Hisun HS200UTV Bedienungsanleitung

Published by Chongqing

Huansong Industries

(Group) Co., Ltd and

Hisun Motors Corp USA.

Chongqing Huansong

Industries (Group) Co., Ltd

and Hisun Motors Corp USA

holds the copy right.

No publishing and reprinting

without permission.

READ THIS

MANUAL CAREFULLY

For questions regarding this

UTV, please contact HISUN at:

(972)446-0760

hisunmotors.com

Rev. 06031601

No one under the age of 12

should operate this vehicle.

Provincial / Municipal

governments have dierent

regulations pertaining to

owning and operating an

o-road vehicle; learn the

regulations in your area.

STRIKE 250

SERVICE MANUAL

GRAB SOME SUN

FOREWORD

Brief introduction to maintenance handbook of

HS250UTV/HS200UTV

The handbook is edited by Technical Center of Chongqing Huansong Science And

Technology Industrial Co.,Ltd, and is supplied to dealers and technicians as document of

technique.Mainly, the handbook gives methods to check, maintain and repair utility terrain

vehicles （UTV）, and supplies some relevant technique and performance data. Some

techniques and method inside may be used to check, maintain and repair other models of

UTV, although it is mainly for HS250UTV/HS200UTV.

Please read the handbook through and fully understand it; otherwise, any improper

repairing and amounting would bring you problems, and accident may occur in your use.

Proper use and maintenance can guarantee UTV being driven safely, reduce its

malfunction, and help the vehicle remain its best performance.

The standards, performances and specifications mentioned in interpretation are

based on the sample in design, and they are subject to changes according to the

product’s improvement without prior notice.

First version , October, 2014

Published by Chongqing Huansong Science And Technology Industrial Co.,Ltd

Chongqing Huansong Science And Technology Industrial Co.,Ltd holds the copy right.

No publishing and reprinting without permission.

