2010 HiSun HS800 UTV Service Manual

2010 HiSun HS800 UTV documentation with detailed procedures, diagrams, and specifications for maintenance, tune-up, repair, and overhaul. PN 40-3100-0000

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Technical Safety Notice
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This official OEM document is intended for professional technicians and skilled operators. Performing service on mechanical equipment involves inherent risks. By purchasing, you acknowledge that RepairLoader provides original manufacturer data for informational purposes. Always prioritize safety: use correct tools, wear protective gear, and consult a certified professional if you are uncertain of any procedure.

HiSun Models Covered & Key Technical Specifications

Models: HiSun HS800
Build Years: 2010
Technical Data:

  • Engine: 800cc V-type twin-cylinder 4-stroke
  • Chassis: Steel tube frame
  • Battery Capacity: 12V, 32.0Ah
  • Ignition System: CDI (Capacitor Discharge Ignition)
  • Lighting: 12V, 35W/35W headlights
  • Vehicle Length: 2,700mm
Technical Specifications
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Document Number / Seller:
30672 / Nancy Robinson
File Size:
58.93 MB
File Type:
PDF
Language:
English
Pages:
362
Printable:
Yes
Category:
UTV
Last updated / verified
Oct 16, 2025

HiSun Manual Features & Content Preview

2010 HiSun HS800 UTV Technical Documentation

  • Covers the 2010 HiSun HS800 UTV platform with 800cc V-twin engine and steel tube chassis
  • Official Chongqing Huansong Industries (Group) Co., Ltd. publication, First version March 2010
  • Contains 362 pages of maintenance, engine, chassis, electrical, and fuel management system documentation
  • Documents torque specifications across engine and chassis sub-assemblies
  • Accessible from your device as soon as the order is placed
  • Suitable for printing individual sections for shop-floor use
  • This official OEM publication provides the foundational reference for the HS800 platform service and engine management diagnostics

Manual Scope and Maintenance Coverage

The 2010 HiSun HS800 service manual details the procedures required for vehicle maintenance and component servicing. The documentation transitions from foundational general information—including safety guidelines, fasteners, shop supplies, and basic service methods—into detailed chapters covering the engine, chassis, and electrical system fundamentals. The content engine principle requirements, starting procedures under varying thermal conditions, and comprehensive troubleshooting for engine performance issues, starting failures, and brake system malfunctions.

Specifications and Technical References

The specifications section provides critical data including chassis dimensions, fluid capacities, and torque settings. Engine oil system pressures are documented at 65 Kpa at 1,500 r/min. Spark plug gap is specified at 0.8–0.9 mm. Tire pressure for both front and rear wheels is listed at 140 Kpa. This reference is intended for professional mechanics and qualified owners. All service data shown here is for reference only — qualified technicians and the original OEM documentation remain the authoritative source for any hands-on work. This is an official 362-page Chongqing Huansong Industries OEM service manual for the 2010 HiSun HS800, providing necessary mechanical, chassis, electrical, and EMS technical data for maintenance and diagnostics.

Document Reference: First version, March 2010, Published by Chongqing Huansong Industries (Group) Co., Ltd.

Manual FAQ, Purchase & Download Details

Is the comprehensive electrical system coverage family included within this document for the HiSun HS800 UTV? keyboard_arrow_down

Document contains extensive electrical coverage, including system fundamentals, component locations, testing methods, and circuit diagrams.

Can you confirm if the engine management system and transmission chapters are covered in this manual? keyboard_arrow_down

Manual includes a dedicated chapter for the engine management system, covering typical components, sensor data, and fault diagnosis codes. Additionally, the transmission system chapter provides information on the gearbox components and gearcase operations.

Does the manual contain specific version or publication details? keyboard_arrow_down

Manual is identified as the first version published in March 2010 by Chongqing Huansong Industries Group Co., Ltd.

Are wiring diagrams, connector pinout references, and harness information available for the electrical components? keyboard_arrow_down

Manual includes detailed wiring diagrams located in the electrical component sections. These sections also contain information on switch continuity and various circuit diagrams for systems like starting, charging, and lighting. Additionally, the text references testing procedures for verifying electrical components using standard test equipment.

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