TM
GRAB SOME SUN
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. 08071501
No one under the age of 16
should operate this vehicle.
Provincial / Municipal
governments have different
regulations pertaining to
owning and operating an
off-road vehicle; learn the
regulations in your area.
VECTOR 500
OWNER’S MANUAL
INTRODUCTION
Congratulations on your purchase of the Vector 500. This Owner’s / Operator’s manual will
provide you information regarding safe operation, operational instructions, maintenance and
care. Fully understanding this manual and following all of the instructions herein will provide
the knowledge needed to have safe and enjoyable UTV operation.
For questions regarding this UTV, please call (972) 446-0760.
IMPORTANT SAFETY MESSAGES
● READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR UTV.
MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS.
● PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE UTV.
● NEVER OPERATE THE UTV WITHOUT PROPER TRAINING OR INSTRUCTION.
● THIS UTV SHOULD NOT BE RIDDEN BY ANYONE UNDER
16 YEARS OF AGE.
1-1
IMPORTANT MANUAL INFORMATION
FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS
INJURY
OR DEATH. Particularly important information is distinguished in this manual by the following
notations:
The Safety Alert Symbol means ATTENTION!
YOUR SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to
the machine operator, bystander or a person inspecting or repairing the
machine.
A CAUTION indicates special precautions that must be taken to avoid damage
to the machine.
NOTE: A NOTE provides key information to make procedures easier
clearer.
1-2
IMPORTANT NOTICE
This UTV is designed and manufactured for OFF - ROAD use only. It is illegal and unsafe to operate this
UTV on any public street, road or highway.
This UTV complies with all applicable OFF - ROAD noise level and spark arrester laws and regulations in
effect at the time of manufacture.
Please check your local riding laws and regulations before operating this UTV.
When the temperature is below -4°F (-20°C), park the UTV in a place where the temperature is higher
than -4°F (-20°C). Start the UTV after the UTV has warmed up. Please see page 7-3 on the warming up
process.
Follow the proper parking procedures when the temperature is higher than 100°F (38°C): turn off the
engine; make sure the radiator fan is on for 3 minutes before turning off the power switch.
Starting the UTV for the first time will take longer because the fuel will need reach the fuel injectors. To
start the UTV the first time, hold the ignition key on at 5-second intervals. Allow the starter to rest 15
seconds between each start attempt.
1-3
UNIVERSAL SYMBOLS
As a guide to the operation of your vehicle, various universal symbols have been utilized on the
instruments and controls. The symbols are shown below with an indication of their meaning.
Safety Alert Symbol
Diesel Fuel
Lift Cylinder-Retract
Lift Cylinder-Extend
Engine coolant-Temperature
Parking Brake
Lift Cylinder-Float
Hazard Warning Lights
Master Lighting Switch
Audible Warning Device
Fault indicator light of EPS system
2WD/ 4WD
Battery Charging Condition
Engine Oil-Pressure
Turn Signal/Hazard
Differential Lock
Position light bulb
1-4
Table of Contents
Subject
Page
1-1
Subject
Page
8-1
Introduction
Starting
1-2
1-3
1-4
1-7
1-8
2-1
2-1
2-2
2-2
2-3
2-3
2-3
2-3
2-4
2-4
2-4
3-1
4-1
5-1
5-3
6-1
7-1
7-1
7-2
7-2
7-2
7-3
Important manual information
Important notice
Seat belt
8-1
Head light switch
8-2
Universal symbols
Location of parts
Emergency light switch
Turn signal light switch
Brake pedal
8-2
8-2
Illustrated contents
Safe operation
8-3
Range gear shift lever
4WD lever
8-4
Safety instructions
Operation
8-5
Accelerator pedal
8-5
Children safety instructions
Driving on a slope
Stopping
8-5
Coolant temperature gauge
Winch mount plate
Transporting vehicle
Service intervals
8-6
Driving in harsh conditions
Driving at high speed
Instructions for carrier
Parking
9-1
9-1
9-2
Periodic service
10-1
10-1
10-1
10-1
10-1
10-1
10-2
10-2
10-2
10-2
10-3
10-3
10-4
10-4
10-5
10-5
10-5
10-6
Transportation
How to open the front hood and seat
Front hood cover
Maintenance
Warning and caution labels
Servicing of vehicle
Specifications table
Vehicle limitations
Operator’s sea
How to raise the cargo bed
Raising and Lowering the Cargo Bed
Jack-up point
Pre-operation
Front end
Operating the engine
Starting the engine
Cold starting
Rear end
Daily check
Walk around inspection
Checking and Refueling
Checking coolant level
Cleaning radiator screen
Checking brake fluid level
Checking brake pedal
Checking parking brake
Checking gauges meter and easy
checker lamps
Stopping the engine
Warming up
Warm-up transmission oil in the low
temperature range
Operating the vehicle
Operating new vehicle
Do not operate the vehicle at full
speed for the first 50 hours
8-1
8-1
8-1
Changing lubricating oil for new vehicles 8-1
Checking head light turn signal light etc 10-6
1-5
Changing brake fluid
10-16
Checking seat belt and ROPS
Checking joint boot
10-6
Flushing Cooling system and changing 10-16
coolant
10-6
Checking tire inflation pressure
10-6
Anti-freeze
Replacing radiator hose (water pipes) 10-18
Replacing fuel hose 10-18
10-17
10-6
Every 50 hours
10-6
Greasing
Checking engine start system
Checking wheel bolt torque
Cleaning air cleaner primary element
Checking battery condition
Adjusting toe-in
10-7
Replacing brake master cylinder (inner 10-18
parts)
10-7
10-8
Replacing front brake seal
Replacing rear brake cylinder seal
Replacing intake air line
Every 4 years
10-18
10-18
10-18
10-18
10-18
10-18
10-19
10-19
10-20
11-1
10-9
10-10
10-11
10-11
10-11
10-12
10-12
10-13
10-14
10-14
10-14
10-14
10-15
10-15
10-15
10-15
10-15
10-16
10-16
10-16
10-16
10-16
10-16
10-16
Cleaning muffler
Every 200 hour
Replacing brake hose
Replacing slow-blow fuses
Storage
Changing engine oil
Replacing engine oil filter
Replacing transmission oil
Checking brake pedal
Checking brake hose and pipe
Checking brake light switch
Checking radiator hose and clamp
Checking intake air line
Every 300 hours
Vehicle storage
Removing the vehicle from storage
Troubleshooting
Engine troubleshooting
Diagnostic trouble code table
Battery troubleshooting
Machine troubleshooting
Vehicle warranty
11-1
11-2
11-3
11-4
Checking tire
12-1
Every 400 hours
Emissions warranty
13-1
Changing transmission fluid
Changing front and rear axle case oil
Every 500 hours
Replacing fuel filter
Every 600 hours
Adjusting engine valve clearance
Every 1500 hours
Checking injection and fuel pump
Every 1 year
Replacing air cleaner primary element 10-16
and secondary element
Every 2 years
10-16
1-6
LOCATION OF PARTS
Front Tire
Front Shock Absorber
1-7
ILLUSTRATED CONTENTS
1-8
1-9
Safe Operation
All operators, including experienced UTV drivers 4. Do not wear loosen articles of clothing
or passengers, should carefully read and fully
understand this Users Manual, and operate
strictly as the manual states in order to achieve
best performance and avoid accidents. Others
who will use you UTV should be trained how to
operate the UTV and be required to read this
manual before operation.
during operation, as these can be drawn into
moving parts on the vehicle and could cause
a severe injury to occur.
You should wear protective devices, such as
helmet, boots, eye protection, earmuff,
gloves,
and etc.
5. Only a qualified driver should operate this
UTV. Never operate after drinking, using
drugs or controlled products, or while
fatigued.
1. Safety Instructions:
1. Understand this UTV by reading this manual
and understanding all the components of the 6. Always perform the pre-operation checks as
vehicle. Only start and operate the vehicle
after finishing reading this manual.
following:
5) Check seat belt for worn or damaged, if
necessary, replace it.
2. Pay close attention to the warning and
caution labels on the UTV.
6) Check brakes, throttle, brake pedal and
other mechanical parts for proper
3. Understand completely and learn to use the
safety devices (roll-over protective structure,
seat belts), and never change original safety
devices. If safety devices are damaged,
consult your local dealer for replacement.
Always use seat belts.
operation.
If
you
discover
any
irregularities, replace related parts as
necessary. Periodically check the fittings
and fasteners.
7) Check engine oil level and engine coolant
level.
8) Check that the UTV is equipped to handle
the surroundings.
9) Check and keep vehicle clean. Sludge,
grease and debris can cause a fire and
severe injury.
7. Passenger quantity and loading:
1) Only the driver and one passenger inside
cab. It is suggested that children under
age of 5 not be allowed as a passenger.