- 1 -

CONTENT

CHAPTER 1

GENERAL INFORMATION

GENERAL INFORMATION……………………………………………………………………1

WATNINGS, CAUTIONS AND NOTES……………………………………………………1

DESCRIPTION……………………………………………………………………………………2

IDENTIFICATION CODE……………………………………………………………………… 3

Frame No. ………………………………………………………………………………… 3

Engine No. ………………………………………………………………………………… 3

SAFETY ………………………………………………………………………………………… 4

Handing gasoline safely…………………………………………………………………… 4

Cleaning parts……………………………………………………………………………… 5

Warning labels……………………………………………………………………………… 5

SERIAL NUMBERS…………………………………………………………………………… 6

FASTENERS…………………………………………………………………………………… 6

Torque specifications ……………………………………………………………………… 6

Self-locking fasteners……………………………………………………………………… 6

Washers…………………………………………………………………………………… 6

Cotter pins…………………………………………………………………………………… 7

Snap rings and E-clips …………………………………………………………………… 7

SHOP SUPPLIES……………………………………………………………………………… 8

Lubricants and Fluids……………………………………………………………………… 8

Engine oils…………………………………………………………………………………… 8

Greases……………………………………………………………………………………… 8

Brake fluid…………………………………………………………………………………… 9

Coolant……………………………………………………………………………………… 9

Cleaners, Degreasers and solvents …………………………………………………… 9

Gasket sealant…………………………………………………………………………… 9

Gasket remover ………………………………………………………………………… 10

Thread locking compound……………………………………………………………… 10

BASIC TOOLS ………………………………………………………………………………… 10

Screwdrivers……………………………………………………………………………… 11

- 1 -

CONTENT

CHAPTER 1

GENERAL INFORMATION

GENERAL INFORMATION……………………………………………………………………1

WATNINGS, CAUTIONS AND NOTES……………………………………………………1

DESCRIPTION……………………………………………………………………………………2

IDENTIFICATION CODE……………………………………………………………………… 3

Frame No. ………………………………………………………………………………… 3

Engine No. ………………………………………………………………………………… 3

SAFETY ………………………………………………………………………………………… 4

Handing gasoline safely…………………………………………………………………… 4

Cleaning parts……………………………………………………………………………… 5

Warning labels……………………………………………………………………………… 5

SERIAL NUMBERS…………………………………………………………………………… 6

FASTENERS…………………………………………………………………………………… 6

Torque specifications ……………………………………………………………………… 6

Self-locking fasteners……………………………………………………………………… 6

Washers…………………………………………………………………………………… 6

Cotter pins…………………………………………………………………………………… 7

Snap rings and E-clips …………………………………………………………………… 7

SHOP SUPPLIES……………………………………………………………………………… 8

Lubricants and Fluids……………………………………………………………………… 8

Engine oils…………………………………………………………………………………… 8

Greases……………………………………………………………………………………… 8

Brake fluid…………………………………………………………………………………… 9

Coolant……………………………………………………………………………………… 9

Cleaners, Degreasers and solvents …………………………………………………… 9

Gasket sealant…………………………………………………………………………… 9

Gasket remover ………………………………………………………………………… 10

Thread locking compound……………………………………………………………… 10

BASIC TOOLS ………………………………………………………………………………… 10

Screwdrivers……………………………………………………………………………… 11

- 2 -

Wrenches ………………………………………………………………………………… 11

Adjustable wrenches …………………………………………………………………… 12

Socket wrenches, ratchets and handles ……………………………………………… 12

Impact drivers …………………………………………………………………………… 13

Allen wrenches…………………………………………………………………………… 13

Torque wrenches………………………………………………………………………… 13

Torque adapters ………………………………………………………………………… 14

Pliers……………………………………………………………………………………… 15

Snap ring pliers…………………………………………………………………………… 15

Hammers ………………………………………………………………………………… 16

Ignition grounding tool…………………………………………………………………… 16

PRECISION MEASURING TOOLS ………………………………………………………… 16

Feeler gauge ……………………………………………………………………………… 16

Calipers…………………………………………………………………………………… 17

Micrometers……………………………………………………………………………… 17

Adjustment ……………………………………………………………………………… 18

Care ……………………………………………………………………………………… 19

Metric micrometer………………………………………………………………………… 19

Standard inch micrometer……………………………………………………………… 20

Telescoping and small bore gauges…………………………………………………… 21

Dial Indicator……………………………………………………………………………… 21

Compression gauge……………………………………………………………………… 22

Multimeter………………………………………………………………………………… 22

Cltp-on ammeter………………………………………………………………………… 22

Magneto puller………………………………………………………………………………23

ELECTRICAL SYSTEM FUNDAMENTALS……………………………………………… 23

Voltage …………………………………………………………………………………… 23

Resistance………………………………………………………………………………… 23

Amperage………………………………………………………………………………… 23

BASIC SERVICE METHODS……………………………………………………………… 24

Removing frozen fasteners……………………………………………………………… 25

Removing broken fasteners …………………………………………………………… 25

