HS500

OWNER’S
MANUAL
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.

READ THIS MANUAL CAREFULLY

For questions regarding this UTV,

please contact HISUN at:
(877) 838-6188
www.hisunmotors.com

REV. 01231401

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 Owner’s Manual

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 Owner Manual

INTRODUCTION
Congratulations on your purchase of the HS500UTV-4/HS500UTV-3. 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.
If you have any questions regarding the operation or maintenance of your UTV, please consult
the dealer.

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, AND ANY OTHER UTV OVER 90cc, SHOULD NOT BE RIDDEN BY ANYONE UNDER 16 YEARS
OF AGE.

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 Owner’s Manual

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 or clearer.

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 Owner Manual

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 6-3 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.

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 Owner’s Manual
Fuel level indicator 4-9
Location of the Warning and Switches 4-9
1
Specification Labels 1-1 On-Command Four-Wheel-Drive and
Differential Gear Lock Switches 4-10
2 Safety Information 2-1
Accelerator Pedal 4-14
Description and Vehicle Brake Pedal 4-15
3 Parking Brake Lever 4-15
Identification 3-1
Identification Number Records 3-3 Drive Select Lever 4-16
Vehicle Identification Number 3-3 Fuel Tank Cap 4-17
Seats 4-17
4 Control Functions 4-1 Seat Belts 4-18
Main Switch 4-1 Glove Compartment 4-21
Indicator and Warning Lights 4-2 Cargo Bed 4-21
Use of EPS system 4-4 Opening and Closing the Tailgate 4-22
Speedometer Unit 4-6 Lifting and Lowering the Cargo Bed 4-22
Odometer and Trip Meter Modes 4-6 Front and Rear Shock Adjustment 4-24
Clock time adjustment 4-7 Spring preload 4-27
Four-wheel drive indicator 4-7 Rebound damping force 4-28
Differential gear lock indicator 4-7 Compression damping force 4-29
Fault code indicator 4-8 Trailer Hitch Bracket 4-30

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 Owner Manual
Auxiliary DC Jack 4-31 Fittings and Fasteners 5-10
Lights 5-10
Switches 5-11
5 Pre Operation Checks 5-1 Tires 5-11
Brakes 5-2 How to Measure Tire Pressure 5-12
Brake Fluid Level 5-2 Tire Wear Limit 5-13
Brake Fluid Leakage 5-3
Brake Operation 5-3 6 Operation 6-1
Fuel 5-4 Starting the Engine in Low
Gasohol 5-4 Temperatures 6-1
Engine Oil 5-5 Starting the Engine 6-2
Coolant 5-6 Warming Up 6-3
Final Gear Oil 5-7 Drive Select Lever Operation and
Differential Gear Oil 5-7 Driving In Reverse 6-4
Throttle Pedal 5-8 Parking 6-8
Throttle Freeplay 5-9 Parking on a Slope 6-8
Throttle Freeplay Inspection 5-9 Vehicle Break-in Period 6-9
Throttle Freeplay Adjustment 5-9 Engine Break-In 6-10
Steering Wheel Inspection 5-10
Accessories 6-11
Seat Belts 5-10
Loading 6-12

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 Owner’s Manual
Hood 8-7
7 Driving Your Vehicle 7-1 Console 8-8
Getting to Know Your Vehicle 7-1 EFI System 8-9
Learning to Operate Your Vehicle 7-5 ECU 8-12
Turning your Vehicle 7-6 EFI System inspection 8-12
Operating Improperly in Reverse 7-7 Engine oil and oil filter cartridge 8-12
Braking 7-8 To Check the Engine Oil Level 8-13
Going Uphill 7-8 To Change the Engine Oil 8-14
Going Downhill 7-10 Final Gear Oil 8-17
Crossing Through Shallow Water 7-12 Changing the Final Gear Oil 8-18
Vehicle Immersion 7-13 Differential Gear Oil 8-19
Riding Over Rough Terrain 7-15 Changing The Differential Gear Oil 8-20
Riding in Brush or Wooded Areas 7-17 Coolant 8-21
Encountering Obstacles on the Trail 7-17 Checking the coolant level 8-21
Axle Boots 8-23
Periodic Maintenance and Spark Plug Inspection 8-23
8
Adjustment 8-1 Inspection 8-24
Periodic Maintenance Chart for the Installation 8-25
Emission Control System 8-3 Cleaning the Engine Air Filter
General Maintenance and Lubrication Elements 8-26
Chart 8-4

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 Owner Manual
V-belt Cooling Duct Check Hose 8-30 Battery 8-43
V-belt Case Drain Plug 8-30 Battery Maintenance 8-45
Cleaning the Spark Arrester 8-31 Fuse Replacement 8-45
Valve Clearance 8-33 Replacing A Headlight Bulb 8-47
Front Brake Pad Check 8-33 Headlight Beam Adjustment 8-50
Rear Brake Pad Check 8-34 Tail/brake Light Bulb Replacement 8-51
Checking the Brake Fluid Level 8-34 Troubleshooting 8-53
Brake Fluid Replacement 8-35 Solution to Common Problems in the
Checking the Brake Pedal 8-35 Vehicle 8-54
Parking Brake Lever Free Play
Adjustment 8-37 9 Electric power steering system 9-1
Brake Light Switch Adjustment 8-38 Electric power steering system
Cable Inspection and Lubrication 8-39 Introduction 9-1
Brake Pedal and Accelerator Pedal Advantages of EPS system: 9-1
Lubrication 8-40 Important information for safety 9-2
Introduction of EPS system 9-3
Rear Knuckle Upper and Lower Pivot
What is EPS system 9-3
Lubrication 8-40
Typical parts of EPS system 9-4
Steering Shaft Lubrication 8-41 Construction of EPS 9-4
Wheel Removal 8-41 Operation and use of EPS system 9-10
Wheel Installation 8-42 EPS system operation 9-10

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 Owner’s Manual
EPS system’s inspection, Fault code of Electronic Injection 12-1
maintenance, repair 9-15 12
System
To drive UTV at every time, need
to do daily inspection of EPS system
Malfunction assortment 9-15 USA EPA Emissions Limited 13-1
13
Solutions for common fault 9-19 Warranty
Maintenance and repair’s
supplemental description 9-26
EPS system periodic maintenance 9-28
EPS system parameter table 9-29
EPS system basic technical
parameters 9-29
EPS system working conditions 9-29
Motor assy basic parameters 9-29

10 Cleaning and Storage 10-1

Cleaning 10-1
Storage 10-3

11 Specifications 11-1

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 1-1 Location of the Warning and Safety Labels
`

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 Location of the Warning and Safety Labels 1-2
Read and understand all of the labels on your vehicle. They contain important information for safe
and proper operation of your vehicle.
Never remove any labels from your vehicle. If a label becomes difficult to read or comes off, a
replacement label is available by contacting your dealer.

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 1-3 Location of the Warning and Safety Labels

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 Location of the Warning and Safety Labels 1-4

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 1-5 Location of the Warning and Safety Labels

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 Location of the Warning and Safety Labels 1-6
9

10

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 1-7 Location of the Warning and Safety Labels
11 12

13

14

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 Safety Information 2-1

SAFETY INFORMATION

This off-highway utility vehicle handles differently from other vehicles including cars and UTVs.
SEVERE INJURY OR DEATH can result if you do not follow these instructions:
● Read this manual and all labels carefully and follow the operating procedures described.
● This vehicle is designed to carry the driver and one passenger. NEVER CARRY PASSENGERS IN
THE CARGO BED.
● Always be sure the driver and passenger are wearing seat belts.
● Never give a ride to a passenger who is too small to reach and hold the handgrip fixed before the
seat.
● Always avoid operating the vehicle on any paved surfaces, including sidewalks, driveways, parking
lots, and streets.
● Never operate this vehicle on any public street, road, or highway, even dirt or gravel streets.
● Never operate this vehicle without wearing an approved motorcycle helmet that fits properly. You
should also wear eye protection (goggles or a face shield), gloves, over-the-ankle boots, long-sleeved
shirt or jacket, and long pants.
● Never consume alcohol or drugs before or while operating this vehicle.
● Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is proper
for the terrain, visibility, operating conditions, and your experience.

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 2-2 Safety Information

● Never attempt jumps or other stunts.

● Always inspect your vehicle each time you use it to be sure it is in safe operating condition, Always
follow the inspection and maintenance procedures and schedules described in this manual.
● Always keep hands, arms, feet, and legs inside the vehicle at all times during operation. Keep your
feet on the floorboard. Never hold onto the enclosure. Your hand could be injured if it is caught
between the enclosure and an obstacle outside the vehicle.
● Always keep both hands on the steering wheel when driving.
● Never wrap your thumbs and fingers around the steering wheel. This is particularly important when
driving in rough terrain. The front wheels will move right and left as they respond to the terrain, and
this movement will be felt in the steering wheel. A sudden jolt could wrench the steering wheel around,
and your thumbs or fingers could be injured if they are in the way of the steering wheel spokes.
● Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to
changing terrain conditions when driving the vehicle.
● Never operate on excessively rough, slippery, or loose terrain until you have learned and practiced
the skills necessary to control the vehicle on such terrain. Always be especially cautious on these
kinds of terrain.
● Never turn at excessive speed. Practice turning at slow speeds before attempting to turn at faster
speeds. Do not attempt turns on steep inclines.
● Never operate the vehicle on hills that are too steep for it or for your abilities. Go straight up and down
hills where possible. Maximum slope angle: 15°.

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 Safety Information 2-3

● Never operate on hills that are slippery or ones where you will not be able to see far enough ahead of
you. Never go over the top of a hill at speed if you cannot see what is on other side.
● Always follow proper procedures for going uphill. If you lose control and cannot continue up a hill,
back down the hill with the engine in reverse gear. Use engine braking to help you go slowly. If
necessary, use the brakes gradually to help you go slowly.
● Always check terrain before going down hills. Go as slowly as possible. Never go down a hill at high
speed.
● Always check for obstacles before operating in a new area.
● Never operate the vehicle in fast flowing water or water deeper than the floorboards on this model.
Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If
necessary, apply the brake several times to let friction dry out the linings.
● Always be sure there are no obstacles or people behind you when you operate in reverse. When it is
safe to proceed in reverse, go slowly.
● Do not brake abruptly when carrying loads in the cargo bed.
● Always use the size and type of tires specified in this manual.
● Always make sure the tires have the proper tire pressure as described in this manual.
● Never exceed the stated load capacity. Cargo should be as far forward in the bed as possible, and
distributed evenly from side to side. Be sure cargo is secured so that it cannot move around during
operation. Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer.
Allow greater distance for braking.

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 2-4 Safety Information

WARNING
POTENTIAL HAZARD
Improper handling of gasoline.
WHAT CAN HAPPEN
Gasoline can catch fire and you could be burned.
HOW TO AVOID THE HAZARD
Always turn off the engine when refueling. Do not refuel right after the engine has been running
and is still very hot. Do not spill gasoline on the engine or exhaust pipe（or muffler）when
refueling. Never refuel while smoking, or while in the vicinity of sparks, open flames, or other
sources of ignition such as the pilot light of water heaters and clothes dryers. When transporting
the vehicle in another vehicle, be sure it is kept in an upright position. Otherwise, fuel may leak
out of the engine or fuel tank.
WHAT CAN HAPPEN
Gasoline is poisonous and can cause injuries.
HOW TO AVOID THE HAZARD
If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in
your eyes, see your doctor immediately. If gasoline spills on your skin, wash with soap and
water. If gasoline spills on your clothing, change your clothes.

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 Safety Information 2-5

WARNING
POTENTIAL HAZARD
Starting or running the engine in a closed area.
WHAT CAN HAPPEN
Exhaust fumes are poisonous and may cause loss of consciousness and death within a short
time.
HOW TO AVOID THE HAZARD
Always operate your vehicle in an area with adequate ventilation.

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 3-1 Description and Vehicle Identification

1. Headlights 13. Spark arrester

2. Front shock absorber assembly adjusting ring 14. Passenger seat belt
3. Brake fluid reservoir 15. Passenger seat
4. Air filter element(engine and air intake duct) 16. Oil filter cartridge
5. V-belt case 17. Engine oil dipstick
6. Driver seat 18. Battery
7. Driver seat belt 19. Fuses
8. Spark plug 20. Coolant reservoir
9. Cargo bed 21. Radiator cap
10. Tail/brake lights 22. Fuel tank cap
11. Rear shock absorber assembly adjusting ring
12. Cargo bed release levers

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 Description and Vehicle Identification 3-2

23. Light switch

24. Steering wheel
25. Starter
26. Main switch
27. On-Command four-wheel-drive and differential lock
switches
28. Multi-function meter unit
29. Auxiliary DC jack
30. Drive select lever
31. Parking brake lever
32. Accelerator pedal
33. Brake pedal

NOTE:
The vehicle you have purchased may differ slightly from
those in the figures of this manual.

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 3-3 Description and Vehicle Identification
Identification Number Records
Record the Vehicle Identification Number and Vehicle Identification Number
model label information in spaces provided for The Vehicle Identification Number (VIN) is
assistance when ordering spare parts from a stamped into the frame.
service center or for reference in case the
vehicle is stolen.

1. VEHICLE IDENTIFICATION NUMBER:

2. MODEL LABEL INFORMATION

1. Vehicle identification number

NOTE:
The vehicle identification number (VIN) is used
to identify your vehicle.

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 Control Functions 4-1
Functions of the respective switch positions
CONTROL FUNCTIONS are as follows:
ON:
Main switch All electrical circuits are supplied with power,
and the headlights and taillights illuminate
when the light switch is on.
OFF:
All electrical circuits are switched off. The key
can be removed in this position.
START:
The electric starter is engaged by turning and
holding the key in this position. Release the
1. Main switch key when the engine starts.

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 4-2 Control Functions
Indicator and Warning Lights
CAUTION:
● Do not operate the electric starter
continuously for more than 5 seconds at
a time or starter damage could occur.
Wait at least 5 seconds between each
start attempt.
● Do not turn the key to the “START”
position with the engine running, or
damage to the electric starter can result. 1. Four-wheel locked showing light
2. Fault indicator light of EPS system
● See starting instructions prior to starting 3. differential gear lock indicator
4. Coolant temperature warning light
the engine. (See pages 6-1 - 6-3 for 5. Emergency indicator
details.) 6. Reverse indicator light “R”
7. Neutral indicator light “N”
8. High-range indicator light “H”
9. Low-range indicator light “L”
10. Mechanical parking brake indicator light “ ”
11. Engine indicator light “P”
12. Position indicator
13. Far light indicator

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 Control Functions 4-3
Low-Range Indicator Light “L” This indicator light comes on when the drive
This indicator light comes on when the drive select lever is in the “R” reverse position.
select lever is in the “L” position.
Coolant Temperature Warning Light “ ”
When the coolant temperature reaches a
Mechanical Parking Brake Indicator Light
specified level, this light comes on to warn
“ ”
that the coolant temperature is too hot. If
This indicator light comes on when the
the light comes on during operation, stop the
mechanical parking brake is applied.
engine as soon as it is safe to do so and
allow the engine to cool down for about 15
High-Range Indicator Light “H”
minutes.
This indicator light comes on when the drive
select lever is in the “H” position.
CAUTION:
Neutral Indicator Light “N” z The engine may overheat if the vehicle is
This indicator light comes on when the drive overloaded. If this happens, reduce the
select lever is in the “N” position. load to specification.
Reverse Indicator Light “R” z After restarting, make sure that the light

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 4-4 Control Functions
is out. Continuous use while the light is monitors working condition of EPS system.
on may cause damage to the engine.
Fault can be displayed by fault indicator light
High beam indicator and fault indicator of EPS system, so the
The light being on means headlight is at high
driver can acknowledge fault of EPS in time
beam mode.
and take some measures to keep
Position light indicator himself/herself safe.
The light being on means that the position
When fault occurs on EPS system, fault
light fixed in the front headlight has been
turned on. indicator light will be lit up. At the same time,
fault indicator of EPS system will display the
Emergency indicator“ ” fault code for maintenance.
The light being on means emergency lamp is
z Open main switch of UTV, and EPS
on.
system will automatically enter into
Use of EPS system working state.
Meter is an important part of UTV.
Meter works together with EPS system and

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 Control Functions 4-5
z Check the meter. If fault indicator light of Speedometer Unit
EPS system does not be lit, ECU can be
for regular use.
z If fault indicator light of EPS system is lit,
that means EPS system find out some
fault during ECU self-checking process,
then you should consult your local
dealer for maintenance in time.

1. Speed indicator
2. Clock/Hour/ fault code meter
3. RPM indicator
4. Metric/mile button
5. “TRIP/ODO” button
6. Right turn indicator light
7. Left turn indicator light
8. Clock/Hour/ fault code reset button

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 4-6 Control Functions
Speedometer unit functions: from the odometer, to the tripometer, and
z a speedometer (which shows the speed) then to the hours meter; then it starts the
z an odometer (which shows the total cycle over.
distance covered) The odometer displays the total distance
z a tripometer (which can be cleared and traveled by the UTV. The tripometer
then show any new distances traveled) records distances for a specific trip and can
z an RPM indicator (which shows the record distances from 0 through 999.9 miles.
revolutions per minute of the engine) To reset a trip meter, select it by pressing the
z a clock left button, Press left button to switch to small
z an EFI fault code indicator (which shows mileage (Trip), press the right button for a
the fault code for problems with the EFI ) long time to reset. The tripometer can be
used to estimate the distance that can be
Odometer and trip meter modes traveled with a full tank of fuel. This
On the display panel there are two large information will enable you to judge the fuel
buttons, one located on the left side and one consumption.
on the right side. Quickly pressing the To change the display from miles per hour to
button on the left side toggles the display kilometers per hour press the right side

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 Control Functions 4-7
button on the display. This will also change circle on the front axle when the grey and
the displayed mileage from miles to yellow 4WD selector buttons are pressed in
kilometers. indicating the “4WD” function has been
Clock time adjustment
activated. This position also indicates that
Press the left button and hold for three
the 4WD is NOT locked. This allows the
seconds and the clock goes into the hour
wheels on the left and right sides to rotate at
‘set’ mode.
different speeds to accommodate turning.
1. Press the right button to set the hour.
2. Press the left button again and the clock Differential gear lock indicator
goes into the minute ‘set’ mode. The right 4WD symbol will show an ‘X’ over
3. Press the right button to set the minutes. the center of the front axle when the lever is
4. Press the left button again and the clock moved to the right and the yellow differential
will exit the ‘set’ mode. gear lock button is set to out position, which
means the differential is not operational and
Four-wheel drive indicator “ ” is locked. When riding an UTV on muddy and
There are two 4WD indicators on the display slippery roads or when climbing a steep hill,
panel. The left 4WD indicator has a blinking make sure the 4WD lock indicator is on.

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 4-8 Control Functions
When riding on a flat road at a comparatively
CAUTION:
high speed, adjust the settings to
If the display indicators flash or the
“2WD/UNLOCK” and there are no symbols
speedometer does not show the speed while
in either of the 4WD indicators.
the UTV is in motion, Ask a dealer to check
Riding an UTV while the differential is
the speed sensor and circuits.
functioning and is NOT locked, may improve
the stability and safety of the UTV operation.
Fault code indicator
CAUTION: When the EFI encounters faults, the ECU will
When the selector is set to 4WD, the right send the fault code to the instrument display,
4WD symbol front axle will have an ‘X’ in the and it will flash on the clock.
middle . When riding on good surfaces you If there are more than one fault code, they
should unlock the differential and press in will be shown in rolling sequence. When
the yellow and the gray buttons to the 2WD fault codes are present, in order to see the
unlocked position. There should be no time press the clock button, the time will be
symbols showing in either the left or right shown. Then after five seconds, the fault
4WD indicators. code returns again. Only after the fault is

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 Control Functions 4-9
fixed, will the time show automatically. Switches
The description for the fault codes are shown
in Chapter 11 of this manual.