2) Single-row vehicle’s loading limit is 350lbs
(159KG).Reduce loading weight according
to road condition. Never exceed the weight
limits for operation.
① Roll-over protective structure；
② Seat belts
2-1
Safe Operation
8. Never allow unauthorized persons to repair 9. (DIFF.LOCK is off) when pressing, the
this UTV. This may affect vehicle
performance and cause injury.
front/rear wheels can turn at different speed.
Otherwise, the vehicle may turnover.
9. This UTV is designed and manufactured for 10. Never drive over terrain such as a ditch, a
off-road use only, so never drive on paved
roadways.
hole, dams, excessive mud, or the vehicle
can get stuck because of the vehicles
weight.
2. Operation
11. Always pay close attention to your
surroundings, and check for streets, trail
intersections or other obstacles.
1. Start the engine only in an open ventilated
area. Carbon monoxide is colorless, odorless 12. Always use signals in advance of turns.
and is emitted from the engine and can 13. Do not allow entrance or exit of the vehicle
cause death in areas with poor ventilation.
while it is moving.
2. Never start the vehicle or operate the gear 14. Clean dash board and Keep the floorboard
selector unless seated in the driver’s seat.
3. Never start the vehicle or operate the gear
selector unless seated in the driver’s seat.
4. The driver and passenger shall always wear
their seat belt while the vehicle is being
operated.
free of debris that can obstruct the ability to
use the brake pedal.
15. Position your hands on the steering wheel.
Always keep your hands and feet inside
passenger area of the vehicle. Never try to
stand while operating the vehicle.
5. Operators of the UTV should not wear 16. Do not tow passengers, or attempt to jump
earphones.
the vehicle.
6. Use trailer hitch to trail cargo, otherwise,
serious injury or death will happen.
3. Children safety instructions
Always watch children when they are around the
vehicle. Children like to imitate adults and this
could lead to an accident.
Do not leave children alone beside the vehicle.
Keep children from the operating area of the
vehicle.
Turn off the engine and remove the key when
children are in the operating area.
① Trailer Hitch
7. Do not accelerate quickly when starting the
engine, especially driving on rough terrain as
this can cause injury or death. Press the
accelerator pedal slowly.
Never carry children in the cargo bed. This is
very dangerous to children. Children under age
of 5 are not allowed to take this vehicle.
Never allow children to touch or climb the vehicle
even if they are under adult supervision, or
climbing on vehicle.
8. Drive at slow speed before braking.
When press the differential unlocked
2-2
Safe Operation
Always check for people or obstacles behind the 3. Under all conditions, both operator and
vehicle before shifting the vehicle into reverse.
Avoid a collision with an obstacle or person.
passengers should wear helmet and
protective equipment.
Park the vehicle on a firm, flat area. If parking on 4. Driver should slow down according to road
a slope, you should use parking brake, remove
the key, and get tires stuck in the tire wedge.
conditions, terrain, visibility conditions.
5. Be cautious when driving over a ditch, stone
road or hidden obstacles.
4. Driving on a slope
6. Avoid operating in any unknown depth of
water.（water depth should not exceed axle
height）
Be cautious when riding on a slope, as this is the
main reason result for loss of control, overturn,
leading to severe injury or even death.
1. Drive in a straight line on a slope at a low-
speed.
6. Driving at high speed
1. Check for front/rear wheels conditions. Pay
attention to the difference of braking
performances between two and four-wheel
drive.
2. Reduce weight when ride on a slope or
rough terrain.
3. Avoid the sudden application of the brakes
when you go uphill or downhill. Be more
careful when vehicle turns on a slope.
4. If you start to lose momentum or need to
park when climbing, use the parking brake to
come to a stop. Release the brake and begin
to coast down the hill.
2. Slow down when turning. Turning at high
speed may result in overturn or even death.
3. Turn on your headlights at high speeds.
4. Drive only when the vehicle speed can be
controlled.
5. Do not use DIFF.LOCK when driving at high
speed. Otherwise, this may cause vehicle
loss of control.
5. If do not believe you can operate the UTV
safely in reverse do not attempt to ascend
the slope any further.
6. When driving at high speed, suddenly turning
the steering wheel will reduce vehicle
stability. Never sharply turn the steering
wheel at high speeds.
6. Riding in mud, a ditch, and on slopes will
increase the risk of an overturn. Be more
cautious when operating. Drive gradually and
slowly when climbing. Avoid sudden changes
of vehicle speed or direction.
7. Instructions for carrier
1. Never carry a passenger in the cargo area.
2. Evenly distribute the cargo to maintain
proper stability. Avoid overloading the carrier.
Cargo should be securely attached.
5. Driving in harsh conditions
1. Vehicle can be operated during the day or
under good light conditions.
3. Reduce loaded weight when driving on poor
road conditions or steep inclines.
2. Operate the vehicle in open, smooth
pavement.
2-3
Safe Operation
4. Do not put your hands and you body under place shift lever on “N” position, stop the engine
the cargo bed when it is raised. Once and remove the key.
lowered, lock the cargo bed in place before 1. When working next to the engine, exhaust or
operating the vehicle. Never driving before
securing and locking the cargo bed.
radiator, work only after it has cooled down.
2. Wait for the engine to stop running and cool
down before checking the coolant level.
Otherwise, you could be burned by hot fluid
or steam blown out.
8. Parking
1. Set the gear shift to the “N” position and To 3. No smoking when adding electrolyte or
release the parking brake, depress the brake
pedal.
refueling. Fuel tank and battery should be
kept away from sparks. Battery produces
hydrogen and oxygen during charging and
this could accelerate the risk of explosion.
4. Read and follow the instructions before
replacing the battery.
5. During maintenance, first aid kits and fire
extinguishers should be placed at your
fingertips.
6. During maintenance, you should disconnect
the battery cables.
① Parking brake.
② Brake pedal
2. Avoid stopping the vehicle on a slope. If
stopping on a slope make sure the vehicle is
stationary before exiting.
9. Transportation
1. Avoid dragging the vehicle behind another
vehicle. Use a trailer or truck to transport the
vehicle.
① Battery
2. When loading or unloading, pay attention to
your surroundings and others in the area.
7. Do not open radiator cap before coolant has
cooled down. When the coolant is cold, open
slowly and let the coolant pressure reduced,
and then open water cooler cap. Check for
the coolant level in the coolant reservoir. If
necessary, add coolant.
10. Maintenance
Stop the vehicle and park it on level ground. Pull
the parking brake and remove all cargo. Then
Tires should be mounted on rims with special
2-4
Safe Operation
8. equipment by professionals.
9. Keeping specified tire pressure can help to
ensure driving safety.
10. Elevate the vehicle and place a suitable
stand under the frame when removing the
wheels, Be sure to tighten the wheel nuts to
specified torque.
2-5
Warning Labels
Warning and caution labels
（1）
(2)
（3）
(6)
（4）
（5）
（7）
（8）
（9）
3-1
Warning Labels
（10）
（11）
(12）
(13)
(14)
(16)
(15)
3-2
Vehicle Identification Number
SERVICING OF VEHICLE
Your dealer is interested in your new vehicle
and has the desire to help you get the most
value from it. After reading this manual
thoroughly, you will find you can do some of
the regular maintenance by yourself.
However, when in need of parts or major
service, be sure to see your dealer.
For service, contact the dealership from
which you purchased your vehicle or your
local dealer.
① Vehicle serial number.
When in need of parts, be prepared to give
your dealer both the vehicle and engine
serial numbers.
Locate the serial numbers now and record
them in the space provided.
Type Serial No.
Vehicle
Engine
① Engine serial number
Product Identification
Number
Date of Purchase
Name of Dealer
4-1
Specifications
SPECIFICATION TABLE
Make
Type
Specification
1-cylinder, 4-cycle, gasoline, SOHC, liquid
cooled
Displacement
Engine
CC
Kw(HP)
rpm
471cm
19.44 HP
7000
Horsepower
Rated revolution
Low idling revolution
rpm
1350 to 1500
Fuel Capacity
L(U.S.gas) 29（7.6）
Transmission
CVT
Wheels, Drive system
Differential lock
Gear selection
4, Rear 2WD or 4WD
Electric control: switch
L-H-N-R
Front/Rear
Brakes
Wet disk brake
Parking brake
Axis brake, pedal-braking
Mechanical
Steering
Front
Suspension
Rear
Independent, Dual A-arm type
Independent, Dual A-arm type
2880 (113.83)
Length
mm(in.)
mm (in.)
Wide
1550（61.02）
Height
mm (in.) 1885（74.21）
Front tread centers
mm (in.)
mm (in.)
mm (in.)
1350 (53.15)
1300 (46.5)
1841.5（72.5）
254（10）
Dimensions
Rear tread centers
Wheelbase
front axle
rear axle
Ground
Clearance
mm (in.)
