all the power performance of EPS so do not repair ECU by yourself If any problem happens on ECU please contact your local dealer to repair it ECU unit Lower housing Upper housing Seal ring Installation position of ECU and reducer Reducer ECU The installation location of the ECU will be greatly effected by temperature changes and external humidity Housing
19. Install the seats Brake light switch adjustment The brake light switch which is activated by the brake pedal is properly adjusted when the brake light comes on just before braking takes effect If necessary adjust the brake light switch as follows 1 Open the hood See pages 8 7 8 8 for hood opening and closing procedures 2 Turn the adjusting nut while holding the brake light switch in place To make the brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction To make the brake light come on later turn the adjusting nut in direction Periodic Maintenance and Adjustment 8 39 A WARNING POTENTIAL HAZARD Damaged control cables WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged Cables can also become frayed or kinked Operation of controls could be restricted which could cause an accident 1 Brake light switch 2 Adjusting nut or injury 3 Close the hood HOW TO AVOID THE HAZARD Cable inspection and lubrication Inspect cables frequently Replace damaged cables Lubricate the inner cables and the cable ends If the cables do not operate smoothly ask a service center to replace them Recommended lubricant Engine oil 8 40 Periodic Maintenance and Adjustment Brake pedal and accelerator pedal with a grease gun lubrication Lubricate the pivoting parts Reco
20. Limit Operation Starting the Engine in Low Temperatures Starting the Engine Warming Up Drive Select Lever Operation and Driving In Reverse Parking Parking on a Slope Vehicle Break in Period Engine Break In Accessories Loading 5 10 5 10 5 11 5 11 5 12 5 13 6 1 6 1 6 2 6 3 6 4 6 8 6 8 6 9 6 10 6 11 6 12 Owner s Manual Driving Your Vehicle Getting to Know Your Vehicle Learning to Operate Your Vehicle Turning your Vehicle Operating Improperly in Reverse Braking Going Uphill Going Downhill Crossing Through Shallow Water Vehicle Immersion Riding Over Rough Terrain Riding in Brush or Wooded Areas Encountering Obstacles on the Trail Periodic Maintenance and Adjustment Periodic Maintenance Chart for the Emission Control System General Maintenance and Lubrication Chart 7 1 7 1 7 5 7 6 7 7 7 8 7 8 7 10 7 12 7 13 7 15 7 17 7 17 8 1 8 3 8 4 Hood Console EFI System ECU EFI System inspection Engine oil and oil filter cartridge To Check the Engine Oil Level To Change the Engine Oil Final Gear Oil Changing the Final Gear Oil Differential Gear Oil Changing The Differential Gear Oil Coolant Checking the coolant level Axle Boots Spark Plug Inspection Inspection Installation Cleaning the Engine Air Filter Elements 8 7 8 8 8 9 8 12 8 12 8 12 8 13 8 14 8 17 8 18 8 19 8 20 8 21 8 21 8 23 8 23 8 24 8 25 8 26 Owner Manual V belt Coo
21. P0201 Injector 1 Circuit Malfunction KsDGDM_INJ_CYL_A_ Fault 201 513 P0202 Injector 2 Circuit Malfunction KsDGDM_INJ_CYL_B_ Fault 202 514 P0230 FPR Coil Circuit Low Voltage or Open KsDGDM_FPP_CircuitShortLow 230 560 P0232 FPR Coil Circuit High Voltage KsDGDM_FPP_CircuitShortHigh 232 562 P0336 CKP Sensor Noisy Signal KsDGDM_CrankNoisySignal 336 822 P0337 CKP Sensor No Signal KsDGDM_CrankNoSignal 337 823 P0351 Cylinder 1 Ignition Coil Malfunction KsDGDM_EST_A Fault 351 849 P0352 Cylinder 2 Ignition Coil Malfunction KsDGDM_EST_B Fault 352 850 P0505 Idle Speed Control Error KsDGDM_lIdleControl 505 1285 P0562 System Voltage Low KsDGDM_SysVoltLow 562 1378 12 3 Fault Code of Electronic Injection System P0563 System Voltage High KsDGDM_SysVoltHigh 563 1379 P0650 MIL Circuit Malfunction KsDGDM_MIL_Circuit 650 1616 P1693 Tachometer Circuit Low Voltage KsDGDM_TAC_Circuit_Low 1693 5779 P1694 Tachometer Circuit High Voltage KsDGDM_TAC_Circuit_High 1694 5780 P0137 O2S 2 Circuit Low Voltage KsDGDM_O2_2_ShortLow 137 311 P0138 O2S 2 Circuit High Voltage KsDGDM_O2_2_ShortHigh 138 312 P0038 O2S Heater 2 Circuit High Voltage KsDGDM_O2_HeaterShortHigh 38 56 P0037 O2S Heater 2 Circuit Low Voltage KsDGDM_O2_HeaterShortLow 37 55 P0500 VSS No Signal KsDGDM_VSS_NoSignal 500 1280 P0850 Park Neutral Switch Error KsDGDM_ParkNeu
22. adjusted valve timing A WARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap Always use a thick rag over the cap Allow any remaining pressure to escape before completely removing the cap 10 Valve gear NOTE EERE ee If it is difficult to get the recommended coolant tap water can be temporarily used provided that it is changed to the recommended coolant as soon as possible 9 1 Electric power steering system INTRODUCTION Our UTV is equipped with Electric Power Steering System EPS To keep reliability of EPS during operation please correctly use EPS system according to the following descriptions and keep daily inspection and maintenance This chapter also provides important information to safely use EPS system If you encounter any problem during operation or maintenance please feel free to consult your local dealer ADVANTAGES OF EPS SYSTEM 1 High efficiency Traditional hydraulic power steering system is connected by mechanical and hydraulic and it is of low 2 3 efficiency usually only 60 70 However EPS system is connected by mechanical and electric motor and it is much high efficiency with up to 90 Less energy consumption In practical driving proce
23. carefully the loading information temperature drops to and trailer hitch sections in the fifteen below zero owner s manual 1 5 Location of the Warning and Safety Labels Improper vehicle use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR FOR OPERATOR AND PASSENGER NEVER USE WITH DRUGS OR ALCOHOL NEVER USE ON PUBLIC ROADS NEVER Operate ALWAYS Keep hands and feet inside vehicle Without first reading and understanding the Owner s Manual With more than one passenger Reduce speed and use extra caution when carrying a passenger and On public roads 7 make sure passenger has read Owner s Manual and understands all e On paved surfaces pavement may seriously affect handling and f warnings control E Operate slowly in reverse Operate through water deeper than 13 33cm or fast flowing Avoid sharp turns or sudden braking water if you must cross shallow slow moving water chose your Wear a seat belt when riding in the vehicle path carefully to avoid sharp drop offs large rocks or slippery Keep your hands and feet inside the vehicle at all times watch for branches or other hazards that could enter vehicle surfaces that could cause the vehicle to roll over a f ant t Make sharp high speed turns the vehicle could roll over or go out J Drive straight up and down inclines driving across the side of an incline increases the risk
24. cause changes in handling which in some situations could lead to an accident HOW TO AVOID THE HAZARD Never modify this vehicle through improper installation or use of accessories All parts and accessories added to this vehicle should be genuine or equivalent components designed for use on this vehicle and should be installed and used according to instructions If you have questions consult an authorized service center Periodic Maintenance and Adjustment 8 3 Periodic Maintenance Chart for the Emission Control System e For vehicles not equipped with an odometer or hour meter follow the month maintenance intervals e For vehicles equipped with an odometer or an hour meter follow the mile km or hours maintenance intervals However keep in mind that if the vehicle is not used for a long period the month maintenance intervals should be followed e Items marked with an asterisk should be performed by service center as they require special tools data and technical skills INITIAL EVERY Whichever Month 1 3 6 6 12 ITEM ROUTINE Comes first miles 200 750 1 500 1 500 3 000 gt km 320 1 200 2 400 2 400 4 800 hours 20 75 150 150 300 Valves e Check valve clearance O O o o e Adjust if necessary Fuel line Check fuel hose for cracks or damage o o o Replace if necessary Check condition Spark plug e Adjust gap and clean O O O oO O Replace if ne
25. e Do not turn the key to the START position with the engine running or BQANDOOD OHOO Four wheel locked showing light Fault indicator light of EPS system differential gear lock indicator Coolant temperature warning light Emergency indicator Reverse indicator light R Neutral indicator light N High range indicator light H 9 Low range indicator light L 10 Mechanical parking brake indicator light 11 Engine indicator light P 12 Position indicator 13 Far light indicator damage to the electric starter can result See starting instructions prior to starting the engine See pages 6 1 6 3 for details CON OV OM EON Low Range Indicator Light L This indicator light comes on when the drive select lever is in the L position Mechanical Parking Brake Indicator Light GT o This indicator light comes on when the mechanical parking brake is applied High Range Indicator Light H This indicator light comes on when the drive select lever is in the H position Neutral Indicator Light N This indicator light comes on when the drive select lever is in the N position Reverse Indicator Light R Control Functions 4 3 This indicator light comes on when the drive select lever is in the R reverse position Coolant Temperature Warning Light When the coolant temperature reaches a specified level this light comes on
26. edge of the hole in the console EFI system EFI engine was completely different from the engine which uses carburetor it consist of ECU EFl cables sensors actuators and other advanced components As the following pictures 1 Oxygen sensor 2 Oxygen sensor threaded sleeve 3 Exhaust Pipe 8 10 Periodic Maintenance and Adjustment 1 High voltage wire 2 Ignition signal plug 3 Ignition coil 1 Throttle 2 Intake Pipe Joint 3 Intake Pipe 4 Fuel injector 5 Fuel injector seat 6 Intake temperature sensor pressure sensor Periodic Maintenance and Adjustment 8 11 LS aS oD A CANNA WiC Wo 1 Idle speed stepper motor 2 Air damper degree sensor 3 Throttle Air damper For the purpose of adjustment of air intake volume Idle speed stepper motor To stabilize the idle speed Fuel injector Inject the fuel into the cylinder Intake air temperature sensor Inspect engine intake air temperature according to the temperature ECU will automatically adjust the fuel injection volume Air intake pipe pressure sensor For testing the negative pressure of the air intake pipe engine has the different working conditions the 2 parameters opening of air damper and pressure of air intake determine the engine s working condition ECU will adjust the fuel injection volume according to different negative pressure and opening of air damper Adjust the engine fuel injection volume can adjust the out
27. has a membrane made of Goretex material for pressure balance between inside the shell and the Electric power steering system 9 6 surrounding environment but also to prevent the parts from moisture intrusion Do not remove the membrane or replace by other parts On the shell of ECU unit there are sets of electric plugs by cables and function as follows e P1 supply power to EPS system e P2 supply power to motor of EPS e P3 connect with cable of UTV and transfer single that ECU required e P4 connect with steering torque sensor supply power to steering torque sensor and accept single of torque e P5 connect with motor 9 7 Electric power steering system Outside view of reducer 4 Reducer 5 Gear rack type steering gear Install reducer on the frame of UTV UTV use gear rack type steering gear to Install motor and steering torque sensor on perform steering function Steering gear was reducer fixed on frame Installation position of steering as follows 6 Electronic connectivity diagram of EPS system Electric power steering system 9 8 Lisreen bleck rpg fault code white yellow black speed signal ECU with waterproof metal box ECU split cable Battery Meter Steering torque sensor Motor Speed sensor Main switch Fuse 9 9 Electric
28. indicator light of EPS system is lit that means EPS system find out some fault during ECU self checking process then you should consult your local dealer for maintenance in time Control Functions Speedometer Unit ONDARON a a ee f g 8 tea f g B 6 898888 8 h Of E ceanat gt lt P L H N R A gt Speed indicator Clock Hour fault code meter RPM indicator Metric mile button TRIP ODO button Right turn indicator light Left turn indicator light Clock Hour fault code reset button ay p 4 5 4 6 Control Functions Speedometer unit functions a speedometer which shows the speed an odometer which shows the total distance covered a tripometer which can be cleared and then show any new distances traveled an RPM indicator which shows the revolutions per minute of the engine aclock an EFI fault code indicator which shows the fault code for problems with the EFI Odometer and trip meter modes On the display panel there are two large buttons one located on the left side and one on the right side Quickly pressing the button on the left side toggles the display from the odometer to the tripometer and then to the hours meter then it starts the cycle over The odometer displays the total distance traveled by the UTV
29. injured in an accident HOW TO AVOID THE HAZARD Always wear your seat belt when riding in the vehicle Be sure the seat belt is close fitting cee Ze palsa biton across your hips and chest and is latched securely Control Functions 4 21 Glove compartment Cargo bed CAUTION To protect from damage do not put metal products like tools or sharply edged products directly in the glove compartment If they must be stored wrap them in appropriate cushion material 1 Cargo bed 2 Tailgate 3 Cargo hook x4 Unlock 4 22 Control Functions Opening and closing the tailgate Lifting and lowering the cargo bed 1 Tailgate 2 Latch x2 To open Unhook the latches and then lower the tailgate To close Place the tailgate in the original position and then hook the latches 1 Cargo bed release lever To lift Push down cargo bed release lever on left or right side of the vehicle slowly lift up cargo bed until it stops To lower Lower cargo bed slowly to its original position and be sure it locks into place Maximum load limit 350Ib 159kg A WARNING POTENTIAL HAZARD Pinch points WHAT CAN HAPPEN You or someone else could be pinched between the cargo bed and the frame when the bed is being lowered HOW TO AVOID THE HAZARD Before closing the bed be sure others are standing away from the vehicle Keep hands and fingers away from the
30. inspect the hole without water left inside If it is muddy water open the CVT cap and wash the parts before you reassemble Check the gearshift release the water inside Wash if necessary CAUTION Make sure all components that are washed and assembled are coated lightly with grease 1 Air filter case check hose Your Vehicle 7 15 1 Drive select lever box check hose 1 V belt case drain plug Riding Over Rough Terrain Operating over rough terrain should be done with caution Look for obstacles that could cause damage to the vehicle or could lead to a rollover accident Avoid jumping the vehicle as injury loss of control and damage to the 7 16 Your Vehicle vehicle could occur A WARNING POTENTIAL HAZARD Failure to use extra care when operating this vehicle on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the vehicle overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the vehicle Your Vehicle 7 17 Riding in Brush or Wooded Areas When operating in areas with brush or trees watch carefully on both sides and above the vehicle for obstacles such as branches that the vehicle might hit causing an accident or for brush that migh
31. interruption of motor control ECU then closed function of EPS system Close the EPS system s bad results will also cause the driver can not obtain power steering But close measure is mainly used for preventing error control motor When fault occurs power steering disappear is a predetermined EPS system response characteristic Although the driver may feel the characteristics of some accidents but increases the control force can ensure the vehicle steering performance is not affected Neither the EPS steering system nor hydraulic power steering system when fault occurs power steering will disappear When a fault occurs the two systems reaction will be similar This fault occurs EPS system fault indicator light inside of meter will be lighten If above circumstances happened EPS system will be no power steering and through the instrument to show the corresponding fault code and remind driver to take care 3 The software function forms limit position Although the mechanical structure of the EPS system has mechanical limit position it is still possible for EPS system to realize the function of decreasing steering power before reaching the mechanical limit position in form of slope curve Although the customer will feel the steering resistance increases when turned to the limited position process will Electric power steering system 9 28 become obviously more smoothly In addition it can also reduce the steering syst