Fuel level indicator

The fuel level display will indicate the fuel
volume. When the fuel is getting low the fuel
pump symbol will flash.

1. Light switch “OFF/ / ”

Light switch “OFF/ / ”

Set the switch to “ ”to turn on the low
beam and the taillights.
Set the switch to “ ”to turn on the high
beam and the taillights.
Set the switch to “OFF” to turn off all the
1. Fuel level indicator 2. Fuel level warning indicator lights.

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 4-10 Control Functions
CAUTION: On-Command Four-Wheel–Drive and
Differential Gear Lock Switches
Do not use the headlights with the engine
turned off for an extended period of time. The
battery may discharge to the point that the
starter motor will not operate properly. If this
happens, remove the battery and recharge it.

1. On-Command four-wheel –drive switch “2WD”/ “4 WD”

2. Differential gear lock switch “LOCK”/ “4WD”

This vehicle is equipped with an

On-Command four–wheel-drive switch
“2WD”/ “4WD”and a differential gear lock
switch “4WD”/ “LOCK”. Select the
appropriate drive according to terrain and the

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 Control Functions 4-11
conditions.
z Two-wheel drive (”2WD”): Power is sup- WARNING
plied to the rear wheels only. POTENTIAL HAZARD
z Four-wheel drive (“4WD’): Power is Changing from 2WD to 4WD or from 2WD
to 2WD-Differential UNLOCK, or
supplied to the rear and front wheels.
vice-versa while the vehicle is moving.
z Four–wheel drive with the differential WHAT CAN HAPPEN
gear locked (“4WD-LOCK”): Power is The vehicle handles differently in 4WD
supplied to the rear and front wheels than in 2WD and in 2WD- Differential
UNLOCK in some circumstances.
when the differential gear is
Changing from 2WD to 4WD or from 2WD
locked.Unlike the 4WD mode, all wheels to 2WD–Differential UNLOCK, or
turn at the same speed regardless of vice-versa while moving may cause the
traction. vehicle to unexpectedly handle
differently. This could distract the
operator and increase the risk of losing
control and an accident.
HOW TO AVOID THE HAZARD
Always stop the vehicle before changing
from 2WD to 4WD or from 2WD to
2WD–Differential UNLOCK.

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 4-12 Control Functions
On-Command four-wheel-drive switch the select lever is set to positionⓐ, and
“2WD/4WD” then set the switch to “2WD”.

On-Command Differential Gear Lock

Switch “4WD”/”LOCK”

1. Select lever
2. On-Command four –wheel-drive switch “2WD/4WD”

To change from 2WD to 4WD ,stop the

vehicle, and then set the switch to 1. On-Command differential gear lock switch “4WD”/ “LOCK”
“4WD”.When the vehicle is in 4WD, the 2. Select lever
4WD indicator will come on in the To lock the differential gear in 4WD, stop the
multi-function meter unit display .To change vehicle, make sure the On-Command
from 4WD to 2WD .stop the vehicle ,be sure four-wheel-drive switch is set to “4WD”,
move the select lever to positionⓑ, and then

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 Control Functions 4-13
set the switch to “LOCK”. When the
differential gear is locked, the differential HOW TO AVOID THE HAZARD
gear lock indicator light will come on along Always ride at a slow speed when the
with the differential gear lock indicatorin the vehicle is in 4WD-LOCK, and allow extra
multifunction meter unit display .To release time and distance for maneuvers.
the differential gear lock , stop the vehicle
and set the switch to “4WD”.
NOTE:
WARNING z When the switch is set to “LOCK”, the
POTENTIAL HAZARD differential gear lock indicator and
Riding too fast while the vehicle is in indicator light will flash until the
4WD-LOCK.
WHAT CAN HAPPEN differential gear is locked.
All wheels turn at the same speed when z When the indicator and indicator light are
the differential is locked, so it takes more flashing, turning the steering wheel back
effort to turn the vehicle. The amount of
and forth will help the differential gear
effort required is greater the faster you
go. You may lose control and have an lock to engage.
accident if you cannot make a sharp z Riding before the differential gear lock is
enough turn for the speed you are properly engaged (e.g., when the
traveling.
indicator and indicator light are flashing)

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 4-14 Control Functions
will cause the engine speed to be limited
until engagement is complete.

Accelerator pedal
Press the accelerator pedal down to increase
engine speed. Spring pressure returns the
pedal to the rest position when released.
Always check that the accelerator pedal
returns normally before staring the engine.
1. Accelerator pedal

Before starting the engine, check the

accelerator pedal to be sure it is operating
smoothly. Make sure the accelerator pedal
fully returns to the idle position as soon as it
is released.

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 Control Functions 4-15
Brake pedal
Press the brake pedal to slow or stop the
vehicle.
WARNING
POTENTIAL HAZARD
Malfunction of the accelerator pedal.
WHAT CAN HAPPEN
A faulty pedal that makes it difficult to
speed up or slow down could cause loss
of control.
1. Brake pedal
HOW TO AVOID THE HAZARD
Check the operation of the accelerator
pedal before you start the engine .If it Parking brake lever
does not work smoothly, check for the The parking brake lever is located at the right
cause. Correct the problem before side of the driver’s seat. It will help keep the
operating the vehicle. Consult a service vehicle from moving while parked.
center if you cannot find or solve the To set the parking brake, pull the lever up
problem yourself. completely.
To release the parking brake, pull up on the

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 4-16 Control Functions
lever, press the release button, and then Drive select lever
push the lever all the way down. Spring The drive select lever is used to shift you
pressure helps return the lever to the vehicle into the low, high, neutral and reverse
released position. Be sure to fully release the positions. (Refer to pages 6-4—6-6 for the
parking brake before starting out, Failure to drive select lever operation.)
do so may result in poor performance and
premature wearing of the rear brake and
V-belt.

1. Drive select lever

1. Parking brake lever 2. Release button

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 Control Functions 4-17
Fuel tank cap Seats
Remove the fuel tank cap by turning it To remove a seat, pull its seat lock lever
counterclockwise. upward, lift the front of the seat, and then
slide the seat forward and up.

1. Fuel tank cap

1. Driver seat 2. Passenger seat
3. Seat lock lever (×2)

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 4-18 Control Functions
To install a seat, insert the projection on the
rear of the seat into the seat holders and
push down on the seat at the front.
WARNING
POTENTIAL HAZARD
A loose seat.
WHAT CAN HAPPEN
The operator could lose control or the
operator or passenger could fall if the
seat is loose during operation.
HOW TO AVOID THE HAZARD Seat belts
Make sure the seat is securely latched.
This vehicle is equipped with three-point seat
belts for both the operator and passenger.
Always wear the seat belt while riding in the
vehicle.

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 Control Functions 4-19
2. Push the latch plate into the buckle until it
clicks. Pull up on the latch plate to make
sure it is secure.

1. Seat belt (×2) 2. Latch plate (×2)

3. Buckle (×2)

To wear the seat belt properly, do the 1. Buckle 2. Latch plate

following: 3. Put the lap portion of the belt low on your
1. Hold the latch plate as you pull the belt hips. Push down on the buckle end of the
across your lap and chest. Make sure the belt as you pull up on the shoulder part
belt is not twisted and is not caught on so the belt is snug across your hips.
any portion of the vehicle, your clothing, 4. Position the shoulder belt over your
or any equipment you are carrying. shoulder and across your chest. The

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 4-20 Control Functions
shoulder belt should fit against your
chest. If it is loose, pull the belt out all the WARNING
way and then let it retract. POTENTIAL HAZARD
5. To release the buckle, firmly press the
Not wearing the seat belt or wearing the
release button.
seat belt improperly.
WHAT CAN HAPPEN
There is increased risk of being killed or
seriously injured in an accident.
HOW TO AVOID THE HAZARD
Always wear your seat belt when riding in
the vehicle.
Be sure the seat belt is close fitting
across your hips and chest and is latched
1. Buckle 2. Release button
securely.

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 Control Functions 4-21
Glove compartment Cargo bed
CAUTION:
To protect from damage, do not put metal
products, like tools or sharply edged
products directly in the glove compartment. If
they must be stored, wrap them in
appropriate cushion material.

1. Cargo bed 2. Tailgate

3. Cargo hook(×4)

a. Unlock b. Open.

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 4-22 Control Functions
Opening and closing the tailgate Lifting and lowering the cargo bed

1. Tailgate 2. Latch (×2) 1. Cargo bed release lever

To open To lift
Push down cargo bed release lever on left or
Unhook the latches, and then lower the
right side of the vehicle; slowly lift up cargo
tailgate. bed until it stops.
To close To lower
Place the tailgate in the original position, and Lower cargo bed slowly to its original position
and be sure it locks into place.
then hook the latches.
Maximum load limit: 350lb (159kg)

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 Control Functions 4-23

WARNING
WARNING
POTENTIAL HAZARD
POTENTIAL HAZARD
Overloading the cargo bed
Pinch points.
WHAT CAN HAPPEN
WHAT CAN HAPPEN
Could cause changes in vehicle handling
You or someone else could be pinched
which could lead to an accident.
between the cargo bed and the frame
HOW TO AVOID THE HAZARD
when the bed is being lowered.
Never exceed the stated maximum load
HOW TO AVOID THE HAZARD
limit for this cargo bed.
Before closing the bed, be sure others
Cargo should be properly distributed and
are standing away from the vehicle. Keep
securely attached.
hands and fingers away from the pinch
Reduce speed when carrying cargo.
points between the bed and the frame.
Allow greater distance for braking.

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 4-24 Control Functions
Front and Rear Shock Adjustment(Option 1)
WARNING The spring preload can be adjusted to suit
POTENTIAL HAZARD the operating conditions.
Carrying a passenger in the cargo bed You can reduce preload for a softer ride, or
WHAT CAN HAPPEN increase preload if frequent bottoming out of
The passenger could fall, be thrown out, the UTV occurs.
or be struck by objects in the cargo bed. CAUTION:
HOW TO AVOID THE HAZARD
Frequent or severe bottoming out of the UTV
Never carry a passenger in the cargo bed.
can cause increased wear or damage to the
This cargo bed is designed to carry cargo
vehicle.
only.

Adjust the spring preload as follows.

To increase the spring preload, turn the
adjusting ring in direction .
To decrease the spring preload, turn the
adjusting ring in direction .

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 Control Functions 4-25

Standard position: B
A-Minimum(soft)
E-Maximum(hard)

1. Spring preload adjusting ring

2. Position indicator
NOTE:
A special wrench can be obtained at a
service center to make this adjustment.
1. Special wrench

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 4-26 Control Functions
Front and Rear Shock Adjustment(Option 2)
WARNING WARNING
POTENTIAL HAZARD These shock absorber assemblies
Improper shock absorber adjustment. contain highly pressurized nitrogen gas,
WHAT CAN HAPPEN read and understand the following
Uneven adjustment can cause poor information before handling the shock
handling and loss of stability, which absorber assemblies.
could lead to an accident. ·Do not tamper with or attempt to open
HOW TO AVOID THE HAZARD the cylinder assemblies.
Always adjust the shock absorbers on · Do not subject the shock absorber
the left and right side to the same setting. assemblies to an open flame or other
high heat source. This may cause the unit
to explode due to excessive gas
pressure.
·Do not deform or damage the cylinders
in any way. Cylinder damage will result in
poor damping performance.

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 Control Functions 4-27
Spring preload
·Do not dispose of a damaged or worn 1. Loosen the locknut.
out shock absorber assembly yourself. 2. Turn the spring preload adjusting nut in
Take the shock absorber assembly to a direction ⓐ to increase the spring
HSUN dealer for any service. preload and thereby harden the
suspension, and in direction ⓑ to
The spring preload, rebound damping and decrease the spring preload and thereby
compression damping forces of the front soften the suspension.
and rear shock absorber assemblies can be
adjusted to suit the operating conditions.
NOTE:
Never turn an adjusting mechanism beyond
the minimum and maximum settings.

1. Locknut 2. Spring preload adjusting nut

3. Special wrench

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 4-28 Control Functions
· A special wrench can be obtained at a
HSUN dealer to make this adjustment. Spring travel setting(Front)
·The spring preload setting is determined Minimum(soft): 412mm(16.22 in)
by measuring distance A, shown in the Maximum(hard): 426mm(16.77 in)
illustration. The shorter distance A is, the
Spring travel setting(Rear)
lower the spring preload; the longer distance
Minimum(soft): 330mm(12.99in)
A is, the higher the spring preload. With each
Maximum(hard): 430mm(16.93 in)
complete turn of the adjusting nut.
3. Tighten the locknut.

NOTE:
Always tighten the locknut against the
adjusting nut, and then tighten it to the
specified torque.
Rebound damping force
Turn the rebound damping force adjusting
screw in direction S to increase the rebound
damping force and thereby harden the
1. Distance A

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 Control Functions 4-29
damping, and in direction F to decrease the Compression damping force
rebound damping force and thereby soften Turn the compression damping force
the damping. adjusting screw (use 3.0 allen wrench) in
direction ⓐ to increase the compression
damping force and thereby harden the
damping, and in direction ⓑ to decrease the
compression damping force and thereby
soften the damping.

1.Rebound damping force adjusting screw

a) Compression damping force adjusting screw

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 4-30 Control Functions
Trailer hitch bracket
WARNING This vehicle is equipped with a 1 ¼ in
·Suspension components become hot receiver bracket for a standard trailer hitch.
during operation. Never touch the Trailer towing equipment can be obtained at
compression damping force adjusting a service center. (See pages 6-12 - 6-14 for
screw, the rebound damping force precaution information.)
adjusting screw or the oil reservoir with
your bare hand or skin until suspension
components have cooled.
·Always adjust the shock absorber
assemblies on the left and right side to
the same setting. Uneven adjustment can
cause poor handling and loss of stability,
which could lead to an accident.

1. Trailer hitch bracket

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 Control Functions 4-31
Auxiliary DC jack jack.
The auxiliary DC jack is located at the right
side of the front panel. The auxiliary DC jack
can be used for suitable work lights, radios,
etc. The auxiliary DC jack should only be
used when the engine is running.

1. Auxiliary DC jack

Maximum rated capacity for the auxiliary

DC jack:
1. Auxiliary DC jack cap DC 12V, 120W (10 A)
1. Set the light switch to “OFF”.
2. Start the engine. (See pages 6-1 - 6-3.)
3. Open the auxiliary DC jack cap, and then
insert the accessory power plug into the

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 4-32 Control Functions
4. When the auxiliary DC jack is not being
used, cover it with the cap.
CAUTION:
z Do not use accessories requiring more
than the above maximum capacity. This
may overload the circuit and cause the
fuse to blow.
z If accessories are used without the
engine running or with the headlights
turned on, the battery will lose its charge
and engine starting may become difficult.
z Do not use an automotive cigarette
lighter or other access with a plug that
gets hot because the jack can be
damaged.

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 Pre Operation Checks 5-1
Before using this vehicle, check the following items:

ITEM ROUTINE PAGE

● Check operation, free play, fluid level and fluid leakage
Brakes 5-2 - 5-3， 8-35
● Fill with DOT 4 brake fluid if necessary
Parking brake ● Check for proper operation, condition and free play 6-8 - 6-9
● Check fuel level
Fuel 5-4 - 5-5
● Fill with fuel if necessary
● Check oil level
Engine/Gear box oil 5-5
● Fill with oil if necessary
● Check coolant level
Coolant reservoir 5-6，8-19 - 8-20
● Fill with coolant if necessary
Final gear oil /
● Check for leakage 5-7
Differential gear oil
Accelerator pedal ● Check for proper accelerator pedal operation 5-8
Seat belts ● Check for proper operation and belt wear 5-10
Steering ● Check for proper operation 5-10
Fittings and fasteners ● Check all fittings and fasteners 5-11
Lights and switches ● Check for proper operation 5-11
Wheels and tires ● Check tire pressure, wear and damage 5-11 - 5-13，8-41 - 8-42
Axle boots ● Check for damage 8-23
Instrument ● Check for complete and correct display 4-2 - 4-8
Light/Indicator ● Check for light / indicator operation 4-2 - 4-8

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 5-2 Pre Operation Checks

WARNING Brakes
POTENTIAL HAZARD Check for correct brake pedal free play. If the
Failure to inspect the vehicle before brake pedal free play is incorrect, have a
operating. Failure to properly maintain the service center adjust it. (See pages 8-38 -
vehicle. 8-40.)
WHAT CAN HAPPEN
Increases the possibility of an accident or Check the operation of the brake pedal. It
equipment damage. should move smoothly and there should be a
HOW TO AVOID THE HAZARD firm feeling when the brakes are applied. If not,
Always inspect your vehicle each time you have the vehicle inspected by a service center.
use it to make sure the vehicle is in safe
operating condition. Always follow the Brake fluid level
inspection and maintenance procedures Check the brake fluid level. Add fluid if
and schedules described in the Owner’s necessary. (See pages 8-35)
Manual.
Recommended brake fluid: DOT 4

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 Pre Operation Checks 5-3
Brake fluid leakage
Check to see if any brake fluid is leaking out of WARNING
the pipe joints or the brake fluid reservoir. Apply POTENTIAL HAZARD
the brakes firmly for one minute. If there is any Driving with improperly operating brakes.
leakage, have the vehicle inspected by a WHAT CAN HAPPEN
service center. You could lose braking ability which could
lead to an accident.
Brake operation HOW TO AVOID THE HAZARD
Test the brakes at slow speed after starting out Always check the brakes at the start of
to make sure they are working properly. If the every ride. Do not operate the vehicle if you
brakes do not provide proper braking find any problem with the brakes. If a
performance, inspect the brake system. (See problem cannot be corrected by the
pages 8-33 - 8-38.) adjustment procedures provided in this
manual, have the vehicle inspected by a
service center.

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 5-4 Pre Operation Checks
Fuel Your engine has been designed to use regular
Make sure there is sufficient gasoline in the unleaded gasoline with a pump octane number
tank. ([R+M] /2) of 91 or higher, or research octane
Recommended fuel: number of 91 or higher. If knocking or pinging
Unleaded gasoline only occurs, use a different brand of gasoline or
Fuel tank capacity: premium unleaded fuel. Unleaded fuel will give
7.7 gal (29L) you longer spark plug life and reduced
maintenance cost.
CAUTION:
Use only unleaded gasoline. The use of leaded Gasohol
gasoline will cause severe damage to internal The UTV uses an electric fuel injection system,
engine parts, such as the valves and piston and its emissions completely meet the
rings, as well as to the exhaust system. requirements of relevant rule of the United
States. Mixed fuel is forbidden to use on the
UTV. Mixed fuel will cause engine to work
abnormally and cause deterioration.

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 Pre Operation Checks 5-5
Engine oil
WARNING Make sure the engine oil is at the specified level.
POTENTIAL HAZARD Add oil as necessary. (See pages 8-12-8-13)
Improper care when refueling. CAUTION:
WHAT CAN HAPPEN
z In order to prevent clutch slippage
Fuel can spill, which can cause a fire and (since the engine oil also lubricates the
severe injury. Fuel expands when it heats clutch), do not mix any chemical
up. If the fuel tank is overfilled, fuel could additives. Do not use oils with a diesel
spill out due to heat from the engine or the specification of “CD” or oils of a
sun. higher quality than specified. In addition,
HOW TO AVOID THE HAZARD do not use oils labeled
Do not overfill the fuel tank. Be careful not “ENERGYCONSERVING II” or
higher.
to spill fuel, especially on the engine or
z Make sure that no foreign material
exhaust pipe. Wipe up any spilled fuel
enters the crankcase.
immediately. Be sure the fuel tank cap is
closed securely.