254（10）
Turning Radius
m (ft)
kg (lbs.)
kg (lbs.)
kg (lbs.)
3.96（13）
544（1200）
159（350）
590（1301）
Max. rolling weight (Towing Capacity)
Payload capacity
Weight
5-1
Specifications
Model
Specification
Width
mm (in.) 1066 (42)
Length
Depth
Volume
mm (in.)
mm (in.)
cu.ft.
787（31）
279（11）
8.28
Cargo bed
Bed height
mm (in.) 927（36.50）
(unloaded)
Cargo bed capacity
(1 row/2 row)
kg (lbs.) 159（350）
Sound level, operator ear
db (A)
85
Front
26×9-12
26×10-12
Camo
Tire
Rear
Body color
NOTE:
The values in “Ground clearance” and “Weight” are those of the machine equipped with the tires
in the table above.
The company reserves the right to change the specifications without notice.
TRAVELING SPEEDS
For Vector 500
Range gear shift lever
km/h (mph)
60（37）
16（10）
High
Reverse
5-2
Specifications
The Vehicle has been thoroughly tested for proper performance with implements sold or
approved by manufacturer. Use with implements which are not sold or approved and which
exceed the maximum specifications listed below, or which are otherwise unfit for use, vehicle
may result in vehicle malfunction or failures with a possibility of the vehicle damage to other
property and injury to the operator or others, [Any malfunctions or failures of the vehicle
resulting from use with improper implements are not covered by the warranty]
Max. Cargo loading weigh
Cargo Bed Capacity=159kg(350lb)
Cargo Load Capacity=190kg(419lb)
*(operator+one passenger+opt+acc )weight
Max. rolling weight
590kg (1300 lbs.)
Max. tongue weight
50kg (110lbs.)
1. Above mentioned specifications are based on level ground condition.
5-3
Pre-Operation
DAILY CHECK
To better prevent troubles, it is important to
know condition of the vehicle well. Check it
before starting.
CAUTION：
To avoid personal injury：
Be sure to check and service the vehicle on
a level surface with the engine shut off and
the parking brake “ON” and implement
lowered to the ground if equipped.
Check items
-Visually inspect the exterior of the vehicle
-Check engine oil level
-Check transmission oil level
-Check brake fluid level
-Check coolant level
-Clean radiator screen
(When used in a dusty place)
-Check brake and pedal
-Check parking brake
-Check indicators, gauges and meters
-Check lights
-Check seat belts and roll-over protective
structures.
-Check front and rear joint boots.
-Check tire inflation pressure.
-Refuel
(See "DAILY CHECK" in "PERIODIC
SERVICE" section.)
-Check of danger, warning and caution labels
(See "DANGER, WARNING AND CAUTION
LABELS＂in＂SAFE OPERATION＂section.)
6-1
Operating the Engine
NOTE：
CAUTION：Section
To avoid personal injury：
The parking brake warning lamp (P) comes on
while parking brake is applied and goes off when
it is released.
Read "SAFE OPERATION" in front of this
manual.
Read the danger, warning and caution
labels located on the vehicle.
To avoid the danger of exhaust fume
poisoning, do not operate the engine in
closed
buildings
without
proper
ventilation.
Start engine only from operator’s seat.
Never start engine while standing on
ground.
①Parking brake warning lamp
Make it a rule to set gear shift lever to
“NEUTRAL” position before starting the
engine.
2. Set gear shift lever to the “NEUTRAL” position.
IMPORTANT:
Do not use starting fluid or ether.
To protect the battery and the starter, make
sure that the starter is not continuously
turned for more than 5 seconds.
STARTING THE ENGINE
1. Make sure the parking brake is set.
①Range gear shift lever.
(F) FRONT Range
(N) “Neutral” position
(R) “REVERSE”
①Parking brake
7-1
Operating the Engine
3. Insert the key into the key switch and turn it
“START”.
OFF
ON
(Stop the Engine)
(Engine runs or headlights on)
①Range gear shift lever.
(L) Low Range
START (Start the Engine)
(H) High Range
(N) Neutral position
(R) REVERS
IMPORTANT :
It is not sufficient to do daily checks on dash
board only. Always conduct daily checks
carefully by referring to “DAILY CHECK“ in
“PERIODIC SERVICE” section.
2. Push the accelerator pedal down slowly.
4. Turn the key to “START” position and
release when the engine starts.
IMPORTANT:
Because of safety devices, the engine will
not start except when the gear shift lever is
placed in the “NEUTRAL” position and the
brake is depressed.
■ Cold Starting
When the ambient temperature is below -
15℃( 5℉), the engine is very cold. If the engine
fails to start after 5 seconds, turn off the key for
30 seconds and start again.
①Speed control pedal
②＝＞③ INCREASE
③＝＞② DECREASE
STOPPING THE ENGINE
1. After slowing the engine to idle, turn the key
to “OFF”.
2. Remove the key.
7-2
Operating the Engine
WARMING UP
CAUTION：
To avoid personal injury:
Be sure to set the parking brake during
warm-up.
Be sure to set the shift lever to the
“NEUTRAL” position during warm-up.
For 5 minutes after engine start-up, allow the
engine to warm up without applying any load.
This is to allow oil to reach every engine part. If
load is applied to the engine without warming-up,
engine damage may occur.
■ Warm-Up Transmission Oil in the Low
Temperature Range
IMPORTANT:
Do not operate the vehicle under full load
condition until it is sufficiently warmed up.
7-3
Operating the Vehicle
OPERATING NEW VEHICLE
■ Changing Lubricating Oil for New Vehicles
The lubricating oil is especially important for a
new vehicle. Various parts need time to wear
and polish themselves to the correct
operating clearances. Small pieces of metal
grit may develop during the operation of the
vehicle; and this may wear out or damage the
parts. Therefore, change the lubricating oil a
little earlier than would ordinarily be required.
For further details of change interval hours,
see “MAINTENANCE” section
How a new vehicle is handled and maintained
determines the life of vehicle.
A new vehicle just off the factory production line
has been, of course, tested, but the various parts
are not aligned to each other, so the operator
should pay more attention to operating the
vehicle for the first 50 hours at a slower speed
and avoid excessive work or operation until the
various parts become “broken-in.” The manner to
which you handle the vehicle during “breaking-in”
period greatly affects the life of your vehicle.
Therefore, to obtain the maximum performance
and the longest life of the vehicle, it is very
important to properly break-in your vehicle. For
better handling a new vehicle, the following
precautions should be observed.
STARTING
1. Fasten the seat belt during operation.
■ Seat Belt
■ Do not operate the vehicle at full speed for
WARNING
the first 50 hours.
To avoid personal injury:
Do not start quickly nor apply the brakes
suddenly.
Seat belts reduce injury. Always wear
your seat belts. The lap-style seat belts
may not provide adequate protection for
small children. Pay special attention
when carrying a child passenger.
In winter, operate the vehicle after fully
warming up the engine.
Do not run the engine at speeds faster than
prescribed.
On rough roads, slow down to suitable
speeds.
CAUTION：
To avoid personal injury:
Do not operate the vehicle at fast speed.
The above precautions are not limited to
new vehicles. However, they should be
especially observed for new vehicles.
Always use the seat belts when operating
and riding the vehicle.
Adjust the seat belts for proper fit and connect
the buckle. This seat belt is an auto-locking
retractable type.
8-1
Operating the Vehicle
NOTE：
Turning the head light switch to the “ON” position
causes the following lamps to light
simultaneously.
1. Tail lights (lamps at the rear portions of the
vehicle)
2. Lamp built in the coolant temperature gauge
3. Lamp built in the fuel gauge
4. Lamp built in the speedometer
5. Front left and right position lights
①Seat belt
2. Selecting light switch position.
■ Emergency Light Switch
[if equipped]
■ Head Light Switch
Press the top half of the emergency light switch,
the light flash along with the indicator on the
instrument panel. Press the bottom half of the
emergency light switch to turn off the light.
Turn on the key switch and toggle the head light
switch to the “ON” position.
Toggle the head light switch to the “OFF” position
to turn off the head light.
Note:
The emergency light switch will operate
when the key switch is in the “ON” position.
Be careful that keeping the switch “ON”
causes the battery to run out.
■ Turn Signal Light Switch
[if equipped]
To indicate a right turn, push on the lower half of
the turn toggle switch.
①Head light switch
②Head lights “OFF”
③ High beam lights "ON"
④Low beam lights "ON"
⑤ 4WD button
To indicate a left turn, push on the upper half of
the turn toggle switch.
When the left or right signal is activated, the
indicated turning light will flash and the other will
stay on.
⑥ 2WD button
⑦ Front axle differential lock
⑧ Front axle differential unlock
⑨ Emergency light "ON"
⑩ Emergency light "OFF"
⑪ Winch cable release
⑫ Winch cable pulled up
⑬ Left turning lights
⑭ Right turning lights
⑮Plug cover
The indicator lamp at the instrument panel also
flashes indicating the direction of the turn.