32. let you use engine braking to help you go downhill slowly Go as slowly as possible If you pick up too much speed apply the brakes gently Avoid sudden application of the brakes which could cause the vehicle to start sliding If you are sliding or skidding try to steer in the direction the vehicle is sliding to help you regain control If you must turn on the hill to avoid an obstacle do so slowly and carefully If the vehicle starts to tip gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance gradually steer again in the direction you want to go 7 12 Your Vehicle CROSSING THROUGH SHALLOW WATER If you must cross shallow slow moving water up to the depth of the vehicle s floorboards choose your path carefully to avoid sharp drop offs large rocks or slippery surfaces that could cause the vehicle to overturn Never operate through water deeper than 13 in 33 cm or fast flowing water Wet brakes may have reduced effectiveness After leaving the water test your brakes If necessary apply the brakes several times to let friction dry out the linings A WARNING POTENTIAL HAZARD Operating this vehicle through deep or fast flowing water WHAT CAN HAPPEN Loss of control which could result in an accident including overturn which could increase the risk of drowning HOW TO AVOID THE HAZARD Never operate this vehicle in fast flowing water or in water deeper
33. need to be removed to check the brake pads See pages 8 41 8 42 for wheel removal and installation procedures 8 34 Periodic Maintenance and Adjustment Rear brake pad check Each brake pad is provided with wear indicator grooves which allow you to check the brake pad wear without having to disassemble the brake To check the brake pad wear check the wear indicator grooves If a brake pad has worn to the point that the wear indicator grooves have almost disappeared have a service center replace the brake pads as a set 1 Brake pad wear indicator groove Checking the brake fluid level Insufficient brake fluid may let air enter the brake system possibly causing the brakes to become ineffective Before riding check that the brake fluid is above the minimum level mark and replenish if necessary N V 5 RR Ce ah le a Ex KX 1 1 Minimum level mark A low brake fluid level may indicate worn brake pads and or brake system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage Periodic Maintenance and Adjustment 8 35 The brake fluid reservoir is located under the hood See pages 8 7 8 8 for hood opening and closing procedures Observe these precautions When checking the fluid level make sure the top of the brake fluid reservoir is level Use only the recommended quality brake fluid Otherwise the rubber seals may
34. switch and wait for 5 seconds No meter alarm The initialization parameter of Restart initialization for Sensor no loosening ECU has error ECU Reinsert pin connector to finish the ECU parameter initialization process Then open the main switch check whether the fault is removed If it is not removed follow the previous steps of initialization process Because the different mechanical clearance of UTV it may require 3 5 times to be repeated in order to get the correct initialization parameters If a customer complaint vehicle deviation it should take into account the fault causes not only includes the EPS system fault also 9 27 Electric power steering system includes a chassis mechanical failure customers may use Deviation to describe a specific situation So four wheel alignment need to be adjusted at first time then ECU replacement and repair needed 2 The Fault of closing function The main objective to research and develop EPS system is needed to ensure that the vehicle is still controlled by driver when malfunction happened Therefore we will not allow any directions clockwise or counterclockwise suddenly appear bigger undesirable steering torque Therefore the EPS system has many monitoring function used to identify the sensor actuator and the involvement of the EPS system function whether is malfunctioning All cannot continue to reliable accurate control motor malfunction will lead to the
35. than 13 in 33cm Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply the brakes several times to let friction dry out the linings Your Vehicle 7 13 CAUTION After riding your vehicle in water be sure to drain the trapped water by removing the check hose at the bottom of the air filter case the V belt cooling duct check hose the drive select lever box check hose and the V belt case drain plug Wash the vehicle in fresh water if it has been operated in salt water or muddy conditions Vehicle Immersion CAUTION If your vehicle becomes immersed major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your service center before starting the engine If it is impossible to take your vehicle to a service center before starting it follow the steps outlined below 1 Move the vehicle to dry land 2 Check the air box If water is present dry the air box and replace the filter with a new filter 3 Remove the spark plugs 4 Turn the engine over several times 7 14 Your Vehicle 5 Dry the spark plugs and reinstall them or install new plugs Attempt to start the engine If necessary repeat the drying procedure Take the vehicle to your service center for service as soon as possible whether you succeed in starting it or not If water has been ingested into the CVT make sure to
36. the periodic maintenance and lubrication chart minimum and maximum level marks To check the engine oil level 1 Place the vehicle on a level surface 2 Remove the console See page 8 7 8 8 for console removal and installation procedures 3 Check the engine oil level on a cold engine NOTE If the engine was started before checking the oil level be sure to warm up the engine sufficiently and then wait at least ten minutes until the oil settles for an accurate reading 4 Remove the engine oil filler cap and wipe 1 Maximum level mark 2 Minimum level mark off the dipstick with a clean rag 3 Dipstick 4 Engine oil filler cap 5 Insert the dipstick in the oil filler hole 6 If the engine oil is at or below the without screwing it in and then remove minimum level mark add sufficient oil of it again to check the oil level the recommended type to raise it to the 8 14 Periodic Maintenance and Adjustment correct level 7 Insert the dipstick into the oil filler hole and then tighten the oil filler cap 8 Install the console To change the engine oil with or without oil filter cartridge replacement 1 Remove the console See page 8 7 8 8 for console removal and installation procedures 2 Place an oil pan under the engine to collect the used oil and then remove the engine oil filler cap 3 Remove the engine oil drain bolt to drain the oil from the crankcase 1 Engine oil drain bolt NOTE
37. to ECU connection is disconnected 5 Check if the inlet pressure temperature sensor is damaged or the ECU connection is disconnected 6 Check if the throttle sensor is damaged or the ECU connection is disconnected 7 Check if the Sub harness cable of the electrical injection is broken Periodic Maintenance and Adjustment 8 63 Table5 Solution of Common Problems in Engine System S N Problems Solutions 1 Power or performance is falling Check and clean the core of air cleaner Check muffler for partly blocked and clean spark arrestor Popping noise in engine Check air cleaner and admission line for leaks No gt do gt Check the connection joint of exhaust pipe with engine or muffler for leaks Check the grade of gasoline to see if it s too low Engine is difficult to start at low temperatures Check if the battery voltage goes down when the temperature goes down N If the temperature is under 18 C place the vehicle in warmer place for starting Coolant boils Check cooling fan of radiator for blockage by soil or dirt Check the speed sensor of radiator for damage and Check the fan for failure ol N Check if antifreeze meets the requirements stated in the owners manual Engine cannot start 1 Check the battery A low battery can cause motor not to star or run poorly
38. waxes as accident many contain abrasives that may scratch HOW TO AVOID THE HAZARD the paint or protective finish When Test the brakes after washing Apply the finished start the engine and let it idle for brakes several times at slow speeds to let several minutes friction dry out the linings Cleaning and Storage 10 3 Storage Long term storage 60 days or more of your vehicle will require some preventive procedures to guard against deterioration After thoroughly cleaning the vehicle prepare for storage as follows 1 Fill the fuel tank with fresh fuel and add the specified amount of Fuel Stabilizer and Conditioner or equivalent product Operate the vehicle for at least 5 minutes to distribute treated fuel through the fuel system 2 Drain the fuel from the fuel system as much as possible and pour the drained fuel into the fuel tank Specified amount 1 oz of stabilizer to each gallon of fuel or 7 5 ml of stabilizer to each liter of fuel NOTE Use of fuel stabilizer and conditioner eliminates the need to drain the fuel system Consult a service center if the fuel system needs to be drained instead 3 Remove the spark plug pour about one tablespoon of SAE 10W40 or 20W40 motor oil in the spark plug Ground the spark plug wire and turn the engine over several times to coat the cylinder wall with oil 4 Lubricate all control cables 5 Block up the frame to raise all wheels off the groun
39. working conditions Motor assy basic parameters Cleaning and Storage Cleaning Storage Specifications Owner s Manual 9 15 9 15 9 19 9 26 9 28 9 29 9 29 9 29 9 29 10 1 10 1 10 3 11 1 12 Fault code of Electronic Injection 12 1 System USA EPA Emissions Limited 13 1 Warranty 1 1 Location of the Warning and Safety Labels Location of the Warning and Safety Labels 1 2 Read and understand all of the labels on your vehicle They contain important information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or comes off a replacement label is available by contacting your dealer The enclosure cannot protect occupants in all foreseeable accidents including Keep hands body other rollover GEZ persons away when closing bed Kav e Do not operate the vehicle with bed up IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL POSSIBLY RESULTING IN SEVERE INJURY OR DEATH OPERATING TIRE PRESSURE Set with tires cold RECOMMENDED FRONT 10 psi 70kPa 70kgf cm REAR 10 psi 70kPa 70kgf cm MINIMUM FRONT 9 psi 63kPa 64kgf cm REAR 9 psi 63kPa 64kgf cm Never set tire pressure below minimum Tire may dislodge from rim Gross Vehicle Weight Rating 18801b 853 kg maximum including weight of operator passenger accessories cargo and if applicable trailer tongue weight 1 3 Loca
40. 1 4 22 for cargo bed lifting and lowering procedures 2 Remove the spark plug cap 8 24 Periodic Maintenance and Adjustment 1 Spark plug cap 3 Use the spark plug wrench in the tool kit to remove the spark plug as shown 1 Spark plug wrench Inspection The spark plug is an important engine component and is easy to inspect The condition of the spark plug can indicate the condition of the engine The ideal color of the porcelain insulator around the center electrode is a medium to light tan for a vehicle that is being ridden normally Periodic Maintenance and Adjustment 8 25 Do not attempt to diagnose such problems yourself Instead take the vehicle to a service center You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode erosion becomes excessive or if carbon and other deposits are excessive you should replace the spark plug with the specified plug Specified spark plug DR8EA NGK Installation 1 Measure the electrode gap with a wire thickness gauge and if necessary adjust the gap to specification Spark plug gap 0 023 0 027 in 0 6 0 7 mm a Spark plug gap Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spark plug threads Install the spark plug and tighten it to the specified torque 8 26
41. 1 Auxiliary DC jack Maximum rated capacity for the auxiliary DC jack DC 12V 120W 10 A 4 32 Control Functions 4 When the auxiliary DC jack is not being used cover it with the cap CAUTION Do not use accessories requiring more than the above maximum capacity This may overload the circuit and cause the fuse to blow If accessories are used without the engine running or with the headlights turned on the battery will lose its charge and engine starting may become difficult Do not use an automotive cigarette lighter or other access with a plug that gets hot because the jack can be damaged Before using this vehicle check the following items Pre Operation Checks 5 1 ITEM ROUTINE PAGE Brakes e Check operation free play fluid level and fluid leakage 52 53 835 e Fill with DOT 4 brake fluid if necessary 4 Parking brake Check for proper operation condition and free play 6 8 6 9 Fuel e Check fuel level 5A 55 e Fill with fuel if necessary Engine Gear box oil 7 eri ope 5 5 Coolant reservoir S a 5 6 8 19 8 20 aSa aroi Check forlealage 57 Accelerator pedal Check for proper accelerator pedal operation 5 8 Seat belts Check for proper operation and belt wear 5 10 Steering Check for proper operation 5 10 Fittings and fasteners Check all fittings and fasteners 5 11 Lights and switches Check for proper operation 5 11 Wheels and tire
42. CAN HAPPEN There is increased risk of being killed or seriously injured in an accident HOW TO AVOID THE HAZARD Always wear your seat belt when riding in the vehicle Be sure the seat belt is close fitting across your hips and chest and is latched securely 7 2 Your Vehicle A WARNING The total weight of operator passenger POTENTIAL HAZARD accessories cargo trailer tongue weight Carrying a passenger in the cargo bed and the vehicle itself must not exceed 1 880 WHAT CAN HAPPEN Ibs 853Kg The passenger could fall or be struck by objects in the cargo bed HOW TO AVOID THE HAZARD Never carry a passenger in the cargo bed The cargo bed is designed to carry cargo only Your Vehicle 7 3 A WARNING POTENTIAL HAZARD Overloading this vehicle or carrying or towing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this vehicle Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking Always follow the instructions in your Owners Manual for carrying cargo or pulling a trailer The driver and passenger must always wear a seat belt an approved motorcycle helmet eye protection and protective clothing including over the ankle boots gloves a long sleeved s
43. CONTROL SYSTEM WARRANTY NOTICE Use of any HISUN brand 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 Hisun Motors Corp U S A Emission Control System Warranty Statement 13 2 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 type 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 972 446 0760 U S Environmental Protection Agency at 2000 Traverwood Drive Ann Arbor MI 48105 or for California registered off road vehicles only th
44. G Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal Immediately contact your service center for service if throttle problems arise Always check the pedal for free movement and return before starting the engine and occasionally during operation Recommended oil SAE 80 API GL 5 Hypoid gear oil Throttle Pedal Check to see that the accelerator pedal operates correctly It must operate smoothly and fully spring back to the idle position when released Have a service center repair as necessary for proper operation Throttle Freeplay If the throttle pedal has excessive play due to cable stretch or mis adjustment it will cause a delay in throttle response especially at low engine speed The throttle may also not open fully If the throttle pedal has no freeplay the throttle may be hard to control and the idle speed may be erratic Check the throttle pedal freeplay Adjust the freeplay if necessary Throttle Freeplay Inspection 1 Lift the parking brake to the top to park the Car 2 Apply the brakes Start the engine Allow it to warm up thoroughly 3 Measure the distance the throttle pedal moves before the engine begins to pick up speed Freeplay should 1 16 to 1 8 inches 1 5 3
