Huansong HS700UTV Referenzhandbuch

FOREWORD

Brief introduction to maintenance handbook of

HS700/600/500UTV

The handbook is edited by Technical Center of Chongqing Huansong Industries (Group)

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 HS700UTV.

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.

Third version , May, 2010

Published by Chongqing Huansong Industries (Group) Co., Ltd.

Chongqing Huansong Industries (Group) Co., Ltd holds the copy right.

No publishing and reprinting without permission.

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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…………………………………………………………………… 5

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

Warning labels……………………………………………………………………………… 6

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

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

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

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

Washers…………………………………………………………………………………… 7

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

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

SHOP SUPPLIES

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

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

Greases……………………………………………………………………………………… 9

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

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

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

Gasket sealant…………………………………………………………………………… 10

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

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

BASIC TOOLS ………………………………………………………………………………… 11

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

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Wrenches ………………………………………………………………………………… 12

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

Socket wrenches, ratchets and handles ……………………………………………… 13

Impact drivers …………………………………………………………………………… 14

Allen wrenches…………………………………………………………………………… 14

Torque wrenches………………………………………………………………………… 14

Torque adapters ………………………………………………………………………… 15

Pliers……………………………………………………………………………………… 16

Snap ring pliers…………………………………………………………………………… 16

Hammers ………………………………………………………………………………… 17

Ignition grounding tool…………………………………………………………………… 17

PRECISION MEASURING TOOLS ………………………………………………………… 17

Feeler gauge ……………………………………………………………………………… 18

Calipers…………………………………………………………………………………… 18

Micrometers……………………………………………………………………………… 19

Adjustment ……………………………………………………………………………… 20

Care ……………………………………………………………………………………… 20

Metric micrometer………………………………………………………………………… 20

Standard inch micrometer……………………………………………………………… 21

Telescoping and small bore gauges…………………………………………………… 22

Dial Indicator……………………………………………………………………………… 22

Compression gauge……………………………………………………………………… 23

Multimeter………………………………………………………………………………… 23

ELECTRICAL SYSTEM FUNDAMENTALS……………………………………………… 24

Voltage …………………………………………………………………………………… 24

Resistance………………………………………………………………………………… 24

Amperage………………………………………………………………………………… 24

BASIC SERVICE METHODS……………………………………………………………… 25

Removing frozen fasteners……………………………………………………………… 26

Removing broken fasteners …………………………………………………………… 26

Repairing damaged threads …………………………………………………………… 27

Stud Removal/Installation ……………………………………………………………… 27

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

Bearings…………………………………………………………………………………… 28

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Removal…………………………………………………………………………………… 28

Installation………………………………………………………………………………… 29

Interference fit …………………………………………………………………………… 29

Seal replacement………………………………………………………………………… 31

STORAGE……………………………………………………………………………………… 31

Storage area selection…………………………………………………………………… 31

Preparing the motorcycle for storage …………………………………………………… 32

Returning the UTV to service…………………………………………………… 32

TROVBLESHOOTING……………………………………………………………………… 33

ENGINE PRINCIPLES AND OPERATING REQUIREMENTS………………………… 34

STARTING THE ENGINE ………………………………………………………………… 34

Engine is cold …………………………………………………………………………… 34

Engine is warm…………………………………………………………………………… 34

Starting the engine after a fall or after the engine stalls……………………………… 34

Flooded engine…………………………………………………………………………… 34

Engine cold with air temperature ……………………………………………………… 35

Engine cold with air temperature above 35℃（95°F）……………………………… 35

Cold engine with air temperature below 10℃(50°F) ……………………………… 35

Engine is hot……………………………………………………………………………… 36

Starting the engine after a fall or after the engine stalls……………………………… 36

Flooded engine…………………………………………………………………………… 36

ENGINE WILL NOT START ……………………………………………………………… 37

Identifying the problem ………………………………………………………………… 37

Spark test………………………………………………………………………………… 38

Starter does not turn over or turns over slowly ……………………………………… 39

POOR ENGINE PERFORMANCE………………………………………………………… 39

Engine starts but stalls and is hard to restart…………………………………………… 39

Engine backfires, cuts out or misfires during acceleration…………………………… 40

Engine backfires on deceleration……………………………………………………… 40

Poor fuel mileage………………………………………………………………………… 40

Engine will not idle or idles roughly …………………………………………………… 41

Low engine power ………………………………………………………………………… 41

Poor idle or low speed performance…………………………………………………… 42

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Poor high speed performance ………………………………………………………… 43