NOTE:
The turn signal light switch is only operative
when the key switch is in the “ON” position.
If the emergency light switch is pressed to
the “ON” position while the turn signal is
8-2
Operating the Vehicle
activated, the indicated turning light will flash
and other will stay on.
control. Reduce the speed.
The brake pedal is the left pedal on the foot
Be sure to return switch to center position board. Depress the pedal to slow or stop the
after turning.
vehicle.
①Brake pedal
4. Selecting the travel speed.
■ Range Gear Shift Lever
CAUTION:
To avoid personal injury:
Avoid changing gears when ascending or
descending a slope.
①Head light
②Head turn signal lamp;
③Tail turn signal lamp
Before ascending or descending a slope,
shift to the “L” range to control the
vehicle speed.
3. Checking the brake pedal.
■ Brake Pedal
If you shift gears while ascending or
descending a slope, be prepared to use
the brake to maintain control.
CAUTION:
To avoid personal injury:
Operate in reverse at slow speeds to
maintain control.
If the operator suddenly brakes, an
accident may occur due to loss of
control or the shifting forward of heavy
loads.
1. The range gear shift lever can only be
shifted only when the vehicle is completely
stopped and the the brake pedal is pressed.
2. To avoid transmission and shift linkage
damage, completely stop the vehicle using
the brake pedal before shifting gears.
When driving on icy, wet or loose surface,
make sure the vehicle is correctly loaded to
avoid skidding or loss of steering
8-3
Operating the Vehicle
3. Select proper gear and engine speed
NOTE:
When range gear shift lever is hard to
depending on the type of job.
4. Before exiting vehicle, shift the gear shift
lever to the “NEUTRAL” position and set
parking brake.
engage, do not force the lever. Set the
parking brake, slightly depress the
accelerator pedal and release it to neutral
position, then shift the lever.
FOR HS450UTV
When the lever is hard to disengage, do not
force the lever.
Depress the brake pedal fully, then shift the
lever. Damage may occur with wrong
shifting operation.
■ 4WD Lever
CAUTION:
To avoid personal injury:
when traveling at road speed. Use only
2WD.
①Range gear shift lever
(L) LOW Range
When driving on icy, wet or loose
surfaces, make sure the vehicle is
correctly loaded to avoid skidding and
loss of steering control. Reduce the
speed and engage front wheel drive.
Accident may occur if the vehicle is
suddenly braked, such as heavy towed
loads shifting forward causing loss of
control.
(H) HIGH Range
(N) NEUTRAL” POSITION
(R) REVERSE
The braking characteristics are different
between two and four wheel drive. Be
aware of the difference and operate
carefully.
IMPORTANT:
5. Unlock the parking brake and start slowly.
To release the parking brake, depress the brake
pedal. Make sure that indicator in the display
goes off.
8-4
Operating the Vehicle
①Parking brake
■ Accelerator Pedal
The accelerator pedal is used to increase the
engine and vehicle speed. Push down on it for
higher speed.
①Fuel gauge
■ Coolant Temperature Gauge
CAUTION:
①Accelerator pedal
To avoid personal injury:
STOPPING
Do not remove radiator cap until coolant
temperature is well below its boiling
point. Then loosen cap slightly to relieve
■ STOPPING
1. Release the accelerator pedal
2. Step on the brake pedal.
pressure
before
removing
cap
completely.
CHECK DURING DRIVING
1. With the key switch “ON” the temperature
gauge indicates the temperature of the
coolant. White Zone for “cold” and Red zone
for “hot”.
■ Immediately Stop the Engine if：
The engine suddenly slows down or
accelerates.
Unusual noises are suddenly heard.
Exhaust fumes suddenly become very white.
2. If the indicator reaches the Red zone, the
engine coolant is overheated. Check the
While driving, check the following items to see if
all parts are functioning normally.
vehicle
by
referring
to
“TROUBLESHOOTING” section.
8-5
Operating the Vehicle
①Coolant temperature gauge
The hour meter indicates in five digits the hours
the vehicle has been used; the last digit indicates
1/10 of an hour.
①Hourmeter
The speedometer indicates the traveling speed.
①Speedometer
8-6
Maintenance and Adjustment
WINCH MOUNT PLATE
Always read and follow the instructions in the winch owner’s manual before attempting to install or
use a winch.
① Winch mount plate
■ Transporting Vehicle
Pay attention to the following points when transporting the vehicle.
1. Use a suitable truck or trailer.
2. Apply the parking brake and place chocks against the front and rear tires.
9-1
Maintenance and Adjustment
CAUTION:
To avoid personal injury and vehicle damage:
Be sure you have sufficient knowledge, experience, the proper replacement parts and
tools before you attempt any vehicle maintenance task.
If you don’t have the knowledge and equipment which are necessary to perform the
maintenance task, consult your local dealer.
Have your local dealer perform inspection items which are marked *4 in the chart below.
SERVICE INTERVALS
IMPORTANT:
The jobs indicated by ◎ must be done after the first 50 hours of operation.
*1 Air cleaner should be cleaned more often in dusty conditions than in normal conditions.
*2 Every year or every 6 times of cleaning.
*3 Replace only if necessary.
*4 Consult your local dealer for this service.
*5 When the battery is used for less than 100 hours per year, check the battery condition by reading
the indicator annually.
The items listed below with a * mark are registered as emission related critical parts parts by the
U.S.EPA. As the engine owner, you are responsible for the performance of the required
maintenance on the engine according to the below instruction. Please see Warranty Statement
for more information.
Indication of
After
No.
Items
700 hrs
50 100 150 200 250 300 350 400 450 500 550 600 650 700
Every
200 hrs
Every
200 hrs
Every
400 hrs
Every
50 hrs
Every
50 hrs
Every
100 hrs
Every
100 hrs
Every
100 hrs
Every
100 hrs
Every
100 hrs
1
2
3
4
5
6
7
8
9
Engine oil
Change
◎
◎
○
○
○
○
○
○
○
○
○
○
○
○
○
○
Engine oil filter Replace
Transmission
Change
fluid
Engine start
Check
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
system
Greasing
*Muffler
Apply
Clean
◎
Spark arrester Clean
Wheel bolt
Check
◎
torque
Battery condition Check
10 Toe-in
Adjust
9-2
Maintenance and Adjustment
Indication of
After
No.
Items
700 hrs
50 100 150 200 250 300 350 400 450 500 550 600 650 700
Every
100 hrs
Every
100 hrs
Every
500 hrs
Every
100 hrs
Every 1
years
Check
○
○
○
○
○
○
○
○
○
○
Fuel filter
element
11
Replace
Check
○
○
○
○
○
12 *Fuel line
Replace
Clean
○
○
○
○
○
○
○
*Air cleaner
element
13
Every
Replace
Check
100 hrs
Every 1
years
Every
200 hrs
Every
200 hrs
Every
200 hrs
Every 2
years
14 Brake pedal
◎
◎
◎
○
○
○
○
○
○
○
○
○
○
○
○
15 Parking brake
Adjust
Brake light
switch
16
Check
Check
Radiator hose
17
and clamp
Replace
Check
Every
○
○
○
○
○
○
○
200 hrs
Every 1
years
18 *Intake air line
Replace
Every
200 hrs
◎
◎
Check
Check
Check
Brake hose &
pipe
19
Every 4years
Every
300 hrs
Every
400 hrs
Every
400 hrs
Every
800 hrs
Every
1500 hrs
Every
3900 hrs
Every 2
years
20 Tire wear
○
Front axle case
21
oil
Change
○
○
22 Knuckle case oil Change
Engine valve
23
Adjust
clearance
24 * Fuel injection Check
25 * Injection
26 Brake fluid
Check
Change
Replace
Replace
Remote
27
Every 2
years
hydraulic hose
Rear brake
cylinder seal
Every 2
years
28
Every 2
years
29 Front brake seal Replace
30 Cooling system Flush
Every 2
years
9-3
Maintenance and Adjustment
Indication of
After
No.
Items
700 hrs
50 100 150 200 250 300 350 400 450 500 550 600 650 700
Every 2
years
31 Coolant
Change
32 Fuel system
33 Fuse
Bleed
Service as
required
Replace
Replace
34 Light bulb
NOTE:
◆Engine Oil:（10W/40SL）
Oil used in the engine should have an American Petroleum Institute (API) service classification and
Proper SAE Engine Oil according to the ambient temperatures as shown above.
◆Brake fluid:
Always use DOT3 GENUINE BRAKE FLUID from a sealed container.
9-4
Periodic Service
① Turn switch
② Front hood cover
CAUTION:
To avoid personal injury:
■ Operator’s Seat
To open the seat, raise the seat to the forward
position.