45. H ETHANOL e USE 100 GAS ONLY e USE WITH ETHANOL MIXED GAS WILL CAUSE DAMAGE TO THE MACHINE AND WILL VOID YOUR WARRANTY Chongqing Huansong Industries Group Co Ltd certifies that this ROV complies with the American National Standard for Recreational Off Highway Vehicles ANSI ROHVA 1 2010 Standard Safety Information 2 1 A SAFETY INFORMATION This off highway utility vehicle handles differently from other vehicles including cars and UTVs SEVERE INJURY OR DEATH can result if you do not follow these instructions Read this manual and all labels carefully and follow the operating procedures described This vehicle is designed to carry the driver and one passenger NEVER CARRY PASSENGERS IN THE CARGO BED Always be sure the driver and passenger are wearing seat belts Never give a ride to a passenger who is too small to reach and hold the handgrip fixed before the seat Always avoid operating the vehicle on any paved surfaces including sidewalks driveways parking lots and streets Never operate this vehicle on any public street road or highway even dirt or gravel streets Never operate this vehicle without wearing an approved motorcycle helmet that fits properly You should also wear eye protection goggles or a face shield gloves over the ankle boots long sleeved shirt or jacket and long pants Never consume alcohol or drugs before or while operating this vehicle Never operate at speeds
46. ON If main switch is not off ECU can be destroyed by battery power in on off condition during the following connection with cables Use screw nut to connect the connecting terminals of cables firmly to and of battery ie D G2 e 8O80 A E t 4 L vA ee Battery Positive Wire Of Cable Positive Wire Of EPS System Negative Wire Of Cable Negative Wire Of EPS System Nut Screw D a goood DIG amp ol CAUTION If connection terminals do not fixed power of ECU may be constantly on off during UTV driving and finally cause ECU damaged Open main switch of UTV and EPS system will automatically enter into working state Check the meter If fault indicator light of EPS system does not be lit ECU can be for regular use If fault indicator light of EPS system is lit that means EPS system find out some fault during ECU self checking process then you should consult your local dealer for maintenance in time Electric power steering system 9 12 Meter BEB er 8s g Cee ee To k EF 000 TRP HOURS mie m CO0 e o P lt P f 1 H m R a 2 gt Fault indicator light of EPS system Fault indicator of EPS system CAUTION Drive UTV with faulty EPS system may caus
47. S N Problems Solutions 1 Check whether brake disc plates deformed or damaged 1 Locked braking system 2 Check whether hydraulic cylinder is locked or brake clamp assembly parts are deformed or damaged 1 Check the disc brake pads for excessive wear Brake performance 2 Check the brake pads and rotor disc for excessive wear or 2 decreases oil which might have gotten on either 3 Check brake fluid and refill if necessary Grinding noises from front 1 Check brake rotor for excess wear 3 brake or brake rotor l l become red during 2 Check whether hydraulic cylinder is locked or brake clamp operation due to heat assembly parts are deformed or damaged 1 Check whether brake disc plates deformed or damaged Grinding noises from front 2 Check whether hydraulic cylinder is locked or brake clamp 4 brake or brake rotor become red during operation due to heat assembly parts are deformed or damaged Check if rear brake is locked and will not release Check if the parking brake is in the ON position Periodic Maintenance and Adjustment 8 57 S N Problems Solutions Pulling to the left or right during high speed braking 1 Check if front brakes left and right are applying equal force to the right and left brake rotors 2 Check if a lack of front brake power has caused the rear wheels to lock up locked before front wheels 3 Check if the left and right absorber springs ar
48. T CAN HAPPEN The operator could lose control or the operator or passenger could fall if the seat is loose during operation HOW TO AVOID THE HAZARD Make sure the seat is securely latched Seat belts This vehicle is equipped with three point seat belts for both the operator and passenger Always wear the seat belt while riding in the vehicle Control Functions 4 19 2 Push the latch plate into the buckle until it clicks Pull up on the latch plate to make sure it is secure 1 Seat belt x2 2 Latch plate x2 3 Buckle x2 To wear the seat belt properly do the 1 Buckle 2 Latch plate following 3 Put the lap portion of the belt low on your 1 Hold the latch plate as you pull the belt hips Push down on the buckle end of the across your lap and chest Make sure the belt as you pull up on the shoulder part belt is not twisted and is not caught on so the belt is snug across your hips any portion of the vehicle your clothing 4 Position the shoulder belt over your or any equipment you are carrying shoulder and across your chest The 4 20 Control Functions shoulder belt should fit against your chest If it is loose pull the belt out all the A WARNING way and then let it retract POTENTIAL HAZARD Torel i S iease the Duckie timily press ME Not wearing the seat belt or wearing the release button seat belt improperly WHAT CAN HAPPEN There is increased risk of being killed or seriously
49. arranty 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 Hisun Motors Corp U S A Emission Control System Warranty Statement 13 4 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 VI 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 the U S Environmental Protection Agency at 2000 Traverwood Drive Ann Arbor MI 48105 or for California registered off road vehicles only the California Air Resources Board at 9528 Telstar Avenue El Monte CA 91731 Hisun Motors Corp U S A 1434 Patton Place S
50. as recommended Pull only light loads Avoid aggressive acceleration and high speed operation during the break in period Accessories Accessories can affect the handing and control of your vehicle Keep the following in mind when considering an accessory or operating a vehicle that has accessories e Choose only accessories designed for your vehicle Your service center has a variety of genuine accessories Other accessories may also be available on the market However it is not possible for to Operation 6 12 test all nonstandard accessories nor with accessories The vehicle may have any control over the quality or handle differently than it does without suitability of them Choose a genuine accessories accessory or one that is equivalent in design and quality Loading e Accessories should be rigidly and Cargo or a trailer can change the stability securely mounted An accessory that can and handling of a vehicle You must use shift position or come off while you are common sense and good judgment when operating could affect your ability to carrying cargo or towing a trailer Keep the control the vehicle following points in mind e Do not mount an accessory where it e Never exceed the weight limits shown could interfere with your ability to control An overloaded vehicle can be unstable the vehicle Examples include but are e Choose a trailer hitch drawbar designed not limited to an object that limits your for use with a 1 i
51. avier loads or when towing a trailer Allow more braking distance A heavier vehicle takes longer to stop Avoid making sharp turns unless at very slow speeds e Avoid hills and rough terrain Choose terrain carefully Added weight affects the stability and handling of the vehicle 6 15 Operation A WARNING POTENTIAL HAZARD Overloading this vehicle or carrying or towing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this vehicle Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking Your Vehicle 7 1 DRIVING YOUR VEHICLE GETTING TO KNOW YOUR VEHICLE This off highway utility vehicle will handle and maneuver differently form an ordinary passenger car or other vehicle Before you begin to use your vehicle be sure you have read this Owners Manual completely and understand all the features Pay particular attention to the safety information on pages 2 1 2 5 Please read all the caution and warning labels on your vehicle This vehicle is designed for the operator and one passenger The driver and passenger must always wear a seat belt Never carry passengers in the cargo bed A WARNING POTENTIAL HAZARD Not wearing the seat belt Wearing the seat belt improperly WHAT
52. can catch fire or explode HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the sponge material 7 Squeeze the excess solvent out of the sponge material and let it dry CAUTION Do not twist the sponge material when squeezing it 8 Inspect the sponge material and replace it if damaged 9 Thoroughly apply foam air filter oil or other quality liquid foam air filter oil not spray type to the sponge material NOTE The sponge material should be wet but not dripping 10 Pull the sponge material over its frame 11 Install the air filter element 12 Install the air filter case cover and be sure the crankcase breather hose is connected Periodic Maintenance and Adjustment 8 29 element rubber joint to the fuel system and manifold fittings securely to avoid the possibility of unfiltered air entering the engine CAUTION Never operate the engine with the air filter element removed This will allow unfiltered air to enter causing rapid engine wear and 1 _Crankcase breather hose 13 Install the console as 44 Install the seats possible engine damage Additionally NOTE operation without the air filter element will affect performance with subsequent poor performance and possible engine overheating The air filter element should be cleaned every 20 40 hours It should be cleaned and lubricated more often if the vehicle is operated in extremely dusty areas Each time
53. cessary Check for leakage Exhaust system Tighten if necessary O Replace gasket s if necessary Crankcase breather Check breather hose for cracks or damage o o O system Replace if necessary Spark arrester Clean O O O 8 4 Periodic Maintenance and Adjustment General maintenance and lubrication chart INITIAL EVERY Whichever Month 1 3 6 6 12 ITEM ROUTINE Comes first Miles 200 750 1 500 1 500 3 000 Km 320 1 200 2 400 2 400 4 800 gt hours 20 75 150 150 300 Check coolant leakage Cooling system Repair if necessary O O O O O Replace coolant every 24 months Pie Clean Every 20 40 hours Air filter element Replace if necessary More often in wet or dusty areas Engine oil Replace warm engine before draining O O O O Engine oil filter cartridge Replace O O O O Final gear oil Check oil lever oil leakage O o Differential gear oil e Replace Accelerator pedal Check operation and free play O O O O O Check operation V belt Check for wear cracks or damage O x Check balance damage runout Wheels Replace if necessary O O Check operation brake pad wear fluid leakage Front brake see page 8 6 O O O O O Correct if necessary Replace pads if worn to the limit Check operation brake pad wear fluid leakage Rear brake see NOTE page 8 6 O O O O O Correct if nece
54. clothing change your clothes Safety Information 2 5 A WARNING POTENTIAL HAZARD Starting or running the engine in a closed area WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time HOW TO AVOID THE HAZARD Always operate your vehicle in an area with adequate ventilation 3 1 OKONAANRWN gt ANA N2O Description and Vehicle Identification O Headlights Front shock absorber assembly adjusting ring Brake fluid reservoir Air filter element engine and air intake duct V belt case Driver seat Driver seat belt Spark plug Cargo bed Tail brake lights Rear shock absorber assembly adjusting ring Cargo bed release levers 13 14 15 16 17 18 19 20 22 Spark arrester Passenger seat belt Passenger seat Oil filter cartridge Engine oil dipstick Battery Fuses Coolant reservoir Radiator cap Fuel tank cap Description and Vehicle Identification 3 2 NOTE The vehicle you have purchased may differ slightly from those in the figures of this manual 23 24 25 26 27 Light switch Steering wheel Starter Main switch On Command four wheel drive and differential lock switches Multi function meter unit Auxiliary DC jack Drive select lever Parking brake lever Accelerator pedal Brake pedal 3 3 Description and Vehicle Identification Identification Number Records
55. d 10 4 Cleaning and Storage 6 Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering 7 If storing in a humid or salty atmosphere coat all exposed metal surfaces with a light film of oil Do not apply oil to any rubber parts or the seat covers 8 Remove the battery and charge Store it in a dry place and recharge it once a month Do not store the battery in an excessively warm or cold place less than 32 F 0 C or more than 86 F 30 C NOTE Make any necessary repairs before storing the vehicle Specifications 11 1 Model HSSOOUTV 4 HSSOOUTV 3 Dimensions Overall length Overall width Overall height Seat height Wheelbase Ground clearance Minimum turning radius 3010mm 118 5 in 1460m m 57 5 in for HS500UTV 4 1670m m 65 7 in for HS500UTV 3 1940mm 76 4 in 818mm 32 2 in 1890mm 74 4 in 280mm 11 0 in 3900mm 154 in Basic weight with oil and full fuel tank 543 kg 1 197 I b Engine Engine type Cylinder arrangement Displacement Bore x stroke Compression ratio Starting system Lubrication system Liquid cooled 4 stroke Water cool Forward inclined single cylinder 471cm 84 5x84 0mm 9 4 1 Electric starter Wet sump 11 2 Specifications Model HS500UTV 4 HS500UTV 3 Engine oil Type Recommended engine oil classification Quantity Without oil filter cartridge replacement With oil filter cartridg
56. deteriorate causing leakage and poor braking performance Recommended brake fluid DOT 4 Refill with the same type of brake fluid Mixing fluids may result a harmful chemical reaction and lead to poor braking performance Be careful that water does not enter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock Brake fluid may deteriorate painted surfaces or plastic parts Always clean up spilled fluid immediately Have a service center inspect the brake system if the brake fluid level goes down Brake fluid replacement Complete fluid replacement should be done only by trained service personnel Have a service center replace the following components during periodic maintenance or when they are damaged or leaking Replace the oil seals every two years Replace the brake hoses every four years Checking the brake pedal Have a service center check the brakes at the intervals specified in the periodic maintenance and lubrication chart There 8 36 Periodic Maintenance and Adjustment should be no free play in the brake pedal The brakes should operate smoothly and there should be no brake drag If the brakes feel soft or spongy this could indicate air in the brake system Have a service center check the brake system if necessary 1 Brake pedal A WARNING POTENTIAL HAZARD Operating with improperly serv
57. dic Maintenance and Adjustment 8 59 S N Problems Solutions Rear wheels sway during operation Check if the rear axle bearings are damaged N Check if the sliding bearings connected to rear axle bearing housing and rocker arm are loose or damaged w Check if the rear wheel and axle locknut are loose or damaged Check if the rear wheel hub inner splines and rear wheel axle outer splines are worn or loose a Check if the rubber washers connected to rear suspension rocker arms and frame are damaged Wheels hop during oper Check if the wheel rims are bent or deformed Check if the front and rear axles are bent Check if the tires are aging deformed or need air Shock absorbers become soft or not comfortable during use Check if the vehicle is overloaded Check if the shocks need replacing VINI gt J IN gt Check if the shock absorbers have lost their damping force and their travel 8 60 Periodic Maintenance and Adjustment S N Problems Solutions 1 Check if the drive shaft spline is broken 2 Check if the splines in left amp right axles and front amp rear drive shafts are broken Front drive shaft makes noise during use 3 Check if the gears in rear drive shaft and reduction gear box differential are worn 4 Check the dust covers of universal joints in right amp left drive shafts are damaged
58. e bulb holder 4 Push a new bulb in and turn it clockwise to install in the bulb holder 5 Install the bulb holder together with the bulb by turning it clockwise 6 Install the panel by installing the quick fasteners and bolts and then tighten the bolts to the specified torque 2 Remove the bulb holder together with the bulb by turning it counterclockwise Periodic Maintenance and Adjustment 8 53 Tightening torque Panel bolt 4 7 ft lbf 6 5N m 0 65 m kgf Troubleshooting Although vehicles receive a rigid inspection before shipment from the factory trouble may occur during operation Any problem in the fuel compression or ignition systems can cause poor starting and loss of power The troubleshooting chart describes a quick easy procedure for making checks If your vehicle requires any repair take it to a service center The skilled technicians at a service center ship have the tools experience and know how to properly service your vehicle Imitation parts may look like genuine parts but they are often inferior Consequently they have a shorter service life and can lead to expensive repair bills A WARNING POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame WHAT CAN HAPPEN Fuel can ignite or explode causing severe injury or property damage HOW TO AVOID THE HAZARD Do not smoke when checking the fuel system Make sure there are on open flames or sparks in