Repairing damaged threads …………………………………………………………… 26

Stud Removal/Installation ……………………………………………………………… 26

- 3 -

Removing hoses ………………………………………………………………………… 27

Bearings…………………………………………………………………………………… 27

Removal…………………………………………………………………………………… 27

Installation………………………………………………………………………………… 28

Interference fit …………………………………………………………………………… 28

Seal replacement………………………………………………………………………… 30

STORAGE……………………………………………………………………………………… 30

Storage area selection…………………………………………………………………… 30

Preparing the motorcycle for storage …………………………………………………… 30

Returning the UTV to service…………………………………………………… 31

TROVBLESHOOTING……………………………………………………………………… 31

ENGINE PRINCIPLES AND OPERATING REQUIREMENTS………………………… 32

STARTING THE ENGINE ………………………………………………………………… 32

Engine is cold …………………………………………………………………………… 33

Engine is warm…………………………………………………………………………… 33

Flooded engine……………………………………………………………………………33

ENGINE WILL NOT START ……………………………………………………………… 34

Identifying the problem ………………………………………………………………… 34

Spark test………………………………………………………………………………… 35

The starter cannot work repeatedly or can only work slowly………………… 36

POOR ENGINE PERFORMANCE………………………………………………………… 36

The engine starts slowly or difficultly…………………………………………… 36

Engine backfires, cuts out or misfires during acceleration…………………………… 36

The engine is not idling or cannot idle stably…………………………………………… 37

Poor fuel mileage………………………………………………………………………… 37

Engine will not idle or idles roughly …………………………………………………… 37

Low engine power ………………………………………………………………………… 38

Poor idle or low speed performance…………………………………………………… 39

Poor high speed performance ………………………………………………………… 39

FUEL SYSTEM……………………………………………………………………………… 40

Rich mixture……………………………………………………………………………… 40

Lean mixture……………………………………………………………………………… 40

ENGINE………………………………………………………………………………………… 40

Engine smoke……………………………………………………………………………… 40

- 3 -

Removing hoses ………………………………………………………………………… 27

Bearings…………………………………………………………………………………… 27

Removal…………………………………………………………………………………… 27

Installation………………………………………………………………………………… 28

Interference fit …………………………………………………………………………… 28

Seal replacement………………………………………………………………………… 30

STORAGE……………………………………………………………………………………… 30

Storage area selection…………………………………………………………………… 30

Preparing the motorcycle for storage …………………………………………………… 30

Returning the UTV to service…………………………………………………… 31

TROVBLESHOOTING……………………………………………………………………… 31

ENGINE PRINCIPLES AND OPERATING REQUIREMENTS………………………… 32

STARTING THE ENGINE ………………………………………………………………… 32

Engine is cold …………………………………………………………………………… 33

Engine is warm…………………………………………………………………………… 33

Flooded engine……………………………………………………………………………33

ENGINE WILL NOT START ……………………………………………………………… 34

Identifying the problem ………………………………………………………………… 34

Spark test………………………………………………………………………………… 35

The starter cannot work repeatedly or can only work slowly………………… 36

POOR ENGINE PERFORMANCE………………………………………………………… 36

The engine starts slowly or difficultly…………………………………………… 36

Engine backfires, cuts out or misfires during acceleration…………………………… 36

The engine is not idling or cannot idle stably…………………………………………… 37

Poor fuel mileage………………………………………………………………………… 37

Engine will not idle or idles roughly …………………………………………………… 37

Low engine power ………………………………………………………………………… 38

Poor idle or low speed performance…………………………………………………… 39

Poor high speed performance ………………………………………………………… 39

FUEL SYSTEM……………………………………………………………………………… 40

Rich mixture……………………………………………………………………………… 40

Lean mixture……………………………………………………………………………… 40

ENGINE………………………………………………………………………………………… 40

Engine smoke……………………………………………………………………………… 40

- 4 -

Black smoke ……………………………………………………………………………… 40

Blue smoke………………………………………………………………………………… 41

White smoke or steam…………………………………………………………………… 41

Low engine compression ………………………………………………………………… 41

High engine compression ……………………………………………………………… 41

Engine overheating (cooling system) ………………………………………………… 42

Engine overheating (engine)…………………………………………………………… 42

The ignition advance angle is too large………………………………………………… 42

Detonation………………………………………………………………………………… 42

Power loss ……………………………………………………………………………… 43

engine noises……………………………………………………………………………… 43

ENGLNE LUBRICATION…………………………………………………………………… 44

HIGH OIL CONSUMPTION OR EXCESSIVE……………………………………………… 44

Exhaust smoke…………………………………………………………………………… 44

Low oil pressure ………………………………………………………………………… 44

High oil pressure ………………………………………………………………………… 44