HOW TO OPEN THE FRONT HOOD
COVER AND SEAT
CAUTION
To avoid personal injury from contact with
moving parts:
Never open operator’s seat while the
engine is running.
■ Front hood cover
To open the hood, turn the switch as the direction
in below picture to release the latch and lift the
hood off. To close, tilt cover back to closed
position and fasten the latches.
① Operator’s seat
HOW TO RAISE THE CARGO
BED
CAUTION
To avoid personal injury:
● When servicing under raised bed, make
sure safety support is properly
mounted.
● Do not touch muffler or exhaust pipes
while they are hot; Otherwise, severe
burns could result.
■ Raising and Lowering the Cargo Bed
◆To raise the cargo bed
1. Apply the parking brake with the engine
off.
2. Pull up the cargo bed handle.
◆To lower the cargo bed
Press down the cargo bed hard to make the
gas spring contractive till it is locked.
10-1
Periodic Service
NOTE:
■ Front End
Pull up the cargo bed handle to raise the cargo
bed with the gas spring elasticity.
Jack up at the front frame tube only.
①Jack
②Front frame tube
①
Cargo bed handle
■ Rear End
② UP
Jack the rear only after placing a wooden block
under the right and left frame tubes for securing
the engine and then supporting it.
③ DOWN
Do not apply jack pressure on the steel plate
directly under the engine.
①Gas spring
JACK-UP POINT
①Jack
②Rear frame tube
WARNING
DAILY CHECK
To avoid personal injury, death or vehicle damage:
Do not work under the vehicle unless it is
secured by safe stands or suitable
blocking.
For your own safety and maximum service life
of the vehicle, make a thorough daily inspection
before starting the engine and operating the
vehicle.
10-2
Periodic Service
IMPORTANT
CAUTION
If oil level is low, do not run engine.
To avoid personal injury:
Checking engine oil level
Be sure to park the vehicle on a flat
surface with the engine off and the parking
brake "ON".
1. Park the vehicle on a flat surface with
engine off, raise the cargo bed, mount the
safety support.
2. To check the oil level, draw out the
dipstick, wipe it clean, replace it, and draw
it out again, check to see if the level is too
low, add new oil to the prescribed level on
the dipstick.
■ Walk Around Inspection
Look around and under the vehicle for such items
as loose bolts, trash build-up, oil or coolant leaks,
broken or worn parts
■ Checking and Refueling
CAUTION
To avoid personal injury:
Do not smoke while refueling.
Be sure to stop the engine before
refueling.
1. Turn the key switch to “ON”, check the
amount of fuel by the fuel gauge
②
Oil Level
Dipstick
③
2. Fill fuel tank when fuel gauge shows1/4 or
less fuel in tank.
IMPORTANT
If oil level is low, do not run engine
①Fuel tank cap
Fuel tank capacity
28L (7.4±0.1U.S.GALS)
10-3
Periodic Service
IMPORTANT
■ Checking Coolant Level
If the radiator cap has to be removed,
follow the cautions above and securely
retighten the cap.
CAUTION
TO avoid personal injury
Use clean fresh water and anti-freeze to fill
the recovery tank.
Do not remove radiator cap while coolant
is hot, when cool, slowly rotate to the first
stop and allow sufficient time for excess
pressure to escape removing the cap
completely.
If water should leak, consult your local
HSUN Dealer.
■ Cleaning radiator screen
1. Park the vehicle on a flat surface, access the
panel under the hood, set the parking brake, and
shut off the engine.
CAUTION
TO avoid personal injury:
2. Check to see that the coolant level is between
the “FULL” and” LOW” marks of recovery tank.
Be sure to stop the engine before
removing the screen
3.
When the coolant level drops due to
1. Park the vehicle on a flat surface,
2. Remove the radiator cover,
3. Detach the screen and remove all foreign
materials,
evaporation, add water only up to the full level. In
case of leakage add anti-freeze and water in the
specified mixing ratio up to the full level.(see flush
cooling system and changing coolant in EVERY 2
YEARS in PERIODIC SERVICE section)
①Radiator screen
IMPORTANT
① Recovery tank
Radiator screen must be cleaned from
debris to prevent engine from overheating
②FULL
③LOW
10-4
Periodic Service
■ Checking brake fluid level
■ Checking brake pedal
CAUTION
CAUTION
TO avoid personal injury:
TO avoid personal injury:
Never operate the vehicle if the brake fluid
is below the minimum mark.
Stop the engine and chock the wheels
before checking brake pedal.
Use only DOT3 from a sealed container. Other
types of brake fluid may ruin synthetic resin or
rubber installed in brake system components
and may cause brake failure.
1.Inspect the brake pedals for free play and
smooth operation.
Adjust if incorrect measurement is found. (see
checking brake pedal in” EVERY 200 HOURS
in PERIODIC SERVICE section)
Avoid clean contamination of the brake
fluid thoroughly before removing the filler
cap. Do not open the brake fluid reservoir
cap unless absolutely necessary.
Use extreme care when filling the
reservoir. If brake fluid spill on power
steering hose, wash off with water
immediately, as brake fluid quickly ruins
synthetic resin or rubber hoses.
1. Check to see that the brake fluid level is up to
the LOWER mark.
①Brake pedal
②FREE TRAVEL
2. If it is below the “LOWER” mark add brake
fluid .
③PEDAL STROKE
■ Checking parking brake
Pull the parking brake to apply the brakes with
the key switch in the "ON" position and the
parking brake indicator should come on.
To release the parking brake, depress the
parking pedal.
Make sure the parking brake warning lamp on
the display goes off when parking brake lever is
applied.
①OIL CUP
②LOWER
10-5
Periodic Service
①Joint boot
②Drive shaft
■ Checking tire inflation pressure
Though the tire pressure is factory-set to the
prescribed level, it naturally drops slowly in the
course of time, thus check it every day and
inflate as necessary.
tire sizes
inflation pressure
70kPa (10psi)
Front: 26x9-12
①Parking brake
Rear: 26x10-12
70kPa (10psi)
■ Checking gauges meter service lamps
1. Inspect the instrument panel for broken
gauges meter and warning lamps.
2. Replace if broken.
EVERY 50 HOURS
■ Greasing
■ Checking head light turn signal light etc
1. Inspect lights for broken bulbs and lenses
2. Replace if broken
Apply a small amount of multi-purpose grease
to the following points every 50 hours. If you
operated the vehicle in extremely wet and
muddy conditions lubricate grease fittings more
often.
■ Checking seat belt and ROPS
1. Always check condition of seat belt and
ROPS attaching hardware before operating
vehicle.
2. Replace if damaged.
■ Checking joint boot
1. Check to see if the joint boots are damaged
or not.
2. If the boots are cut crashed or show signs of
deterioration. consult your local dealer.
①Parking brake
② Parking brake pivot（spray type grease）
10-6
Periodic Service
①Range gear shift lever pivot (spray type grease )
①Range gear shift lever
■ Checking engine start system
CAUTION
TO avoid personal injury
■ Checking wheel bolt torque
Do not allow anyone near the vehicle while
testing.
CAUTION
To avoid personal injury
If the vehicle does not pass the test, do
not operate the vehicle.
Never operate vehicle with a loose
wheel bolts.
Any time these bolts are loosened they
should be retightened to the specified
torque.
◆ Preparation before testing
1. Place all control levers in the “NEUTRAL”
position.
2. Set the parking brake and stop the engine.
◆ Test gear shift range lever safety switch
1. Sit on the operator’s seat.
2. Shift the range gear shift lever to: “F”, “N” or
REVERSE position.
3. Turn the key to “START” position.
4. The engine must not crank.
5. If it cranks consult your local dealer for this
service.
10-7
Periodic Service
Check all bolts frequently and keep them
tight.
Check wheel bolts regularly especially when new
if they are loose tighten them as follows:
①Air filter element
①Torque wheel bolts to 75 to 90 N.m
■ Cleaning air cleaner primary element
1. Remove the air cleaner cover and primary
element.
①Air filter element
②Locating pad
2. Remove the sponge material from its frame.
3. Wash the sponge material gently but
thoroughly in solvent.
4. Squeeze the excess solvent out of the
sponge material and let it dry.
5. Inspect the sponge material and replace it if
damaged.
6. Thoroughly apply foam air filter oil or other
quality liquid foam air filter oil (not spray type)
to the sponge material.
①Mounting point
②Air filter case cover
7. Re-install the air filter element.
8. Install the air filter case cover and be sure the
crankcase breather hose is connected.
IMPORTANT
The air cleaner uses a dry element never
apply oil.
Do not run the engine with filter element
removed.
10-8
Periodic Service
Be sure to refit the cower with the arrow (on
pump entrance. Even a small amount of dust or
dirt cause premature wear and malfunction of
the fuel pump and injector components.
the rear of cower ) upright if the cover is
improperly fitted the evacuator valve will not
function and dust will adhere to the element.
