Hisun 700UTV Manuel utilisateur

700UTV Maintenance Manual

Catalog

General Information

……………………………...5

1 Description

…………………………………………………..5

1.1 Identification code………..……………………………..6

1.1.1. Frame No. …………………………………………………6

1.1.2. Engine No.…………………………………………………7

1.2 Special tools, instruments and meters…………………7

1.3 Periodic maintenance chart……………………………….10

Engine

………………………………………………………….11

2. Inspection and adjustment of engine

…………….11

2.1 Inspection of cylinder head, intake

and exhaust valve………………………………………….11

2.2 Inspection of spark Plug………………………………….14

2.3 Inspection of cylinder, piston and piston ring…….15

2.4 Inspection of crankshaft………………………………….18

2.5 Inspection of clutch……………………………………….19

2.6 Inspection of carburetor………………………………….19

2.7 Inspection of air filter………………………………….20

2.8 Inspection of oil filter………………………………….21

2.9 Inspection of lubrication system……………………….21

2.10 Lubrication of engine…………………………………….22

2.11 Inspection of cylinder head…………………………….22

3.Disassembly of engine

……………………………………27

3.1 Cylinder head and block………………………………….27

3.2 Piston and connecting rod……………………………….32

3.3 starting mechanism………………………………………..33

3.4 Sensor………………………………………………….…….33

3.5 Left crankcase cover……………………………….…….33

3.6 Magneto…………………………………………………..….34

3.7 Oil pump………………………………………….……..….34

3.8 Clutch…………………………………………………...….36

3.9 Carburetor……………………………………………...….36

3.9.1 Structure of carburetor………………………...…..36

3.9.2 Inspection and adjustment of carburetor…....….37

4.Chassis

4.1 Direction system………………………...……………...42

4.2 Brake system…………………………………………...….57

4.3 Wheels and tires……………………………………...….77

4.4 Transmission system…………………………….…...….81

4.5．Reverse mechanism parts…………………………………89

4.6 Suspension…………………………..…………………...91

4.7 Cooling System of Engine..……。。。。。………………..97

4.8 Iubrication points………………..………………….102

5. Electrical system………………………..……....….105

5.1 Ignition system…………………………..……....….108

5.2 Magneto and charging system…………..……....….109

5.3 Battery……………………………………..……....….110

5.4 Lighting system…………………………..……....….111

5.5 Meterand signal system…………………………..……112

5.6 Electrical starting system…………….……..…….113

6.Appendix

………………..…………………..……....…115

6.1 Specification………..…………………..……....….115

6.2 Requirements for torque of fastener……………….121

6.3 Electrical circuits……………………………....….122

General Information

1.Description

1.1 Identification code

1.1.1. Frame No.

Frame No. is carved in the lower right side of Figure 1-1

Figure 1-1

1.1.2. Engine NO.

Engine NO. is carved on the right side of the engine,

fighre 1-2

1.2 Special tools, instruments and meters

1.2.1 Oil filter detacher

To fasten and detach the oil filter

1.2.2 Height gauge

To gauge the height of various components

1.2.3 Vernier

To measure the length of various components

1.2.4 尺 Outside micrometer

To accurately measure external

diameter of a column

1.2.5 Inside micrometer

To accurately measure internal

diameter of a hole

1.2.6 Dial indicator

To accurately measure a small distance

1.2.7 Torque Spanner

To measure torque force

1.2.8 Feeler gauge

To measure gap-width

1.2.9 Multimeter

To check electrical circuits and parts

1.2.10 Barometer

To measure pressure of the tyre

1.2.11 Magneto drawing device

To detach the magneto

1.2.12 Snap ring clamp

To install and detach snap rings

1．2．13 Steering wheel pull tool

1.3 Maintenance schedule

Maintenance schedule

EVERY INITAL

month

1 3 6 6 12

km 320 1,200 2,400

2,400 4,800

(mi) (200) (750) (1,500)

(1,500) (3,000)

ITEM

ROUTINE

Whicheve

comes first

hours 20 75 150 150 300

Valves ● Check valve clearance.

●Adjust if necessary.

○ ○ ○ ○

Sparkplug

●Check condition.

●Adjust gap and clean.

●Rep;ace if necessary.

○ ○ ○ ○ ○

Air fiter element

● clean.

●Replace if necessary.

Every20-40hours

（More often in wet of dusty areas.）

Carburetor* ● Checkandadjustidlespeed/starteroperation.

● Adjust if necessary.

○

Crankcase

breathersystem*

● Check breather hose for cracks of

damage.

● Replace if necessary.

○

Exhaust system*

● Check for lecakage.

● Tighten if necessany.

● Replace gasket(s) if necessary.

○

Spark arrester ● Clean.

○

Fuel line* ● Check fuel hose for cracks or damage.

● Replace if necessaly.

○

Engine oil ●Replace.(Wamenginebefore draining.)

○ ○ ○ ○

Engine oil filter

cartridge ●Replace.

○ ○ ○ ○

Engine oil strainer*

●Clean.

○ ○ ○ ○

Final gear oil

Differential gear oil

● Check for oil leakage.

● Replace eveny 12 months.

○

Front brake*

● Check operation/fuid leakage.(See NOTE

page 8).

● Correct if necessary.

○○○○ ○

Rear brake* ● Check operation.

● Adjust if necessary.

○○○○ ○

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