59. e coolant level varies with engine temperature 8 22 Periodic Maintenance and Adjustment NOTE The coolant should be between the minimum Coolant reservoir capacity and maximum level marks up to the maximum level mark 0 37 qt 0 35L CAUTION Mix anti freeze with distilled water only However if distilled water is not available soft water may be used for refilling Changing the coolant The coolant must be changed by a service center at the intervals specified in the 1 Coolant reservoir cap periodic maintenance and lubrication chart 2 Maximum level mark 3 Minimum level mark NOTE 4 lf the coolant is at or below the minimum e Adding water instead of coolant lowers level mark remove the reservoir cap the antifreeze content of the coolant If add coolant to the maximum level mark water is used instead of coolant have a install the reservoir cap and then close service center check the antifreeze the hood content of the coolant as soon as Periodic Maintenance and Adjustment 8 23 possible e The radiator fan is automatically switched on or off according to the coolant temperature in the radiator Axle boots Check the protective boots for holes or tears If any damage is found have them replaced by a service center 1 Front axle boot x2 each side 1 Rear axle boot x2 each side Spark plug inspection Removal 1 Lift the cargo bed up See pages 4 2
60. e California Air Resources Board at 9528 Telstar Avenue El Monte CA 91731 YOUR WARRANTY RIGHTS AND OBLIGATIONS Hisun Motors Corp U S A warrants that each HISUN brand 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 the California Air Resources Board and B 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 or the California Air Resources Board for the periods specified above l 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 and the California Air Resources Board Any part or parts replaced under this warranty shall become the property of HISUN Il Limitations This Emission Control System Warranty shall not cover any of the following A Repair or replacement as a result of 1 accident Hisun Motors Corp U S A Emission Control System Warranty Statement 13 3 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 no
61. e Select Lever Operation and Driving In Reverse CAUTION Before shifting you must stop the UTV and return the throttle lever to the closed position otherwise the transmission may be damaged Shifting Neutral to High and High to Low 1 Stop the vehicle Keep your foot off the accelerator pedal 2 Apply the brakes and then shift by moving the drive select lever along the shift guide NOTE Make sure that the drive select lever is completely shifted into position 6 5 Operation Low High Neutral L 4 H 4 N R Reverse 1 Drive select lever 3 Release the brakes and press the accelerator pedal gradually Shifting Neutral to Reverse 1 2 3 Stop the vehicle Keep your foot off the accelerator pedal Apply the brake pedal Shift from neutral to reverse or vice versa by moving the drive select lever along the shift guide NOTE Please kick the brake pedal first before place gearshifts lever to reverse position In the brake pedal there is a cable which is connected to a position pin located on the gearshift assembly Only when the brake pedal is depressed the position pin will be retracked and gearshifts can be removed to reverse position 2 Cadle 1 Position pin 3 Adjust Operation 6 6 until the vehicle starts moving Ev gt L Low 4 Check behind for people or obstacles H and then release the brake pedal N H
62. e accident severe injury or even death Never operate UTV with faulty EPS system 9 13 Electric power steering system Supply steering power according to speed UTV s steering power can change as different various speeds and steering angle 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 Power Torque In Static Condition Power Torque At Middle Speed Power Torque At The Highest Speed Stationary the maximum power torque can make UTV U turn or stop into place as much as possible to ease the steering operation With increased speed reduce power torque can make UTV 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 UTV is in straight line steering system will be not sensitive the steering wheel does not move from side to side Fault alarm and protection function In order to ensure EPS system can supply a long term reliable working a variety of detection and alarm functions a
63. e applying the same force and are within the specifications 4 Check if the front wheels and front wheel axle nuts are loose or damaged 5 Check if the front wheel hub inner splines and front wheel axle outer splines are worn or loose 6 Check whether rubber washers connected to front suspension rocker and frame are damaged 8 58 Periodic Maintenance and Adjustment Table 3 Solution of Common Problems in Running System S N Problems Solutions 1 Check if the steering wheel nut is loose or damaged Steering wheel is loose 2 Check if the steering column clip and clip seat loose or 1 and shifts up and down damaged when pulled 3 Check if the steering column bottom end inner bearing is damaged 1 Check if the tie rod and steering column locknut has 2 Front wheel steering loosened or become damaged or if the steering knuckle and clearance excessive steering column locknut has loosened or is damaged 2 Check if the tie rod two ball joints are damaged or loose 1 Check if the steering knuckle bearing is damaged 2 Check if the king pin ball joint is damaged Front wheels sway during 3 Check if the front wheel and axle locknut is loose or damaged operation 4 Check if the front wheel hub inner splines and front wheel axle outer splines are worn or loose 5 Check if the rubber washers connected to front suspension rocker arms and frame are damaged Perio
64. e of many components 1 Before cleaning the vehicle a Block off the end of the exhaust pipe to prevent water entry A plastic bag and strong rubber band may be used b Make sure the spark plug and all filler caps are properly installed 2 If the engine case is excessively greasy apply degreaser with a paintbrush Do not apply degreaser to the wheel axles 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job CAUTION Excessive water pressure may cause water seepage and deterioration of wheel bearings brakes transmission seals and electrical devices Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin operated car washes 4 Once the majority of the dirt is hosed off wash all surfaces with warm water and mild detergent type soap An old toothbrush or bottlebrush is handy for hard to get at places 5 Rinse the vehicle off immediately with clean water and dry all surfaces with a 10 2 Cleaning and Storage chamois clean towel or soft absorbent cloth A WARNING 6 Clean the seats with vinyl upholstery POTENTIAL HAZARD cleaner to keep the cover pliable and Operation with wet brakes after washing glossy WHAT CAN HAPPEN 7 Automotive type wax may be applied to Wet brakes may have reduced stopping all painted and chrome plated surfaces ability increasing the chance of an Avoid combination cleaner
65. e replacement ie a T i 88 i ye 1 gt SAE 20W40 r i i i i i SAE 10W40 i SRESW3D i i i 20 10 10 20 30 40 50 C API service SG type or higher JASO standard MA CAUTION s In order to prevent clutch slippage since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher 1 90L 2 01 qt 2 10L 2 22 qt Specifications 11 3 Model HS500UTV 4 HS500UTV 3 Final gear case oil Type SAE80 API GL 4 Hypoid gear oil Quantity 0 25L 0 26 qt Differential gear case oil Type SAE80 API GL 5 Hypoid gear oil Quantity 0 32L 0 34 qt Radiator capacity including all routes 2 50L 2 64 qt Air filter Engine Wet element Intake duct Dry element Fuel Type Unleaded gasoline only Fuel tank capacity 29 L 7 6 gal Throttle valve Type quantity DELPHI MT05 11 4 Specifications Model HS500UTV 4 HS500UTV 3 Spark plug Type DR8EA Spark plug gap 0 6 0 7 mm 0 023 0 027 in Clutch type Wet centrifugal automatic Transmission Primary reduction system Secondary reduction system Secondary reduction ratio Transmission type V belt Shaft drive V belt automatic Caster angle Trail Operation R
66. ee what is on the other side there could be another person an obstacle or a sharp drop off If you start to lose traction or momentum when climbing and you decide you will be unable to continue use the brakes to come to a stop Do not attempt to turn the vehicle around With your foot on the brake look behind you and plan your descent Shift the drive select lever in reverse so you can use the engine brake if necessary to slow your descent Release the brake and begin to coast down the hill Use engine braking as much as possible gently applying the brakes when necessary GOING DOWNHILL Check the terrain carefully before going down a hill When possible choose a path that lets you drive your vehicle straight downhill Avoid sharp angles that could allow the vehicle to pitch or roll over Carefully choose your path and drive no faster than Your Vehicle 7 11 you will be able to react to obstacles that may appear A WARNING POTENTIAL HAZARD Going down a hill improperly WHAT CAN HAPPEN Could cause loss of control or cause the vehicle to overturn HOW TO AVOID THE HAZARD Always check the terrain carefully before you start down any hill Never go down a hill at high speed Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side Go straight down the hill where possible Before starting downhill make sure the vehicle is in low range 4WD On most slopes this will
67. em s mechanical and electrical components load which helps in obtaining reliable function and long service life 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 9 29 Electric power steering system CAUTION Before adjust ECU for every time please check the clearance of mechanical part and adjust four wheels fixed position of UTV EPS SYSTEM PARAMETER TABLE EPS system basic technical parameters EPS system working conditions 1 Working environment temperature 40 C 85 C 2 Working voltage 9 16V DC The seal type IP65 4 Input shaft rotation angle large than 1 25rmp 5 Wheel rotation speed 10round min 15round min w Motor assy basic parameters Type DC permanent magnet control motor Rated working time 3 min per time Rated power 170W nominal value Rated operational voltage 12V DC Rated motor revolving speed 1050r 300r min Rated operational current 30A 3A 1 6N m 0 16N m Rated output torque Cleaning and Storage 10 1 Cleaning Frequent thorough cleaning of your vehicle will not only enhance its appearance but also will improve its general performance and extend the useful lif
68. es should be equal Turn the steering wheel to rotate back and forth turning shall be smoothly no block no recoil forces which opposite of operation force If any problem found it must driven to dealer and repair it immediately oO Steering force s checking during running conditions During running process the feeling of steering force to the left and right must be consistent During steering turning shall be smoothly no block no recoil force which opposite of operation force During return process the return force is equal to the velocity at both left and right directions If any problem occurs it must driven to dealer and repair it immediately Electric power steering system 9 18 9 19 Electric power steering system Solutions for common fault 1 Open the main switch no auxiliary power of left and right steering FAULT PHENOMENON FAULT POINT SOLUTION Meter warning fault code F00010 Special fuses of ECU is blown in fuses box see figure 1 Or ECU is damaged Replace fuses To dealers for repair Meter warning fault code F00001 amp F00002 Sensor is damaged or sensor s connector with bad contact or ECU is damaged To dealers for repair Meter warning fault code F00005 Low battery voltage in storage Charge storage battery replace it if necessary FAULT PHENOMENON Electric power steering system FAULT POINT 9 20 SOLUTION
69. g preload 1 2 Loosen the locknut Turn the spring preload adjusting nut in direction to increase the spring preload and thereby harden the suspension and in direction to decrease the spring preload and thereby soften the suspension 1 Locknut 2 Spring preload adjusting nut 3 Special wrench 4 28 Control Functions e A special wrench can be obtained at a HSUN dealer to make this adjustment e The spring preload setting is determined by measuring distance A shown in the illustration The shorter distance A is the lower the spring preload the longer distance A is the higher the spring preload With each complete turn of the adjusting nut 1 DistanceA Spring travel setting Front Minimum soft 412mm 16 22 in Maximum hard 426mm 16 77 in Spring travel setting Rear Minimum soft 330mm 12 99in Maximum hard 430mm 16 93 in 3 Tighten the locknut NOTE Always tighten the locknut against the adjusting nut and then tighten it to the specified torque Rebound damping force Turn the rebound damping force adjusting screw in direction S to increase the rebound damping force and thereby harden the damping and in direction F to decrease the rebound damping force and thereby soften the damping 1 Rebound damping force adjusting screw Control Functions 4 29 Compression damping force Turn the compression damping force adjusting screw use 3 0 allen wrench
70. g techniques to avoid overturns on hills and slopes Drive straight up hills and avoid crossing the side of a hill which increases your chance of rollover Practice first on gentle slopes before attempting steeper hills Always check the terrain carefully before attempting any hill Use common sense and remember that Your Vehicle 7 9 some hills are too steep for you to climb Maximum slope angle 15 15 Maximum Choose carefully which hills you attempt to climb Avoid hills with slippery surfaces or ones where you will not be able to see far enough ahead of you A WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can over turn more easily on extremely steep hills than on level surfaces or small hills HOW TO AVOID THE HAZARD Never operate your vehicle on hills too steep for it or your abilities Never operate vehicles on hills steeper than 15 Do not drive across the face of a hill Go straight up the hill Practice on smaller hills before attempting large hills 7 10 Your Vehicle Before climbing the hill first be sure you are operating in low range 4WD or if necessary with 4WD To climb a hill you need traction momentum and steady throttle Travel fast enough to keep your momentum going but not so fast that you cannot react to changes in the terrain as you climb Slow down when you reach the crest of the hill if you cannot clearly s
71. he machine operator bystander or a person inspecting or repairing the machine A CAUTION indicates special precautions that must be taken to avoid damage to the machine CAUTION NOTE A NOTE provides key information to make procedures easier or clearer Owner Manual 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 Start the UTV after the UTV has warmed up Please see page 6 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 4 Location of the Warning and Specification Labels 2 Safety Information 3 Description and Vehicle Ident
72. heck the headlights and tail brake lights to make sure they are in working condition Repair Pre Operation Checks 5 11 as necessary for proper operation Switches Check the operation of all switches Have a service center repair as necessary for proper operation Tires A WARNING POTENTIAL HAZARD Operating this vehicle with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires on this vehicle or operation of this vehicle with improper or uneven tire pressure may cause loss of control increasing your risk of accident HOW TO AVOID THE HAZARD 1 The tires listed below have been approved by Manufacturer for this model Other tire combinations are not recommended Type Size Front 25X8 12 6PR Rear 25X10 12 6PR 5 12 Pre Operation Checks 3 The tires should be set to the recommended pressure Front 10psi 70kpa 0 7 kgficm Rear 10psi 70kpa 0 7 kgficm Check and adjust tire pressures when the tires are cold Tire pressures must be equal on both sides 4 Tire pressure below the minimum specified could cause the tire to dislodge from the rim under severe riding conditions The following are minimums Front 9psi 63 kpa 0 64kgficm Rear 9psi 63 kpa 0 64kgf cm 5 Use no more than the following pressures when seating the tire beads Front 36psi 250kpa 2 5kgficm Rear 36psi 250kpa 2 5kgficm H