◆ Evacuator Valve
Open the air cleaner cover once a week under
ordinary conditions –or daily when used in a dusty
place-to get rid of large particles of dust and dirt.
Check fuel line and fuel filter.
CAUTION
To avoid personal injury:
①Fuel pump
②Fuel line
Be sure to stop the engine and remove the
key when attempting to make the following
checks and changes.
③Exit pipe
■ Checking battery condition
Never fail to check the fuel lines
periodically the fuel lines are subject to
wear and aging fuel may leak out onto the
running engine causing a fire.
DANGER
If you store a battery in a diminished state
of charge you will probably have to replace
the battery.
The fuel line connections should be
checked annually or every 100 service
hours whichever comes first.
CAUTION
To avoid personal injury
1. Park the vehicle on a flat surface and raise
the cargo bed.
Never remove the battery while the
engine is running.
2. The fuel line is made of rubble and ages
regardless of service period.
Keep electrolyte away from eyes, hands
and clothes. If you are spattered with it,
wash it away completely with water
immediately and get medical attention.
Wear eye protection and rubber gloves
when working around the battery.
3. If the fuel line and clamps are found to be
damaged or deteriorated replace them.
4. Check fuel filter if it is clogged by debris or
contaminated with water replace it.
IMPORTANT
When the fuel line is disconnected for
maintenance or repair, close both ends of the fuel
line with a piece of clean cloth or paper to prevent
dust and dirt from entering. Particular, care must
be taken not to admit dust and dirt into the fuel
The factory –installed battery is non-
refillable type if the battery is weak, charge
the battery or replace it with new one.
◆ Battery charging
10-9
Periodic Service
CAUTION
To avoid personal injury
Battery type
Volts
12
12V32Ah
When the battery is being activated,
hydrogen and oxygen gases in the battery
are extremely explosive. Keep open sparks
and flames away from the battery at all
times, especially when charging the
battery.
◆ Direction for storage
1. When storing the vehicle for a long period,
remove the battery from the vehicle, store
in a dry place out of direct sunlight.
2. The battery shall self self-discharge while it
is shored recharge it once every three
months in hot seasons and once every six
months in cold seasons.
When disconnecting the cable from the
battery start with the negative terminal
first; when connection the cable to the
battery start with the positive terminal
first.
■ Adjusting toe-in
Always check battery charge by using a
voltmeter.
Proper toe-in
0 to12 mm (0 to 0.47 in)
1. Park vehicle on flat place.
2. Turn steering wheel so front wheels are in
the straight ahead position.
3. Lock the park brake and stop the engine.
4. Measure distance between front tire beads
at rear of tire at hub height.
5. Front distance should be shorter than rear
distance if not adjust tie rod length.
①Battery
1. To slow charge the battery connect the
battery positive terminal to the charger
positive terminal and the negative to the
negative. then recharge in the standard
fashion.
2. A boost charge is only for emergencies it will
partially charge the battery as early as
possible.
①Wheel-to-wheel distance at front
②FRONT
◆ Adjusting procedures
3. When exchanging an old battery for a new
one use battery of equal specification shown
in table 1.
1. Loosen the lock nut and turn the tie rod to
adjust the rod length until the proper toe-in
10-10
Periodic Service
measurement is obtained.
2. Retighten the lock nut.
IMPORTANT
IMPORTANT:
Visually check the muffler for cracks or
holes in the body, weldment or pipes at
regular intervals.
Keep the equal length of the left and right tie-
rod.
USDA approval
requires
clearance
■ Cleaning Muffler
between spark arrester sleeve and muffler
body to be no larger than 0.023”(0.584
mm).
CAUTION
To avoid personal injury:
Replace the entire muffler if it is damaged.
Do not operate the vehicle with a damaged
muffler.
Before touching any part of an exhaust
system, be absolutely sure that it has
sufficient time to cool!
Always wear safety goggles and face
mask.
The particulate matter contained in the
muffler contains chemicals that are
harmful to people, animals and marine life.
If you are unable to do this work, have it
done by your dealer.
①Muffler
③Back cover
②Spark arrester
Cleaning spark arrester of muffler.
Maintenance & cleanout procedure:
The screen type spark arrester should be EVERY 200 HOURS
removed, cleaned, and inspected after every ■ Changing Engine Oil
100 hours of use.
CAUTION
1. The spark arrester is located inside of the
To avoid personal injury:
muffler body, and fastened with bolts.
Be sure to stop the engine before
2. Loosen the bolts and remove the spark
arrester.
replacing oil.
Allow engine to cool down sufficiently,
oil can be hot and can burn.
3. Shake loosened particles out of the screen
assembly and lightly clean the screen with
wire brush. Soak in solvent and again clean
with wire brush if necessary.
1. Park the vehicle on flat surface and raise
the cargo bed.
2. To drain the used oil, remove the drain
plug at the bottom of the engine and
completely drain the oil into an oil pan.
3. After draining, reinstall the drain plug.
4. If any breaks in the screen or welds are
discovered, the assembly must be replaced.
5. Return the spark arrester to the muffler body
and refasten the bolts.
10-11
Periodic Service
4. Fill with the new oil up to the upper notch on
the dipstick.
(See “LUBRICANTS, FUEL AND COOLANT” 1. Park the vehicle on a flat surface, remove
Allow engine to cool down sufficiently,
oil can be hot and can burn.
in “MAINTENANCE” section.)
the seat and open the adjust hatch cover.
2. Remove the oil filter.
[Filter exchanged]
1.8L (1.89U.S. qts.)
3. Put a film of clean engine oil on the rubber
seal of the new filter.
Oil capacity
[Filter non-exchanged] 1.6L (1.68U.S. qts.)
4. Tighten the filter quickly until it contacts the
mounting surface.
Tighten filter by hand an additional 1/2 turn
only.
5. After the new filter has been replaced, the
engine oil normally decreases a little.
Make sure that the engine oil does not leak
through the seal and check the oil level on
the dipstick. Then replenish the engine oil
up to the prescribed level.
①
②
Oil Lever
Dipstick
■ Replacing Engine Oil Filter
CAUTION
To avoid personal injury:
Be sure to stop the engine before
changing the oil filter cartridge.
①Bolt;
②Cover
③“O” seal ring;
④Engine oil filter
IMPORANT:
To prevent serious damage to the engine,
use only a genuine filter.
■ Replacing Transmission Oil
CAUTION
To avoid personal injury:
10-12
Periodic Service
Be sure to stop the engine before
changing oil.
■ Checking Brake Pedal
Allow engine to cool down sufficiently, oil
can be hot and can burn.
CAUTION
1. Park the vehicle on a flat surface, raise the
cargo bed, and mount the safety support.
2. Put a film of clean transmission oil;
3. Quickly tighten the filter until it contacts the
mounting surface, tighten it an additional 1
turn only.
Stop the engine and chock the wheels
before checking brake pedal.
If movement is outside of the specifications
contact your local dealer for adjusting the
brake.
◆Checking the brake pedal free travel
4. After running the engine for a few minutes,
stop the engine and check the oil level again.
Add oil to the prescribed level.
Proper brake
7 to 14mm
pedal
(0.3 to in.)On the pedal
free travel
Oil capacity
[Filter exchanged]
1L (1.05U.S. qts.)
1. Release the parking brake.
2. Slightly depress the brake pedal and
measure free travel at the top of the pedal
stroke.
3. If brake pedal free travel is outside of the
specifications, contact your local dealer for
adjusting the brake.
◆ Checking the brake pedal stroke
①
Oil Lever
Dipstick
Less than 120mm (4.7in.)
Pedal stroke
②
On the pedal
1. Release the parking brake.
2. Step on the pedal and measure the pedal
stroke.
3. If brake pedal stroke is outside of the
specifications, contact your local dealer for
adjusting the brake.
10-13
Periodic Service
3. securely, if radiator hoses are swollen,
hardened or cracked. Replace hoses and
hose clamps every 2 years or earlier, if
checked and found that hoses are swollen,
hardened or cracked.
①Brake pedal
②“FREE TRAVEL”
③“PEDAL STROKE”
■ Checking Brake Hose and Pipe
1. Check to see that brake hose and lines are
not swollen, hardened or cracked.
2. Check the brake hose and pipe joints for oil
leaks.
①Radiator hose
②Clamp bands
◆Precaution at Overheating
Take the following actions in the event the
coolant temperature is close to or more than
the boiling point, which is called “Overheating”.
1. Stop the vehicle operation in a safe place
and keep the engine unloaded idling.
3. If there is any abnormality, consult your local
dealer for this service.
■ Checking Brake Light Switch
1. Park the vehicle on a flat surface and raise
the cargo bed.
2. Don’t stop the engine suddenly, but stop it
after about 5 minutes of unloaded idling.
3. Keep yourself well away from the vehicle
for at least 10 minutes or while the steam
is blowing out.