FUEL SYSTEM……………………………………………………………………………… 43

Rich mixture……………………………………………………………………………… 43

Lean mixture……………………………………………………………………………… 44

ENGINE………………………………………………………………………………………… 44

Engine smoke……………………………………………………………………………… 44

Black smoke ……………………………………………………………………………… 44

Blue smoke………………………………………………………………………………… 44

White smoke or steam…………………………………………………………………… 44

Low engine compression ………………………………………………………………… 45

High engine compression ……………………………………………………………… 45

Engine overheating (cooling system) ………………………………………………… 45

Engine overheating (engine)…………………………………………………………… 46

Preignition………………………………………………………………………………… 46

Detonation………………………………………………………………………………… 46

Power loss ……………………………………………………………………………… 46

engine noises……………………………………………………………………………… 46

ENGLNE LUBRICATION…………………………………………………………………… 47

HIGH OIL CONSUMPTION OR EXCESSIVE……………………………………………… 47

Exhaust smoke…………………………………………………………………………… 47

Low oil pressure ………………………………………………………………………… 47

High oil pressure ………………………………………………………………………… 48

No oil pressure…………………………………………………………………………… 48

Oil level too low…………………………………………………………………………… 48

Oil contamination………………………………………………………………………… 48

CYLINDER LEAK DOWN TEST…………………………………………………………… 48

ELECTRICAL TESTING…………………………………………………………………… 51

Preliminary checks and precautions …………………………………………………… 51

Intermittent problems…………………………………………………………………… 52

Electrical component replacement ……………………………………………………… 53

Test equipment …………………………………………………………………………… 53

Ammeter …………………………………………………………………………………… 53

Self-powered test light …………………………………………………………………… 53

Ohmmeter ………………………………………………………………………………… 54

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Jumper wire……………………………………………………………………………… 54

TEST PROCEDURES………………………………………………………………………… 55

Voltage test……………………………………………………………………………… 55

Voltage drop test………………………………………………………………………… 55

Peak voltage test………………………………………………………………………… 56

Continuity test……………………………………………………………………………… 56

Testing for a short with a self-powered test light or ohmmeter……………………… 56

Testing for a short with a test light or voltmeter………………………………………… 57

BRAKE SYSTEM……………………………………………………………………………… 57

Soft or spongy brake lever or pedal…………………………………………………… 57

Brake drag………………………………………………………………………………… 58

Hard brake lever or pedal operation…………………………………………………… 59

Brake Grabs……………………………………………………………………………… 59

Brake squeal or chatter ………………………………………………………………… 59

Leaking brake caliper …………………………………………………………………… 60

Leaking master cylinder………………………………………………………………… 60

CHAPTER 2

SPECIFICATIONS

HOW TO USE CONVERSION TABLE OF UNIT…………………………………………… 61

How to use conversion table…………………………………………………………… 61

Definition of unit ………………………………………………………………………… 61

GEBERAR SPECIFICATIONS ……………………………………………………………… 62

ENGINE SPECIFICATIONS ………………………………………………………………… 65

CHASSIS SPECIFICATIONS………………………………………………………………… 71

ELECTRICAL SPECIFICATIONS…………………………………………………………… 73

TIGHTENING TORQUES …………………………………………………………………… 75

Engine tightening torques………………………………………………………………… 75

Chassis tightening torques ……………………………………………………………… 78

GENERAL TIGHTENING TORQUE SPECIFICATIONS ………………………………… 81

LUBRICATION PIONTS AND LUBRICANT TYPES……………………………………… 82

Engine……………………………………………………………………………………… 82

Chassis……………………………………………………………………………………… 83

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HYDROGRAPHIC CHART…………………………………………………………………… 84

LUBRICATION OIL WAY…………………………………………………………………… 85

CHAPTER 3

MAINTENCE AND ADJUSTMENT OF THE UTV

MAINTENANCE SCHEDULE……………………………………………………………… 86

ENGINE

Adjusting the valve clearance…………………………………………………………… 88

Idle adjustment …………………………………………………………………………… 91

Adjusting the throttle cable……………………………………………………………… 91

Adjusting the starter cable……………………………………………………………… 92

Checking the spark plug ………………………………………………………………… 93

Checking the ignition timing……………………………………………………………… 94

Measuring the compression pressure………………………………………………… 95

Checking the engine oil level …………………………………………………………… 97

Changing the engine oil ………………………………………………………………… 98

CHASSIS

Cleaning the air filter………………………………………………………………… 101

Checking the coolant level …………………………………………………………… 102

Changing the coolant…………………………………………………………………… 103

Checking the coolant temperature warning light …………………………………… 106

Checking the v-belt……………………………………………………………………… 107

Cleaning the spark arrester …………………………………………………………… 108

Adjusting the brake pedal……………………………………………………………… 109

Adjusting the parking brake…………………………………………………………… 110

Checking the brake fluid level ………………………………………………………… 111

Checking the front brake pads………………………………………………………… 111

Checking the rear brake pads………………………………………………………… 112

Checking the brake hoses and brake pipes ………………………………………… 113

Bleeding the hydraulic brake system ………………………………………………… 113

Adjusting the select lever shift rod …………………………………………………… 115

Adjusting the brake light switch ……………………………………………………… 115

Checking the final gear oil level ……………………………………………………… 116

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Changing the final gear oil……………………………………………………………… 116

