2010-2013 Hisun HS800 UTV manual

Product Information

Table of Contents

Chapter 1: General Information

• General Information
• Warnings, Cautions, and Notes
• Description
• Identification Code
  • Frame No.
  • Engine No.
• Safety
  • Handling gasoline safely
  • Cleaning parts
  • Warning labels
• Serial Numbers
• Fasteners
  • Torque specifications
  • Selecting fasteners
  • Washers
  • Cotter pins
  • Snap rings and E-clips

Shop Supplies

• Lubricants and Fluids
• Engine oil
• Grease
• Coolant/Antifreeze
• Cleaning, Degreasers, and Solvents
• Gasket remover
• Thread locking compound

Basic Tools

• Screwdrivers
• Wrenches
• Adjustable wrenches
• Socket wrenches, ratchets, and handles
• Impact drivers
• Allen wrenches
• Torque wrenches
• Torque adapters
• Pliers
• Snap ring pliers
• Hammers
• Ignition grounding tool

Precision Measuring Tools

• Feeler gauge
• Calipers
• Micrometers
• Adjustments
• Care
• Metric micrometer
• Standard inch micrometer
• Telescoping and small bore gauges
• Compression gauge
• Dual scale
• Multimeter

Electrical System Fundamentals

• Voltage
• Resistance
• Amperage

Basic Service Methods

• Removing frozen fasteners
• Removing broken fasteners
• Repairing damaged threads
• Stud Removal/Installation
• Removing heads
• Bearings
• Removal
• Installation
• Interference fit
• Seal replacement

Storage

• Storage area selection
• Preparing the motorcycle for storage
• Returning the UTV to service

Troubleshooting

Engine Principles and Operating Requirements

• Starting the Engine
  • Engine is cold
  • Engine is warm
  • Starting the engine after a fall or after the engine stalls
  • Flooded engine
  • Engine cold with air temperature above 35°C (95°F)
  • Engine cold with air temperature below 10°C (50°F)
  • Engine cold with air temperature between 10°C (50°F) and 35°C (95°F)
  • Starting the engine after a fall or after the engine stalls
• Engine Will Not Start
  • Identifying the problem
  • Fuel
  • Spark test
  • Engine does not turn over or turns over slowly
  • Engine starts but cuts out or misfires during acceleration
• Poor Engine Performance
  • Engine misfires or runs erratically
  • Engine backfires, cuts out, or misfires during acceleration
  • Engine stalls
  • Engine idles poorly or idles roughly
  • Engine speed does not increase
  • Engine over-revving
  • Low power
  • Engine overheating
  • Engine smoke
  • Poor fuel economy

Fuel System

• Rich mixture
• Lean mixture

Engine

• Engine smoke
  • Black smoke
  • Blue smoke
  • White smoke or steam
• Low engine compression
• High engine compression
• Engine overheating (cooling system)
• Engine overheating (engine)
• Preignition
• Detonation
• Power loss
• Engine noises

Engine Lubrication

• High Oil Consumption or Excessive
  • Exhaust smoke
  • Low oil pressure
  • High oil pressure
  • No oil pressure
  • Oil contamination

Cylinder Leak Down Test

Electrical Testing

• Preliminary checks and precautions
• Intermittent component replacement
• Test equipment
  • Ammeter
  • Self-powered test light
  • Ohmmeter
  • Jumper wire

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