Hisun HS 500UTV-5,HS 550UTV,HS 600UTV-3,HS700UTV-7,HS 750UTV Owner's Manual

GRAB SOME SUN

Published by Chongqing
Huansong Industries
(Group) Co., Ltd and
Hisun Motors Corp USA.

Chongqing Huansong
Industries (Group) Co., Ltd
and Hisun Motors Corp USA
holds the copy right.
No publishing and reprinting
without permission.

READ THIS
MANUAL CAREFULLY

TM

For questions regarding this
UTV, please contact HISUN at:
[phone]
hisunmotors.com

Rev. 08071501

No one under the age of 16
should operate this vehicle.

Provincial / Municipal
governments have dierent
regulations pertaining to
owning and operating an
o-road vehicle; learn the
regulations in your area.

SECTOR 550/750

OWNER’S MANUAL

Introduction HS 550/750UTV

1-1

INTRODUCTION

Congratulations on your purchase of the HS 500UTV-5/HS 550UTV/HS 600UTV-3/HS
700UTV-7/HS 750UTV. This Owner’s / Operator’s manual will provide you information
regarding safe operation, operational instructions, maintenance and care. Fully
understanding this manual and following all of the instructions herein will provide the
knowledge needed to have safe and enjoyable UTV operation.

For questions regarding this UTV, please call [phone].

IMPORTANT SAFETY MESSAGES

● READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR UTV.

MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS.

● PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE UTV.

● NEVER OPERATE THE UTV WITHOUT PROPER TRAINING OR INSTRUCTION.

● THIS UTV SHOULD NOT BE RIDDEN BY ANYONE UNDER

16 YEARS OF AGE.

Introduction HS 550/750UTV

1-2

IMPORTANT MANUAL INFORMATION

FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS
INJURY OR DEATH.

Particularly important information is distinguished in this manual by the

following notations:

The Safety Alert Symbol means ATTENTION!

YOUR SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to
the machine operator, bystander or a person inspecting or repairing the
machine.

A CAUTION indicates special precautions that must be taken to avoid damage
to the machine.

NOTE: A NOTE provides key information to make procedures easier clearer.

1-3

Introduction HS 550/750UTV

IMPORTANT NOTICE

This UTV is designed and manufactured for OFF - ROAD use only. It is illegal and unsafe to operate this
UTV on any public street, road or highway.

This UTV complies with all applicable OFF - ROAD noise level and spark arrester laws and regulations in
effect at the time of manufacture.

Please check your local riding laws and regulations before operating this UTV.

When the temperature is below -4°F (-20°C), park the UTV in a place where the temperature is higher
than -4°F (-20°C). Start the UTV after the UTV has warmed up. Please see page 7-3 on the warming up
process.

Follow the proper parking procedures when the temperature is higher than 100°F (38°C): turn off the
engine; make sure the radiator fan is on for 3 minutes before turning off the power switch.

Starting the UTV for the first time will take longer because the fuel will need reach the fuel injectors. To
start the UTV the first time, hold the ignition key on at 5-second intervals. Allow the starter to rest 15
seconds between each start attempt.

1-4

Introduction HS 550/750UTV

NIVERSAL SYMBOLS

As a guide to the operation of your vehicle, various universal symbols have been utilized on the

instruments and controls. The symbols are shown below with an indication of their meaning.