Checking the differential gear oil……………………………………………………… 117

Changing the differential gear oil……………………………………………………… 117

Checking the constant velocity joint dust boots……………………………………… 118

Checking the steering system………………………………………………………… 119

Adjusting the toe-in …………………………………………………………………… 120

Adjusting the front shock absorbers………………………………………………… 121

Adjusting the rear shock absorbers …………………………………………………… 121

Checking the tires ……………………………………………………………………… 122

Checking the wheels…………………………………………………………………… 124

Checking and lubricating the cables ………………………………………………… 124

ELECTRICAL

Checking and charging the battery…………………………………………………… 125

Checking the fuses …………………………………………………………………… 130

Adjusting the headlight beam ………………………………………………………… 131

Changing the headlight bulb ………………………………………………………… 132

Changing the tail/brake light bulb …………………………………………………… 133

CHAPTER 4

ENGINE

ENGINE NOTE……………………………………………………………………………… 134

ENGINE REMOVAL………………………………………………………………………… 135

CYLINDER HEAD AND CYLINDER HEAD COVER…………………………………… 137

ROCKER ARMS AND CAMSHAFT……………………………………………………… 142

VALVES AND VALVE SPRINGS………………………………………………………… 148

CYLINDER AND PISTON………………………………………………………………… 154

ENGINE COOLING FAN AND A.C. MAGNETO ……………………………………… 158

BALANCER GEARS AND OIL PUMP GEARS………………………………………… 163

PRIMARY AND SECONDARY SHEAVES

Primary and secondary sheaves ……………………………………………………… 166

Primary sheave………………………………………………………………………… 167

Secondary sheave ……………………………………………………………………… 168

CLUTCH ……………………………………………………………………………………… 173

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CRANKCASE

Starter motorand oil filter……………………………………………………………… 177

Crankcase……………………………………………………………………………… 179

Crankcase bearings…………………………………………………………………… 180

CRANKSHAFT AND OIL PUMP

Crankshaft and oil pump ……………………………………………………………184

Oil pump…………………………………………………………………………………185

TRANSMISSION

Transmission…………………………………………………………………………… 188

Drive axle assembly…………………………………………………………………… 189

MIDDLE GEAR

Middle drive shaft………………………………………………………………………… 193

Middle driven shaft ……………………………………………………………………… 194

CARBURETOR……………………………………………………………………………… 200

CHAPTER 5

CHASSIS

MALFUNCTION INSPECTION…………………………………………………………… 205

DIRECTION SYSTEM

The structure of the steering…………………………………………………………… 208

The structure of steering wheel part…………………………………………………… 210

Diassembling the parts of the steering wheel ………………………………………… 211

Checking the parts of the steering wheel……………………………………………… 211

Diassembling the steering column parts……………………………………………… 212

Checking and service the steering column parts……………………………………… 213

Diassembling the steering drive axle ………………………………………………… 213

Checking and service the steering drive axle………………………………………… 214

Diassembling the steering machine part……………………………………………… 215

The structure of the steering………………………………………………………… 215

Reinstalls the steering system parts…………………………………………………… 216

BRAKE SYSTEM…………………………………………………………………………… 217

Front disk brake components ………………………………………………………… 219

Front brake discs ……………………………………………………………………… 220

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Checking the front brake disc ………………………………………………………… 221

Front brake pads………………………………………………………………………… 222

Replacing the front brake pads………………………………………………………… 223

Front brake caliper……………………………………………………………………… 224

Disassembling the front brake calipers ……………………………………………… 226

Assembling the front brake calipers…………………………………………………… 227

Installing the front brake calipers …………………………………………………… 227

Rear brake disc ………………………………………………………………………… 229

Checking the rear brake disc…………………………………………………………… 230

Rear brake caliper and brake pads…………………………………………………… 231

Replacing the rear brake pads………………………………………………………… 234

Disassembling the rear brake caliper ………………………………………………… 234

Assembling the rear brake caliper …………………………………………………… 235

Installing the rear brake caliper………………………………………………………… 237

Brake master cylinder…………………………………………………………………… 239

Checking the master cylinder ………………………………………………………… 240

Assembling the brake master cylinder………………………………………………… 240

Installing the brake master cylinder…………………………………………………… 240

FOOTREST ASSEMBLY ………………………………………………………………… 242

WHEEL AND TYRE PARTS ……………………………………………………………… 245

Front wheels……………………………………………………………………………… 245

Rear wheels……………………………………………………………………………… 246

Checking the wheel tyre………………………………………………………………… 247

Checking the wheel hub………………………………………………………………… 247

Installing the wheel hub………………………………………………………………… 247

Installing the wheel tyre………………………………………………………………… 248

Specification of wheel and tyre………………………………………………………… 248

TRANSMISSION SYSTEM ………………………………………………………………… 249

Front bridge……………………………………………………………………………… 249

Disassembling the front bridge………………………………………………………… 254

Disassembling the universal joint …………………………………………………… 254

Removing the differential gear assembly…………………………………………… 254

Checking the joints……………………………………………………………………… 255

Checking the differential gear…………………………………………………………… 255

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