2. Turn the key switch to the “ON” position.
3. Step on the brake pedal to check if the brake
light comes on.
4. If it does not, check the bulb or brake light
switch.
4. Check to see if there is no danger such as
burning, get rid of the causes of
overheating
according
to
the
■ Checking Radiator Hose and Clamp
Park the vehicle on a flat surface and raise the
cargo bed. Check to see if radiator hoses are
properly fixed every 200 hours of operation or six
months, whichever comes first.
“TROUBLESHOOTING” section of the
manual, and then start the engine again.
■ Checking Intake Air Line
1. Check to see if the hoses and hose clamps
1. If hose clamps are loose or water leaks,
tighten bands securely.
are tight and not damaged.
If hoses and clamps are found to be worn or
damaged, replace or repair them at once.
2. Replace hoses and tighten hose clamps
10-14
Periodic Service
Allow engine to cool down sufficiently,
oil can be hot and can burn.
1. Park the vehicle on a flat surface, raise the
cargo bed, mount the safety support.
2. To drain the used oil, remove the drain
plug at the bottom of the transmission case
and drain the oil completely into the oil
pan.
①Hose
②Hose joint
3. After draining, reinstall the drain plug.
4. After running the engine for a few minutes,
stop the engine and check the oil level
again; add oil to prescribed level.
EVERY 300 HOURS
■ Checking Tire
1. Check to see if tires are not damaged.
2. If the tires are cracked, bulged, or cut, or they
are worn out, replace or repair them at once.
◆Tire Tread Depth
Always replace the tires when the tread depth is
worn to minimum allowable.
①Drain plug
IMPORTANT:
Do not operate the vehicle immediately
after changing the transmission fluid.
Run the engine at medium speed for a few
minutes to prevent damage to the
transmission.
①3mm(0.12in)
■ Changing Front and Rear Axle Case Oil
1. Park the vehicle on a firm, flat and level
surface.
EVERY 400 HOURS
■ Changing Transmission Fluid
2. To drain the used oil, remove the drain the
oil completely into the oil pan.
CAUTION
To avoid personal injury:
3. Fill with the new oil up to the upper
notch on the dipstick.
Park the vehicle on a flat surface, raise the
cargo bed, mount the safety support.
10-15
Periodic Service
■ Replacing Air Cleaner Primary Element
and Secondary Element
Oil capacity for
front axle case
Oil capacity for
rear axle case
0.28L
0.20L
（
（
0.072U.S.gals.
0.052U.S.gals.
）
）
(See “Cleaning Air Cleaner Primary
Element” in “every 100 HOURS” in
“PERIODIC SERVICE” section.)
EVERY 2 YEARS
■ Changing Brake Fluid
Consult your local Dealer for this service.
(See “Checking Brake Fluid Level” in “DAILY
CHECK” in “PERIODIC SERVICE” section.
■ Flushing Cooling System and Changing
Coolant
CAUTION
To avoid personal injury:
Do not remove the radiator cap while
coolant is hot. When cool, slowly rotate
cap to the first stop and allow sufficient
time for excess pressure to escape
before removing the cap completely.
1. Stop the engine and let cool down.
2. To drain the coolant, open the radiator
drain plug and remove radiator cap. The
radiator cap must be removed to
completely drain the coolant.
① Front axle case drain plug
② Rear axle case drain plug
EVERY 500 HOURS
■ Replacing Fuel Filter
Consult your local dealer for this service.
3. After all coolant is drained, close the drain
plug.
EVERY 600 HOURS
■ Adjusting Engine Valve Clearance
4. Fill with clean water and cooling system
cleaner.
Consult your local dealer for this service.
5. Follow directions of the cleaner instruction.
6. After flushing, fill with clean water and anti-
freeze until the coolant level is just below
the radiator cap.
EVERY 1500 HOURS
■ Checking Injection and Fuel Pump
Consult your local dealer for this service.
7. Fill with fresh water up to the “FULL” mark
EVERY 1 YEAR
10-16
Periodic Service
on the recovery tank.
once and take medical attention.
8. Start and operate the engine for few minutes.
9. Stop the engine and let cool.
10. Check coolant level of recovery tank and
coolant if necessary.
When antifreeze comes in contact with the
skin or clothing, wash it off immediately.。
Do not mix different types of Antifreeze.
The mixture can produce chemical reaction
causing harmful substances.
Coolant capacity
1.8L (1.89 U.S.qts.)
Antifreeze is extremely flammable and
explosive under certain conditions. Keep
fire and children away from antifreeze.
When draining fluids from the engine,
place some container underneath the
engine body.
Do not pour waste onto the grounds, down
a drain, or into any water source.
Also, observe the relevant environmental
protection regulations when disposing of
antifreeze.
①Recovery tank
②“ FULL”
③“ LOW”
If it freezes, coolant can damage the cylinders
and radiator. If the ambient temperature falls
below 0℃(32°F) or before a long-term storage,
let out cooling water completely, or mix fresh
water with long-life coolant and fill the radiator
and recovery tank with the mixture.·
1. Long-life coolant (hereafter LLC) comes in
several types. Use ethylene glycol(EG)
type for this engine.
IMPORTANT:
Do not start engine without coolant.
Use clean, fresh water and anti-freeze to fill
the radiator and recovery tank.
When the anti-freeze is mixed with water, the
antifreeze mixing ratio must be less than
50%.
Securely tighten radiator cap. If the cap is
loose or improperly fitted, water may leak out
and the engine could overheat.
2. Before employing LLC-mixed cooling
water, fill the radiator with fresh water and
empty it again.
■ Anti-Freeze
Repeat this procedure 2 or 3 times to
clean up the inside.
CAUTION
To avoid personal injury:
3. Mixing the LLC
When using antifreeze, put on some
protection such as rubber gloves.(Antifreeze
contains poison.)
4. The procedure for the mixing of water and
antifreeze differs according to the make of
the antifreeze and the ambient temperature.
If you should drink antifreeze, throw up at
10-17
Periodic Service
Refer to SEA J1034 standard, more
specifically also to SAE J814c.
coolant every 2 years.
NOTE:
The above data represent industry
IMPORTANT:
standards that necessitate a minimum glycol
content in the concentrated antifreeze.
When the coolant level drops due to
evaporation, add water only to keep the
antifreeze mixing ratio less than 50%. In
case of leakage, add antifreeze and water in
the specified mixing ratio before filling into
the radiator.
When the antifreeze is mixed with water, the
antifreeze mixing ratio must be less than
50%.
Freezing point
Boiling point
VOL%
℃
°F
℃
°F
Anti-freeze
40
50
-24
-37
-12
-34
106
108
222
226
■ Replacing Radiator Hose (Water pipes)
Replace the hoses and clamps.
*
At 1.013×105Pa (760mmHg) pressure (atmospheric).
(See “Checking Radiator Hose and Clamp” in
“EVERY 200 HOURS” in “PERIODIC SERVICE”
section.)
A higher boiling point is obtained by using a
radiator
pressure cap which permits the development of
pressure within the cooling system.
■ Replacing Fuel Hose
Consult your local HUANSONG Dealer for this
service.
5. Adding the LLC
1) Add only water if the mixture reduces in
amount by evaporation.
■ Replacing Brake Master Cylinder (Inner
parts)
2) If there is a mixture leak, add the LLC of the
same manufacturer and type in the same
mixture percentage.
Consult your local dealer for this service.
■ Replacing Front Brake Seal
* Never add any long-life coolant of different
manufacturer.(Different brands may have
different additive components, and the
engine may fail to perform as specified.)
6. When the LLC is mixed, do not employ any
radiator cleaning agent. The LLC contains
anticorrosive agent. If mixed with the
cleaning agent, sludge may build up,
adversely affecting the engine parts.
Consult your local dealer for this service.
■ Replacing Rear Brake Cylinder Seal
Consult your local dealer for this service.
■ Replacing Intake Air Line
Consult your local dealer for this service.
EVERY 4 YEARS
■ Replacing Brake Hose
Consult your local Dealer for this service.
7. The vehicle’s genuine long-life coolant has a
service life of 2 years. Be sure to change the
■ Replacing Slow-Blow Fuses
The slow-blow fuses are intended to protect the
10-18
Periodic Service
electrical cabling. If any of them have blown out, STORAGE
be sure to pinpoint the cause.
CAUTION
To avoid personal injury:
◆Replacing procedure
1) Disconnect the negative cable of the battery.
2) Open the slow-blow fuse box cover.
3) Pull out the slow-blow fuse.
Do not clean the vehicle when the engine
is running.
To avoid the danger of exhaust fume
poisoning, do not operate the engine in a
4) Insert a new slow-blow fuse into the box.
5) Close the slow-blow fuse box cover.
6) Connect the negative battery cable.
closed
building
without
proper
ventilation.