73. heel drive switch 2WD 4WD and a differential gear lock switch 4WD LOCK Select the appropriate drive according to terrain and the conditions Two wheel drive 2WD Power is sup plied to the rear wheels only Four wheel drive 4WD Power is supplied to the rear and front wheels Four wheel drive with the differential gear locked 4WD LOCK Power is supplied to the rear and front wheels when the differential gear is locked Unlike the 4WD mode all wheels turn at the same speed regardless of traction Control Functions 4 11 A WARNING POTENTIAL HAZARD Changing from 2WD to 4WD or from 2WD to 2WD Differential UNLOCK or vice versa while the vehicle is moving WHAT CAN HAPPEN The vehicle handles differently in 4WD than in 2WD and in 2WD Differential UNLOCK in some circumstances Changing from 2WD to 4WD or from 2WD to 2WD Differential UNLOCK or vice versa while moving may cause the vehicle to unexpectedly handle differently This could distract the operator and increase the risk of losing control and an accident HOW TO AVOID THE HAZARD Always stop the vehicle before changing from 2WD to 4WD or from 2WD to 2WD Differential UNLOCK 4 12 Control Functions On Command four wheel drive switch 2WD 4WD 1 Select lever 2 On Command four wheel drive switch 2WD 4WD To change from 2WD to 4WD stop the vehicle and then set the switch to AWD
74. hirt or jacket and long pants Keep hands and feet inside the vehicle at all times 7 4 Your Vehicle A WARNING POTENTIAL HAZARD Operating this vehicle without wearing an approved motorcycle helmet eye protection and protective clothing WHAT CAN l HAPPEN TE Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident Gloves Boots HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket long pants Your Vehicle 7 5 LEARNING TO OPERATE YOUR VEHICLE You should become familiar with the performance characteristics of the vehicle in a large flat area that is free of obstacles and other vehicles Practice control of the accelerator pedal brakes steering and drive select lever Drive at a slow speed and become comfortable at that speed before gradually increasing your speed Become familiar with the way the vehicle feels in low and high ranges first in two wheel drive 2WD and then in four wheel drive 4WD and four wheel drive with the differential locked Practice driving in reverse Take the time to learn basic operation before atte
75. ial gear lock indicator The right 4WD symbol will show an X over the center of the front axle when the lever is moved to the right and the yellow differential gear lock button is set to out position which means the differential is not operational and is locked When riding an UTV on muddy and slippery roads or when climbing a steep hill make sure the 4WD lock indicator is on 4 8 Control Functions When riding on a flat road at a comparatively high speed adjust the settings to 2WD UNLOCKk and there are no symbols in either of the 4WD indicators Riding an UTV while the differential is functioning and is NOT locked may improve the stability and safety of the UTV operation CAUTION When the selector is set to 4WD the right 4WD symbol front axle will have an X in the middle When riding on good surfaces you should unlock the differential and press in the yellow and the gray buttons to the 2WD unlocked position There should be no symbols showing in either the left or right 4WD indicators CAUTION If the display indicators flash or the speedometer does not show the speed while the UTV is in motion Ask a dealer to check the speed sensor and circuits Fault code indicator When the EFI encounters faults the ECU will send the fault code to the instrument display and it will flash on the clock If there are more than one fault code they will be shown in rolling sequence When fault codes are present
76. icator NOTE A special wrench can be obtained ata service center to make this adjustment 1 Special wrench 4 26 Control Functions Front and Rear Shock Adjustment Option 2 A WARNING A WARNING POTENTIAL HAZARD Improper shock absorber adjustment WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability which could lead to an accident HOW TO AVOID THE HAZARD Always adjust the shock absorbers on the left and right side to the same setting These shock absorber assemblies contain highly pressurized nitrogen gas read and understand the following information before handling the shock absorber assemblies Do not tamper with or attempt to open the cylinder assemblies e Do not subject the shock absorber assemblies to an open flame or other high heat source This may cause the unit to explode due to excessive gas pressure Do not deform or damage the cylinders in any way Cylinder damage will result in poor damping performance Do not dispose of a damaged or worn out shock absorber assembly yourself Take the shock absorber assembly to a HSUN dealer for any service The spring preload rebound damping and compression damping forces of the front and rear shock absorber assemblies can be adjusted to suit the operating conditions NOTE Never turn an adjusting mechanism beyond the minimum and maximum settings Control Functions 4 27 Sprin
77. iced or adjusted brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the brake pedal position is correct Make sure the brakes do not drag All air must be bled from the brake system Replacement of brake components requires professional knowledge These procedures should be performed by a service center Periodic Maintenance and Adjustment 8 37 Parking brake lever free play adjustment Periodically check the parking brake lever free play and adjust it if necessary 1 Shift the drive select lever into low gear ax cae 2 Remove the seats See page 4 16 4 17 for seat removal and installation procedures 3 Remove the console See page 8 7 8 8 for console removal and installation procedures 1 Parking brake lever free a 4 Check the parking brake lever free play NOTE The maximum free play is equal to one The parking brake lever must be released click of the parking brake lever If when checking and adjusting the parking necessary adjust the free play as brake lever free play follows 5 Loosen the locknut 8 38 Periodic Maintenance and Adjustment oe 1 Locknut 2 Adjusting nut Turn the adjusting nut in direction to increase the free play or in direction to decrease the free play Tighten the locknut Install the console
78. ich could lead to an accident or collision HOW TO AVOID THE HAZARD When riding in cold weather always make sure all control cables work smoothly before you begin riding 1 Check the throttle cable parking cable and the reverse lock out cable and make sure that they are not frozen 2 Start the engine see P6 2 Operation 6 2 Starting the Engine CAUTION See the Engine Break In section prior to operating the engine for the first time 1 Turning the key to ON the light in the display will turn on and electronic injection system s fuel pump will start to work wait for 10 second before the following operation Apply the brake Shift the drive select lever into the neutral position NOTE When the drive select lever is in the neutral position N the neutral indicator light should come on If the neutral indicator light does not come on ask a service center to inspect the electric circuit e The engine can be started in any gear if the brake is applied However it is recommended to shift into neutral N before starting the engine 4 With your foot off the accelerator pedal start the engine by turning the key to START NOTE If the engine fails to start release the key and then try starting again Wait a few seconds before the next attempt Each cranking should be as short as possible to preserve battery energy Do not crank the e
79. ification Identification Number Records Vehicle Identification Number 4 Control Functions Main Switch Indicator and Warning Lights Use of EPS system Speedometer Unit Odometer and Trip Meter Modes Clock time adjustment Four wheel drive indicator Differential gear lock indicator Fault code indicator Owner s Manual 2 1 3 1 3 3 4 1 4 1 4 2 4 4 4 6 4 6 4 7 4 7 4 7 4 8 Fuel level indicator Switches On Command Four Wheel Drive and Differential Gear Lock Switches Accelerator Pedal Brake Pedal Parking Brake Lever Drive Select Lever Fuel Tank Cap Seats Seat Belts Glove Compartment Cargo Bed Opening and Closing the Tailgate Lifting and Lowering the Cargo Bed Front and Rear Shock Adjustment Spring preload Rebound damping force Compression damping force Trailer Hitch Bracket 4 9 4 9 4 10 4 14 4 15 4 15 4 16 4 17 4 17 4 18 4 21 4 21 4 22 4 22 4 24 4 27 4 28 4 29 4 30 Auxiliary DC Jack Pre Operation Checks Brakes Brake Fluid Level Brake Fluid Leakage Brake Operation Fuel Gasohol Engine Oil Coolant Final Gear Oil Differential Gear Oil Throttle Pedal Throttle Freeplay Throttle Freeplay Inspection Throttle Freeplay Adjustment Steering Wheel Inspection Seat Belts Owner Manual 4 31 5 1 5 2 5 2 5 3 5 3 5 4 5 4 5 5 5 6 5 7 5 7 5 8 5 9 5 9 5 10 5 10 Fittings and Fasteners Lights Switches Tires How to Measure Tire Pressure Tire Wear
80. igher pressures may cause the tire to burst Inflate the tires very slowly and carefully Fast inflation could cause the tire to burst How to measure tire pressure Use the tire pressure gauge NOTE The tire pressure gauge is included as standard equipment Make two measurements of the tire pressure and use the second reading Dust or dirt in the gauge could cause the first reading to be incorrect Pre Operation Checks 5 13 Set pressure with tires cold Set tire pressures Tire wear limit to the following specifications When the tire groove decreases to 0 12 in 3 Recommended Minimum Maximum mm due to wear replace the tire Pressure 10psi 70kpa 9 psi 63kpa 11 psi 77kpa Front 9 7okgfi cm _ 0 64kgf cm 0 77kgf cm 10psi 7Okpa 9 psi 63kpa 11 psi 77kpa Rear ZoKgt cm _ 0 64kgf cm _ 0 77kgfi cm a Tire wear limit 1 Tire pressure gauge 6 1 Operation A WARNING POTENTIAL HAZARD Operating vehicle without being familiar with all controls WHAT CAN HAPPEN Loss of control which could cause an accident or injury HOW TO AVOID THE HAZARD Read the Owner s Manual carefully If there is a control or function you do not understand ask your service center Starting the engine in low temperatures A WARNING POTENTIAL HAZARD Freezing control cables due to cold weather conditions WHAT CAN HAPPEN Loss of vehicle control wh
81. ight hand operation Reverse gear 1 471 Sub transmission ratio low 2 059 High 1 238 Chassis Frame type Steel tube frame 5 0 26 0mm 1 02 in Specifications 11 5 Model HSSOOUTV 4 HS500UTV 3 Tire Type Tubeless Size front 25x8 12 rear 25 10 12 Brakes I Front brake Type Dual disc brake Operation Foot operation Rear brake Type Single disc brake Operation Foot operation Il Front brake Type Dual disc brake Operation Foot operation Rear brake Type Dual disc brake Operation Foot operation Suspension Front rear suspension Double wishbone 11 6 Specifications Model HSSOOUTV 4 HSSOOUTV 3 Shock absorber Front shock absorber Rear shock absorber Coil spring oil damper for HS500UTV 4 Coil spring oil or airbag damping for HSSOOUTV 3 Coil spring oil damper for HS500UTV 4 Coil spring oil or airbag damping for HSSOOUTV 3 Wheel travel Front wheel travel Rear wheel travel 130mm 5 12in 150mm 5 91in Electrical Ignition system Generator system Battery type Battery capacity ECU AC magneto U1L 11 or GSU1 9 12V32 0Ah or 12V30 0Ah Headlight Tail brake light Bulb voltage wattage x quantity 12V30 3W 30 0W x 2 12V5 0W 21 0W x 2 Specifications 11 7 Model HS500UTV 4 HS500UTV 3 Indicator lights Neutral Reverse indicator light LED Coolant temperature warning light LED Parking brake indicator light LED
82. in order to see the time press the clock button the time will be shown Then after five seconds the fault code returns again Only after the fault is fixed will the time show automatically The description for the fault codes are shown in Chapter 11 of this manual Fuel level indicator The fuel level display will indicate the fuel volume When the fuel is getting low the fuel pump symbol will flash GG er AE 0 eee Ma ria Emma m gt P L H R A 1 Fuel level indicator 2 Fuel level warning indicator Control Functions 4 9 Switches 1 Light switch oFF OS OE Light switch OFF O S Set the switch to O to turn on the low beam and the taillights Set the switch to to turn on the high beam and the taillights Set the switch to OFF to turn off all the lights 4 10 Control Functions CAUTION Do not use the headlights with the engine turned off for an extended period of time The battery may discharge to the point that the starter motor will not operate properly If this happens remove the battery and recharge it On Command Four Wheel Drive and Differential Gear Lock Switches 1 On Command four wheel drive switch 2WD 4 WD 2 Differential gear lock switch LOCK 4WD This vehicle is equipped with an On Command four w
83. ling Duct Check Hose V belt Case Drain Plug Cleaning the Spark Arrester Valve Clearance Front Brake Pad Check Rear Brake Pad Check Checking the Brake Fluid Level Brake Fluid Replacement Checking the Brake Pedal Parking Brake Lever Free Play Adjustment Brake Light Switch Adjustment Cable Inspection and Lubrication Brake Pedal and Accelerator Pedal Lubrication Rear Knuckle Upper and Lower Pivot Lubrication Steering Shaft Lubrication Wheel Removal Wheel Installation 8 30 8 30 8 31 8 33 8 33 8 34 8 34 8 35 8 35 8 37 8 38 8 39 8 40 8 40 8 41 8 41 8 42 Battery Battery Maintenance Fuse Replacement Replacing A Headlight Bulb Headlight Beam Adjustment Tail orake Light Bulb Replacement Troubleshooting Solution to Common Problems in the Vehicle Electric power steering system Electric power steering system Introduction Advantages of EPS system Important information for safety Introduction of EPS system What is EPS system Typical parts of EPS system Construction of EPS Operation and use of EPS system EPS system operation 8 43 8 45 8 45 8 47 8 50 8 51 8 53 EPS system s inspection maintenance repair To drive UTV at every time need to do daily inspection of EPS system Malfunction assortment Solutions for common fault Maintenance and repair s supplemental description EPS system periodic maintenance EPS system parameter table EPS system basic technical parameters EPS system
84. mm Pre Operation Checks 5 9 Throttle Freeplay Adjustment 1 2 3 Remove both seats Remove the middle cover of the engine Loosen the nut of throttle cable on the valve Spin the throttle cable inside outside to increase the throttle pedal s moving distance to 1 5 3 mm 1 Accelerator Cable column nut Tighten the the nut 5 10 Pre Operation Checks 4 Resume the center cover and seat to their position Steering Wheel Inspection Check the steering wheel for specified freeplay and smooth operation 1 Position the vehicle on level ground 2 Lightly turn the steering wheel left and right 3 There should be 0 8 1 0 20 25 mm of freeplay If there is excessive freeplay strange noises or the steering feels rough or catchy have the steering system inspected by an authorized service center Seat belts Make sure that both seat belts are not frayed or damaged The seat belt must move smoothly when pulled out and retract on its own when released The latch plate should click securely into the buckle and release when the release button is pushed firmly Wash off any dirt or mud which could affect operation Have a service center repair as necessary for proper operation Fittings and fasteners Always check the tightness of chassis fittings and fasteners before a ride Take the vehicle to a service center or refer to the Service Manual for correct tightening torque Lights C
85. mmended lubricant Lithium soap based grease all purpose grease Recommended lubricant Lithium soap based grease Rear knuckle upper and lower pivot lubrication Lubricate the knuckle upper and lower pivots Periodic Maintenance and Adjustment 8 41 Steering shaft lubrication Wheel removal Lubricate the pivot points Loosen the wheel nuts Recommended lubricant Elevate the vehicle and place a suitable Lithium soap based grease stand under the frame all purpose grease Remove the nuts from the wheel Remove the wheel 1 Nut x4 8 42 Periodic Maintenance and Adjustment Wheel installation 1 Install the wheel and the nuts NOTE e The arrow mark amp on the tire must point toward the rotating direction of the wheel e Tapered nuts are used for both the front and rear wheels Install the nut with its tapered side towards the wheel 1 Tapered nut 2 Lower the vehicle so that the wheel is on the ground 3 Tighten the wheel nuts to the specified torque Wheel nut torque Front 40 ft lbf 55Nm 5 5 m kgf Rear 40 ft lbf 55Nm 5 5 m kgf 1 Arrow mark Periodic Maintenance and Adjustment 8 43 Battery This vehicle is equipped with a sealed type battery Therefore it is not necessary to check the electrolyte or add distilled water in the battery If the battery seems to have discharged consult a service center
