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2010-2013 Hisun HS800 UTV manual

Includes the following models

Hisun HS800

  • 2010
    • HS800 UTV Standard
  • 2011
    • HS800 UTV Standard
    • HS800 UTV with EPS (Electronic Power Steering) [If applicable]
  • 2012
    • HS800 UTV Standard
    • HS800 UTV with EPS (Electronic Power Steering) [If applicable]
  • 2013
    • HS800 UTV Standard
    • HS800 UTV with EPS (Electronic Power Steering) [If applicable]

File specifications

File size: 58.93 MB
File type: PDF
Language: English

Printable: Yes
Estimated download time: 1.21 Minutes
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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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