Hisun Rhino HS500, HS600 & HS700 UTV Service & Repair Manual

This Hisun Rhino UTV service manual was prepared by the Technical Center of Chongqing Huansong Industries (Group) Co., Ltd. The HS700UTV is the main repair model. The HS600UTV supplement contains model-specific general and engine specifications. The HS500UTV supplement adds specifications and procedures for engine removal and top-end service, including the cylinder head, timing-chain tensioner, rocker arms, camshaft, decompression mechanism, valves, springs, cylinder, and piston.

PDF Format and Wiring Diagram Readability

Text search and diagram labels: Text search is unavailable for the workshop content, and the PDF has no embedded bookmarks. Small wire labels in the shared wiring diagram require zooming, and some switch-table labels remain crowded when enlarged.

One printable English PDF, 390 pages, including 15 opening pages for the added cover, foreword, and contents. The numbered pages comprise 346 pages of main handbook content, 3 pages for the HS600 supplement, 25 pages for the HS500 supplement, and 1 shared full-vehicle wiring diagram.

Engine, CVT, Chassis, and Electrical Service

This selection of workshop procedures includes routine adjustments, component overhaul, and circuit diagnosis. The handbook also covers fuel pump testing and oil cooler inspection.

• Maintenance and adjustment: Follow the scheduled-service chart for valve clearance, throttle and starter cables, ignition timing, compression, brakes, select-lever linkage, toe-in, shock preload, battery service, and headlight adjustment.
• Engine and fuel system: Covers engine removal and installation, cylinder-head and valve train service, cylinder and piston inspection, crankcase and bearing work, crankshaft and oil pump service, and carburetor float and fuel-level adjustment.
• CVT and gearbox: Details drive-belt inspection, primary and secondary sheave disassembly, centrifugal clutch checks, gearbox teardown, and middle-drive service.
• Steering, brakes, and axles: Covers rack-and-pinion steering, steering-column service, brake bleeding, master-cylinder and caliper repair, wheel hubs, CV joints, front and rear axle assemblies, reverse linkage, and front and rear suspension.
• Cooling and electrical diagnosis: Includes radiator testing, water-pump mechanical seal replacement, starter and charging checks, and troubleshooting for ignition, lighting, signaling, the cooling fan, and the 2WD/4WD selector.
• Workshop reference data: Component torque tables, fluid and lubricant specifications, clearances, wear limits, gear backlash, electrical test values, exploded views, and symptom-based troubleshooting charts.

The handbook was supplied to dealers and technicians. Experienced mechanics can use common hand tools for routine work, while sheave, differential, and internal engine jobs call for dedicated fixtures and measuring tools.

Model Fit for Rebadged UTVs

The cover lists Bennche, BMS, Big Muddy, JMC, Massimo, Powermax, Precision, QLink, Supermach, and Yardsport as rebadges. Confirm fit by matching the frame and engine identification, displacement, brake layout, and drivetrain configuration before selecting a procedure or ordering parts.

Engine and Driveline Overhaul

Engine inspections cover valve seats and guides, cam timing, piston and ring wear, the engine cooling fan and A.C. magneto, and the balancer and oil pump gears. Exploded views show the valve train and CVT sheaves. The tooling references include a sheave fixed block, locknut wrench, spring compressor, sheave and clutch holders, and a valve spring compressor.

The middle-drive and differential procedures pair gear-lash measurements with shim selection, so a mechanic can check the gear setup after replacing parts. The middle driven-shaft bearing retainer has left-hand threads. The universal-joint section explains how a displaced needle roller can prevent the yoke from seating and damage the bearing. It identifies the gear-lash tool, ring-nut and bearing-retainer wrenches, and universal-joint holder.

Cooling and Fault Diagnosis

The cooling section pairs radiator and cap tests with water-pump service and identifies the cap tester, adapter, and seal installers. Compression and cylinder leak-down tests help distinguish leakage at the valves, piston rings, or head gasket.

Electrical diagnosis covers continuity, voltage drop, peak voltage, and short circuits. Individual circuit diagrams support no-spark, no-crank, and no-charge checks with an electrical pocket tester. The shared schematic ties those circuits into the vehicle wiring.

Securely support the UTV before chassis or driveline work, let the cooling system cool before opening it, and keep fuel-system service away from ignition sources.

Sample Valve and Starter Specifications

For the HS700UTV, cold valve clearance is 0.10–0.15 mm on the intake side and 0.15–0.20 mm on the exhaust side.

The HS700UTV starter motor brush has a standard overall length of 12.5 mm and a service limit of 5 mm.