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 5-6 Pre Operation Checks
CAUTION:
Recommended engine oil type and
Hard water or salt water is harmful to the engine.
quantity: You may use soft water if you cannot get
See page 10-2 distilled water.

Coolant Coolant reservoir capacity

Check the coolant level in the coolant reservoir (up to the maximum level mark):
when the engine is cold. (The coolant level will 0.37 qt, (0.35L)
vary with engine temperature.) The coolant
level is satisfactory if it is between the minimum
and maximum level marks on the coolant
reservoir. If the coolant level is at or below the
minimum level mark, add additional coolant to
bring the level up to maximum level mark. If
coolant is not available, add distilled water.
Change the coolant every two years.

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 Pre Operation Checks 5-7
Final gear oil
WARNING Make sure the final gear oil is at the specified
POTENTIAL HAZARD level. Add oil as necessary. (See pages 8-17 -
Removing the radiator cap when the engine 8-18 for details)
and radiator are still hot.
Recommended oil:
WHAT CAN HAPPEN
SAE 80 API GL-4 Hypoid gear oil
You could be burned by hot fluid and steam
blown out under pressure. If desired, an SAE 80W90 hypoid gear oil may
HOW TO AVOID THE HAZARD be used for all conditions.
Wait for the engine to cool before removing NOTE:
the radiator cap. Always use a thick rag over GL-4 is a quality and additive rating, GL-5 or
GL-6 rated hypoid gear oils may also be used.
the cap. Allow any remaining pressure to
escape before completely removing the cap.
Differential gear oil
Make sure the differential gear oil is at the
specified level. Add oil as necessary. (See
pages 8-19 - 8-20 for details.)

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 5-8 Pre Operation Checks

WARNING
Failure to check or maintain proper Recommended oil:
operation of the throttle system can result in SAE 80 API GL-5 Hypoid gear oil
an accident and lead to serious injury or
death if the throttle pedal sticks during Throttle Pedal
operation. Check to see that the accelerator pedal
Never start or operate this vehicle if it has a operates correctly. It must operate smoothly
sticking or improperly operating throttle and fully spring back to the idle position when
pedal. released. Have a service center repair as
Immediately contact your service center for necessary for proper operation.
service if throttle problems arise.
Always check the pedal for free movement
and return before starting the engine and
occasionally during operation.

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 Pre Operation Checks 5-9
Throttle Freeplay Throttle Freeplay Adjustment
If the throttle pedal has excessive play due to 1. Remove both seats. Remove the middle
cable stretch or mis-adjustment, it will cause a cover of the engine.
delay in throttle response, especially at low 2. Loosen the nut of throttle cable on the
engine speed. The throttle may also not open valve,
fully. If the throttle pedal has no freeplay, the Spin the throttle cable inside/ outside to
increase the throttle pedal’s moving
throttle may be hard to control, and the idle
distance to 1.5-3 mm.
speed may be erratic. Check the throttle pedal
freeplay. Adjust the freeplay if necessary.

Throttle Freeplay Inspection

1. Lift the parking brake to the top to park the
car.
2. Apply the brakes. Start the engine. Allow it
to warm up thoroughly.
3. Measure the distance the throttle pedal
moves before the engine begins to pick up
speed. Freeplay should 1/16 to 1/8 inches 1．Accelerator Cable column nut
(1.5-3mm). 3. Tighten the the nut.

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 5-10 Pre Operation Checks
4. Resume the center cover and seat to their when pulled out and retract on its own when
position released. The latch plate should click securely
into the buckle and release when the release
Steering Wheel Inspection button is pushed firmly. Wash off any dirt or
Check the steering wheel for specified freeplay mud which could affect operation. Have a
and smooth operation. service center repair as necessary for proper
1. Position the vehicle on level ground. operation.
2. Lightly turn the steering wheel left and right.
3. There should be 0.8″-1.0″ (20-25 mm) Fittings and fasteners
of freeplay. Always check the tightness of chassis fittings
If there is excessive freeplay, strange noises, or and fasteners before a ride. Take the vehicle to
the steering feels rough or″catchy, ″have the a service center or refer to the Service Manual
steering system inspected by an authorized for correct tightening torque.
service center。
Seat belts Lights
Make sure that both seat belts are not frayed or Check the headlights and tail/brake lights to
damaged. The seat belt must move smoothly make sure they are in working condition. Repair

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 Pre Operation Checks 5-11
as necessary for proper operation. Tires
WARNING
Switches POTENTIAL HAZARD
Check the operation of all switches. Have a Operating this vehicle with improper tires,
or with improper or uneven tire pressure.
service center repair as necessary for proper
WHAT CAN HAPPEN
operation. Use of improper tires on this vehicle, or
operation of this vehicle with improper or
uneven tire pressure, may cause loss of
control, increasing your risk of accident.
HOW TO AVOID THE HAZARD
1. The tires listed below have been
approved by Manufacturer for this
model. Other tire combinations are not
recommended.
2.
Type Size
Front 25×8-12 6PR
Rear 25×10-12 6PR

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 5-12 Pre Operation Checks

3. The tires should be set to the 5. Use no more than the following pressures
recommended pressure: when seating the tire beads.
Front 10psi (70kpa, 0.7 kgf/cm2) Front 36psi (250kpa, 2.5kgf/cm2)
2
Rear 10psi (70kpa, 0.7 kgf/cm ) Rear 36psi (250kpa, 2.5kgf/cm2)
Check and adjust tire pressures when the Higher pressures may cause the tire to burst.
tires are cold. Tire pressures must be Inflate the tires very slowly and carefully. Fast
equal on both sides. inflation could cause the tire to burst.

How to measure tire pressure

4. Tire pressure below the minimum Use the tire pressure gauge.
specified could cause the tire to dislodge NOTE:
from the rim under severe riding The tire pressure gauge is included as standard
conditions. The following are minimums: equipment. Make two measurements of the tire
Front 9psi (63 kpa, 0.64kgf/cm2) pressure and use the second reading. Dust or
Rear 9psi (63 kpa, 0.64kgf/cm2) dirt in the gauge could cause the first reading to
be incorrect.

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 Pre Operation Checks 5-13
Set pressure with tires cold. Set tire pressures Tire wear limit
to the following specifications: When the tire groove decreases to 0.12 in (3
Recommended mm) due to wear, replace the tire.
Minimum Maximum
Pressure
10psi (70kpa 9 psi (63kpa, 11 psi, (77kpa,
Front
(0.70kgf/ cm2) 0.64kgf/ cm2) 0.77kgf/ cm2)
10psi (70kpa 9 psi (63kpa, 11 psi, (77kpa,
Rear
(0.70kgf/ cm2) 0.64kgf/ cm2) 0.77kgf/ cm2)

a. Tire wear limit

1. Tire pressure gauge

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 6-1 Operation

WARNING WARNING
POTENTIAL HAZARD POTENTIAL HAZARD
Operating vehicle without being familiar Freezing control cables due to cold
with all controls. weather conditions.
WHAT CAN HAPPEN WHAT CAN HAPPEN
Loss of control, which could cause an Loss of vehicle control, which could
accident or injury. lead to an accident or collision.
HOW TO AVOID THE HAZARD HOW TO AVOID THE HAZARD
Read the Owner’s Manual carefully. If When riding in cold weather, always
there is a control or function you do not make sure all control cables work
understand, ask your service center. smoothly before you begin riding.

1. Check the throttle cable, parking cable,

and the reverse lock out cable, and make
sure that they are not frozen.
Starting the engine in low 2. Start the engine (see P6-2).
temperatures

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 Operation 6-2
Starting the Engine service center to inspect the electric
circuit.
CAUTION: ● The engine can be started in any gear if
See the “Engine Break-In”section prior to the brake is applied. However, it is
operating the engine for the first time. recommended to shift into neutral ”N”
before starting the engine.
1. Turning the key to “ON”, the light in the
display will turn on, and electronic
injection system’s fuel pump will start to 4. With your foot off the accelerator pedal,
work; wait for 10 second before the start the engine by turning the key to
following operation. “START”.
2. Apply the brake. NOTE:
If the engine fails to start, release the key,
3. Shift the drive select lever into the neutral
and then try starting again. Wait a few
position. seconds before the next attempt. Each
NOTE: cranking should be as short as possible to
● When the drive select lever is in the preserve battery energy. Do not crank the
neutral position“N”, the neutral indicator engine more than 5 seconds on each
light should come on. If the neutral attempt.
indicator light does not come on, ask a

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 6-3 Operation
5. Continue warming up the engine until it
idles smoothly before riding. 2500RPM to charge the battery for 5-10
minutes; when the voltage of battery is over
WARNING 12V, the idle speed will be normal. If the
POTENTIAL HAZARD idle speed is still high, please contact your
service center.
Engine idle speed exceeds the regulated
speed. Warming Up
WHAT CAN HAPPEN To get maximum engine life, always warm up
Will make it difficult to select the proper gear, the engine before driving. Never accelerate
which could lead to loss of control, causing hard with a cold engine! To see whether or
not the engine is warm, check if it responds
serious injury or even death.
to the throttle normally.
HOW TO AVOID THE HAZARD
Because of electronic injection system, the idle
1. Release the brakes and press the
speed will be speed up when the voltage of
accelerator pedal gradually.
battery is low.
2. If the rotation rate of the engine
Place the gear on position ‘N’, and press the accelerates with pedal steadily, the
throttle pedal to make the engine run at warming-up procedure has been ready
and the vehicle can been ridden.

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 Operation 6-4
Otherwise, go on with the third step. 1. Stop the vehicle. Keep your foot off the
3. Continue warming up the engine until it
accelerator pedal.
idles smoothly.
2. Apply the brakes, and then shift by
CAUTION:
See the “Engine break-in” section prior to moving the drive select lever along the
operating the engine for the first time. shift guide.
NOTE:
Make sure that the drive select lever is
Drive Select Lever Operation and completely shifted into position.
Driving In Reverse

CAUTION:
Before shifting, you must stop the UTV and
return the throttle lever to the closed position;
otherwise the transmission may be
damaged.

Shifting: Neutral to High and High to Low

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 6-5 Operation
the shift guide.

NOTE:
● Please kick the brake pedal first, before place
gearshifts lever to“reverse”position.
● In the brake pedal, there is a cable, which is
connected to a position pin located on the
gearshift assembly. Only when the brake pedal
is depressed, the position pin will be retracked,
and gearshifts can be removed to “reverse”
1. Drive select lever position.

3. Release the brakes and press the

accelerator pedal gradually.

Shifting: Neutral to Reverse

1. Stop the vehicle. Keep your foot off the
accelerator pedal.
2. Apply the brake pedal.
3. Shift from neutral to reverse or vice versa
by moving the drive select lever along 1.Position pin 2.Cadle 3. Adjust

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 Operation 6-6
until the vehicle starts moving.

4. Check behind for people or obstacles,

and then release the brake pedal.
5. Press the accelerator pedal gradually
and continue to watch to the rear while
backing up.

1. Drive select lever

NOTE:
● When in reverse, the reverse indicator
light should be on. If the light does not
come on, ask a service center to inspect
the reverse indicator light electrical
circuit.
● Due to the synchronizing mechanism in
the engine, the light may not come on

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 6-7 Operation

WARNING
WARNING
POTENTIAL HAZARD
POTENTIAL HAZARD
Parking on a hill or other incline.
Improperly operating in reverse.
WHAT CAN HAPPEN
WHAT CAN HAPPEN
The vehicle could roll out of control,
You could hit an obstacle or person
increasing the chance of an accident.
behind you, resulting in serious injury.
HOW TO AVOID THE HAZARD
HOW TO AVOID THE HAZARD
Avoid parking on hills or other inclines. If
When you shift into reverse, make sure
you must park on an incline, apply the
there are no obstacles or people behind
parking brake, and block the front and
you. When it is safe to proceed, go
rear wheels with rocks or other objects.
slowly.
Never park the vehicle on hills that are
too steep.

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 Operation 6-8
Parking Parking on a Slope

a) When parking, stop the engine and shift

the drive select lever into the neutral
position.

b) Push the brake pedal down, and pull the

parking brake to top position to park the
vehicle

1. Bring the vehicle to a stop by applying

the brakes.
2. Stop the engine.
3. With the brakes applied, set the parking
brake.

1．Parking handbar

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 6-9 Operation
Vehicle Break-in Period
The break-in period for your new UTV
vehicle is the first 25 hours of operation, or
the time it takes to use the first three tanks
full of gasoline. No single action on your part
is as important as a proper break-in period.
Careful treatment of a new engine and drive
components will result in more efficient
performance and longer life for these
1．parking handbar components. Perform the following
procedures carefully.
NOTE:
CAUTION:
Like many other vehicles, the parking brake
● Excessive heat build-up during the first
acts on the rear wheels. For the parking
three hours of operation will damage
brake to operate all four wheels, shift to 4WD
close-fitted engine parts and drive
before stopping the engine.
components. Do not operate at full throttle
or high speeds during the first three hours

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 Operation 6-10
of use. momentary (2-3 seconds maximum) full
● Use of any engine oil not mentioned in throttle operation under load does not harm
this manual will cause severe damage to the engine.
the engine. Each full throttle acceleration sequence
should be followed with a substantial rest
period for the engine by cruising at lower
Engine Break-In
r/min so the engine can rid itself of the
There is never a more important period in the
temporary build up of heat. If any abnormality
life of your vehicle than the period between 0
is noticed during this period, consult a
and 25 hours. For this reason, we ask that
service center.
you carefully read the following material.
Because the engine is brand new, you must
not put an excessive load on it for the first 0-10 Hours:
several hours of running. Avoid continuous operation above half
During the first 25 hours, the various parts in throttle. Allow a cooling off period of five to
the engine wear and polish themselves to the ten minutes after every hour of operation.
correct operating clearances. During this Vary the speed of the vehicle from time to
period, prolonged full throttle operation or time. Do not operate it at one set throttle
any condition which might result in excessive position.
engine heating must be avoided. However,

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 6-11 Operation
10-25 Hours: performance. Break in the clutches and belt
Avoid prolonged operation above 3/4 throttle. by operating at slower speeds during the
Rev the vehicle freely but do not use full break-in period as recommended. Pull only
throttle at any time. light loads. Avoid aggressive acceleration
and high speed operation during the break-in
After break-in: period.
The vehicle can now be operated normally.
Accessories
Brake System Break-in Accessories can affect the handing and
Apply only moderate braking force for the control of your vehicle. Keep the following in
first 50 stops. Aggressive or overly forceful mind when considering an accessory or
braking when the brake system is new could operating a vehicle that has accessories.
damage brake pads and rotors. ● Choose only accessories designed for

your vehicle. Your service center has a

CVT Break-in (Clutches/Belt) variety of genuine accessories. Other
A proper break-in of the clutches and drive accessories may also be available on the
belt will ensure a longer life and better market. However, it is not possible for to

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 Operation 6-12
test all nonstandard accessories, nor with accessories. The vehicle may
have any control over the quality or handle differently than it does without
suitability of them. Choose a genuine accessories.
accessory, or one that is equivalent in
design and quality. Loading
● Accessories should be rigidly and Cargo or a trailer can change the stability
securely mounted. An accessory that can and handling of a vehicle. You must use
shift position or come off while you are common sense and good judgment when
operating could affect your ability to carrying cargo or towing a trailer. Keep the
control the vehicle. following points in mind:
● Do not mount an accessory where it ● Never exceed the weight limits shown.

could interfere with your ability to control An overloaded vehicle can be unstable.
the vehicle. Examples include (but are ● Choose a trailer hitch drawbar designed

not limited to) an object that limits your for use with a 1 ¼ in receiver.
ability to turn the steering wheel or one ● Do not exceed the maximum tongue

that limits your view. weight. You can measure tongue weight
● Use extra caution when driving a vehicle with a bathroom scale. Put the tongue of

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 6-13 Operation
the loaded trailer on the scale with the
tongue at hitch height. Adjust the load in MAXIMUM LOADING LIMIT
the trailer, if necessary, to reduce the ● Vehicle loading limit (total weight of

weight on hitch. If you are carrying cargo cargo, operator, passenger and
and towing a trailer, include the tongue accessories, and tongue weight):
weight in the maximum vehicle load limit. 882 lb (400Kg)
● Cargo bed:350 lb (159Kg)
● Trailer hitch:
Pulling load (total weight of trailer
and cargo): 1,212lbf (550Kgf)
Tongue weight (vertical weight on
trailer hitch point): 110lbf (50Kgf)

● Load cargo in the cargo bed as close to

the center of the vehicle as possible and
tie it down using the cargo hooks
equipped on the cargo bed.
● Tie down cargo securely in the trailer.

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 Operation 6-14
Make sure cargo in the trailer cannot ● Avoid hills and rough terrain. Choose
move around. A shifting load can cause terrain carefully. Added weight affects the
an accident. stability and handling of the vehicle.
● Make sure the load does not interfere
with controls or your ability to see where
you are going.
● Drive more slowly than you would without
a load. The more weight you carry, the
slower you should go. Although
conditions vary, it is good practice not to
exceed low range whenever you are
carrying heavier loads or when towing a
trailer.
● Allow more braking distance. A heavier
vehicle takes longer to stop.
● Avoid making sharp turns unless at very
slow speeds.

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 6-15 Operation

WARNING
POTENTIAL HAZARD
Overloading this vehicle or carrying or
towing cargo improperly.
WHAT CAN HAPPEN
Could cause changes in vehicle handling
which could lead to an accident.
HOW TO AVOID THE HAZARD
Never exceed the stated load capacity for
this vehicle.
Cargo should be properly distributed and
securely attached.
Reduce speed when carrying cargo or
pulling a trailer. Allow greater distance
for braking.

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 Your Vehicle 7-1

DRIVING YOUR VEHICLE

WARNING
GETTING TO KNOW YOUR VEHICLE POTENTIAL HAZARD
This off-highway utility vehicle will handle Not wearing the seat belt.
and maneuver differently form an ordinary Wearing the seat belt improperly.
passenger car or other vehicle. WHAT CAN HAPPEN
Before you begin to use your vehicle, be sure There is increased risk of being killed or
you have read this Owners Manual seriously injured in an accident.
completely and understand all the features. HOW TO AVOID THE HAZARD
Pay particular attention to the safety Always wear your seat belt when riding in
information on pages 2-1 - 2-5. Please read the vehicle.
all the caution and warning labels on your Be sure the seat belt is close fitting
vehicle. across your hips and chest and is latched
This vehicle is designed for the operator and securely.
one passenger. The driver and passenger
must always wear a seat belt. Never carry
passengers in the cargo bed.

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 7-2 Your Vehicle

WARNING The total weight of operator, passenger,

POTENTIAL HAZARD accessories, cargo, trailer tongue weight,
Carrying a passenger in the cargo bed. and the vehicle itself must not exceed 1,880
WHAT CAN HAPPEN lbs (853Kg).
The passenger could fall or be struck by
objects in the cargo bed.
HOW TO AVOID THE HAZARD
Never carry a passenger in the cargo bed.
The cargo bed is designed to carry cargo
only.