Safe

ty Alert Symbol

Lift Cylinder-Retract

Diesel Fu

el

Lift Cylinder-Extend

Engine

coolant-Temperature

Lift Cylinder-Float

Parking

Brake

Hazard Warning Lights

Batt

ery Charging Condition

Master Lighting Switch

Engin

e Oil-Pressure

Audible Warning Device

Turn

Signal/Hazard

Fault indicato

r light of EPS system

Differe

ntial Lock

2WD/ 4W

D

Position light bulb

Introduction HS 550/750UTV

1-5

Table of Contents

Subject Page

Introduction 1-1

Important manual information

1-2

Important notice

1-3

Universal symbols

1-4

Location of parts

1-7

Illustrated contents

1-11

Safe operation 2-1

Safety instructions 2-1

Operation 2-2

Children safety instructions 2-3

Driving on a slope 2-3

Driving in harsh conditions 2-3

Driving at high speed 2-3

Instructions for carrier 2-4

Parking 2-4

Transportation 2-4

Maintenance 2-4

Warning and caution labels 3-1

Servicing of vehicle 4-1

Specifications table 5-1

Vehicle limitations 5-4

Pre-operation 6-1

Operating the engine 7-1

Starting the engine 7-1

Cold starting 7-2

Stopping the engine 7-2

Warming up 7-2

Warm-up transmission oil in the low

temperature range

7-3

Operating the vehicle 8-1

Operating new vehicle 8-1

Do not operate the vehicle at full

speed for the first 50 hours

8-1

Changing lubricating oil for new vehicles

8-1

Subject

Page

Starting 8-1

Seat belt 8-1

Head light switch 8-2

Emergency light switch 8-2

Turn signal light switch 8-2

Brake pedal 8-3

Range gear shift lever 8-4

4WD lever 8-5

Accelerator pedal 8-5

Stopping 8-5

Fuel gauge 8-6

Winch mount plate 9-1

Transporting vehicle 9-1

Service intervals 9-2

Periodic service 10-1

How to open the front hood and seat 10-1

Front hood cover 10-1

Operator’s sea 10-1

How to raise the cargo bed 10-1

Raising and Lowering the Cargo Bed 10-1

Jack-up point 10-2

Front end 10-2

Rear end 10-2

Daily check 10-2

Walk around inspection 10-3

Checking and Refueling 10-3

Checking coolant level 10-3

Cleaning radiator screen 10-4

Checking brake fluid level 10-4

Checking brake pedal 10-5

Checking parking brake 10-5

Checking gauges meter and easy

checker lamps

10-5

Checking head light turn signal light etc

10-5

Introduction HS 550/750UTV

1-6

Checking seat belt and ROPS 10-5

Checking joint boot 10-5

Checking tire inflation pressure 10-6

Every 50 hours

10-6

Greasing

10-6

Checking engine start system 10-7

Checking wheel bolt torque 10-7

Cleaning air cleaner primary element 10-8

Checking battery condition 10-9

Adjusting toe-in 10-10

Cleaning muffler 10-11

Every 200 hour 10-11

Changing engine oil 10-11

Replacing engine oil filter 10-12

Replacing transmission oil 10-12

Checking brake pedal 10-13

Checking brake hose and pipe 10-13

Checking brake light switch 10-13

Checking radiator hose and clamp 10-13

Checking intake air line 10-14

Every 300 hours 10-14

Checking tire 10-14

Every 400 hours 10-15

Changing transmission fluid 10-15

Changing front and rear axle case oil 10-15

Every 500 hours 10-15

Replacing fuel filter 10-15

Every 600 hours 10-15

Adjusting engine valve clearance 10-16

Every 1500 hours 10-16

Checking injection and fuel pump 10-16

Every 1 year 10-16

Replacing air cleaner primary element

and secondary element

10-16

Every 2 years 10-16

Changing brake fluid 10-16

Flushing Cooling system and changing

coolant

10-16

Anti-freeze 10-16

Replacing radiator hose (water pipes) 10-18

Replacing fuel hose 10-18

Replacing brake master cylinder (inner

parts)

10-18

Replacing front brake seal 10-18

Replacing rear brake cylinder seal 10-18

Replacing intake air line 10-18

Every 4 years 10-18

Replacing brake hose 10-18

Replacing slow-blow fuses 10-18

Storage 10-19

Vehicle storage 10-19

Removing the vehicle from storage 10-20

Troubleshooting 11-1

Engine troubleshooting 11-1

Diagnostic trouble code table 11-2

Battery troubleshooting 11-3

Machine troubleshooting 11-4

Options 12-1

Emissions warranty 13-1

Introduction HS 550/750UTV

1-7

LOCATION OF PARTS
Bench seat

Introduction HS 550/750UTV

1-8

Bucket seat

1-9

Introduction HS 550/750UTV

ILLUSTRATED CONTENTS
Bench seat

Introduction HS 550/750UTV

1-10

Bucket seat

Introduction HS 550/750UTV

1-11

Bench seat

Introduction HS 550/750UTV

1-12

Bucket seat

Safe Operation

2-1

All operators, including experienced UTV drivers

or passengers, should carefully read and fully

understand this Users Manual, and operate

strictly as the manual states in order to achieve

the best performance and avoid accidents.

Others who will use you UTV should be trained

how to operate the UTV and be required to read

this manual before operation.

1. Safety Instructions:

1. Understand this UTV by reading this manual

and underst

anding all the components of the

vehicle. Only start and operate the vehicle

after finishin

g reading this manual.

2.

Pay close attention to the warning

and

caution labels on the UTV.

3. Understand completely and learn to use

the

safety devices (roll-over protective structure,

seat belt

s), and never change original safety

devices. If safety devices are damaged,

consult your local dealer for replacement.

Always use seat belts.