86. mpting maneuvers that are more difficult Perform the Pre Operation Checks on pages 5 1 5 11 Set the parking brake shift to neutral and follow the instructions on page 6 1 to start the engine Once it has warmed up you are ready to begin driving your vehicle With the engine idling shift the drive select lever into low or high Then release the parking brake Press the accelerator pedal slowly and smoothly The centrifugal clutch will engage and you will start to accelerate Avoid higher speeds until you are thoroughly familiar with the operation of your vehicle When slowing down or stopping take your foot off the accelerator pedal and smoothly press the brake pedal Improper use of the brakes can cause the tires to lose traction reducing control and increasing the possibility of an accident 7 6 Your Vehicle CAUTION Do not shift from low to high or vice versa without coming to a complete stop and waiting for the engine to return to normal idle speed Damage to the engine or drive train may occur TURNING YOUR VEHICLE The vehicle is easier to steer in two wheel drive 2WD than four wheel drive 4WD Steering takes the most effort in 4WD with the differential locked It is possible for the vehicle to roll over or go out of control if you attempt sharp high speed turns You should also be careful making sharp turns on rough terrain Do not attempt to turn around or make abrupt maneuvers on slope Position yo
87. n receiver ability to turn the steering wheel or one e Do not exceed the maximum tongue that limits your view weight You can measure tongue weight Use extra caution when driving a vehicle with a bathroom scale Put the tongue of 6 13 Operation the loaded trailer on the scale with the tongue at hitch height Adjust the load in the trailer if necessary to reduce the weight on hitch If you are carrying cargo and towing a trailer include the tongue weight in the maximum vehicle load limit MAXIMUM LOADING LIMIT Vehicle loading limit total weight of cargo operator passenger and accessories and tongue weight 882 Ib 400Kg e Cargo bed 350 Ib 159Kg Trailer hitch Pulling load total weight of trailer and cargo 1 212Ibf 550Kgf Tongue weight vertical weight on trailer hitch point 110lbf 50Kgf e Load cargo in the cargo bed as close to the center of the vehicle as possible and tie it down using the cargo hooks equipped on the cargo bed e Tie down cargo securely in the trailer Operation 6 14 Make sure cargo in the trailer cannot move around A shifting load can cause an accident Make sure the load does not interfere with controls or your ability to see where you are going Drive more slowly than you would without a load The more weight you carry the slower you should go Although conditions vary it is good practice not to exceed low range whenever you are carrying he
88. nd maximum level marks on the coolant reservoir If the coolant level is at or below the minimum level mark add additional coolant to bring the level up to maximum level mark If coolant is not available add distilled water Change the coolant every two years CAUTION Hard water or salt water is harmful to the engine You may use soft water if you cannot get distilled water Coolant reservoir capacity up to the maximum level mark 0 37 qt 0 35L A WARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap Always use a thick rag over the cap Allow any remaining pressure to escape before completely removing the cap Pre Operation Checks 5 7 Final gear oil Make sure the final gear oil is at the specified level Add oil as necessary See pages 8 17 8 18 for details Recommended oil SAE 80 API GL 4 Hypoid gear oil If desired an SAE 80W90 hypoid gear oil may be used for all conditions NOTE GL 4 is a quality and additive rating GL 5 or GL 6 rated hypoid gear oils may also be used Differential gear oil Make sure the differential gear oil is at the specified level Add oil as necessary See pages 8 19 8 20 for details 5 8 Pre Operation Checks A WARNIN
89. ng the brakes 2 Stop the engine 3 With the brakes applied set the parking brake 1 Parking handbar 6 9 Operation 1 parking handbar NOTE Like many other vehicles the parking brake acts on the rear wheels For the parking brake to operate all four wheels shift to 4WD before stopping the engine Vehicle Break in Period The break in period for your new UTV vehicle is the first 25 hours of operation or the time it takes to use the first three tanks full of gasoline No single action on your part is as important as a proper break in period Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components Perform the following procedures carefully CAUTION e Excessive heat build up during the first three hours of operation will damage close fitted engine parts and drive components Do not operate at full throttle or high speeds during the first three hours Operation 6 10 of use e Use of any engine oil not mentioned in this manual will cause severe damage to the engine Engine Break In There is never a more important period in the life of your vehicle than the period between 0 and 25 hours For this reason we ask that you Carefully read the following material Because the engine is brand new you must not put an excessive load on it for the first several hours of running During the first 25 hours the va
90. ngine more than 5 seconds on each attempt 6 3 Operation 5 Continue warming up the engine until it idles smoothly before riding A WARNING POTENTIAL HAZARD Engine idle speed exceeds the regulated speed WHAT CAN HAPPEN Will make it difficult to select the proper gear which could lead to loss of control causing serious injury or even death HOW TO AVOID THE HAZARD Because of electronic injection system the idle speed will be speed up when the voltage of battery is low Place the gear on position N and press the throttle pedal to make the engine run at 2500RPM to charge the battery for 5 10 minutes when the voltage of battery is over 12V the idle speed will be normal If the idle speed is still high please contact your service center Warming Up To get maximum engine life always warm up the engine before driving Never accelerate hard with a cold engine To see whether or not the engine is warm check if it responds to the throttle normally 1 Release the brakes and press the accelerator pedal gradually 2 If the rotation rate of the engine accelerates with pedal steadily the warming up procedure has been ready and the vehicle can been ridden Operation 6 4 Otherwise go on with the third step 3 Continue warming up the engine until it idles smoothly CAUTION See the Engine break in section prior to operating the engine for the first time Driv
91. nical Retighten loose bolts mechanical parts has parts become loose or Replace damaged the big gap damaged spare parts Mechanical parts ECU damaged or the ECU without gap software program has error To dealers for repair 9 23 4 When running all have power assisted to turn left or right when return ability is slowly or during return processing out of nimbleness Electric power steering system S N Fault phenomenon Fault point Solution The speed sensor damaged Replace speed sensor or from meter to ECU transmit Meter warning fault 3 Check and repair 1 speed signal s guide wire cod F00011 ee cables Replace broken circuits or ECU connector assembly connectors is loose Positional arameter of f j Adjust front whee s 2 No meter alarm steering wheel front wheel p positional parameter error EPS system s speed reducer f 3 No meter alarm f P To dealers for repair damaged Electric power steering system 9 24 5 All have power assisted to turn left or right but steering become more heavy S N Fault phenomenon Fault point Solution ECU radiator overheat ECU i Remove dirt or another reduce the power of the motor s 1 Meter warning fault E T or covering on shell of code F00006 ee yY OF Ecu ECU s inside temperature f To dealers for repair alarm sensor damaged No meter alarm 2 steering becomes Mechanical steering system
92. of rollover LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS IF OWNER S MANUAL IS MISSING CONTACT YOUR DEALER FOR A REPLACEMENT of control Location of the Warning and Safety Labels 1 6 9 Select gear L on rough road and slope road NEVER operate this vehicle if you are under age 16 or without a valid driver s license Operating this vehicle if you are under the age of 16 increases your chance of severe injury or death Max speed not to exceed 40 MPH 65 KPH Turn speed not to exceed 18 MPH 30 KPH 1 7 Location of the Warning and Safety Labels 11 14 Improper use can result in SEVERE INJURY or DEATH This off highway utility vehicle will handle and maneuver differently from an ordinary passenger car or other vehicle Gross Vehicle Weight Rating 18801b 853kg maximum including operator passenger accessories cargo and trailer tongue weight This vehicle is recommended only for operators 16 and older with a valid motor vehicle license Adults must supervise use by minors Check state laws for minimum age requirements Passenger and cargo can affect vehicle handling Vehicle capacity 1 operator and 1 passenger Passenger must be able to reach and hold the handgrip inside enclosure 12 e You could be severely injured if you try to stop a vehicle rollover using your arm or leg If vehicle starts to rollover keep arms and legs inside vehicle DO NOT USE GAS MIXED WIT
93. ons are correct when putting the battery back in Fuse replacement the vehicle The main fuse and the fuse box are located under the hood the ECU are located under the seat See pages 8 8 for hood opening and closing procedures And see page 4 17 for remove seat If a fuse is blown turn off the main switch and install a new fuse of the specified amperage 8 46 Periodic Maintenance and Adjustment If a fuse is blown replace it as follows a fuse 1 Turn the key to OFF and turn off the ST _OAJ_ S_ a electrical circuit in question 3 Remove the blown fuse and then install 2 Remove the hood opening then unplug a new fuse of the specified amperage the relay assembly and open the relay cover 1 Relay assembly 2 Backup fuse 3 Relay 4 Fuse box 1 Screw M3 X4 2 Relay cover 5 Adapter connector 3 6 Adapter connector 2 CAUTION 7 Adapter connector 1 8 ECU To prevent accidental short circuiting turn off the main switch when checking or replacing Periodic Maintenance and Adjustment 8 47 Specified Fuse Main Fuse Headlight Fuse ECU Fuse Auxiliary DC Jack Fuse Signaling System Fuse 2WD 4WD Fuse Backup Fuse Speedmeter ECU normal open Fuse 30 0A 15 0A 15 0A 10 0A 10 0A 10 0A 5 0A 10 0A 15 0A 5 0A 4 Turn the key to ON and turn on the electrical circuit in question to check if the device operates 5 If the fuse immediately blows again have a ser
94. our vehicle in the safest and most efficient condition possible Safety is an obligation of the vehicle owner The most important points of vehicle inspection adjustment and lubrication are explained on the following pages The service information included in this manual is intended to provide you the owner with the necessary information for completing your own preventive maintenance and minor repairs The tools provided in the Owner s tool kit are sufficient for this purpose except that a torque wrench is also necessary to properly tighten nuts and bolts NOTE If you do not have a torque wrench available during a service operation requiring one take your vehicle to service center to check the torque settings and adjust them as necessary 1 Owner s tool kit 2 Tire pressure gauge 8 2 Periodic Maintenance and Adjustment A WARNING POTENTIAL HAZARD Servicing an engine while it is running WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body causing injury Electrical components can cause shocks or can start fires HOW TO AVOID THE HAZARD Turn off the engine when performing maintenance unless otherwise specified Have a service center perform service if you are not familiar with vehicle service A WARNING POTENTIAL HAZARD Operating this vehicle with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may
95. perature is very high it may cause ECU radiator of high temperature and at this time ECU can get through detection temperature sensor s signal to issue ECU over heating failure warning s fault code to meter Meanwhile EPS system fault indicator light is lighten 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 lighten When ECU detected the storage batter s voltage is lower than 9VDC through sensor it will indicate the fault code of storage battery voltage low to dash board Meanwhile EPS system fault indicator light will be lighten When ECU detected motor is out of work through sensor it will indicate fault code of dynamic motor without power warning to dash board Meanwhile EPS system fault indicator light is lighten When ECU detected the speed sensor had fault it will indicate vehicle speed sensor fault code to dash board Meanwhile EPS system fault indicator light is lighten When ECU detected its own fault and can not be work normally it will indicate EUC stop working code to dash board Meanwhile EPS system fault indicator light is lighten To drive UTV at every time need to do Electric power steering system 9 16 daily inspection of EPS system Before drive UTV at every time need to do daily inspection a
96. pinch points between the bed and the frame Control Functions 4 23 A WARNING POTENTIAL HAZARD Overloading the cargo bed WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated maximum load limit for this cargo bed Cargo should be properly distributed and securely attached Reduce speed when carrying cargo Allow greater distance for braking 4 24 Control Functions A WARNING POTENTIAL HAZARD Carrying a passenger in the cargo bed WHAT CAN HAPPEN The passenger could fall be thrown out or be struck by objects in the cargo bed HOW TO AVOID THE HAZARD Never carry a passenger in the cargo bed This cargo bed is designed to carry cargo only Front and Rear Shock Adjustment Option 1 The spring preload can be adjusted to suit the operating conditions You can reduce preload for a softer ride or increase preload if frequent bottoming out of the UTV occurs CAUTION Frequent or severe bottoming out of the UTV can cause increased wear or damage to the vehicle Adjust the spring preload as follows To increase the spring preload turn the adjusting ring in direction To decrease the spring preload turn the adjusting ring in direction Control Functions 4 25 Standard position B A Minimum soft E Maximum hard 1 Spring preload adjusting ring 2 Position ind
97. place the oil seals every two years e Replace the brake hoses every four years or if cracked or damaged Periodic Maintenance and Adjustment 8 7 Hood To open Unhook the hood latches and then slowly tilt the hood up until it stops 1 Hood To close Lower the hood slowly to its original position and then hook the hood latches Secure projections on the underside of the hood into slots on the back of the instrument panel Secure slots on the side of the hood around projections on the frame 1 Latch x2 8 8 Periodic Maintenance and Adjustment Console To remove 1 Remove the seats See pages 4 17 4 18 for seat removal and installation procedures 2 Remove the parking brake lever boot 3 Pull the console upward the drive select lever boot will come loose 1 Projection x2 2 Slot x2 3 Slot x2 4 Projection x2 CAUTION Make sure that all cables and wires are in place when closing the hood Do not drive the vehicle with the hood open unlatched or removed 1 Console To install 1 Place the console in its original position Periodic Maintenance and Adjustment 8 9 2 Install the parking brake lever boot 3 Install the seats CAUTION When installing the console be sure not to pinch the cables or wires Make sure that the groove at the bottom of the parking brake lever boot and the drive select lever boot fits securely around the