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 Your Vehicle 7-3
The driver and passenger must always wear
WARNING a seat belt, an approved motorcycle helmet,
POTENTIAL HAZARD eye protection and protective clothing,
Overloading this vehicle or carrying or including over-the-ankle boots, gloves, a
towing cargo improperly. long-sleeved shirt or jacket, and long pants.
WHAT CAN HAPPEN
Keep hands and feet inside the vehicle at all
Could cause changes in vehicle
handling which could lead to an times.
accident.
HOW TO AVOID THE HAZARD
Never exceed the stated load capacity
for this vehicle.
Cargo should be properly distributed
and securely attached.
Reduce speed when carrying cargo or
pulling a trailer. Allow greater distance
for braking.
Always follow the instructions in your
Owner’s Manual for carrying cargo or
pulling a trailer.

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 7-4 Your Vehicle

WARNING HOW TO AVOID THE HAZARD

POTENTIAL HAZARD Always wear an approved motorcycle
Operating this vehicle without wearing an
helmet that fits properly. You should also
approved motorcycle helmet, eye
protection, and protective clothing. wear:
WHAT CAN eye protection
HAPPEN
(goggles or face shield)
Operating without
an approved gloves
motorcycle helmet boots
increases your long-sleeved shirt or jacket
chances of a severe
head injury or death
in the event of an long pants
accident.
Operating without eye protection can
result in an accident and increases your
chances of a severe injury in the event of
an accident.

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 Your Vehicle 7-5
Perform the Pre-Operation Checks on pages
LEARNING TO OPERATE YOUR VEHICLE 5-1 - 5-11. Set the parking brake, shift to
You should become familiar with the neutral, and follow the instructions on page
performance characteristics of the vehicle in 6-1 to start the engine. Once it has warmed
a large, flat area that is free of obstacles and up you are ready to begin driving your
other vehicles. Practice control of the vehicle. With the engine idling, shift the drive
accelerator pedal, brakes, steering, and drive select lever into low or high. Then release the
select lever. Drive at a slow speed and parking brake. Press the accelerator pedal
become comfortable at that speed before slowly and smoothly. The centrifugal clutch
gradually increasing your speed. Become will engage and you will start to accelerate.
familiar with the way the vehicle feels in low Avoid higher speeds until you are thoroughly
and high ranges, first in two-wheel drive familiar with the operation of your vehicle.
(2WD) and then in four-wheel drive (4WD) When slowing down or stopping, take your
and four-wheel drive with the differential foot off the accelerator pedal and smoothly
locked. Practice driving in reverse. Take the press the brake pedal. Improper use of the
time to learn basic operation before brakes can cause the tires to lose traction,
attempting maneuvers that are more difficult. reducing control and increasing the
possibility of an accident.

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 7-6 Your Vehicle
maneuvers on slope.
CAUTION: Position your hands on the steering wheel so
Do not shift from low to high or vice versa that your thumbs and fingers do not wrap
around the wheel. This is particularly important
without coming to a complete stop and
when driving in rough terrain. The front
waiting for the engine to return to normal idle
wheels will move right and left as they
speed. Damage to the engine or drive train respond to the terrain, and this movement
may occur. will be felt in the steering wheel. A sudden jolt
could wrench the steering wheel around, and
your thumbs or fingers could be injured if
TURNING YOUR VEHICLE they are in the way of the steering wheel
The vehicle is easier to steer in two-wheel spokes.
drive (2WD) than four-wheel drive (4WD).
Steering takes the most effort in 4WD with
the differential locked.
It is possible for the vehicle to roll over or go
out of control if you attempt sharp,
high-speed turns. You should also be careful
making sharp turns on rough terrain. Do not
attempt to turn around or make abrupt

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 Your Vehicle 7-7

Follow these precautions when operating in

reverse:
1. Always check for obstacles or people
behind the vehicle.
2. Apply the throttle lightly. Never open the
throttle suddenly.
3. Back up slowly.
4. Apply the brakes lightly for stopping.
5. Avoid making sharp turns.

Operating Improperly in Reverse Before shifting into reverse gear, always

Improperly operating in reverse could result check for obstacles or people behind the
in a collision with an obstacle or person. vehicle. When it is safe to proceed, back up
Always follow proper operating procedures. slowly.

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 7-8 Your Vehicle
BRAKING
Braking ability is affected by the type of
terrain. In most cases, gradual application of
the brakes is more effective than abrupt
braking, particularly on loose surfaces like
gravel. Always allow for greater braking
distance on rough, loose, or slippery
surfaces.

GOING UPHILL
Do not attempt to climb hills until you have
mastered basic maneuvers on flat ground.
Use proper driving techniques to avoid
overturns on hills and slopes. Drive straight
up hills, and avoid crossing the side of a hill,
which increases your chance of rollover.
Practice first on gentle slopes before
attempting steeper hills. Always check the
terrain carefully before attempting any hill.
Use common sense and remember that

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 Your Vehicle 7-9
some hills are too steep for you to climb.

Maximum slope angle:15°

WARNING
POTENTIAL HAZARD
Operating on excessively steep hills.
WHAT CAN HAPPEN
The vehicle can over turn more easily on
extremely steep hills than on level
surfaces or small hills.
HOW TO AVOID THE HAZARD
Never operate your vehicle on hills too
steep for it or your abilities. Never
operate vehicles on hills steeper than 15
°.
Choose carefully which hills you attempt to
Do not drive across the face of a hill. Go
climb. Avoid hills with slippery surfaces or
straight up the hill.
ones where you will not be able to see far
Practice on smaller hills before
enough ahead of you.
attempting large hills.

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 7-10 Your Vehicle
Before climbing the hill, first be sure you are around. With your foot on the brake, look
operating in low range 4WD or, if necessary, behind you and plan your descent. Shift the
with 4WD. To climb a hill, you need traction, drive select lever in reverse so you can use
momentum, and steady throttle. Travel fast the engine brake if necessary to slow your
enough to keep your momentum going, but descent. Release the brake and begin to
not so fast that you cannot react to changes coast down the hill. Use engine braking as
in the terrain as you climb. Slow down when much as possible, gently applying the brakes
you reach the crest of the hill if you cannot when necessary.
clearly see what is on the other side-there
could be another person, an obstacle, or a GOING DOWNHILL
sharp drop off. Check the terrain carefully before going
down a hill. When possible, choose a path
If you start to lose traction or momentum that lets you drive your vehicle straight
when climbing, and you decide you will be downhill. Avoid sharp angles that could allow
unable to continue, use the brakes to come the vehicle to pitch or roll over. Carefully
to a stop. Do not attempt to turn the vehicle choose your path and drive no faster than

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 Your Vehicle 7-11
you will be able to react to obstacles that may Before starting downhill, make sure the
appear. vehicle is in low-range 4WD. On most slopes,
this will let you use engine braking to help
you go downhill slowly. Go as slowly as
WARNING
possible. If you pick up too much speed,
POTENTIAL HAZARD
apply the brakes gently. Avoid sudden
Going down a hill improperly.
application of the brakes, which could cause
WHAT CAN HAPPEN
the vehicle to start sliding.
Could cause loss of control or cause the
If you are sliding or skidding, try to steer in
vehicle to overturn.
the direction the vehicle is sliding to help you
HOW TO AVOID THE HAZARD regain control.
Always check the terrain carefully before If you must turn on the hill to avoid an
you start down any hill. Never go down a obstacle, do so slowly and carefully. If the
hill at high speed. Avoid going down a hill vehicle starts to tip, gradually steer in the
at an angle that would cause the vehicle downhill direction if there are no obstacles in
to lean sharply to one side. Go straight your path. As you regain proper balance,
down the hill where possible. gradually steer again in the direction you
want to go.

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 7-12 Your Vehicle
CROSSING THROUGH SHALLOW WATER
If you must cross shallow, slow moving water WARNING
up to the depth of the vehicle’s floorboards, POTENTIAL HAZARD
Operating this vehicle through deep or
choose your path carefully to avoid sharp
fast-flowing water.
drop-offs, large rocks, or slippery surfaces WHAT CAN HAPPEN
that could cause the vehicle to overturn. Loss of control, which could result in an
accident including overturn, which could
Never operate through water deeper than 13
increase the risk of drowning.
in (33 cm) or fast flowing water. HOW TO AVOID THE HAZARD
Wet brakes may have reduced effectiveness. Never operate this vehicle in fast flowing
water or in water deeper than 13 in
After leaving the water, test your brakes. If
(33cm).
necessary, apply the brakes several times to Remember that wet brakes may have
let friction dry out the linings. reduced stopping ability. Test your
brakes after leaving water. If necessary,
apply the brakes several times to let
friction dry out the linings.

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 Your Vehicle 7-13
Vehicle Immersion
CAUTION:
CAUTION:
After riding your vehicle in water, be sure to
If your vehicle becomes immersed, major
drain the trapped water by removing the
engine damage can result if the machine is
check hose at the bottom of the air filter case,
not thoroughly inspected. Take the vehicle to
the V-belt cooling duct check hose, the drive
your service center before starting the
select lever box check hose and the V-belt
engine.
case drain plug. Wash the vehicle in fresh
If it is impossible to take your vehicle to a
water if it has been operated in salt water or
service center before starting it, follow the
muddy conditions.
steps outlined below.
1. Move the vehicle to dry land.
2. Check the air box. If water is present, dry
the air box and replace the filter with a
new filter.
3. Remove the spark plugs.
4. Turn the engine over several times.

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 7-14 Your Vehicle
5. Dry the spark plugs and reinstall them, or
install new plugs. CAUTION:
6. Attempt to start the engine. If necessary, Make sure all components that are washed
repeat the drying procedure. and assembled are coated lightly with
7. Take the vehicle to your service center
grease.
for service as soon as possible, whether
you succeed in starting it or not.
8. If water has been ingested into the CVT,
make sure to inspect the hole without
water left inside. If it is muddy water,
open the CVT cap and wash the parts
before you reassemble.
9. Check the gearshift, release the water
inside. Wash if necessary.

1．Air filter case check hose

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 Your Vehicle 7-15
1. Drive select lever box check hose

1．V-belt cooling duct check hose

1．V-belt case drain plug

Riding Over Rough Terrain

Operating over rough terrain should be done
with caution. Look for obstacles that could
cause damage to the vehicle or could lead to
a rollover accident. Avoid jumping the vehicle
as injury, loss of control, and damage to the

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 7-16 Your Vehicle
vehicle could occur.
WARNING
POTENTIAL HAZARD
Failure to use extra care when operating
this vehicle on unfamiliar terrain.
WHAT CAN HAPPEN
You can come upon hidden rocks,
bumps, or holes, without enough time to
react. Could result in the vehicle
overturning or going out of control.
HOW TO AVOID THE HAZARD
Go slowly and be extra careful when
operating on unfamiliar terrain. Always
be alert to changing terrain conditions
when operating the vehicle.

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 Your Vehicle 7-17
Riding in Brush or Wooded Areas thoroughly. Look from both your approach
When operating in areas with brush or trees, side and the exit side. If you believe you can
watch carefully on both sides and above the continue safely, decide the path that will
allow you to get over the obstacle at as close
vehicle for obstacles such as branches that
to a right angle as possible to minimize
the vehicle might hit, causing an accident, or
vehicle tipping. Go only fast enough to
for brush that might enter the vehicle as you
maintain your momentum but still give
pass and strike the driver or passenger. yourself plenty of time to react to changes in
Never hold onto the enclosure so your hand conditions. If there is any question about
is outside the vehicle. Hold the handgrip your ability to maneuver safely over the
inside the enclosure. obstacle, you should turn around, if the
ground is flat and you have the room, or back
Encountering Obstacles on the Trail up until you find a less difficult path.
If you cannot go around an obstacle such as
a fallen tree trunk or a ditch, stop the vehicle
where it is safe to do so. Set the parking
brake and get out to inspect the area

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 7-18 Your Vehicle

WARNING
POTENTIAL HAZARD
Improperly operating over obstacles.
WHAT CAN HAPPEN
Could cause loss of control or a collision.
Could cause the vehicle to overturn.
HOW TO AVOID THE HAZARD
Before operating in a new area, check for
obstacles.
Use extreme caution when operating over
large obstacles, such as large rocks or
fallen trees.

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 Periodic Maintenance and Adjustment 8-1
NOTE:
Periodic Maintenance and Adjustment If you do not have a torque wrench available
Periodic inspection, adjustment and during a service operation requiring
lubrication will keep your vehicle in the safest one, take your vehicle to service center to
and most efficient condition possible. Safety
check the torque settings and adjust them as
is an obligation of the vehicle owner. The
most important points of vehicle inspection, necessary.
adjustment and lubrication are explained on
the following pages.
The service information included in this
manual is intended to provide you, the owner,
with the necessary information for
completing your own preventive
maintenance and minor repairs. The tools
provided in the Owner’s tool kit are sufficient
for this purpose, except that a torque wrench
is also necessary to properly tighten nuts and
bolts.
1. Owner’s tool kit 2. Tire pressure gauge

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 8-2 Periodic Maintenance and Adjustment

WARNING WARNING
POTENTIAL HAZARD POTENTIAL HAZARD
Servicing an engine while it is running. Operating this vehicle with improper
WHAT CAN HAPPEN modifications.
Moving parts can catch clothing or parts WHAT CAN HAPPEN
of the body, causing injury. Improper installation of accessories or
Electrical components can cause shocks modification of this vehicle may cause
or can start fires. changes in handling which in some
HOW TO AVOID THE HAZARD situations could lead to an accident.
Turn off the engine when performing HOW TO AVOID THE HAZARD
maintenance unless otherwise specified. Never modify this vehicle through
Have a service center perform service if improper installation or use of
you are not familiar with vehicle service. accessories. All parts and accessories
added to this vehicle should be genuine
or equivalent components designed for
use on this vehicle and should be
installed and used according to
instructions.
If you have questions, consult an
authorized service center.

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 Periodic Maintenance and Adjustment 8-3
Periodic Maintenance Chart for the Emission Control System
● For vehicles not equipped with an odometer or hour meter, follow the month maintenance intervals.
● For vehicles equipped with an odometer or an hour meter, follow the mile (km) or hours maintenance intervals. However, keep in mind
that if the vehicle is not used for a long period, the month maintenance intervals should be followed.
● Items marked with an asterisk should be performed by service center, as they require special tools, data and technical skills.

INITIAL EVERY
Whichever Month 1 3 6 6 12
ITEM ROUTINE Comes first miles 200 750 1,500 1,500 3,000
(km) (320) (1,200) (2,400) (2,400) (4,800)
hours 20 75 150 150 300
● Check valve clearance.
Valves* ○ ○ ○ ○
● Adjust if necessary.
● Check fuel hose for cracks or damage.
Fuel line* ○ ○ ○
● Replace if necessary.
● Check condition.
Spark plug ● Adjust gap and clean. ○ ○ ○ ○ ○
● Replace if necessary.
● Check for leakage.
Exhaust system* ● Tighten if necessary. ○ ○ ○
● Replace gasket(s) if necessary.
Crankcase breather ● Check breather hose for cracks or damage.
○ ○ ○
system* ● Replace if necessary.

Spark arrester ● Clean. ○ ○ ○

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 8-4 Periodic Maintenance and Adjustment
General maintenance and lubrication chart
INITIAL EVERY
Whichever Month 1 3 6 6 12
ITEM ROUTINE Miles 200 750 1,500 1,500 3,000
Comes first
(Km) (320) (1,200) (2,400) (2,400) (4,800)
hours 20 75 150 150 300
● Check coolant leakage.
Cooling system ● Repair if necessary. ○ ○ ○ ○ ○
● Replace coolant every 24 months.
● Clean. Every 20─40 hours
Air filter element
● Replace if necessary. (More often in wet or dusty areas.)
Engine oil ● Replace (warm engine before draining.) ○ ○ ○ ○
Engine oil filter cartridge ● Replace ○ ○ ○ ○
Final gear oil ● Check oil lever oil leakage.
○ ○
Differential gear oil ● Replace.

Accelerator pedal* ● Check operation and free play. ○ ○ ○ ○ ○

● Check operation.
V-belt* ○ ○ ○
● Check for wear, cracks, or damage.
● Check balance/damage/runout.
Wheels* ○ ○ ○ ○
● Replace if necessary.
● Check operation/brake pad wear/fluid leakage/
Front brake* see page 8-6. ○ ○ ○ ○ ○
● Correct if necessary. Replace pads if worn to the limit.
● Check operation/brake pad wear/fluid leakage/
Rear brake* see NOTE page 8-6. ○ ○ ○ ○ ○
● Correct if necessary. Replace pads if worn to the limit.
● Check operation and for leakage.
Front and rear suspension* ○ ○
● Check toe-in/Adjust if necessary.

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 Periodic Maintenance and Adjustment 8-5

INITIAL EVERY
Whichever Month 1 3 6 6 12
ITEM ROUTINE Miles 200 750 1,500 1,500 3,000
Comes first
(Km) (320) (1,200) (2,400) (2,400) (4,800)
hours 20 75 150 150 300
● Check bearing assemblies for looseness/damaged.
Wheel bearings* ○ ○ ○ ○
● Repair if damaged.

Stabilizer bushings* ● Check for cracks or damage. ○ ○ ○

● Check all chassis fittings and fasteners.
Fittings and fasteners* ○ ○ ○ ○ ○
● Check if necessary.
Rear upper and lower
● Lubricate with lithium–soap-based grease. ○ ○ ○
knuckle pivots*
● Lubricate with lithium-soap-based grease. ○ ○ ○
Drive shaft universal joint*
● Check operation and for looseness/Replace if
Steering system* damaged. ○ ○ ○ ○ ○
● Check toe-in/Adjust if necessary
● Check for cracks or damage.
Engine mount* ○ ○ ○
● Check bolt tightness.
● Check operation.
Front and rear axle boots* ○ ○ ○ ○ ○
● Replace if damaged.

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 8-6 Periodic Maintenance and Adjustment
NOTE:
● Recommended brake fluld:DOT4
● Brake fluid replacement.
● When disassembling the master cylinder or caliper, replace the brake fluid. Check the brake fluid level
and add fluid as required.
● On the inner parts of the master cylinder and caliper, replace the oil seals every two years.
● Replace the brake hoses every four years, or if cracked or damaged.

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 Periodic Maintenance and Adjustment 8-7
Hood
To open
Unhook the hood latches, and then slowly tilt
the hood up until it stops.

1. Hood

To close
Lower the hood slowly to its original position,
1. Latch (×2)
and then hook the hood latches.
Secure projections ① on the underside of the
hood into slots ② on the back of the
instrument panel. Secure slots ③ on the side
of the hood around projections ④ on the
frame.

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 8-8 Periodic Maintenance and Adjustment
Console
To remove
1. Remove the seats. (See pages 4-17─
4-18 for seat removal and installation
procedures.)
2. Remove the parking brake lever boot.
3. Pull the console upward (the drive select
lever boot will come loose.)

1. Projection (×2) 2. Slot (×2)

3. Slot (×2) 4. Projection (×2)

CAUTION:
z Make sure that all cables and wires are in
place when closing the hood.
z Do not drive the vehicle with the hood
open, unlatched, or removed. 1. Console

To install
1. Place the console in its original position.

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 Periodic Maintenance and Adjustment 8-9
2. Install the parking brake lever boot. EFI system
3. Install the seats. EFI engine was completely different from the
engine which uses carburetor, it consist of
CAUTION:
ECU, EFI-cables, sensors, actuators and
z When installing the console, be sure not
other advanced components.
to pinch the cables or wires.
As the following pictures:
z Make sure that the groove at the bottom
of the parking brake lever boot and the
drive select lever boot fits securely
around the edge of the hole in the
console.