When storing, remove the key from the
key switch to avoid unauthorized
persons from operating the vehicle and
getting injured.
VEHICLE STORAGE
If you intend to store your vehicle for an
extended period of time, follow the procedures
outlined below.
①Slow-blow fuse box cover
These procedures will insure that the vehicle is
ready to operate with minimum preparation when
it is removed from storage.
■ Replacing Light Bulb
Head lights
1. Check the bolts and nuts for looseness. and
tighten if necessary.
Take the bulb out of the light body and
replace it with a new one.
Other lights
2. Apply grease to vehicle areas where bare
metal will rust also to pivot areas.
Detach the lens and replace the bulb
3. Unload from cargo bed.
Light
Head lights
Capacity
2x55W
4. Inflate the tire to a pressure a little higher
than usual.
Tail light
LED 0.5W
LED 1W
5. Charge the engine oil and run the engine to
circulate oil throughout the engine block and
internal moving parts for about 5 minutes.
6. With all implements lowered to the ground,
coat any exposed rods with grease (if
equipped).
Brake light
Instrument panel light 1W
7. Remove the battery from the vehicle. Store
10-19
Periodic Service
the battery following the battery storage
8. procedures.
5. Start the engine. Observe all gauges. If all
gauges are functioning properly and reading
normal, move the vehicle outside. Once
outside, park the vehicle and let the engine
idle for at least five minutes. Shut the engine
off and work around vehicle and make a
visual inspection looking for evidence of oil
or water leaks.
9. Keep the vehicle in a dry place where the
vehicle is sheltered from the elements.
Cover the vehicle.
10. Keep the vehicle indoors in a dry area that is
protected from sunlight and excessive heat.
If the vehicle must be stored outdoors. cover
it with a waterproof tarpaulin.
6. With the engine fully warm up. Release the
parking brake and test the brakes for proper
adjustment as you move forward. Adjust the
brake as necessary
Put boards under the tires to keep
dampness away from tire.
Keep the tries out of direct sunlight and
extreme heat.
IMPORTANT:
When washing the vehicle, be sure to stop
the engine.
Allow sufficient time for the engine to cool
before washing.
Do not wash with a high-pressure car-
washing machine.
Cover the vehicle after the muffler and the
engine have cooled down.
REMOVING THE VEHICLE FROM
STORAGE
1. Check the tire air pressure and inflate the
tires if they are low.
2. Install battery before installing the battery,
Be sure it is fully charged.
3. Check to see if the fan works.
4. Check all fluid levels (engine oil,
transmission
oil,
engine
coolant,
transmission coolant and any attached
implements).
10-20
Troubleshooting
ENGINE TROUBLESHOOTING
If something is wrong with the engine, refer to the table below for the cause and its corrective
countermeasure.
Trouble
Cause
Countermeasure
Check the fuel tank and fuel
filter。
Check the electric fuel pump.
Check the injector.
Check the ECU with Motor Scan
KF90121.
No fuel flow
Replace filter electric fuel pump
injector and ECU If necessary.
Check to see if the fuel tank cover
is tight.
·Water is in the fuel system
Engine is difficult to start or
will not start.
In winter, oil viscosity increases
,
Use oils of different viscosities,
depending on ambient temperatures.
Clean battery cables and terminals.
Charge the battery.
and Engine revolution is slow.
Battery becomes weak and
the engine does not turn over
quick enough.
In cold weather (-15℃), always
remove the battery from the vehicle,
charge and store it indoors. install
it on the vehicle only when the
vehicle is going to be used。
Check the fuel system.
Clean or replace the injector.
Replace crankshaft position sensor.
Insufficient fuel.
The injector is clogged.
Crankshaft position sensor is
bad..
Engine
power
is
insufficient
The air cleaner is clogged.
Spark plug is dirty or fouled.
Ignition coil is bad.
Clean or replace the air cleaner.
Clean or replace the spark plug.
Replace the ignition coil.
Check with the diagnostic
Engine stops suddenly
instrument
KF90121 ).
(Motor
Scan
Engine overloaded
Shift to lower gear or reduce load.
Fill cooling system to the correct
level;
Check radiator and hoses for
loose connections or leaks.
Check to see if the fuse is not blown.
Check the electric system.
Low coolant level.
Engine overheats
The motor driven fan does
not turn.
Dirty radiator core or grille
screens.
Remove all trash.
Coolant flow route corroded.
Flush cooling system.
If you have any questions, consult your local dealer.
11-1
Troubleshooting
Diagnostic Trouble Code Table
MT05 ECU Malf Code
Table:23
Malf code in MT05
P0107
Description
MAP Circuit Low Voltage or Open
MAP Circuit High Voltage
P0108
P0112
IAT Circuit Low Voltage
P0113
IAT Circuit High Voltage or Open
Coolant/Oil Temperature Sensor Circuit Low Voltage
Coolant/Oil Temperature Sensor Circuit High Voltage or Open
TPS Circuit Low Voltage or Open
TPS Circuit High Voltage
P0117
P0118
P0122
P0123
P0131
O2A Circuit Low Voltage
P0132
O2A Circuit High Voltage
P0031
O2A Heater Circuit High Voltage
O2A Heater Circuit Low Voltage
Injector 1 Circuit Malfunction
Injector 2 Circuit Malfunction
FPR Coil Circuit Low Voltage or Open
FPR Coil Circuit High Voltage
CKP Sensor Noisy Signal
P0032
P0201
P0202
P0230
P0232
P0336
P0337
CKP Sensor No Signal
P0351
Cylinder 1 Ignition Coil Malfunction
Cylinder 2 Ignition Coil Malfunction
Idle Speed Control Error
P0352
P0505
P0562
System Voltage Low
P0563
System Voltage High
P0650
MIL Circuit Malfunction
P1693
Tachometer Circuit Low Voltage
Tachometer Circuit High Voltage
P1694
If you have any questions, consult your local dealer.
11-2
Troubleshooting
BATTERY TROUBLESHOOTING
Trouble
Cause
Countermeasure
Preventive measure
Battery overused
until lights are dim.
Battery has not
been recharged.
Charge the battery
Charge the battery
properly.
sufficiently.
Keep the terminal
clean and tight.
Starter does not function
Clean the terminal
Poor
terminal
and
tighten
connection
Apply grease and
securely.
treat with anti-corrosive.
Replace
battery
new
Battery life expired
At initial start the starter
does not function, and
lights soon become dim
Battery must be
serviced properly
Insufficient
charging
Charge
battery
Insufficiently
before initial use
Battery was used
with an insufficient
Add distilled water
and charge the
battery.
Regularly check the
electrolyte level.
When viewed from the
amount
of
top,
the
battery
electrolyte.
terminals look white.
* Refillable type battery
only
Battery was used
with too much
Charge
battery
Charge
battery
Insufficiently
properly
without recharging.
Battery life expired.
Recharging is impossible
.
Replace battery.
Keep the terminal
clean and tight.
Clean the terminal
Terminals are severely
corroded and heat up.
Poor
terminal
and
tighten
Apply grease and
connection
securely.
treat
with
anti-
corrosives.
There is a crack or
pin holes in the
electrolytic cells.
Battery electrolyte level
drops rapidly.
Replace battery.
* Refillable type battery
only
Charging
trouble.
system
Consult your local
dealer.
If you have any questions, consult your local dealer.
The factory installed battery is non-refillable type.
11-3
Troubleshooting
MACHINE TROUBLESHOOTING
Trouble
Cause
Countermeasure
Replace throttle cable
Replace throttle petal
Replace the throttle
High idling speed of engine
High rotary speed for clutch
connection.
Replace he junior clutch spring;
Replace the primary clutch.
Put the gearshift rod into the
position of “N”.
Trouble shifting gears
Gearshift cable is out of
adjustment.
Put the gearshift arm of engine
into ”N”.
Adjust the shift cable and the bolt.
Lock tightly.
Gear abrasion
Replace the gears
Poor clearance for the inner
and
outside
gears
of
Replace the gears
Replace the gears
transmission shaft
Transmission noise
Reduced vehicle power
Brake noise
Poor clearance of transmission
gears.
Poor connection of gear end
face
Replace the gears
Parking brake engaged
Hydraulic disc braking system
is activated
Loosen the parking brake
Contact servicing dealer.
Removing the grease for the
clutch.
CVT transmission sliding
Replace CVT transmission belt
Servicing dealer to replace the
clutch.
Insufficient brake oil
Air inside the braking system.
Brake discs abrasion
Assembling bolt of disc plate
loose
Check the braking oil level
Contact servicing dealer.
Contact servicing dealer.
Lock tightly
Lock tightly
Assembling bolt for disc brake
clippers loose
If you have any questions, consult your local servicing dealer.
11-4
TM
HISUN MOTORS
310 East University Dr
McKinney, Texas 75069
PH (972) 446-0760
TF (877) 838-6188
hisunmotors.com
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