98. power steering system 7 Meter Meter is an important part of UTV Meter works together with EPS system and monitors working condition of EPS system Fault can be displayed by fault indicator light and fault indicator of EPS system so the driver can acknowledge fault of EPS in time and take some measures to keep himself herself safe When fault occurs on EPS system fault indicator light will be lit up At the same time fault indicator of EPS system will display the fault code for maintenance BB a A Bs z CACHI T k aac 8 ODO TRP HOURS mile km E P lt P 1 H N R 4 2 Fault indicator light of EPS system Fault indicator of EPS system Fault code diagram Fault code Fault style Fault indicator light of EPS system FO0001 1 fault of steering torque sensor lit F00002 2 fault of steering torque sensor F00006 ECU overheating F00005 low voltage battery alarm F00003 Dynamic motor without power alarm F00011 Fault of sensor speed F00010 ECU non working Electric power steering system 9 10 OPERATION AND USE OF EPS SYSTEM EPS system operation Operate as the following steps Assembling your new UTV Ensure main switch is off main switch Main switch ON OFF START 9 11 Electric power steering system CAUTI
99. put power and output torque Water temperature sensor For testing cooling water temperature 8 12 Periodic Maintenance and Adjustment according to the temperature difference ECU will automatically revise fuel injection volume to ensure the smooth operation of the engine all the time Ignition signal Ignition signal arising from the magneto to provide the ECU with correct ignition timing signal ECU It is the core of EFI system it used a specially designed micro computer chip as a controller according to the information from sensors has been calculated to ensure accurate control in different conditions from the nozzle of the fuel injection volume To achieve fuel efficient low emissions performance of the EFI engine EFI System inspection If the EFI system has failure the meter will display the appropriate failure code you can also use the special EFI system failure diagnostic apparatus for inspection diagnostic apparatus can provide a more detailed faliure information Diagnostic apparatus equipped with its own user manual uy plug A amp B into each other 2 EFI cables 1 Diagnostic apparatus cable Engine oil and oil filter cartridge The engine oil level should be checked before each operation In addition the oil Periodic Maintenance and Adjustment 8 13 must be changed and the oil filter cartridge NOTE replaced at the intervals specified in the The engine oil should be between
100. quirements of relevant rule of the United States Mixed fuel is forbidden to use on the UTV Mixed fuel will cause engine to work abnormally and cause deterioration A WARNING POTENTIAL HAZARD Improper care when refueling WHAT CAN HAPPEN Fuel can spill which can cause a fire and severe injury Fuel expands when it heats up If the fuel tank is overfilled fuel could spill out due to heat from the engine or the sun HOW TO AVOID THE HAZARD Do not overfill the fuel tank Be careful not to spill fuel especially on the engine or exhaust pipe Wipe up any spilled fuel immediately Be sure the fuel tank cap is closed securely Pre Operation Checks 5 5 Engine oil Make sure the engine oil is at the specified level Add oil as necessary See pages 8 12 8 13 CAUTION In order to prevent clutch slippage since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specification of CD oroils ofa higher quality than specified In addition do not use oils labeled ENERGYCONSERVING II or higher Make sure that no foreign material enters the crankcase 5 6 Pre Operation Checks Recommended engine oil type and quantity See page 10 2 Coolant Check the coolant level in the coolant reservoir when the engine is cold The coolant level will vary with engine temperature The coolant level is satisfactory if it is between the minimum a
101. r at the rear of the headlight CAUTION Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly 9 Close the hood 10 Adjust the headlight beam if necessary 1 Do not touch the glass part of the bulb Headlight beam adjustment CAUTION ee It is advisable to have a service center make this adjustment CAUTION Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thoroughly clean off any dirt and To raise the beam turn the adjusting screw in fingerprints on the headlight bulb using a direction tM cloth moistened with alcohol or thinner To lower the beam turn the adjusting screw in direction 7 Install the bulb holder by pushing it is and Periodic Maintenance and Adjustment 8 51 1 1 Headlight beam adjusting screw Tail brake light bulb replacement If a tail brake light bulb burns out replace it as follows 1 Remove panel A if replacing the left tail brake bulb or panel B if replacing the right tail orake bulb by removing the quick fasteners and bolts 1 Panel B 8 52 Periodic Maintenance and Adjustment 1 Quick fastener x8 2 Bolt x2 1 Tail brake light bulb holder 3 PanelA 3 Push the defective bulb in and turn it counterclockwise to remove it from th
102. r bolt and the drain bolt to drain the oil 1 Final gear oil drain bolt 4 Install the drain bolt and then tighten it to the specified torque Tightening torque Final gear oil drain bolt 14 ft lbf 20 Nm 2 0 m kgf 5 Add the recommended final gear oil up to the brim of the filler hole Periodic Maintenance and Adjustment 8 19 Recommended oil SAE 80 API GL 4Hypoid gear oil Oil quantity 0 26 qt 0 25 L CAUTION Be sure no foreign material enters the final gear case 6 Install the oil filler bolt and then tighten it to the specified torque Tightening torque Final gear oil filler bolt 17 ft lbf 23 Nm 2 3 m kgf 7 Check for oil leakage If oil leakage is found check for the cause Differential gear oil Checking the differential gear oil level 1 Place the vehicle on a level surface 2 Remove the differential gear oil filler bolt and check the oil level It should be up to the brim of the filler hole If the level is low add sufficient oil of the recommended type to raise it to the specified level CAUTION Be sure no foreign material enters the differential gear case 8 20 Periodic Maintenance and Adjustment Changing the differential gear oil 1 Place the vehicle on a level surface 2 Place a container under the differential gear case to collect the used oil 3 Remove the differential gear oil filler bolt and differential gear oil d
103. rain bolt to drain the oil INK Eos 1 Differential gear oil filler bolt 7 vate Sit eo 2 Correct oil level 3 Differential gear oil NE IA Wy if T w 3 Install the differential gear oil filler bolt a ugt SY and then tighten it to the specified torque Tightening torque Differential gear oil filler bolt 17 ft lbf 23Nm 2 3 m kgf 1 Differential gear oil drain bolt 4 Install the differential gear oil drain bolt and tighten it to the specified torque Periodic Maintenance and Adjustment 8 21 Tightening torque Differential gear oil drain bolt 7 1 ft lbf 9 8Nm 0 98 m kgf 5 Fill the differential gear case with the recommended oil Recommended oil SAE 80 API GL 5 Hypoid gear oil Oil quantity 0 34 qt 0 32 L CAUTION Be sure no foreign material enters the differential gear case 6 Install the differential gear oil filler bolt and then tighten it to the specified torque Tightening torque Differential gear oil filler bolt 17 ft lbf 23Nm 2 3m kgf 7 Check for oil leakage If oil leakage is found check for the cause Coolant The coolant level should be checked before each ride Checking the coolant level 1 Place the vehicle on a level surface 2 Open the hood See pages 8 7 8 8 for hood opening and closing procedures 3 Check the coolant level in the coolant reservoir when the engine is cold as th
104. re set in the ECU software program Once fault has been checked on EPS system UTV can accurate shutdown the EPS system Shut off the EPS system 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 9 14 increases you can continue your driving of UTV only throw a greater force to operate the steering system Electric power steering system CAUTION s When meter indicated malfunction of EPS system or when the driver found EPS system operation abnormally please do some steps as below Stop vehicles immediately close the main switch open the front panel s repair cover and pull up the outlet which power supply for EPS system See page 9 7 Driving UTV to dealer by lower velocity and repair EPS system 9 15 Electric power steering system EPS SYSTEM S INSPECTION MAINTENANCE REPAIR EPS system had already 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 EPS system work abnormally or spare parts in EPS system are damaged abnormally When EPS system work wrong or get malfunction the malfunction warning and fault code can be indicated on meter Malfunction assortment During long time continuous fast steering especially when ambient tem
105. rious parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throttle operation or any condition which might result in excessive engine heating must be avoided However momentary 2 3 seconds maximum full throttle operation under load does not harm the engine Each full throttle acceleration sequence should be followed with a substantial rest period for the engine by cruising at lower r min so the engine can rid itself of the temporary build up of heat If any abnormality is noticed during this period consult a service center 0 10 Hours Avoid continuous operation above half throttle Allow a cooling off period of five to ten minutes after every hour of operation Vary the speed of the vehicle from time to time Do not operate it at one set throttle position 6 11 Operation 10 25 Hours Avoid prolonged operation above 3 4 throttle Rev the vehicle freely but do not use full throttle at any time After break in The vehicle can now be operated normally Brake System Break in Apply only moderate braking force for the first 50 stops Aggressive or overly forceful braking when the brake system is new could damage brake pads and rotors CVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and better performance Break in the clutches and belt by operating at slower speeds during the break in period
106. s Check tire pressure wear and damage 5 11 5 13 8 41 8 42 Axle boots Check for damage 8 23 Instrument Check for complete and correct display 4 2 4 8 Light Indicator Check for light indicator operation 4 2 4 8 5 2 Pre Operation Checks A WARNING POTENTIAL HAZARD Failure to inspect the vehicle before operating Failure to properly maintain the vehicle WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the Owner s Manual Brakes Check for correct brake pedal free play If the brake pedal free play is incorrect have a service center adjust it See pages 8 38 8 40 Check the operation of the brake pedal It should move smoothly and there should be a firm feeling when the brakes are applied If not have the vehicle inspected by a service center Brake fluid level Check the brake fluid level Add fluid if necessary See pages 8 35 Recommended brake fluid DOT 4 Brake fluid leakage Check to see if any brake fluid is leaking out of the pipe joints or the brake fluid reservoir Apply the brakes firmly for one minute If there is any leakage have the vehicle inspected by a service center Brake operation Test the brakes a
107. s following steps 1 Check steering system s mechanical part of each part s interval Check steering wheel is loosened or not Move steering wheel and Check whether is loosen or with squeak through axis direction and horizontal direction If defection found repair or replace it Steering wheels range of free clearance is 0 15mm 0 0 59in If the free clearance is over range check spare parts as below any defection found replace it Any defection found replace it 9 17 Electric power steering system Steering tie rod ball head is whether to wear down Swizzle ball of knuckle wear out or not Gear rack on steering wheel wear out or not Spline on steering drive shaft is loosen or not 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 required smoothly and no blocking allowed 2 Check steering power in static condition Let UTV stop on the level road steering wheel is placed in a straight forward position 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 Open the main switch Turn the steering wheel left and right successively turning force on both sid
108. s set to LOCK the differential gear lock indicator and indicator light will flash until the differential gear is locked When the indicator and indicator light are flashing turning the steering wheel back and forth will help the differential gear lock to engage Riding before the differential gear lock is properly engaged e g when the indicator and indicator light are flashing 4 14 Control Functions will cause the engine speed to be limited until engagement is complete Accelerator pedal Press the accelerator pedal down to increase engine speed Spring pressure returns the pedal to the rest position when released Always check that the accelerator pedal returns normally before staring the engine 1 Accelerator pedal Before starting the engine check the accelerator pedal to be sure it is operating smoothly Make sure the accelerator pedal fully returns to the idle position as soon as it is released Brake pedal Press the brake pedal to slow or stop the vehicle A WARNING POTENTIAL HAZARD Malfunction of the accelerator pedal WHAT CAN HAPPEN A faulty pedal that makes it difficult to speed up or slow down could cause loss of control HOW TO AVOID THE HAZARD Check the operation of the accelerator pedal before you start the engine If it does not work smoothly check for the cause Correct the problem before operating the vehicle Consult a service center if you cannot find or solve the
109. se kinds of terrain Never turn at excessive speed Practice turning at slow speeds before attempting to turn at faster speeds Do not attempt turns on steep inclines Never operate the vehicle on hills that are too steep for it or for your abilities Go straight up and down hills where possible Maximum slope angle 15 Safety Information 2 3 Never operate on hills that are slippery or ones where you will not be able to see far enough ahead of you Never go over the top of a hill at speed if you cannot see what is on other side Always follow proper procedures for going uphill If you lose control and cannot continue up a hill back down the hill with the engine in reverse gear Use engine braking to help you go slowly If necessary use the brakes gradually to help you go slowly Always check terrain before going down hills Go as slowly as possible Never go down a hill at high speed Always check for obstacles before operating in a new area Never operate the vehicle in fast flowing water or water deeper than the floorboards on this model Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply the brake several times to let friction dry out the linings Always be sure there are no obstacles or people behind you when you operate in reverse When it is safe to proceed in reverse go slowly Do not brake abruptly when carrying loads in the cargo bed Always use the size and
110. sert the tailpipe into the muffler and align the bolt holes 5 Install the tailpipe by installing the bolts and then tighten the bolts to the specified torque 2 Spark arrester Tightening torque Tailpipe bolt 6 9 ft lbf 9 5 Nm 0 95 m kgf A WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester Hot exhaust system WHAT CAN HAPPEN Could injure the eyes Could cause burns Could cause carbon monoxide poisoning possibly leading to death Could start a fire HOW TO AVOID THE HAZARD When cleaning the spark arrester Always let the exhaust system cool prior to touching exhaust components Do not start the engine when cleaning the exhaust system Periodic Maintenance and Adjustment 8 33 Valve clearance The correct valve clearance changes with use resulting in improper fuel air supply or engine noise To prevent this the valve clearance must be adjusted regularly This adjustment however should be left to a professional service technician Front brake pad check Each brake pad is provided with wear indicator grooves which allow you to check the brake pad wear without having to disassemble the brake To check the brake pad wear check the wear indicator grooves If a brake pad has worn to the point that the wear indicator grooves have almost disappeared have a service center replace the brake pads as a set 1 Brake pad wear indicator groove NOTE The wheels