1. Oxygen sensor
2. Oxygen sensor threaded sleeve
3. Exhaust Pipe

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 8-10 Periodic Maintenance and Adjustment

1. High voltage wire 2.Ignition signal plug

3. Ignition coil

1. ECU

1. Throttle 2. Intake Pipe Joint

3. Intake Pipe 4. Fuel injector
5. Fuel injector seat
6. Intake temperature sensor/pressure sensor

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 Periodic Maintenance and Adjustment 8-11
Fuel injector
Inject the fuel into the cylinder

Intake air temperature sensor

Inspect engine intake air temperature,
according to the temperature, ECU will
automatically adjust the fuel injection volume.

Air intake pipe pressure sensor

For testing the negative pressure of the air
intake pipe, engine has the different working
conditions, the 2 parameters- opening of air
1. Idle speed stepper motor damper and pressure of air intake determine
2. Air damper degree sensor
the engine’s working condition, ECU will
3. Throttle
adjust the fuel injection volume according to
different negative pressure and opening of
Air damper
air damper. Adjust the engine fuel injection
For the purpose of adjustment of air intake
volume can adjust the output power and
volume.
output torque.
Idle speed stepper motor
Water temperature sensor
To stabilize the idle speed
For testing cooling water temperature,

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 8-12 Periodic Maintenance and Adjustment
according to the temperature difference, diagnostic apparatus" for inspection,
ECU will automatically revise fuel injection diagnostic apparatus can provide a more
volume, to ensure the smooth operation of detailed faliure information. Diagnostic
the engine all the time. apparatus equipped with its own user
Ignition signal manual.
Ignition signal arising from the magneto to
provide the ECU with correct ignition timing signal.

ECU
It is the core of EFI system, it used a
specially designed micro computer chip as a
controller，according to the information from
sensors, has been calculated to ensure
accurate control in different conditions from
the nozzle of the fuel injection volume. To
achieve fuel-efficient low emissions
performance of the EFI engine.
1. Diagnostic apparatus cable 2. EFI cables

EFI System inspection

If the EFI system has failure, the meter will Engine oil and oil filter cartridge
The engine oil level should be checked
display the appropriate failure code, you can
before each operation. In addition, the oil
also use the special "EFI system failure

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 Periodic Maintenance and Adjustment 8-13
must be changed and the oil filter cartridge NOTE:
replaced at the intervals specified in the The engine oil should be between the
periodic maintenance and lubrication chart. minimum and maximum level marks.
To check the engine oil level
1. Place the vehicle on a level surface.
2. Remove the console. (See page 8-7-8-8
for console removal and installation
procedures.)
3. Check the engine oil level on a cold
engine.
NOTE:
If the engine was started before checking the
oil level, be sure to warm up the engine
sufficiently, and then wait at least ten minutes
until the oil settles for an accurate reading.
4. Remove the engine oil filler cap and wipe 1. Maximum level mark 2. Minimum level mark
off the dipstick with a clean rag. 3. Dipstick 4. Engine oil filler cap

5. Insert the dipstick in the oil filler hole 6. If the engine oil is at or below the
(without screwing it in), and then remove minimum level mark, add sufficient oil of
it again to check the oil level. the recommended type to raise it to the

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 8-14 Periodic Maintenance and Adjustment
correct level.
7. Insert the dipstick into the oil filler hole,
and then tighten the oil filler cap.
8. Install the console.

To change the engine oil (with or without

oil filter cartridge replacement)
1. Remove the console. (See page 8-7-8-8
for console removal and installation
procedures.)
2. Place an oil pan under the engine to 1. Engine oil drain bolt
collect the used oil, and then remove the NOTE:
engine oil filler cap. Skip steps 4-6 if the oil filter cartridge is not
3. Remove the engine oil drain bolt to drain being replaced.
the oil from the crankcase.
4. Remove the oil filter cartridge with an oil
filter wrench.

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 Periodic Maintenance and Adjustment 8-15

1. Oil filter cartridge 2. Oil filter wrench 1. O-ring

NOTE: 6. Install the new oil filter cartridge with an
An oil filter wrench is available at a nearby oil filter wrench, and then tighten it to the
specified torque with a torque wrench.
service center.
Tightening torque:
Oil filter cartridge:
5. Apply a light coat of engine oil to the 12 ft·lbf (17Nm, 1.7m·kgf)
O-ring of the new oil filter cartridge.
NOTE:
Make sure the O-ring is seated properly.

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 8-16 Periodic Maintenance and Adjustment

Recommended engine oil:

See page 10-2.
Oil quantity:
Without oil filter cartridge replacement
2.01 qt (1.9L)
With oil filter cartridge replacement:
2.22 qt (2.1L)

CAUTION:
z In order to prevent clutch slippage (since
1. Oil filler cartridge 2. Torque wrench the engine oil also lubricates the clutch),
7. Install the engine oil drain bolt, and then do not mix any chemical additives. Do
tighten it to the specified torque. not use oils with a diesel specification of
Tightening torque: “CD” or oils of a higher quality than
Engine oil drain bolt: specified. In addition, do not use oils
22 ft·lbf (30Nm, 3.0m·kgf) labeled “ENERGY CONSERVING II” or
higher.
8. Add the specified amount of z Make sure that no foreign material enters
recommended engine oil, and then install the crankcase.
engine oil filler cap and tighten.

9. Start the engine, and then let it idle for

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 Periodic Maintenance and Adjustment 8-17
several minutes while checking it for oil
leakage. If oil is leaking, immediately turn
the engine off and check for the cause.
10. Turn the engine off, wait at least ten
minutes, and then check the oil level and
correct it if necessary.
11. Install the console.

Final gear oil

1. Speedometer sensor 2. final gear oil
Checking the final gear oil level
3. Correct oil level
1. Place the vehicle on a level surface.
NOTE:
2. Remove the oil filler bolt, and then check
The oil level should be at the brim of the filler
the oil level in the final gear case.
hole.
3. If the oil is below the brim of the filler hole,
add sufficient oil of the recommended
type to raise it to the correct level.

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 8-18 Periodic Maintenance and Adjustment
bolt to drain the oil.
CAUTION:
1. Be sure no foreign material enters the
final gear case.
2. Please clean the sensor every 320 mile
period.
3. Install the oil filler bolt, and then tighten it
to the specified torque.

Tightening torque: 1. Final gear oil drain bolt

Final gear oil filler bolt: 4. Install the drain bolt, and then tighten it to
17 ft·lbf (23 Nm, 2.3 m·kgf,) the specified torque.

Changing the final gear oil Tightening torque:

1. Place the vehicle on a level surface. Final gear oil drain bolt:
14 ft·lbf (20 Nm, 2.0 m·kgf )
2. Place a container under the final gear
5. Add the recommended final gear oil up to
case to collect the used oil.
the brim of the filler hole.
3. Remove the oil filler bolt and the drain

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 Periodic Maintenance and Adjustment 8-19
Differential gear oil
Checking the differential gear oil level
Recommended oil: 1. Place the vehicle on a level surface.
SAE 80 API GL-4Hypoid gear oil 2. Remove the differential gear oil filler bolt
Oil quantity: and check the oil level. It should be up to
0.26 qt (0.25 L) the brim of the filler hole. If the level is
low, add sufficient oil of the
CAUTION: recommended type to raise it to the
Be sure no foreign material enters the final specified level.
gear case.
CAUTION:
6. Install the oil filler bolt, and then tighten it Be sure no foreign material enters the
to the specified torque. differential gear case.

Tightening torque:
Final gear oil filler bolt:
17 ft·lbf (23 Nm, 2.3 m·kgf)
7. Check for oil leakage. If oil leakage is
found, check for the cause.

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 8-20 Periodic Maintenance and Adjustment
Changing the differential gear oil
1. Place the vehicle on a level surface.
2. Place a container under the differential
gear case to collect the used oil.
3. Remove the differential gear oil filler bolt
and differential gear oil drain bolt to drain
the oil.

1. Differential gear oil filler bolt

2. Correct oil level 3. Differential gear oil

3. Install the differential gear oil filler bolt,

and then tighten it to the specified torque.

Tightening torque:
Differential gear oil filler bolt:
17 ft·lbf (23Nm, 2.3 m·kgf) 1. Differential gear oil drain bolt
4. Install the differential gear oil drain bolt,
and tighten it to the specified torque.

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 Periodic Maintenance and Adjustment 8-21

Tightening torque: Tightening torque:

Differential gear oil drain bolt: Differential gear oil filler bolt:
7.1 ft·lbf (9.8Nm, 0.98 m·kgf) 17 ft·lbf (23Nm, 2.3m·kgf)

7. Check for oil leakage. If oil leakage is

5. Fill the differential gear case with the
found, check for the cause.
recommended oil.
Recommended oil: Coolant
SAE 80 API GL-5 Hypoid gear oil The coolant level should be checked before
Oil quantity: each ride.
0.34 qt (0.32 L)
Checking the coolant level
CAUTION:
1. Place the vehicle on a level surface.
Be sure no foreign material enters the
2. Open the hood. (See pages 8-7－8-8 for
differential gear case.
hood opening and closing procedures.)
3. Check the coolant level in the coolant
6. Install the differential gear oil filler bolt,
reservoir when the engine is cold as the
and then tighten it to the specified torque.
coolant level varies with engine
temperature.

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 8-22 Periodic Maintenance and Adjustment
NOTE:
The coolant should be between the minimum Coolant reservoir capacity
and maximum level marks. (up to the maximum level mark):
0.37 qt (0.35L)

CAUTION:
Mix anti freeze with distilled water only.
However, if distilled water is not available,
soft water may be used for refilling.

Changing the coolant

The coolant must be changed by a service
center at the intervals specified in the
1. Coolant reservoir cap periodic maintenance and lubrication chart.
2. Maximum level mark 3. Minimum level mark NOTE:
4. If the coolant is at or below the minimum ● Adding water instead of coolant lowers
level mark, remove the reservoir cap, the antifreeze content of the coolant. If
add coolant to the maximum level mark, water is used instead of coolant, have a
install the reservoir cap, and then close service center check the antifreeze
the hood. content of the coolant as soon as

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 Periodic Maintenance and Adjustment 8-23
possible. 1.

● The radiator fan is automatically

switched on or off according to the
coolant temperature in the radiator.

Axle boots
Check the protective boots for holes or tears.
If any damage is found, have them replaced
by a service center.
1. Rear axle boot (×2 each side)

Spark plug inspection

Removal
1. Lift the cargo bed up. (See pages 4-21 -
4-22 for cargo bed lifting and lowering
procedures.)
2. Remove the spark plug cap.

1.Front axle boot (×2 each side)

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 8-24 Periodic Maintenance and Adjustment

1. Spark plug cap 1. Spark plug wrench

3. Use the spark plug wrench in the tool kit
to remove the spark plug as shown. Inspection
The spark plug is an important engine
component and is easy to inspect. The
condition of the spark plug can indicate the
condition of the engine. The ideal color of the
porcelain insulator around the center
electrode is a medium-to-light tan for a
vehicle that is being ridden normally.

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 Periodic Maintenance and Adjustment 8-25
Do not attempt to diagnose such problems
yourself. Instead, take the vehicle to a
service center. You should periodically
remove and inspect the spark plug because
heat and deposits will cause the spark plug
to slowly break down and erode. If electrode
erosion becomes excessive, or if carbon and
other deposits are excessive, you should
replace the spark plug with the specified
plug.
Specified spark plug:
a. Spark plug gap
DR8EA (NGK)
2. Clean the surface of the spark plug
gasket and its mating surface, and then
Installation wipe off any grime from the spark plug
1. Measure the electrode gap with a wire
threads.
thickness gauge and, if necessary, adjust
3. Install the spark plug and tighten it to the
the gap to specification.
specified torque.
Spark plug gap:
0.023-0.027 in (0.6 - 0.7 mm)

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 8-26 Periodic Maintenance and Adjustment
element and air filter case.
Tightening torque:
Spark plug:
12.7 ft·lbf (17.5 Nm, 1.75 m·kgf)

NOTE:
If a torque wrench is not available when you
are installing the spark plug, a good estimate
of the correct torque is 1/4 to 1/2 turn past
finger tight. Have the spark plug tightened to
the specified torque as soon as possible.
1. Air filter check hose
4. Install the spark plug cap. 1. Remove the seats. (See pages 4-17 -
5. Lower the cargo bed. 4-18 for seat removal and installation
procedures.)
Cleaning the engine air filter element 2. Remove the console. (See page 8-7-8-8
for console removal and installation
NOTE:
procedures.)
There is a check hose at the bottom of the air
3. Remove the air filter case cover by
filter case. If dust or water collects in this
unhooking the holders.
hose, empty the hose and clean the air filter

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 Periodic Maintenance and Adjustment 8-27

1. Air filter element

1. Holder (×4) 2. Air filter case cover

4. Remove the air filter element.

5. Remove the sponge material from its
frame.

1. Air filter frame 2. Sponge material

3. Element retaining plate

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 8-28 Periodic Maintenance and Adjustment
6. Wash the sponge material gently but CAUTION:
thoroughly in solvent. Do not twist the sponge material when
WARNING squeezing it.
POTENTIAL HAZARD 8. Inspect the sponge material and replace
Using low flash point solvents or it if damaged.
gasoline to clean the sponge material. 9. Thoroughly apply foam air filter oil or
WHAT CAN HAPPEN other quality liquid foam air filter oil (not
Low flash point solvents or gasoline can spray type) to the sponge material.
catch fire or explode.
HOW TO AVOID THE HAZARD NOTE:
Use parts cleaning solvent to clean the The sponge material should be wet but not
sponge material. dripping.

7. Squeeze the excess solvent out of the 10. Pull the sponge material over its frame.
sponge material and let it dry. 11. Install the air filter element.
12. Install the air filter case cover and be
sure the crankcase breather hose is
connected.

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 Periodic Maintenance and Adjustment 8-29
element rubber joint to the fuel system and
manifold fittings securely to avoid the
possibility of unfiltered air entering the
engine.

CAUTION:
Never operate the engine with the air filter
element removed. This will allow unfiltered
1. Crankcase breather hose
air to enter, causing rapid engine wear and
13. Install the console.
14. Install the seats. possible engine damage. Additionally,
operation without the air filter element will
NOTE:
The air filter element should be cleaned affect performance with subsequent poor
every 20-40 hours. It should be cleaned and performance and possible engine
lubricated more often if the vehicle is overheating.
operated in extremely dusty areas. Each time
air filter element maintenance is performed,
check the air inlet to the air filter case for
obstructions. Check the air filter

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 8-30 Periodic Maintenance and Adjustment
V-belt cooling duct check hose V-belt case drain plug
The V-belt cooling duct check hose is located The V-belt case drain plug is located under
under the driver seat. (See pages 4-17 - 4-18 the driver seat. (See pages 4-17 - 4-18 for
for seat removal and installation procedures.) seat removal and installation procedures.)
If dust or water collects in the V-belt cooling After riding in water deep enough to allow
duct check hose, remove the hose and clean water to enter the V-belt case, remove the
it. drain plug to drain any water from the case.

NOTE:
If water drains from the V-belt case after
removing the drain plug, have a service
center inspect the vehicle as the water may
affect other engine parts.

1. V-belt cooling duct check hose

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 Periodic Maintenance and Adjustment 8-31

1. V-belt case drain plug 1. Bolt(×3)

2. Remove the tailpipe by pulling it out of
Cleaning the spark arrester the muffler.
Be sure the exhaust pipe and muffler are 3. Tap the tailpipe lightly, and then use a
cool before cleaning the spark arrester. wire brush to remove any carbon
1. Remove the bolts. deposits from the spark arrester portion
of the tailpipe and inside of the tailpipe
housing.

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 8-32 Periodic Maintenance and Adjustment

WARNING
POTENTIAL HAZARD
Improper cleaning of the spark arrester.
Hot exhaust system
WHAT CAN HAPPEN
Could injure the eyes.
Could cause burns.
Could cause carbon monoxide
poisoning, possibly leading to death.
Could start a fire.
HOW TO AVOID THE HAZARD
1. Tailpipe 2. Spark arrester
When cleaning the spark arrester:
4. Insert the tailpipe into the muffler and Always let the exhaust system cool prior
align the bolt holes. to touching exhaust components.
5. Install the tailpipe by installing the bolts, Do not start the engine when cleaning the
and then tighten the bolts to the specified exhaust system.
torque.
Tightening torque:
Tailpipe bolt:
6.9 ft·lbf (9.5 Nm, 0.95 m·kgf)

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 Periodic Maintenance and Adjustment 8-33
Valve clearance
The correct valve clearance changes with
use, resulting in improper fuel-air supply or
engine noise. To prevent this, the valve
clearance must be adjusted regularly. This
adjustment however, should be left to a
professional service technician.

Front brake pad check

1. Brake pad wear indicator groove
Each brake pad is provided with wear
indicator grooves, which allow you to check
NOTE:
the brake pad wear without having to
disassemble the brake. To check the brake The wheels need to be removed to check the
pad wear, check the wear indicator grooves. brake pads. (See pages 8-41-8-42 for wheel
If a brake pad has worn to the point that the removal and installation procedures.)
wear indicator grooves have almost
disappeared, have a service center replace
the brake pads as a set.

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 8-34 Periodic Maintenance and Adjustment
Rear brake pad check Checking the brake fluid level
Each brake pad is provided with wear Insufficient brake fluid may let air enter the
indicator grooves, which allow you to check brake system, possibly causing the brakes to
the brake pad wear without having to become ineffective. Before riding, check that
disassemble the brake. To check the brake the brake fluid is above the minimum level
pad wear, check the wear indicator grooves. mark and replenish if necessary.
If a brake pad has worn to the point that the
wear indicator grooves have almost
disappeared, have a service center replace
the brake pads as a set.

1. Minimum level mark

A low brake fluid level may indicate worn
brake pads and/or brake system leakage. If
the brake fluid level is low, be sure to check
the brake pads for wear and the brake
1. Brake pad wear indicator groove system for leakage.

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 Periodic Maintenance and Adjustment 8-35
The brake fluid reservoir is located under the the fluid and may result in vapor lock.
hood. (See pages 8-7- 8-8 for hood opening z Brake fluid may deteriorate painted
and closing procedures.) surfaces or plastic parts. Always clean up
spilled fluid immediately.
Observe these precautions: z Have a service center inspect the brake
z When checking the fluid level, make sure system if the brake fluid level goes down.
the top of the brake fluid reservoir is
level. Brake fluid replacement
z Use only the recommended quality brake Complete fluid replacement should be done
fluid. Otherwise, the rubber seals may only by trained service personnel. Have a
service center replace the following
deteriorate, causing leakage and poor
components during periodic maintenance
braking performance
or when they are damaged or leaking.
Recommended brake fluid: DOT 4 z Replace the oil seals every two years.
z Refill with the same type of brake fluid. z Replace the brake hoses every four
Mixing fluids may result a harmful years.
chemical reaction and lead to poor
Checking the brake pedal
braking performance.
Have a service center check the brakes at
z Be careful that water does not enter the
the intervals specified in the periodic
brake fluid reservoir when refilling. Water
maintenance and lubrication chart. There
will significantly lower the boiling point of

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 8-36 Periodic Maintenance and Adjustment
should be no free play in the brake pedal.
The brakes should operate smoothly and WARNING
there should be no brake drag. If the brakes POTENTIAL HAZARD
feel soft or spongy, this could indicate air in Operating with improperly serviced or
the brake system. Have a service center adjusted brakes.
check the brake system if necessary.
WHAT CAN HAPPEN
You could lose braking ability, which
could lead to an accident.
HOW TO AVOID THE HAZARD
After servicing:
z Make sure the brakes operate
smoothly and that the brake pedal
position is correct.
z Make sure the brakes do not drag.
z All air must be bled from the brake
1. Brake pedal system.
Replacement of brake components
requires professional knowledge. These
procedures should be performed by a
service center.