Bench Seat

① Roll-over protective structure；

② Seat belts

Bucket seat

① Roll-over protective structure；

② Seat belts

4. Do not wear loosen articles of clothing

during operation, as these can be drawn into

moving

parts on the vehicle and could cause

a severe injury to occur

.

You should always wear protective equipment,

such as helmet, boots, eye protection, ear

protection, and gloves etc.

5.

Only a qua

lified driver should operate this

UTV

. Never operate after drinking, using

drugs or controlled products

, or while

fatigued.

6.

Always perform the pre-operation checks

as

following:

1) C

heck seat belt for worn or damaged, if

necessary

, replace it.

2) Check brakes, throttle, brake pedal and

other mechanical parts for proper operation.

If you discover any irregularities, replace

related parts as necessary. Periodically

check

the fitting

s and fastener

s.

3)

Check engine oil level and engine coolant

level.

4) Check t

hat the UTV is equipped to handle

Safe Operation

2-2

the surroundings.

5)

Check and keep vehicle clean.

Sludge,

grease and debris can cause a fire and

severe injury.

7.

Passenger quantity and loading:

1) Only the driver and one passenger inside

cab.

It is suggested that children

under

age of 5 not

be allowed as a passenger

.

2)

Single-row vehicle’s loading limit is 3

50lbs

(159KG).

Reduce the loading weight

according to road conditions. Never

exceed the weight limit

s for operatio

n.

8.

Never allow unauthorized persons to repair

this UTV. This may af

fect vehicle

performance and cause

injury

.

9. This UTV is designed and manufactured for

of

f-road use only, so never drive on p

aved

roadways.

2. Operation

1. Start the engine only in an open ventilated

area. Carbon monoxide is colorless,

odorless

and is emi

tted from t

he engine and can

cause death

in areas with poor ventilation.

2.

Never start the vehicle or operate the

gear

selector unless seated in the driver’s seat.

3.

Never start the vehicle or operate the

gear

selector un

less seated in the driver’s seat.

4.

The driver and passenger shall always

wear

their seatb

elt while the vehicle is being

operated.

5. Operators of the UTV should

not wear

earphones.

6.

Use trailer hitch to trail cargo, ot

herwise,

seriou

s injury or death will happen.

① Trailer Hitch

7. Do not accelerate quickly when starting the

engine, especially driving on rough terrain as

this can cause injury or death. Press the

accelerator

pedal slowly

.

8.

Drive at slow speed before braking.

9. When press the differential unlocked button

(DIFF.LOCK is off), the front/rear wheels can

turn at different spe

ed. Otherwise, the

vehicle may

turnover

.

10.

Never drive over terrain such as a ditch,

a

hole, dams, excessive mud, or the vehicle

can get st

uck because of the

vehicles

weight.

11.

Always pay close attention to

your

surrounding

s, and check for street

s, trail

intersections or other obstacles.

12. Always use signals in ad

vance of turns.

13.

Do not allow entrance or exit of the vehicle

while it is m

oving.

14.

Clean dash board and Keep the floorboard

free of debris that can obstruct the ability to

use the brake pedal.

15.

Position your hands on the steering wheel.

Always keep your hands and feet inside

passenger area of the vehicle. Never try to

stand while operating the vehicle.

16. Do not tow passengers, or attempt to jump

the vehicle.

Safe Operation

2-3

3. Children safety instructions

Always watch children when they are around the

vehicle. Children like to imitate adults and this

could lead to an accident.

Do not leave children alone beside the vehicle.

Keep children from the operating area of the

vehicle.

Turn off the engine and remove the key when

children are in the operating area. Never carry

children in the cargo bed. This is very dangerous

to children. Children under age of 5 are not be

allowed in this vehicle.

Never allow children to touch or climb the vehicle

even if they are under adult supervision, or

climbing on vehicle.

Always check for people or obstacles behind the

vehicle before shifting the vehicle into reverse.

Avoid a collision with an obstacle or person.

Park the vehicle on a firm, flat area. If parking on

a slope, you should use parking brake, remove

the key, and get tires stuck in the tire wedge.

4. Driving on a slope

Be cautious when riding on a slope, as this is the

main reason result for loss of control, overturn,

leading to severe injury or even death.

1.

Drive in a straight line on a slope at a low-

speed.

2. Reduce weight when ride on a slope or

rough terrain.

3.

Avoid the sudden application

of the brakes

when you

go uphill or downhill. Be more

careful when vehicle turns on a slop

e.

If you st

art to lose momentum or need to park
when climbing, use the parking brake to come to
a stop. Release the brake and begin to

4.

coast down the hill.

5.

If do not believe you can operate the

UTV

safely

in reverse do not attempt to ascend

the slope any further.