111. ss of UTV time in steering condition is only 5 among the total travelling time As to hydraulic power steering system as long as the engine is running the hydraulic pump is always in working condition and fuel consumption will increase 4 6 However EPS system starts the motor only when it needs steering to generate power without increasing fuel consumption The power characteristics of EPS system can be controlled by software so that UTV can be satisfied with power steering 4 5 6 characteristics at various speeds Feeling comfortable on road Inside of EPS system we use rigid connection so under auxiliary of start motor the impact of road barriers on steering wheel can be greatly decreased No pollution to environment For the traditional hydraulic power steering system the hydraulic circuit has hydraulic hose and fittings inside so oil leaks may occur and hydraulic hose is not recycled so this is produce pollution to environment However EPS system has not pollution to environment When engine does not start EPS system can also work as battery and once sufficient power generate steering power can be workable Electric power steering system 9 2 IMPORTANT INFORMATION FOR SAFETY UTV you buy is equipped with EPS system please read this chapter carefully before operating UTV and only you are familiar with and master enough of EPS system about using methods and precautions information can you star
112. ssary Replace pads if worn to the limit nhid Check operation and for leakage Front and rear suspension Check toe in Adjust if necessary Q O Periodic Maintenance and Adjustment 8 5 INITIAL EVERY i Month 1 3 6 6 12 Whichever ITEM ROUTINE Comes first Miles 200 750 1 500 1 500 3 000 Km 320 1 200 2 400 2 400 4 800 gt hours 20 75 150 150 300 aes Check bearing assemblies for looseness damaged Wheel bearings Repair if damaged O Q O O Stabilizer bushings Check for cracks or damage O O O Fittings and fasteners Check all chassis fittings and fasteners O O o O O Check if necessary Rear upper and lower EA knuckle pivots Lubricate with lithium soap based grease O O O EEE e Lubricate with lithium soap based grease O O O Drive shaft universal joint Check operation and for looseness Replace if Steering system damaged O Q O O O Check toe in Adjust if necessary i Check for cracks or damage Engine mount Check bolt tightness 2 2 9 Front and rear axle boots See operation O O Q Replace if damaged 8 6 Periodic Maintenance and Adjustment NOTE Recommended brake fluld DOT4 Brake fluid replacement e When disassembling the master cylinder or caliper replace the brake fluid Check the brake fluid level and add fluid as required e On the inner parts of the master cylinder and caliper re
113. t 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 lll 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 incidental consequential or exemplary arising in connection with the sale or use of or inability to use the HISUN brand 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 B No express emission 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 mechanability or fitness for a particular purpose is limited to the express emission control system w
114. t enter the vehicle as you pass and strike the driver or passenger Never hold onto the enclosure so your hand is outside the vehicle Hold the handgrip inside the enclosure Encountering Obstacles on the Trail If you cannot go around an obstacle such as a fallen tree trunk or a ditch stop the vehicle where it is safe to do so Set the parking brake and get out to inspect the area thoroughly Look from both your approach side and the exit side If you believe you can continue safely decide the path that will allow you to get over the obstacle at as close to a right angle as possible to minimize vehicle tipping Go only fast enough to maintain your momentum but still give yourself plenty of time to react to changes in conditions If there is any question about your ability to maneuver safely over the obstacle you should turn around if the ground is flat and you have the room or back up until you find a less difficult path 7 18 Your Vehicle A WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or a collision Could cause the vehicle to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Use extreme caution when operating over large obstacles such as large rocks or fallen trees Periodic Maintenance and Adjustment 8 1 Periodic Maintenance and Adjustment Periodic inspection adjustment and lubrication will keep y
115. t slow speed after starting out to make sure they are working properly If the brakes do not provide proper braking performance inspect the brake system See pages 8 33 8 38 Pre Operation Checks 5 3 A WARNING POTENTIAL HAZARD Driving with improperly operating brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride Do not operate the vehicle if you find any problem with the brakes If a problem cannot be corrected by the adjustment procedures provided in this manual have the vehicle inspected by a service center 5 4 Pre Operation Checks Fuel Make sure there is sufficient gasoline in the tank Recommended fuel Unleaded gasoline only Fuel tank capacity 7 7 gal 29L CAUTION Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system Your engine has been designed to use regular unleaded gasoline with a pump octane number R M 2 of 91 or higher or research octane number of 91 or higher If knocking or pinging occurs use a different brand of gasoline or premium unleaded fuel Unleaded fuel will give you longer spark plug life and reduced maintenance cost Gasohol The UTV uses an electric fuel injection system and its emissions completely meet the re
116. t to drive your UTV Make inspection and maintenance on EPS system on regular and ensure the security and reliability when you use your UTV Please carefully read this chapter before operation or driving to acknowledge completely about correct way to operate and drive the UTV with EPS system and also characteristics functions and limits of UTV Doing inspection and 9 3 Electric power steering system INTRODUCTION OF EPS SYSTEM maintenance on EPS system on regular 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 and no problem please follow the method for maintenance in this chapter This chapter also includes detailed disassembly and maintenance information User wants to repair by themselves must have qualified mechanical skills electronic maintenance skills and the special tools mentioned in the manual What is EPS system The EPS system Electric Power Steering System is a complete set of parts including a special ECU only for EPS system hereinafter referred to as ECU many sensors and actuators by signal such as monitoring UTV speed the operating force of the steering wheel as well as temperature of ECU and motor to provide an accurate power torque of the motor and aligning torque As a result it will have easy steering function and soft effect of steering wheel aligning Typical parts of EPS system
117. te 106 Carrollton TX 75007 Phone 972 446 0760 Fax 972 446 0765 RSUN HISUN MOTORS 1434 Patton Place Suite 106 Carrollton Texas 75007 PH 972 446 0760 TF 877 838 6188 www hisunmotors com
118. the area including pilot lights from water heaters of furnaces 8 54 Periodic Maintenance and Adjustment Solution to Common Problems in Vehicle The below tables show some common problems that may come up when you are driving a UTV which will help to solve these problems To repair a UTV requires technical skills if you cannot repair the UTV yourself please contact your service center Table 1 Solution of Common Problems in Appearance Parts and Impact Fittings S N Problems Solutions 1 Replace whit a new plastic cover 2 Check if support brackets are bent or deformed repair and 1 Plastic cover damaged HPR re paint if needed before replacing new plastic cover 3 Re apply decals and re rivet warning labels 1 Replace with a new bumper 2 Check if support brackets are bent or deformed repair and 2 Bumper damaged he re paint if needed before replacing new bumper Periodic Maintenance and Adjustment 8 55 S N Problems Solutions 1 Replace Front Skid Plate with a new one Damaged Front Skip Plate 2 Check if the gearbox or front differential rear axles are damaged or leaking 3 Check plastic cover for damaged and replace if needed 4 Warning labels 1 Replace damaged warning labels 8 56 Periodic Maintenance and Adjustment Table 2 Solution of Common Problems in Brake System
119. tion of the Warning and Safety Labels Max Tongue Weight 110 Lbs Max Trailer Weight 1 200 Lbs Severe INJURY or DEATH can result if you ignore the following guidelines e Maximum load in cargo bed is3501b 159kg e Never carry passengers in cargo bed Passengers can be thrown off causing serious injury or death 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 e 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 EXHAUST FUMES MAY CAUSE HAR E xt ains chemicals k Location of the Warning and Safety Labels 1 4 Improperly loading a trailer Operation takes more effort while the vehicle and failure to use extra care isin 4WD LOCK when pulling trailer can cause an accident or injury Never When in 4WD LOCK operate at a slow speed load more than 110lbs 50kg and allow extra time and distance for turns to tongue weight on the towing avoid loss of control bracket Do not tow more than 1212lbs 550kg rolling weight trailer plus cargo Operate in low range gears only allow for increased braking distance and use extreme caution when operating on inclines Read Change the oil when the
120. to warn that the coolant temperature is too hot If the light comes on during operation stop the engine as soon as it is safe to do so and allow the engine to cool down for about 15 minutes CAUTION The engine may overheat if the vehicle is overloaded If this happens reduce the load to specification After restarting make sure that the light 4 4 Control Functions is out Continuous use while the light is on may cause damage to the engine High beam indicator The light being on means headlight is at high beam mode Position light indicator The light being on means that the position light fixed in the front headlight has been turned on Emergency indicator A The light being on means emergency lamp is on Use of EPS system Meter is an important part of UTV Meter works together with EPS system and monitors working condition of EPS system Fault can be displayed by fault indicator light and fault indicator of EPS system so the driver can acknowledge fault of EPS in time and take some measures to keep himself herself safe When fault occurs on EPS system fault indicator light will be lit up At the same time fault indicator of EPS system will display the fault code for maintenance Open main switch of UTV and EPS system will automatically enter into working state Check the meter If fault indicator light of EPS system does not be lit ECU can be for regular use If fault
121. too fast for your skills or the conditions Always go at a speed that is proper for the terrain visibility operating conditions and your experience 2 2 Safety Information Never attempt jumps or other stunts Always inspect your vehicle each time you use it to be sure it is in safe operating condition Always follow the inspection and maintenance procedures and schedules described in this manual Always keep hands arms feet and legs inside the vehicle at all times during operation Keep your feet on the floorboard Never hold onto the enclosure Your hand could be injured if it is caught between the enclosure and an obstacle outside the vehicle Always keep both hands on the steering wheel when driving Never wrap your thumbs and fingers around the steering wheel This is particularly important when driving in rough terrain The front wheels will move right and left as they respond to the terrain and this movement will be felt in the steering wheel A sudden jolt could wrench the steering wheel around and your thumbs or fingers could be injured if they are in the way of the steering wheel spokes Always go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when driving the vehicle Never operate on excessively rough slippery or loose terrain until you have learned and practiced the skills necessary to control the vehicle on such terrain Always be especially cautious on the
122. tralSwitch 850 2128 P0445 CCP short to high KsDGDM_CCP_CircuitShortHigh 445 1093 P0444 CCP short to low open KsDGDM_CCP_CircuitShortLlow 444 1092 P0171 BLM Max Adapt Kohler Special KsFDIAG_BLM_MaxAdapt 171 369 P0172 BLM Min Adapt Kohler Special KsFDIAG_BLM_MinAdapt 172 370 P0174 PE System Lean Kohler Special KsFDIAG_PESystLean 174 372 Hisun Motors Corp U S A Emission Control System Warranty Statement 13 1 YOUR WARRANTY RIGHTS AND OBLIGATIONS Hisun Motors Corp U S A hereinafter HISUN is pleased to explain the emission control system warranty on your Off Road ATV or UTV vehicle New off road motor vehicles must be designed built and equipped to meet California s 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 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 If an emission related part on your vehicle is defective the part will be repaired or replaced by HISUN This is your EMISSION
123. type of tires specified in this manual Always make sure the tires have the proper tire pressure as described in this manual Never exceed the stated load capacity Cargo should be as far forward in the bed as possible and distributed evenly from side to side Be sure cargo is secured so that it cannot move around during operation Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer Allow greater distance for braking 2 4 Safety Information A WARNING POTENTIAL HAZARD Improper handling of gasoline WHAT CAN HAPPEN Gasoline can catch fire and you could be burned HOW TO AVOID THE HAZARD Always turn off the engine when refueling Do not refuel right after the engine has been running and is still very hot Do not spill gasoline on the engine or exhaust pipe or muffler when refueling Never refuel while smoking or while in the vicinity of sparks open flames or other sources of ignition such as the pilot light of water heaters and clothes dryers When transporting the vehicle in another vehicle be sure it is kept in an upright position Otherwise fuel may leak out of the engine or fuel tank WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries HOW TO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot of gasoline vapor or get some gasoline in your eyes see your doctor immediately If gasoline spills on your skin wash with soap and water If gasoline spills on your
124. ur hands on the steering wheel so that your thumbs and fingers do not wrap around the wheel This is particularly important when driving in rough terrain The front wheels will move right and left as they respond to the terrain and this movement will be felt in the steering wheel A sudden jolt could wrench the steering wheel around and your thumbs or fingers could be injured if they are in the way of the steering wheel spokes Your Vehicle 7 7 Operating Improperly in Reverse Improperly operating in reverse could result in acollision with an obstacle or person Always follow proper operating procedures Follow these precautions when operating in reverse 1 Always check for obstacles or people behind the vehicle 2 Apply the throttle lightly Never open the throttle suddenly 3 Back up slowly 4 Apply the brakes lightly for stopping 5 Avoid making sharp turns Before shifting into reverse gear always check for obstacles or people behind the vehicle When it is safe to proceed back up slowly 7 8 Your Vehicle BRAKING Braking ability is affected by the type of terrain In most cases gradual application of the brakes is more effective than abrupt braking particularly on loose surfaces like gravel Always allow for greater braking distance on rough loose or slippery surfaces GOING UPHILL Do not attempt to climb hills until you have mastered basic maneuvers on flat ground Use proper drivin
125. vice center check the electrical system A WARNING POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire HOW TO AVOID THE HAZARD Always use a fuse of the specified rating Never use a material in place of the proper fuse Replacing a headlight bulb If a headlight bulb bums out replace it as follows 1 Lift the hood up See pages 8 7 8 8 for hood opening and closing procedures 2 Remove the cover at the rear of the headlight by pulling it off 8 48 Periodic Maintenance and Adjustment 1 Cover at the rear of the headlight 1 Headlight bulb holder cover 3 Remove the headlight bulb holder cover 4 Remove the headlight bulb holder by by pulling it off pushing it in and turning it counterclockwise Periodic Maintenance and Adjustment 8 49 A WARNING POTENTIAL HAZARD A headlight bulb is hot when it is on and immediately after it is turned off WHAT CAN HAPPEN You can be burned or a fire could start if the bulb touches something flammable HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it 6 Insert a new headlight bulb into the bulb holder by pushing it in 1 Headlight bulb holder 5 Remove the defective bulb by pulling it out 8 50 Periodic Maintenance and Adjustment turning it clockwise 8 Install the bulb holder cover and the cove

HS 500 - Hisun Motors Corp, USA

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