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 Periodic Maintenance and Adjustment 8-37
Parking brake lever free play adjustment
Periodically check the parking brake lever
free play and adjust it if necessary.
1. Shift the drive select lever into low gear
“L”.
2. Remove the seats. (See page 4-16 -
4-17 for seat removal and installation
procedures.)
3. Remove the console. (See page 8-7-8-8
for console removal and installation
procedures.) 1.Parking brake lever free play

4. Check the parking brake lever free play. NOTE:

The maximum free play is equal to one The parking brake lever must be released
click of the parking brake lever. If when checking and adjusting the parking
necessary, adjust the free play as brake lever free play.
follows. 5. Loosen the locknut.

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 8-38 Periodic Maintenance and Adjustment
Brake light switch adjustment
The brake light switch, which is activated by
the brake pedal, is properly adjusted when
the brake light comes on just before braking
takes effect. If necessary, adjust the brake
light switch as follows.
1. Open the hood. (See pages 8-7 - 8-8 for
hood opening and closing procedures.)
2. Turn the adjusting nut while holding the
brake light switch in place. To make the
brake light switch in place. To make the
1. Locknut 2. Adjusting nut brake light come on earlier, turn the
6. Turn the adjusting nut in direction to adjusting nut in direction . To make
the brake light come on later, turn the
increase the free play or in direction
adjusting nut in direction .
to decrease the free play.
7. Tighten the locknut.
8. Install the console.
9. Install the seats.

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 Periodic Maintenance and Adjustment 8-39

WARNING
POTENTIAL HAZARD
Damaged control cables.
WHAT CAN HAPPEN
Corrosion can result when the outer
covering of control cables becomes
damaged. Cables can also become frayed
or kinked. Operation of controls could be
restricted, which could cause an accident
1. Brake light switch. 2. Adjusting nut
or injury.
3. Close the hood.
HOW TO AVOID THE HAZARD
Cable inspection and lubrication Inspect cables frequently. Replace
damaged cables.
Lubricate the inner cables and the cable
ends. If the cables do not operate smoothly,
ask a service center to replace them. Recommended lubricant:
Engine oil

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 8-40 Periodic Maintenance and Adjustment
Brake pedal and accelerator pedal with a grease gun.
lubrication
Lubricate the pivoting parts.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)

Recommended lubricant:
Lithium-soap-based grease

Rear knuckle upper and lower pivot

lubrication
Lubricate the knuckle upper and lower pivots

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 Periodic Maintenance and Adjustment 8-41
Steering shaft lubrication Wheel removal
Lubricate the pivot points. Loosen the wheel nuts .
Recommended lubricant: Elevate the vehicle and place a suitable
Lithium-soap-based grease stand under the frame.
(all-purpose grease) Remove the nuts from the wheel.
Remove the wheel.

1. Nut（×4）

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 8-42 Periodic Maintenance and Adjustment
Wheel installation
1. Install the wheel and the nuts.
NOTE:
● The arrow mark on the tire must
point toward the rotating direction of the
wheel.
● Tapered nuts are used for both the front
and rear wheels. Install the nut with its
tapered side towards the wheel.

1. Tapered nut
2. Lower the vehicle so that the wheel is on
the ground.
3. Tighten the wheel nuts to the specified
torque.

Wheel nut torque:

Front：40 ft·lbf (55Nm, 5.5 m·kgf）
Rear：40 ft·lbf (55Nm, 5.5 m·kgf）

1. Arrow mark

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 Periodic Maintenance and Adjustment 8-43
Battery
This vehicle is equipped with a sealed-type
battery. Therefore it is not necessary to
check the electrolyte or add distilled water in
the battery. If the battery seems to have
discharged, consult a service center.
CAUTION:
Do not try to remove the sealing caps of the
battery cells. You may damage the battery.

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 8-44 Periodic Maintenance and Adjustment

WARNING
POTENTIAL HAZARD
Failure to handle batteries or battery electrolyte carefully.
WHAT CAN HAPPEN
You could be poisoned. You could be severely burned by the sulfuric acid in battery
electrolyte. Batteries produce explosive gases.
HOW TO AVOID THE HAZARD
Avoid contact with skin, eyes or clothing. Always shield eyes when working near batteries.
Keep out of reach of children.
Antidote:
EXTERNAL: Flush with water.
INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten
egg or vegetable oil. Get prompt medical attention.
EYES: Flush with water for 15 minutes and get prompt medical attention. Keep batteries
away from sparks, flames, cigarettes or other sources of ignition. Ventilate when charging
or using in a closed space.

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 Periodic Maintenance and Adjustment 8-45
Battery maintenance
1. When the vehicle is not used for a month
or longer, remove the battery and store it
in a cool, dark place. Completely
recharge the battery before reinstallation.
CAUTION:
A special battery charger (constant
voltage/ampere or constant voltage) is
required for recharging a sealed-type battery.
Using a conventional battery charger may
shorten the battery life.
1. Positive battery lead 2. Negative battery lead
2. Always make sure the connections are
correct when putting the battery back in Fuse replacement
the vehicle. The main fuse and the fuse box are located
under the hood, the ECU are located under
the seat.（See pages 8-8 for hood opening
and closing procedures. And see page 4-17
for remove seat.）
If a fuse is blown, turn off the main switch
and install a new fuse of the specified
amperage.

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 8-46 Periodic Maintenance and Adjustment
If a fuse is blown, replace it as follows. a fuse.
1. Turn the key to “OFF” and turn off the
electrical circuit in question. 3. Remove the blown fuse, and then install
2. Remove the hood opening, then unplug a new fuse of the specified amperage.
the relay assembly and open the relay
cover.

1. Relay assembly 2. Backup fuse

3. Relay 4. Fuse box
1. Screw M3 （×4） 2. Relay cover
5. Adapter connector 3 6. Adapter connector 2

CAUTION: 7. Adapter connector 1 8. ECU

To prevent accidental short-circuiting, turn off

the main switch when checking or replacing

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 Periodic Maintenance and Adjustment 8-47

Specified Fuse: WARNING

Main Fuse: 30.0A POTENTIAL HAZARD
Using an improper fuse
Headlight Fuse: 15.0A
WHAT CAN HAPPEN
ECU Fuse: 15.0A An improper fuse can cause damage to
Auxiliary DC Jack Fuse: 10.0A the electrical system, which could lead to
Signaling System Fuse: 10.0A a fire.
HOW TO AVOID THE HAZARD
2WD/4WD Fuse 10.0A
A/ways use a fuse of the specified rating.
Backup Fuse: 5.0A/10.0A/15.0A Never use a material in place of the
Speedmeter/ECU 5.0A proper fuse.
-normal open Fuse:
Replacing a headlight bulb
4. Turn the key to “ON” and turn on the If a headlight bulb bums out, replace it as
electrical circuit in question to check if follows.
the device operates. 1. Lift the hood up.（See pages 8-7-8-8 for
5. If the fuse immediately blows again, have hood opening and closing procedures.）
a service center check the electrical 2. Remove the cover at the rear of the
system.
headlight by pulling it off.

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 8-48 Periodic Maintenance and Adjustment

1. Cover at the rear of the headlight 1. Headlight bulb holder cover

3. Remove the headlight bulb holder cover 4. Remove the headlight bulb holder by
by pulling it off. pushing it in and turning it
counterclockwise.

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 Periodic Maintenance and Adjustment 8-49

WARNING
POTENTIAL HAZARD
A headlight bulb is hot when it is on and
immediately after it is turned off.
WHAT CAN HAPPEN
You can be burned, or a fire could start if
the bulb touches something flammable.
HOW TO AVOID THE HAZARD
Wait for the bulb to cool before touching
or removing it.
6. Insert a new headlight bulb into the bulb
1. Headlight bulb holder
holder by pushing it in.
5. Remove the defective bulb by pulling it
out.

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 8-50 Periodic Maintenance and Adjustment
turning it clockwise.
8. Install the bulb holder cover and the
cover at the rear of the headlight.
CAUTION:
Make sure the headlight bulb holder cover is
securely fitted over the bulb holder and
seated properly.

9. Close the hood.

10. Adjust the headlight beam if necessary.
1. Do not touch the glass part of the bulb.
Headlight beam adjustment
CAUTION:
Do not touch the glass part of the headlight CAUTION:
bulb to keep it free from oil, otherwise the It is advisable to have a service center make
transparency of the glass, the luminosity of this adjustment.
the bulb, and the bulb life will be adversely
To raise the beam, turn the adjusting screw in
affected. Thoroughly clean off any dirt and
fingerprints on the headlight bulb using a direction 。
cloth moistened with alcohol or thinner. To lower the beam, turn the adjusting screw
in direction .
7. Install the bulb holder by pushing it is and

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 Periodic Maintenance and Adjustment 8-51

1. Panel A
1. Headlight beam adjusting screw

Tail/brake light bulb replacement

If a tail/brake light bulb burns out, replace it
as follows:
1. Remove panel A (if replacing the left
tail/brake bulb) or panel B (if replacing
the right tail/brake bulb) by removing the
quick fasteners and bolts.

1. Panel B

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 8-52 Periodic Maintenance and Adjustment

1. Quick fastener（×8） 2. Bolt（×2）

1. Tail/brake light bulb holder
3. Panel A
3. Push the defective bulb in and turn it
counterclockwise to remove it from the
2. Remove the bulb holder（together with
bulb holder.
the bulb）by turning it counterclockwise.
4. Push a new bulb in and turn it clockwise
to install in the bulb holder.
5. Install the bulb holder（together with the
bulb）by turning it clockwise.
6. Install the panel by installing the quick
fasteners and bolts, and then tighten the
bolts to the specified torque.

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 Periodic Maintenance and Adjustment 8-53
Imitation parts may look like genuine parts,
Tightening torque: but they are often inferior.
Panel bolt: Consequently, they have a shorter service
4.7 ft·lbf (6.5N·m, 0.65 m·kgf）
life and can lead to expensive repair bills.

Troubleshooting WARNING
Although vehicles receive a rigid inspection POTENTIAL HAZARD
before shipment from the factory, trouble Checking the fuel system while smoking
may occur during operation. Any problem in or near an open flame.
WHAT CAN HAPPEN
the fuel, compression, or ignition systems
Fuel can ignite or explode, causing
can cause poor starting and loss of power. severe injury or property damage.
The troubleshooting chart describes a quick, HOW TO AVOID THE HAZARD
easy procedure for making checks. If your Do not smoke when checking the fuel
vehicle requires any repair, take it to a system. Make sure there are on open
flames or sparks in the area, including
service center.
pilot lights from water heaters of
The skilled technicians at a service center furnaces.
ship have the tools, experience, and know
how to properly service your vehicle.

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 8-54 Periodic Maintenance and Adjustment
Solution to Common Problems in Vehicle
The below tables show some common problems that may come up when you are driving a UTV,
which will help to solve these problems. To repair a UTV requires technical skills, if you cannot
repair the UTV yourself, please contact your service center.

Table 1: Solution of Common Problems in Appearance Parts and Impact Fittings.

S/N Problems Solutions

1. Replace whit a new plastic cover.

2. Check if support brackets are bent or deformed, repair and

1 Plastic cover damaged
re-paint if needed before replacing new plastic cover.
3. Re-apply decals and re-rivet warning labels.

1. Replace with a new bumper.

2 Bumper damaged 2. Check if support brackets are bent or deformed, repair and
re-paint if needed before replacing new bumper.

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 Periodic Maintenance and Adjustment 8-55

S/N Problems Solutions

1. Replace Front Skid Plate with a new one.
Damaged Front Skip Plate 2. Check if the gearbox or front differential / rear axles are
3
damaged or leaking.
3. Check plastic cover for damaged and replace if needed.

4 Warning labels 1. Replace damaged warning labels

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 8-56 Periodic Maintenance and Adjustment
Table 2：Solution of Common Problems in Brake System

S/N Problems Solutions

1. Check whether brake disc plates deformed or damaged.
1 Locked braking system 2. Check whether hydraulic cylinder is locked or brake clamp
assembly parts are deformed or damaged.
1. Check the disc brake pads for excessive wear.
Brake performance 2. Check the brake pads and rotor disc for excessive wear or
2
decreases oil which might have gotten on either.
3. Check brake fluid and refill if necessary.
Grinding noises from front 1. Check brake rotor for excess wear.
3 brake or brake rotor
become red during 2. Check whether hydraulic cylinder is locked or brake clamp
operation due to heat. assembly parts are deformed or damaged.
1. Check whether brake disc plates deformed or damaged.
Grinding noises from front 2. Check whether hydraulic cylinder is locked or brake clamp
4 brake or brake rotor
become red during assembly parts are deformed or damaged.
operation due to heat. 3. Check if rear brake is locked and will not release. Check if
the parking brake is in the “ON” position.

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 Periodic Maintenance and Adjustment 8-57

S/N Problems Solutions

1. Check if front brakes (left and right) are applying equal force
to the right and left brake rotors.
2. Check if a lack of front brake power has caused the rear
wheels to “lock up” locked before front wheels.
3. Check if the left and right absorber springs are applying the
Pulling to the left or right same force and are within the specifications.
5
during high speed braking 4. Check if the front wheels and front wheel axle nuts are loose
or damaged.
5. Check if the front wheel hub inner splines and front wheel
axle outer splines are worn or loose.
6. Check whether rubber washers connected to front
suspension rocker and frame are damaged.

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 8-58 Periodic Maintenance and Adjustment
Table 3: Solution of Common Problems in Running System

S/N Problems Solutions

1. Check if the steering wheel nut is loose or damaged.
Steering wheel is loose 2. Check if the steering column clip and clip seat loose or
1 and shifts up and down damaged.
when pulled.
3. Check if the steering column bottom end inner bearing is
damaged.
1. Check if the tie-rod and steering column locknut has
Front wheel steering loosened or become damaged, or if the steering knuckle and
2
clearance excessive steering column locknut has loosened or is damaged.
2. Check if the tie-rod two ball joints are damaged or loose.
1. Check if the steering knuckle bearing is damaged.
2. Check if the king pin ball joint is damaged.
Front wheels sway during 3. Check if the front wheel and axle locknut is loose or damaged.
3
operation 4. Check if the front wheel hub inner splines and front wheel
axle outer splines are worn or loose.
5. Check if the rubber washers connected to front suspension
rocker arms and frame are damaged.

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 Periodic Maintenance and Adjustment 8-59

S/N Problems Solutions

1. Check if the rear axle bearings are damaged.
2. Check if the sliding bearings connected to rear axle bearing
housing and rocker arm are loose or damaged.
Rear wheels sway 3. Check if the rear wheel and axle locknut are loose or
4 during operation damaged.
4. Check if the rear wheel hub inner splines and rear wheel
axle outer splines are worn or loose.
5. Check if the rubber washers connected to rear suspension
rocker arms and frame are damaged.
1. Check if the wheel rims are bent or deformed.
5 Wheels hop during oper 2. Check if the front and rear axles are bent.
3. Check if the tires are aging, deformed or need air.
1. Check if the vehicle is overloaded.
Shock absorbers become 2. Check if the shocks need replacing.
6 soft or not comfortable
during use. 3. Check if the shock absorbers have lost their damping force
and their travel.

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 8-60 Periodic Maintenance and Adjustment

S/N Problems Solutions

1. Check if the drive shaft spline is broken.
2. Check if the splines in left & right axles and front & rear drive
shafts are broken.
7 Front drive shaft makes
noise during use. 3. Check if the gears in rear drive shaft and reduction gear box
differential are worn.
4. Check the dust covers of universal joints in right & left drive
shafts are damaged.

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 Periodic Maintenance and Adjustment 8-61
Table 4: Solution of Common Problems in Electrical System

S/N Problems Solutions

1. Check if the headlight switch functions well.
1 Lights do not work. 2. Check if the wires are broken.
3. Check if the lamps or bulbs are broken.
1. Check if the control switch on meter board works well.
Vehicle cannot go into 4 2. Check if the differential lock control magneto plug in rear
2 reduction gear box is damaged.
wheel drive mode.
3. Check if any wires are broken.
Rear differential will not
3 1. Check if the control switch on meter board works well.
work.
Rear differential will not 1. Check if the differential lock control magneto plug in rear
4 reduction gear box is broken.
work. 2. Check if any wires are broken.
1. Check if the sensor is damaged.
Meter display is not 2. Check if the meter is broken.
5
normal. 3. Check if the surface of speed sensor is contaminated with
iron dust.
1. Check if the switch is broken.
Start switch on meter
6 2. Check if any wires are broken.
board will not work. 3. Check if the ECU is broken

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 8-62 Periodic Maintenance and Adjustment

S/N Problems Solutions

1. Check if the ECU is broken.
2. Check if the nozzle is clogged or the nozzle to the ECU
connection is disconnected.
3. Check if the engine speed signal sensor is broken.
4. Check if the engine speed signal to ECU connection is
disconnected.
7 EFI system
5. Check if the inlet pressure/temperature sensor is
damaged or the ECU connection is disconnected.
6. Check if the throttle sensor is damaged or the ECU
connection is disconnected.
7. Check if the Sub-harness (cable) of the electrical injection
is broken.

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 Periodic Maintenance and Adjustment 8-63
Table5: Solution of Common Problems in Engine System
S/N Problems Solutions
Power or performance is 1. Check and clean the core of air cleaner.
1 falling. 2. Check muffler for partly blocked and clean spark arrestor.
1. Check air cleaner and admission line for leaks.
2 Popping noise in engine. 2. Check the connection joint of exhaust pipe with engine or
muffler for leaks.
3. Check the grade of gasoline to see if it’s too low.
1. Check if the battery voltage goes down when the
Engine is difficult to start temperature goes down.
3
at low temperatures. 2. If the temperature is under -18Ԩ, place the vehicle in
warmer place for starting.
1. Check cooling fan of radiator for blockage by soil or dirt.
2. Check the speed sensor of radiator for damage and Check
4 Coolant boils. the fan for failure.
3. Check if antifreeze meets the requirements stated in the
owners manual
1. Check the battery. A low battery can cause motor not to
star or run poorly
5 Engine cannot start. 2. Check the starting motor for damage.
3. Check if the spark plug is fouled or burned.
4. Check if the air cleaner is blocked.

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 8-64 Periodic Maintenance and Adjustment

S/N Problems Solutions

5. Check if the oil circuit is working properly.
5 Engine cannot start.
6. Check if the exhaust system is blocked.
1. Check if the spark plug is loose.
Cylinder and cylinder 2. Check if the cylinder head or cylinder body is loose.
6 head 3. Check if the cylinder head gasket is broken.
4. Check if the cylinder gasket is broken.
5. Check if the cylinder body is worn, damaged or seized.
1. Check for an improperly installed piston ring.
2. Check if the piston ring is worn or broken.
7 Piston and piston rings
3. Check if the piston ring is seized.
4. Check if the piston is seized or damaged.
1. Check for an Improperly sealed valve.
Valve, camshaft and 2. Check for improperly connected valve and valve seat.
8 crankshaft 3. Check if the valve timing is improper.
4. Check if the valve spring is broken.
5. Check if the camshaft is seized.

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 Periodic Maintenance and Adjustment 8-65

S/N Problems Solutions

Crankcase and 1. Check if the crankcase installed improperly.
9
crankshaft 2. Check if the crankshaft is seized.
1. Check for improperly adjusted valve clearance.
10 Valve gear
2. Check for improperly adjusted valve timing.