No oil pressure…………………………………………………………………………… 44

Oil level too low…………………………………………………………………………… 44

Oil contamination………………………………………………………………………… 45

CYLINDER LEAK DOWN TEST…………………………………………………………… 45

ELECTRICAL TESTING…………………………………………………………………… 47

Preliminary checks and precautions …………………………………………………… 47

Intermittent problems…………………………………………………………………… 48

Electrical component replacement ……………………………………………………… 49

Test equipment …………………………………………………………………………… 49

Ammeter …………………………………………………………………………………… 49

Self-powered test light …………………………………………………………………… 49

Ohmmeter ………………………………………………………………………………… 50

Jumper wire……………………………………………………………………………… 50

TEST PROCEDURES………………………………………………………………………… 51

Voltage test……………………………………………………………………………… 51

Voltage drop test………………………………………………………………………… 51

Peak voltage test………………………………………………………………………… 52

Continuity test……………………………………………………………………………… 52

- 5 -

Testing for a short with a self-powered test light or ohmmeter……………………… 52

Testing for a short with a test light or voltmeter………………………………………… 53

BRAKE SYSTEM……………………………………………………………………………… 53

Soft or spongy brake lever or pedal…………………………………………………… 53

Brake drag………………………………………………………………………………… 54

Hard brake lever or pedal operation…………………………………………………… 55

Brake Grabs……………………………………………………………………………… 55

Brake squeal or chatter ………………………………………………………………… 55

Leaking brake caliper …………………………………………………………………… 55

Leaking master cylinder………………………………………………………………… 56

CHAPTER 2

SPECIFICATIONS

HOW TO USE CONVERSION TABLE OF UNIT…………………………………………… 57

How to use conversion table…………………………………………………………… 57

Definition of unit ………………………………………………………………………… 57

GEBERAR SPECIFICATIONS ……………………………………………………………… 58

ENGINE SPECIFICATIONS ………………………………………………………………… 61

CHASSIS SPECIFICATIONS………………………………………………………………… 67

ELECTRICAL SPECIFICATIONS…………………………………………………………… 69

TIGHTENING TORQUES …………………………………………………………………… 71

Engine tightening torques………………………………………………………………… 71

Chassis tightening torques ……………………………………………………………… 74

GENERAL TIGHTENING TORQUE SPECIFICATIONS ………………………………… 76

LUBRICATION PIONTS AND LUBRICANT TYPES……………………………………… 77

Engine……………………………………………………………………………………… 77

Chassis……………………………………………………………………………………… 78

HYDROGRAPHIC CHART…………………………………………………………………… 79

LUBRICATION OIL WAY…………………………………………………………………… 80

- 5 -

Testing for a short with a self-powered test light or ohmmeter……………………… 52

Testing for a short with a test light or voltmeter………………………………………… 53

BRAKE SYSTEM……………………………………………………………………………… 53

Soft or spongy brake lever or pedal…………………………………………………… 53

Brake drag………………………………………………………………………………… 54

Hard brake lever or pedal operation…………………………………………………… 55

Brake Grabs……………………………………………………………………………… 55

Brake squeal or chatter ………………………………………………………………… 55

Leaking brake caliper …………………………………………………………………… 55

Leaking master cylinder………………………………………………………………… 56

CHAPTER 2

SPECIFICATIONS

HOW TO USE CONVERSION TABLE OF UNIT…………………………………………… 57

How to use conversion table…………………………………………………………… 57

Definition of unit ………………………………………………………………………… 57

GEBERAR SPECIFICATIONS ……………………………………………………………… 58

ENGINE SPECIFICATIONS ………………………………………………………………… 61

CHASSIS SPECIFICATIONS………………………………………………………………… 67

ELECTRICAL SPECIFICATIONS…………………………………………………………… 69

TIGHTENING TORQUES …………………………………………………………………… 71

Engine tightening torques………………………………………………………………… 71

Chassis tightening torques ……………………………………………………………… 74

GENERAL TIGHTENING TORQUE SPECIFICATIONS ………………………………… 76

LUBRICATION PIONTS AND LUBRICANT TYPES……………………………………… 77

Engine……………………………………………………………………………………… 77

Chassis……………………………………………………………………………………… 78

HYDROGRAPHIC CHART…………………………………………………………………… 79

LUBRICATION OIL WAY…………………………………………………………………… 80

- 6 -

CHAPTER 3

MAINTENCE AND ADJUSTMENT OF THE UTV

MAINTENANCE SCHEDULE……………………………………………………………… 81

ENGINE

Adjusting the valve clearance…………………………………………………………… 83

Checking the spark plug ………………………………………………………………… 86

Checking the ignition timing……………………………………………………………… 87

Measuring the compression pressure………………………………………………… 88

Checking the engine oil level …………………………………………………………… 89

Changing the engine oil ………………………………………………………………… 90

CHASSIS

Cleaning the air filter………………………………………………………………… 92

Checking the coolant level …………………………………………………………… 93

Changing the coolant…………………………………………………………………… 94

Checking the coolant temperature warning light …………………………………… 97