6. Riding in mud, a ditch, and on sl

opes will

increase

the risk of an overturn. Be more

cautious when operating. Drive grad

ually and

slowly

when climbing. Avoid sudden

changes

of vehicle speed or direction.

5. Driving in harsh conditions

1. Vehicle can be operated during the day or

under good light conditio

ns.

2.

Operate the vehicle in open, smooth

pave

ment.

3.

Under all conditions,

both operator and

passengers should wear helmet and

protective equipment.

4. Driver should slow down according to road

conditions, terrain, visibility condition

s.

5.

Be cautious when driving over a ditch, stone

road or hidden obstacles.

6. Avoid operating in any unknown

depth of

w

ater.（water depth should not exceed axle

height）

6. Driving at high speed

1. Check for front/rear wheels conditions. Pay

attention t

o the differences of

braking

performances

between two and f

our-wheel

drive.

2.

Slow down when turning. Turning

at high

speed may result in overturn or even death.

3. Turn on your headlights at high spee

ds.

4.

Only drive at a speed that can be co

ntrolled.

Do not use DIFF.LOCK when driving at high

Safe Operation

2-4

5. speed. Otherwise, this may cause vehicle

loss of contro

l.

6.

When driving at high speed, suddenly turning

the steering wheel will reduce vehicle

stability. Never sharply turn the steering

wheel at high speeds.

7. Instructions for carrier

1. Never carry a passenger in the cargo area.

2. Evenly distribute the cargo to maintain

proper stability. Avoid overloading the carrier

.

Cargo should be securely attached.

3. Reduce loaded weight when driving on poor

road conditions or steep inclines.

4.

Do not put your hands and you bo

dy under

the cargo

bed when it is ra

ised. Once

lowered,

lock the cargo bed in place

before

operating th

e vehicle. Never drivin

g before

securing and locking the cargo bed.

8. Parking

1. Set the gear shift to the “N” position and To

release the parking brake, depress the brake

pedal.

① Parking brake.

2. Avoid stopping the vehicle on a slope. If

stopping on

a slope make sure the vehicle is

stationary before exiting.

9. Transportation

1. Avoid dragging the vehicle behind another

vehicle. Use

a trailer or truck to transport the

vehicle.

2.

When loading or unloading, pay attention to

your surroundings and others in the

area.

10. Maintenance

Stop the vehicle and park it on level ground. Pull

the parking brake and remove all cargo. Then

place shift lever on “N” position, stop the engine

and remove the key.

1.

When working next to the engine, exhaust

or

radiator, work only after it has cooled down.

2. Wait for the engine to stop running and

cool

down before checking

the coola

nt level.

Otherwise, you could b

e burned by hot fluid

or steam blown out.

3.

No smoking when adding electrolyte or

refueling. F

uel tank and battery should be

kept away from sparks. Battery

produces

hydrogen and oxygen

during char

ging and

this could accelerate the

risk of explosion.

4. Read and follow the instructions before

replacing the battery.

5.

During maintenance, first aid kits and fire

extinguishers should be placed

at your

fingertip

s.

6. During maintenance, you should disconnect

the battery cables.

Safe Operation

2-5

① Battery

7. Do not open radiator cap before coolant has

cooled dow

n. When the coolant is cold, open

slowly and let the coolant pressure reduced,

and then open water cooler cap. Check

for

the coolant

level in the coolant reservoir

. If

necessary, add coolant.

8.

Tires should be mounted on rims with specia

l

equipment by profession

als.

9.

Keeping specified tire pressure can help to

ensure driving safety

.

10.

Elevate the vehicle and place a suitable

stand under the frame when removing the

wheels. Be sure to tighten the wheel nuts

to

specified

tor

que.

Warning Labels

3

-1

Warning and caution labels

（1） （2） （3）

（4） （5） （6）

（7）

（8）

（9）

Warning Labels

3

-2

（10） （11）

(12） (13)

(14) (15)

(16)

Vehicle Identification Number

4

-1

SERVICING OF VEHICLE

Your

dealer is interested in your new vehicle

and has the desire to help you get the most

value from it. After reading this manual

thoroughly, you will find you can do some of

the regular maintenance by yourself.

However, when in need of parts or major

service, be sure to see your dealer.

For service, contact the dealership from

which you purchased your vehicle or your

local dealer.

When in need of parts, be prepared to give

your dealer both the vehicle and engine

serial numbers.

Locate the serial numbers now and record

them in the space provided.

Type Serial No.

Vehicle

Engine

Product Identification

Number

Date of Purchase

Name of Dealer

① Vehicle serial number.

① Engine serial number