WARNING
POTENTIAL HAZARD
Removing the radiator cap when the engine and radiator are still hot.
WHAT CAN HAPPEN
You could be burned by hot fluid and steam blown out under pressure.
HOW TO AVOID THE HAZARD
Wait for the engine to cool before removing the radiator cap. Always use a thick rag over the
cap. Allow any remaining pressure to escape before completely removing the cap.

NOTE:
If it is difficult to get the recommended coolant, tap water can be temporarily used, provided that
it is changed to the recommended coolant as soon as possible.

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 9-1 Electric power steering system
efficiency, usually only 60%-70%.
However, EPS system is connected by
INTRODUCTION
mechanical and electric motor and it is
Our UTV is equipped with Electric Power
much high efficiency with up to 90%.
Steering System (EPS). To keep reliability of
2） Less energy consumption. In practical
EPS during operation, please correctly use
driving process of UTV, time in steering
EPS system according to the following
condition is only 5% among the total
descriptions and keep daily inspection and
travelling time. As to hydraulic power
maintenance.
steering system, as long as the engine is
This chapter also provides important
running, the hydraulic pump is always in
information to safely use EPS system. If you
working condition, and fuel consumption
encounter any problem during operation or
will increase 4%-6%. However, EPS
maintenance, please feel free to consult your
system starts the motor, only when it
local dealer.
needs steering, to generate power
without increasing fuel consumption.
ADVANTAGES OF EPS SYSTEM:
3） The power characteristics of EPS system
1） High efficiency. Traditional hydraulic
can be controlled by software, so that
power steering system is connected by
UTV can be satisfied with power steering
mechanical and hydraulic, and it is of low

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 Electric power steering system 9-2
characteristics at various speeds. IMPORTANT INFORMATION
4） Feeling comfortable on road. Inside of FOR SAFETY:
EPS system, we use rigid connection, so UTV you buy is equipped with EPS system,
under auxiliary of start motor, the impact please read this chapter carefully before
of road barriers on steering wheel can be operating UTV, and only you are familiar with
greatly decreased. and master enough of EPS system about
5） No pollution to environment. For the using methods and precautions information
traditional hydraulic power steering can you start to drive your UTV.
system, the hydraulic circuit has Make inspection and maintenance on EPS
hydraulic hose and fittings inside so oil system on regular, and ensure the security
leaks may occur, and hydraulic hose is and reliability when you use your UTV.
not recycled, so this is produce pollution
to environment. However, EPS system z Please carefully read this chapter before
has not pollution to environment. operation or driving to acknowledge
6） When engine does not start, EPS system completely about correct way to operate
can also work as battery, and once and drive the UTV with EPS system, and
sufficient power generate, steering power also characteristics, functions and limits
can be workable. of UTV. Doing inspection and

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 9-3 Electric power steering system
maintenance on EPS system on regular, INTRODUCTION OF EPS SYSTEM
correct operation and driving skills will
What is EPS system
ensure the security and reliability of
UTV. The EPS system (Electric Power Steering
System) is a complete set of parts, including
z To make sure your EPS system will be
a special ECU only for EPS system
useful for a long time and no problem,
(hereinafter referred to as ECU), many
please follow the method for
sensors and actuators, by signal such as
maintenance in this chapter.
monitoring UTV speed, the operating force of
z This chapter also includes detailed the steering wheel, as well as temperature of
disassembly and maintenance ECU and motor to provide an accurate power
information. User wants to repair by torque of the motor and aligning torque. As a
themselves must have qualified result, it will have easy steering function and
mechanical skills, electronic soft effect of steering wheel aligning.
maintenance skills and the special tools
mentioned in the manual.

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 Electric power steering system 9-4
Typical parts of EPS system Construction of EPS
In general, EPS system has the following 1. Structure chart of EPS
parts:
• Steering torque sensor
• Motor to generate power torque
• EPS system control unit （ECU）。
• Speed sensor。
• Temperature sensor
• Battery voltage sensor
• Mechanical reduction transmission
mechanism（Reducer）
• Gear/rack type steering gear
• Steering rod joint
• Ball stud of steering knuckle
• Steering shaft and universal joint
① Steering wheel ② Reducer
③ Motor ④ Steering transmission shaft
⑤ Universal joint ⑥ Tie rod joint
⑦ Tie rod ⑧ Steering knuckle ⑨ Steering gear

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 9-5 Electric power steering system
2. Steering Torque Sensor： 3. ECU：
Install sensor on the reducer. ECU is sophisticated electronic equipment,
and controls all the power performance of
EPS, so do not repair ECU by yourself.
If any problem happens on ECU, please
contact your local dealer to repair it.

① Sensor

No change after the sensor fixed.

Sensor assembly position is certained and
can not make any change, if found sensor
① Upper housing ② ECU unit
postion was changed caused by bolt
③ Seal ring ④ Lower housing
looseness, please tighten the bolt and
initialize the ECU at once（See Page 9-27）

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 Electric power steering system 9-6
Installation position of ECU and reducer surrounding environment, but also to prevent
the parts from moisture intrusion.
Do not remove the membrane or replace by
other parts.
On the shell of ECU unit, there are sets of
electric plugs by cables and function as
follows:
• P1：supply power to EPS system
• P2：supply power to motor of EPS
• P3 ： connect with cable of UTV and
transfer single that ECU required
① ECU ② Reducer
• P4：connect with steering torque sensor,
The installation location of the ECU will be supply power to steering torque
greatly effected by temperature changes and sensor and accept single of torque
external humidity. Housing has a membrane • P5：connect with motor
made of Goretex material for pressure
balance between inside the shell and the

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 9-7 Electric power steering system
Outside view of reducer

4. Reducer： 5. Gear/rack type steering gear

Install reducer on the frame of UTV. UTV use gear/rack type steering gear to
Install motor and steering torque sensor on perform steering function. Steering gear was
reducer. fixed on frame.

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 Electric power steering system 9-8
Installation position of steering as follows:

6. Electronic connectivity diagram of EPS

system：

① ECU (with waterproof metal box) ② ECU split cable

③ Battery ④ Meter
⑤ Steering torque sensor ⑥ Motor
⑦ Speed sensor ⑧ Main switch
⑨ Fuse

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 9-9 Electric power steering system
7. Meter：
Meter is an important part of UTV.
Meter works together with EPS system and
monitors working condition of EPS system.
Fault can be displayed by fault indicator light
and fault indicator of EPS system, so the
driver can acknowledge fault of EPS in time
and take some measures to keep
himself/herself safe.
When fault occurs on EPS system, fault
indicator light will be lit up. At the same time, ① Fault indicator light of EPS system
fault indicator of EPS system will display the ② Fault indicator of EPS system

fault code for maintenance.

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 Electric power steering system 9-10
Fault code diagram OPERATION AND USE OF EPS SYSTEM
Fault indicator EPS system operation
Fault
No. Fault style light of EPS Operate as the following steps:
code
system z Assembling your new UTV.
1#fault of steering z Ensure main switch is off.
1 F00001 lit
torque sensor

2#fault of steering main switch

2 F00002 lit
torque sensor
3 F00006 ECU overheating lit
low voltage battery
4 F00005 lit
alarm

Dynamic motor without

5 F00003 lit
power alarm
Fault of speed
6 F00011 lit
sensor

7 F00010 ECU non-working lit

① Main switch ② OFF
③ ON ④ START

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 9-11 Electric power steering system
CAUTION:
If main switch is not off, ECU can be
destroyed by battery power in on-off
condition during the following connection
with cables.

z Use screw/nut to connect the connecting

terminals of cables firmly to ○
+ and ○
- of
battery.
① Battery
② Positive Wire Of Cable
③ Positive Wire Of EPS System
④ Negative Wire Of Cable
⑤ Negative Wire Of EPS System
⑥ Nut
⑦ Screw

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 Electric power steering system 9-12
CAUTION: Meter
If connection terminals do not fixed, power of
ECU may be constantly on-off during UTV
driving, and finally cause ECU damaged.

z Open main switch of UTV, and EPS

system will automatically enter into
working state.
z Check the meter. If fault indicator light of
EPS system does not be lit, ECU can be
for regular use. ① Fault indicator light of EPS system

z If fault indicator light of EPS system is lit, ② Fault indicator of EPS system

that means EPS system find out some

fault during ECU self-checking process, CAUTION:
then you should consult your local Drive UTV with faulty EPS system may
dealer for maintenance in time. cause accident, severe injury or even death.
Never operate UTV with faulty EPS system.

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 9-13 Electric power steering system
z Supply steering power according to speed system
③ Power Torque In Static Condition
UTV’s steering power can change as
④ Power Torque At Middle Speed
different various speeds and steering angle. ⑤ Power Torque At The Highest Speed
EPS systems can supply different power
torque depending on the speed and steering
angle. Stationary, the maximum power torque can
make UTV U-turn or stop into place as much
as possible to ease the steering operation.
With increased speed, reduce power torque
can make UTV at high speed, to make ii
easier to maintain driving direction.

As shown, power auxiliary effect depends not

only on speed, but also steering torque
exerted by the driver. If the driver is to
impose a smaller steering torque, power
① T1：steering resistant torque which is checked by steering torque of the EPS system will be relatively
power sensor small. This can be achieved outstanding
② T2：power torque on steering gear which is supplied by EPS

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 Electric power steering system 9-14
auto-centering effect, that means when UTV increases, you can continue your driving of
is in straight-line, steering system will be not UTV only throw a greater force to operate the
sensitive (the steering wheel does not move steering system.
from side to side).

z Fault alarm and protection function

CAUTION:
In order to ensure EPS system can supply a
When meter indicated malfunction of EPS
long-term, reliable working, a variety of
system or when the driver found EPS system
detection and alarm functions are set in the
operation abnormally, please do some steps
ECU software program. Once fault has been
as below：
checked on EPS system, UTV can accurate
z Stop vehicles immediately, close the
shutdown the EPS system.
main switch, open the front panel’s
repair cover, and pull up the outlet which
Shut off the EPS system, UTV will be able to
power supply for EPS system (See page
continue to complete the steering function
9-7)
through the mechanical structure of the
z Driving UTV to dealer by lower velocity
steering system. However, at this time the
and repair EPS system.
driver will feel the turning resistance

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 9-15 Electric power steering system
EPS SYSTEM’S INSPECTION, ECU radiator of high temperature, and at
MAINTENANCE, REPAIR： this time ECU can get through detection
EPS system had already inspected by strict temperature sensor’s signal to issue
quality restriction before delivery, so it has ECU over-heating failure warning’s fault
high reliability. code to meter. Meanwhile, EPS system
But if there is no inspection or maintenance fault indicator light is lighten.
as stated time period during in use of EPS, it z When ECU detected 1# steering torque
may cause EPS system work abnormally or sensor or 2# steering torque sensor had
spare parts in EPS system are damaged fault, then it will indicate 1# steering
abnormally. torque sensor fault or 2# steering torque
When EPS system work wrong or get sensor fault code to dash board.
malfunction, the malfunction warning and Meanwhile, EPS system fault indicator
fault code can be indicated on meter. light is lighten.
When ECU detected the storage batter’s
Malfunction assortment： voltage is lower than 9VDC through
z During long time continuous fast sensor, it will indicate the fault code of
steering, especially when ambient storage battery voltage low to dash
temperature is very high, it may cause board. Meanwhile, EPS system fault

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 Electric power steering system 9-16
indicator light will be lighten. daily inspection of EPS system
z When ECU detected motor is out of Before drive UTV at every time, need to do
work through sensor, it will indicate fault daily inspection as following steps.
code of dynamic motor without power
warning to dash board. Meanwhile, EPS 1. Check steering system’s mechanical part
system fault indicator light is lighten. of each part’s interval.
z When ECU detected the speed sensor z Check steering wheel is loosened or not.
had fault, it will indicate vehicle speed Move steering wheel and Check whether is
sensor fault code to dash board. loosen or with squeak through axis direction
Meanwhile, EPS system fault indicator and horizontal direction. If defection found,
light is lighten. repair or replace it.
z When ECU detected its own fault and
can not be work normally, it will indicate z Steering wheel’s range of free
EUC stop working code to dash board. clearance is：0-15mm（0-0.59in.）
Meanwhile, EPS system fault indicator If the free clearance is over range, check
light is lighten. spare parts as below, any defection found,
replace it. Any defection found, replace it.
To drive UTV at every time, need to do

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 9-17 Electric power steering system
z Steering tie rod ball head is whether to wheel is placed in a straight forward position.
wear down。 z Check tire inflation pressure whether
z Swizzle ball of knuckle wear out or not meet specified requirements (see tire
z Gear rack on steering wheel wear out or instructions or UTV user manual).
not If necessary, refill it.
z Spline on steering drive shaft is loosen z Check front wheel’s front beam, wheel
or not offset positioning whether is correct (see
z Between input and output shaft’s UTV user manual).
reducer whether had idle running. If necessary, adjust it.
z The steering system checking in z Open the main switch.
steering process: z Turn the steering wheel left and right
successively, turning force on both sides
Turn the steering wheel from left to right and should be equal.
right to left .it required smoothly and no Turn the steering wheel to rotate back and
blocking allowed. forth; turning shall be smoothly, no block, no
recoil forces which opposite of operation
2. Check steering power in static condition force.
Let UTV stop on the level road, steering If any problem found, it must driven to dealer

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 Electric power steering system 9-18
and repair it immediately.

3. Steering force’s checking during running

conditions：
z During running process, the feeling of
steering force to the left and right must
be consistent.
z During steering, turning shall be
smoothly, no block, no recoil force which
opposite of operation force.
z During return process, the return force is
equal to the velocity at both left and right
directions.
If any problem occurs, it must driven to
dealer and repair it immediately.

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 9-19 Electric power steering system

Solutions for common fault：

1. Open the main switch, no auxiliary power of left and right steering.

S/N FAULT PHENOMENON FAULT POINT SOLUTION

Special fuses of ECU is

Meter warning fault Replace fuses. To
1 blown in fuses box (see
code:F00010 dealers for repair
figure 1), Or ECU is damaged

Sensor is damaged or
Meter warning fault
2 sensor’s connector with bad To dealers for repair
code：F00001&F00002
contact or ECU is damaged

Meter warning fault Low voltage in storage Charge storage battery,

3
code：F00005 battery replace it if necessary.

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 Electric power steering system 9-20

S/N FAULT PHENOMENON FAULT POINT SOLUTION

Motor is damaged or driving

Meter warning fault circuit in motor is damaged or Replace fuses, to
4
code：F00003 power motor special fuses dealer for repair
are blown.

No electrical power
5 Main fuses melted. Replace fuses
connected

ECU initialization choose pin

No meter alarm, UTV Reinsert well, replace
connector with poor contact
6 can electrify connector or repair
(sees attached figure 2), or in
cables.
the wire cable is disconnect

7 No meter alarm ECU is damaged To dealers for repair.

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 9-21 Electric power steering system
Figure 1：Fuses box

① ECU dedicated fuse

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 Electric power steering system 9-22
2. Open the main switch, only steering left or right is power-assisted.

S/N Fault phenomenon Fault point Solution

1 No meter alarm ECU damaged To dealers for repair.

Meter warning fault Sensor damaged, sensor’s

2 code ： F00001 or connector with bad contact or To dealer for repair.
F00002 ECU damaged

3. All have auxiliary power to turn left or right, when turned the steering wheel is not smooth,
locked, backswing and other feelings.
S/N Fault phenomenon Fault point Solution

Steering system Steering system mechanical Retighten loose bolts.

1 mechanical parts has parts become loose or Replace damaged
the big gap damaged. spare parts.

Mechanical parts ECU damaged, or the ECU

2 To dealers for repair.
without gap software program has error.

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 9-23 Electric power steering system
4. When running, all have power-assisted to turn left or right, when return ability is slowly or
during return processing out of nimbleness.

S/N Fault phenomenon Fault point Solution

The speed sensor damaged,

Replace speed sensor.
or from meter to ECU transmit
Meter warning fault Check and repair
1 speed signal ‘s guide wire
cod：F00011 cables. Replace
broken circuits or ECU
connector assembly.
connectors is loose

Positional parameter of
Adjust front wheel’s
2 No meter alarm steering wheel (front wheel)
positional parameter.
error.

EPS system’s speed reducer

3 No meter alarm To dealers for repair.
damaged

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 Electric power steering system 9-24
5. All have power-assisted to turn left or right，but steering become more heavy.

S/N Fault phenomenon Fault point Solution

ECU radiator overheat, ECU

Remove dirt or another
reduce the power of the motor’s
Meter warning fault covering on shell of
1 output torque automatically, or
code：F00006 ECU.
ECU‘s inside temperature
To dealers for repair.
alarm sensor damaged.

No meter alarm,
steering becomes Mechanical steering system’s Adjust、repair damaged
2
more difficult if no spare parts are damaged. spare parts.
power.

ECU damaged, or the ECU

3 No meter alarm To dealers for repair.
software program has error.

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 9-25 Electric power steering system
6. All have power-assisted to turn left or right，the power of steering to left and right is
different.