Checking the v-belt……………………………………………………………………… 98

Cleaning the spark arrester …………………………………………………………… 99

Adjusting the brake pedal……………………………………………………………… 101

Checking the brake fluid level ………………………………………………………… 101

Checking the front brake pads………………………………………………………… 102

Checking the rear brake pads………………………………………………………… 102

Checking the brake hoses and brake pipes ………………………………………… 103

Bleeding the hydraulic brake system ………………………………………………… 103

Adjusting the select lever shift rod …………………………………………………… 105

Checking the steering system………………………………………………………… 106

Adjusting the toe-in …………………………………………………………………… 107

Adjusting the front and rear shock absorbers………………………………………… 108

Checking the tires ……………………………………………………………………… 109

Checking the wheels…………………………………………………………………… 111

Checking and lubricating the cables ………………………………………………… 111

ELECTRICAL

Checking and charging the battery…………………………………………………… 112

Checking the fuses …………………………………………………………………… 118

- 7 -

Changing the headlight bulb Ⅰ………………………………………………………… 120

Changing the headlight bulb Ⅱ………………………………………………………… 121

Changing the tail/brake light bulb …………………………………………………… 122

CHAPTER 4

ENGINE

ENGINE NOTE……………………………………………………………………………… 124

ENGINE REMOVAL………………………………………………………………………… 125

CYLINDER HEAD AND CYLINDER HEAD COVER…………………………………… 126

ROCKER ARMS VALES AND CAMSHAFT……………………………………………… 130

CYLINDER AND PISTON………………………………………………………………… 138

ENGINE LEFT CRANKCASE COVER AND A.C. MAGNETO…………………………142

STARTER MOTOR AND WATER PUMP…………………………………………………146

RIGHT CRANKCASE COVER AND OIL FILTER…………………………………………148

PRIMARY AND SECONDARY SHEAVES…………………………………………………150

CRANKCASE AND OIL PUMP……………………………………………………………154

BALANCE SHAFT…………………………………………………………………………156

SHIFT AND CONTROL MECHANISM……………………………………………………161

GEARCASE TRANSMISSION………………………………………………………………163

CHAPTER 5

CHASSIS

MALFUNCTION INSPECTION…………………………………………………………… 167

PANEL AND CARGO BED

Front panel………………………………………………………………………………… 169

Side cover………………………………………………………………………………… 171

Side cover parts…………………………………………………………………………… 172

Cargo bed………………………………………………………………………………… 175

Head shed frame………………………………………………………………………… 176

- 7 -

Changing the headlight bulb Ⅰ………………………………………………………… 120

Changing the headlight bulb Ⅱ………………………………………………………… 121

Changing the tail/brake light bulb …………………………………………………… 122

CHAPTER 4

ENGINE

ENGINE NOTE……………………………………………………………………………… 124

ENGINE REMOVAL………………………………………………………………………… 125

CYLINDER HEAD AND CYLINDER HEAD COVER…………………………………… 126

ROCKER ARMS VALES AND CAMSHAFT……………………………………………… 130

CYLINDER AND PISTON………………………………………………………………… 138

ENGINE LEFT CRANKCASE COVER AND A.C. MAGNETO…………………………142

STARTER MOTOR AND WATER PUMP…………………………………………………146

RIGHT CRANKCASE COVER AND OIL FILTER…………………………………………148

PRIMARY AND SECONDARY SHEAVES…………………………………………………150

CRANKCASE AND OIL PUMP……………………………………………………………154

BALANCE SHAFT…………………………………………………………………………156

SHIFT AND CONTROL MECHANISM……………………………………………………161

GEARCASE TRANSMISSION………………………………………………………………163

CHAPTER 5

CHASSIS

MALFUNCTION INSPECTION…………………………………………………………… 167

PANEL AND CARGO BED

Front panel………………………………………………………………………………… 169

Side cover………………………………………………………………………………… 171

Side cover parts…………………………………………………………………………… 172

Cargo bed………………………………………………………………………………… 175

Head shed frame………………………………………………………………………… 176

Dieses Handbuch passt für folgende Modelle

Inhaltsverzeichnis

Andere Hisun Motorrad Handbücher

Hisun

Hisun 450ATV-2 Bedienungsanleitung

Beliebte Motorrad Handbücher anderer Marken

OHVALE

OHVALE GP-0 Stücklistenhandbuch

Yamaha

Yamaha Star XV19CTSZ 2009 Bedienungsanleitung

KTM

KTM 350 XCF-W USA Bedienungsanleitung

HYOSUNG

HYOSUNG ST7 Bedienungsanleitung

Husqvarna

Husqvarna FC 250 2016 Bedienungsanleitung

Ducati

Ducati SCRAMBLER 800 Gebrauchsanweisung

MOTO GUZZI

MOTO GUZZI QUOTA 1100 ES Bedienungsanleitung

APRILIA

APRILIA ETV MILLE CAPONORD - PART1 02-2001 Bedienungsanleitung

Yamaha

Yamaha 2006 YZF-R1V Bedienungsanleitung

KTM

KTM Freeride E-XC 2021 Bedienungsanleitung

Fantic

Fantic Enduro 125 Bedienungsanleitung

Ducati

Ducati Supersport 750 desmodue Bedienungsanleitung

MV Agusta

MV Agusta 2008 F4 312RR 1078 Gebrauchsanweisung

Yamaha

Yamaha XVS650A Bedienungsanleitung

Yamaha

Yamaha YZF-R6T(C) Handbuch

Ducati

Ducati 748 monoposto strada Bedienungsanleitung

ATK

ATK 1988 250 Bedienungsanleitung

Excelsior-HENDERSON

Excelsior-HENDERSON 1999 HCX Bedienungsanleitung