S/N Fault phenomenon Fault point Solution

Two channels’ parameters of Replace sensor or go

1 No meter alarm
sensor changed to dealers for repair.

No meter alarm. No
power-assisted the
Mechanical steering system’s Adjust、repair damaged
2 power of steering to
spare parts are damaged. spare parts.
left and right is
different

ECU damaged, or the ECU

3 No meter alarm To dealers for repair.
software program has error.

The initialization parameter of Restart initialization for

4 No meter alarm
ECU has error. ECU

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 Electric power steering system 9-26
7. Open main switch, steering to the same direction automatically.
S/N Fault phenomenon Fault point Solution
1 No meter alarm Sensor is loosen To dealers for repair.
No meter alarm , The initialization parameter of Restart initialization for
2
Sensor no loosening. ECU has error. ECU

Maintenance and repair’s supplemental z Reinsert pin connector to finish the ECU
description: parameter initialization process.
1. Restart initialization to ECU parameter: Then, open the main switch; check whether
z Park UTV on the flat ground and keep the fault is removed. If it is not removed,
the front wheels to be forward always. follow the previous steps of initialization
z Pull-out initialization selects connector. process. Because the different mechanical
（See Page 9-22 ） clearance of UTV, it may require 3-5 times to
z Push UTV back and forth for several be repeated in order to get the correct
times, and flap the wheels for several initialization parameters.
times. If a customer complaint" vehicle deviation", it
z Open the main switch and wait for 5 should take into account the fault causes not
seconds. only includes the EPS system fault, also

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 9-27 Electric power steering system
includes a chassis mechanical failure, malfunctioning. All cannot continue to
customers may use" Deviation" to describe a reliable accurate control motor malfunction
specific situation. So four wheel alignment will lead to the interruption of motor control
need to be adjusted at first time, then ECU ECU, then closed function of EPS system.
replacement and repair needed. Close the EPS system’s bad results will also
cause the driver can not obtain power
2. The Fault of closing function steering.
The main objective to research and develop But close measure is mainly used for
EPS system is needed to ensure that the preventing error control motor.
vehicle is still controlled by driver when When fault occurs, power steering disappear
malfunction happened. Therefore we will not is a predetermined EPS system response
allow any directions (clockwise or characteristic. Although the driver may feel
counterclockwise) suddenly appear bigger the characteristics of some accidents, but
undesirable steering torque. increases the control force, can ensure the
Therefore, the EPS system has many vehicle steering performance is not affected.
monitoring function, used to identify the Neither the EPS steering system nor
sensor, actuator and the involvement of the hydraulic power steering system, when fault
EPS system function whether is occurs, power steering will disappear. When

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 Electric power steering system 9-28
a fault occurs, the two systems reaction will become obviously more smoothly.
be similar. This fault occurs, EPS system In addition, it can also reduce the steering
fault indicator light inside of meter will be system’s mechanical and electrical
lighten. If above circumstances happened, components’ load, which helps in obtaining
EPS system will be no power steering, and reliable function and long service life.
through the instrument to show the
corresponding fault code and remind driver EPS system Periodic maintenance
to take care. For primary use after 50 hours, adjust EPS
system part of parameters according to the
3. The software function forms’ limit position steering system’s clearance variation and
Although the mechanical structure of the chassis changes.
EPS system has mechanical limit position, it Please go to the dealer for alignment.
is still possible for EPS system to realize the For every 100 hours using time, according to
function of decreasing steering power before the steering system and the chassis changes,
reaching the mechanical limit position in form adjust EPS system relevant parameters.
of slope curve. Although the customer will
feel the steering resistance increases, when
turned to the limited position process will

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 9-29 Electric power steering system

CAUTION: Motor assy basic parameters

Before adjust ECU for every time, please z Type: DC permanent magnet control
check the clearance of mechanical part and motor
adjust four wheels fixed position of UTV. z Rated working time: 3 min/per time
z Rated power：170W（nominal value）
EPS SYSTEM PARAMETER TABLE z Rated operational voltage: 12V DC
EPS system basic technical parameters z Rated motor revolving speed ：
（1050r±300r）/min
EPS system working conditions z Rated operational current：30A±3A
1. Working environment temperature： Rated output torque ：1.6N·m±0.16N·m
-40℃～＋85℃
2. Working voltage：（9～16V） DC
3. The seal type：IP65
4. Input shaft rotation angle：
large than ±1.25rmp
5. Wheel rotation speed：
10round/min～15round/min

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 Cleaning and Storage 10-1
Cleaning
Frequent, thorough cleaning of your vehicle CAUTION:
will not only enhance its appearance but also Excessive water pressure may cause water
will improve its general performance and seepage and deterioration of wheel bearings,
extend the useful life of many components. brakes, transmission seals and electrical
1. Before cleaning the vehicle: devices. Many expensive repair bills have
a. Block off the end of the exhaust pipe to resulted from improper high-pressure
prevent water entry. A plastic bag and detergent applications such as those
strong rubber band may be used. available in coin-operated car washes.
b. Make sure the spark plug and all filler
caps are properly installed. 4. Once the majority of the dirt is hosed off,
2. If the engine case is excessively greasy, wash all surfaces with warm water and
apply degreaser with a paintbrush. Do mild, detergent-type soap. An old
not apply degreaser to the wheel axles. toothbrush or bottlebrush is handy for
3. Rinse the dirt and degreaser off with a hard-to-get-at places.
garden hose. Use only enough pressure 5. Rinse the vehicle off immediately with
to do the job. clean water and dry all surfaces with a

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 10-2 Cleaning and Storage
chamois, clean towel or soft absorbent
cloth. WARNING
6. Clean the seats with vinyl upholstery POTENTIAL HAZARD
cleaner to keep the cover pliable and Operation with wet brakes after washing.
glossy. WHAT CAN HAPPEN
7. Automotive type wax may be applied to Wet brakes may have reduced stopping
all painted and chrome plated surfaces. ability, increasing the chance of an
Avoid combination cleaner waxes as accident.
many contain abrasives that may scratch HOW TO AVOID THE HAZARD
the paint or protective finish. When Test the brakes after washing. Apply the
finished, start the engine and let it idle for brakes several times at slow speeds to let
several minutes. friction dry out the linings.

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 Cleaning and Storage 10-3
Storage
Long-term storage (60 days or more) of your Specified amount:
vehicle will require some preventive 1 oz of stabilizer to each gallon of fuel (or
procedures to guard against deterioration. 7.5 ml of stabilizer to each liter of fuel)
After thoroughly cleaning the vehicle, NOTE:
prepare for storage as follows: Use of fuel stabilizer and conditioner
1. Fill the fuel tank with fresh fuel and add eliminates the need to drain the fuel system.
the specified amount of Fuel Stabilizer Consult a service center if the fuel system
and Conditioner or equivalent product. needs to be drained instead.
Operate the vehicle for at least 5 minutes
to distribute treated fuel through the fuel 3. Remove the spark plug, pour about one
system. tablespoon of SAE 10W40 or 20W40
2. Drain the fuel from the fuel system as motor oil in the spark plug. Ground the
much as possible and pour the drained spark plug wire and turn the engine over
fuel into the fuel tank. several times to coat the cylinder wall
with oil.
4. Lubricate all control cables.
5. Block up the frame to raise all wheels off
the ground.

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 10-4 Cleaning and Storage

6. Tie a plastic bag over the exhaust pipe

outlet to prevent moisture from entering.
7. If storing in a humid or salty atmosphere,
coat all exposed metal surfaces with a
light film of oil. Do not apply oil to any
rubber parts or the seat covers.
8. Remove the battery and charge. Store it
in a dry place and recharge it once a
month. Do not store the battery in an
excessively warm or cold place (less
than 32°F (0°C) or more than 86°F
(30°C)).
NOTE:
Make any necessary repairs before storing
the vehicle.

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 Specifications 11-1

Model HS500UTV-4/HS500UTV-3
Dimensions:
Overall length 3010mm (118.5 in)
Overall width 1460m m (57.5 in) for HS500UTV-4
1670m m (65.7 in) for HS500UTV-3
Overall height 1940mm (76.4 in)
Seat height 818mm (32.2 in)
Wheelbase 1890mm (74.4 in)
Ground clearance 280mm (11.0 in)
Minimum turning radius 3900mm (154 in)
Basic weight with oil and full fuel tank 543 kg (1,197 l b)
Engine:
Engine type Liquid cooled 4-stroke, Water cool
Cylinder arrangement Forward-inclined single cylinder
3
Displacement 471cm
Bore × stroke 84.5×84.0mm
Compression ratio 9.4:1
Starting system Electric starter
Lubrication system Wet sump

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 11-2 Specifications

Model HS500UTV-4/HS500UTV-3
Engine oil:
Type

Recommended engine oil classification API service SG type or higher, JASO standard MA

CAUTION:
In order to prevent clutch slippage（since the engine
oil also lubricates the clutch ）, do not mix any
chemical additives. Do not use oils with a diesel
specification of “CD” or oils of a higher quality than
specified. In addition, do not use oils labeled
“ENERGY CONSERVING Ⅱ” or higher.
Quantity:
Without oil filter cartridge replacement 1.90L (2.01 qt )
With oil filter cartridge replacement 2.10L (2.22 qt )

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 Specifications 11-3

Model HS500UTV-4/HS500UTV-3
Final gear case oil:
Type SAE80 API GL-4 Hypoid gear oil
Quantity: 0.25L (0.26 qt )
Differential gear case oil:
Type SAE80 API GL-5 Hypoid gear oil
Quantity: 0.32L (0.34 qt )
Radiator capacity（including all routes）: 2.50L (2.64 qt )
Air filter:
Engine Wet element
Intake duct Dry element
Fuel:
Type Unleaded gasoline only
Fuel tank capacity 29 L (7.6 gal )
Throttle valve:
Type/quantity DELPHI / MT05

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 11-4 Specifications

Model HS500UTV-4/HS500UTV-3
Spark plug:
Type DR8EA
Spark plug gap 0.6-0.7 mm (0.023-0.027 in)
Clutch type: Wet, centrifugal automatic
Transmission:
Primary reduction system V-belt
Secondary reduction system Shaft drive
Secondary reduction ratio
Transmission type V-belt automatic
Operation Right hand operation
Reverse gear 1.471
Sub transmission ratio low 2.059
High 1.238
Chassis:
Frame type Steel tube frame
Caster angle 5.0°
Trail 26.0mm (1.02 in )

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 Specifications 11-5

Model HS500UTV-4/HS500UTV-3
Tire:
Type Tubeless
Size front 25×8-12
rear 25×10-12
Brakes:
Ⅰ: Front brake Type Dual disc brake
Operation Foot operation
Rear brake Type Single disc brake
Operation Foot operation
Ⅱ: Front brake Type Dual disc brake
Operation Foot operation
Rear brake Type Dual disc brake
Operation Foot operation
Suspension:
Front / rear suspension Double wishbone

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 11-6 Specifications

Model HS500UTV-4/HS500UTV-3
Shock absorber:
Front shock absorber Coil spring/oil damper for HS500UTV-4
Coil spring/oil or airbag damping for HS500UTV-3
Rear shock absorber Coil spring/oil damper for HS500UTV-4
Coil spring/oil or airbag damping for HS500UTV-3
Wheel travel:
Front wheel travel 130mm (5.12in)
Rear wheel travel 150mm (5.91in)
Electrical:
Ignition system ECU
Generator system AC magneto
Battery type U1L-11 or GSU1-9
Battery capacity 12V32.0Ah or 12V30.0Ah
Bulb voltage, wattage × quantity:
Headlight 12V30.3W/30.0W × 2
Tail/brake light 12V5.0W/21.0W × 2

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 Specifications 11-7

Model HS500UTV-4/HS500UTV-3
Indicator lights:
Neutral / Reverse indicator light LED
Coolant temperature warning light LED
Parking brake indicator light LED
On-Command four-wheel-drive/differential gear
lock indicator LED
On-Command differential gear lock indicator light LED
High-range/ Low-range indicator light LED
Main Fuse: 30.0A
Headlight Fuse: 15.0A
ECU Fuse: 15.0A
Auxiliary DC Jack Fuse: 10.0A
Signaling System Fuse: 10.0A
2WD/4WD Fuse 10.0A

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 12-1 Fault Code of Electronic Injection System
Fault Code of Electronic Injection System

DTC
DTC Description Related Calibration HEX DEC
Number

P0107 MAP Circuit Low Voltage or Open KsDGDM_MAP_ShortLow 107 263

P0108 MAP Circuit High Voltage KsDGDM_MAP_ShortHigh 108 264

P0112 IAT Circuit Low Voltage KsDGDM_IAT_ShortLow 112 274

P0113 IAT Circuit High Voltage or Open KsDGDM_IAT_ShortHigh 113 275

Coolant/Oil Temperature Sensor Circuit
P0117 KsDGDM_CoolantShortLow 117 279
Low Voltage
Coolant/Oil Temperature Sensor Circuit
P0118 KsDGDM_CoolantShortHigh 118 280
High Voltage or Open
P0122 TPS Circuit Low Voltage or Open KsDGDM_TPS_ShortLow 122 290

P0123 TPS Circuit High Voltage KsDGDM_TPS_ShortHigh 123 291

P0131 O2S 1 Circuit Low Voltage KsDGDM_O2_1_ShortLow 131 305

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 Fault Code of Electronic Injection System 12-2

P0132 O2S 1 Circuit High Voltage KsDGDM_O2_1_ShortHigh 132 306

P0031 O2S Heater Circuit High Voltage KsDGDM_O2_HeaterShortHigh 31 49

P0032 O2S Heater Circuit Low Voltage KsDGDM_O2_HeaterShortLow 32 50

P0201 Injector 1 Circuit Malfunction KsDGDM_INJ_CYL_A_Fault 201 513

P0202 Injector 2 Circuit Malfunction KsDGDM_INJ_CYL_B_Fault 202 514

P0230 FPR Coil Circuit Low Voltage or Open KsDGDM_FPP_CircuitShortLow 230 560

P0232 FPR Coil Circuit High Voltage KsDGDM_FPP_CircuitShortHigh 232 562

P0336 CKP Sensor Noisy Signal KsDGDM_CrankNoisySignal 336 822

P0337 CKP Sensor No Signal KsDGDM_CrankNoSignal 337 823

P0351 Cylinder 1 Ignition Coil Malfunction KsDGDM_EST_A_Fault 351 849

P0352 Cylinder 2 Ignition Coil Malfunction KsDGDM_EST_B_Fault 352 850

P0505 Idle Speed Control Error KsDGDM_IdleControl 505 1285

P0562 System Voltage Low KsDGDM_SysVoltLow 562 1378

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 12-3 Fault Code of Electronic Injection System

P0563 System Voltage High KsDGDM_SysVoltHigh 563 1379

P0650 MIL Circuit Malfunction KsDGDM_MIL_Circuit 650 1616
P1693 Tachometer Circuit Low Voltage KsDGDM_TAC_Circuit_Low 1693 5779
P1694 Tachometer Circuit High Voltage KsDGDM_TAC_Circuit_High 1694 5780
P0137 O2S 2 Circuit Low Voltage KsDGDM_O2_2_ShortLow 137 311
P0138 O2S 2 Circuit High Voltage KsDGDM_O2_2_ShortHigh 138 312
P0038 O2S Heater 2 Circuit High Voltage KsDGDM_O2_HeaterShortHigh 38 56
P0037 O2S Heater 2 Circuit Low Voltage KsDGDM_O2_HeaterShortLow 37 55
P0500 VSS No Signal KsDGDM_VSS_NoSignal 500 1280
P0850 Park Neutral Switch Error KsDGDM_ParkNeutralSwitch 850 2128
P0445 CCP short to high KsDGDM_CCP_CircuitShortHigh 445 1093

P0444 CCP short to low/open KsDGDM_CCP_CircuitShortLow 444 1092

P0171 BLM Max Adapt(Kohler Special) KsFDIAG_BLM_MaxAdapt 171 369
P0172 BLM Min Adapt(Kohler Special) KsFDIAG_BLM_MinAdapt 172 370
P0174 PE System Lean(Kohler Special) KsFDIAG_PESystLean 174 372

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 Hisun Motors Corp., U.S.A.
Emission Control System Warranty Statement
13-1
YOUR WARRANTY RIGHTS AND OBLIGATIONS
Hisun Motors Corp., U.S.A. (hereinafter “HISUN”) is pleased to explain the emission control system
warranty on your Off-Road ATV or UTV vehicle. New off-road motor vehicles must be designed, built
and equipped to meet California’s anti-smog standards. HISUN must warrant the emission control system
on your vehicle for 5,000 km, or at least 30 months, whichever comes first, provided that there has been no
abuse, neglect or improper maintenance of your vehicle. This off-road vehicle was designed to meet the
emission standards for 10,000 km, or five years, whichever comes first.
Your emission control system warranty covers components whose failure would increase an engine’s
emissions of any regulated pollutant
Where a warrantable condition exists, HISUN will repair your vehicle at no cost to you, including diagnosis,
parts and labor.
If an emission-related part on your vehicle is defective, the part will be repaired or replaced by HISUN. This
is your EMISSION CONTROL SYSTEM WARRANTY.
NOTICE! Use of any HISUN brand vehicle in any type of competitive event completely and absolutely
voids this and all other warranties offered by HISUN.
OWNER’S WARRANTY RESPONSIBILITIES
As the vehicle owner, you are responsible for the performance of the required maintenance listed in your
owner’s manual. HISUN recommends that you retain all receipts covering maintenance on your vehicle,
but HISUN cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance
of all scheduled maintenance.
You are responsible for presenting your vehicle to the HISUN dealer as soon as a problem exists. The
warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.

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 Hisun Motors Corp., U.S.A.
Emission Control System Warranty Statement
13-2
As the vehicle owner, you should be aware that HISUN may deny your warranty coverage if your vehicle or
a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.
If you use your vehicle in any type of competitive event, this warranty is immediately and completely void.
If you have any questions regarding your warranty rights and responsibilities, you should contact Hisun
Motors Corp., U.S.A., 1434 Patton Place, Ste. 106, Carrollton, TX 75007, 972-446-0760, U.S.
Environmental Protection Agency at 2000 Traverwood Drive, Ann Arbor, MI 48105, or (for California registered
off-road vehicles only) the California Air Resources Board at 9528 Telstar Avenue, El Monte, CA 91731.
YOUR WARRANTY RIGHTS AND OBLIGATIONS
Hisun Motors Corp., U.S.A. warrants that each HISUN brand off-road vehicle:
A. is designed, built and equipped so as to conform at the time of initial retail purchase with all
applicable regulations of the United States Environmental Protection Agency, and the California Air
Resources Board; and
B. is free from defects in material and workmanship which cause such vehicle to fail to conform to
applicable regulations of the United States Environmental Protection Agency or the California Air
Resources Board for the periods specified above.
I. Coverage. Warranty defects shall be remedied during customary business hours at any
authorized HISUN dealer located within the United States of America in compliance with the Clean
Air Act and applicable regulations of the United States Environmental Protection Agency and the
California Air Resources Board. Any part or parts replaced under this warranty shall become the
property of HISUN.
II. Limitations This Emission Control System Warranty shall not cover any of the following:
A. Repair or replacement as a result of
(1) accident,

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 Hisun Motors Corp., U.S.A.
Emission Control System Warranty Statement
13-3
(2) misuse,
(3) repairs improperly performed or replacements improperly installed, unless performed by a HISUN
authorized dealer,
(4) use of improper replacement parts or accessories not conforming to
specifications set forth by HISUN, which adversely affect performance and/or
(5) Use in competitive racing or related events.
B. Inspections, replacement of parts and other services and adjustments required for required
maintenance.
C. Any vehicle equipped with an odometer or hour meter on which the odometer mileage or
hour meter reading has been changed so that actual mileage cannot be readily determined.
III. Limited Liability
A. The liability of HISUN under this Emission Control System Warranty is limited solely to the
remedying of defects in material or workmanship by an authorized HISUN dealer at its
place of business during customary business hours. This warranty does not cover
inconvenience or loss of use of the vehicle or transportation of the vehicle to or from the
HISUN dealer. HISUN shall not be liable for any other expenses, loss or damage, whether
direct, incidental, consequential or exemplary arising in connection with the sale or use of
or inability to use the HISUN brand vehicle for any purpose. Some states do not allow the exclusion or
limitation of any incidental or consequential damages, so the above limitations may not apply to you.

B. No express emission control system warranty is given by HISUN except as specifically set
forth herein. Any emission control system warranty implied by law, including any warranty
of mechanability or fitness for a particular purpose, is limited to the express emission
control system warranty terms stated in this warranty. The foregoing statements of
warranty are exclusive and in lieu of all other remedies. Some states do not allow limitations on how long an
implied warranty lasts, so the above limitations may not apply to you.

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 Hisun Motors Corp., U.S.A.
Emission Control System Warranty Statement
13-4
C. No dealer is authorized to modify this Limited Emission Control System Warranty issued by
HISUN.
IV. LEGAL RIGHTS. This warranty gives you specific legal rights, and you may also have other rights
which vary from state to state.
V. This warranty is in addition to the limited vehicle warranty.
VI. ADDITIONAL INFORMATION. Any replacement part that is equivalent in performance and
durability may be used in the performance of any maintenance or repairs by the owner. However, HISUN
is not liable for these parts. The owner is responsible for the performance of all required maintenance.
Such maintenance may be performed at a service establishment or by any individual. The warranty period
begins when the vehicle is placed into service.

If you have any questions regarding your warranty rights and responsibilities, you should contact Hisun
Motors Corp., U.S.A., the U.S. Environmental Protection Agency at 2000 Traverwood Drive, Ann Arbor, MI
48105, or (for California registered off-road vehicles only) the California Air Resources Board at 9528
Telstar Avenue, El Monte, CA 91731.
Hisun Motors Corp., U.S.A.
1434 Patton Place, Ste. 106
Carrollton, TX 75007
Phone: 972-446-0760
Fax: 972-446-0765

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 HISUN MOTORS
1434 Patton Place
Suite 106
Carrollton, Texas 75007

PH (972) 446-0760
TF (877) 838-6188

www.hisunmotors.com

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