TM GRAB SOME SUN Published by Chongqing Huansong Industries (Group) Co., Ltd and Hisun Motors Corp USA. Chongqing Huansong Industries (Group) Co., Ltd and Hisun Motors Corp USA holds the copy right. No publishing and reprinting without permission. READ THIS MANUAL CAREFULLY For questions regarding this UTV, please contact HISUN at: (972)446-0760 hisunmotors.com Rev. 08071501 No one under the age of 16 should operate this vehicle.
INTRODUCTION Congratulations on your purchase of the Vector 500. This Owner’s / Operator’s manual will provide you information regarding safe operation, operational instructions, maintenance and care. Fully understanding this manual and following all of the instructions herein will provide the knowledge needed to have safe and enjoyable UTV operation. For questions regarding this UTV, please call (972) 446-0760.
IMPORTANT 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.
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).
UNIVERSAL SYMBOLS As a guide to the operation of your vehicle, various universal symbols have been utilized on the instruments and controls. The symbols are shown below with an indication of their meaning.
Table of Contents Subject Page Subject Page Introduction 1-1 Starting 8-1 Important manual information 1-2 Seat belt 8-1 Important notice 1-3 Head light switch 8-2 Universal symbols 1-4 Emergency light switch 8-2 Location of parts 1-7 Turn signal light switch 8-2 Illustrated contents 1-8 Brake pedal 8-3 Safe operation 2-1 Range gear shift lever 8-4 Safety instructions 2-1 4WD lever 8-5 Operation 2-2 Accelerator pedal 8-5 Children safety instructions 2-2 Stopping 8-
Checking seat belt and ROPS 10-6 Changing brake fluid Checking joint boot 10-6 Flushing Cooling system and changing 10-16 Checking tire inflation pressure 10-6 coolant Every 50 hours 10-6 Anti-freeze 10-17 Greasing 10-6 Replacing radiator hose (water pipes) 10-18 Checking engine start system 10-7 Replacing fuel hose 10-18 Checking wheel bolt torque 10-7 Replacing brake master cylinder (inner 10-18 Cleaning air cleaner primary element 10-8 parts) Checking battery condition 10-9 R
LOCATION OF PARTS Front Tire Front Shock Absorber 1-7
ILLUSTRATED CONTENTS 1-8
1-9
Safe Operation All operators, including experienced UTV drivers 4. Do not wear loosen articles of clothing or passengers, should carefully read and fully during operation, as these can be drawn into understand this Users Manual, and operate moving parts on the vehicle and could cause strictly as the manual states in order to achieve a severe injury to occur. best performance and avoid accidents.
Safe Operation 8. Never allow unauthorized persons to repair 9. (DIFF.LOCK is off) when pressing, the this front/rear wheels can turn at different speed. UTV. This may affect vehicle performance and cause injury. 9. Otherwise, the vehicle may turnover. This UTV is designed and manufactured for 10. Never drive over terrain such as a ditch, a off-road use only, so never drive on paved hole, dams, excessive mud, or the vehicle roadways. can get stuck because of the vehicles weight. 2.
Safe Operation Always check for people or obstacles behind the 3. Under all conditions, both operator and vehicle before shifting the vehicle into reverse. passengers Avoid a collision with an obstacle or person. protective equipment. Park the vehicle on a firm, flat area. If parking on 4. Driver should slow down according to road a slope, you should use parking brake, remove conditions, terrain, visibility conditions. the key, and get tires stuck in the tire wedge. 5.
Safe Operation 4. Do not put your hands and you body under place shift lever on “N” position, stop the engine the cargo bed when it is raised. Once and remove the key. lowered, lock the cargo bed in place before 1. When working next to the engine, exhaust or operating the vehicle. Never driving before radiator, work only after it has cooled down. securing and locking the cargo bed. 2. Wait for the engine to stop running and cool down before checking the coolant level. 8.
Safe Operation 8. equipment by professionals. 9. Keeping specified tire pressure can help to ensure driving safety. 10. Elevate the vehicle and place a suitable stand under the frame when removing the wheels, Be sure to tighten the wheel nuts to specified torque.
Warning Labels Warning and caution labels (1) (2) (3) (4) (5) (6) (7) (8) (9) 3-1
Warning Labels (10) (11) (12) (13) (14) (15) (16) 3-2
Vehicle Identification Number SERVICING OF VEHICLE Your dealer is interested in your new vehicle and has the desire to help you get the most value from it. After reading this manual thoroughly, you will find you can do some of the regular maintenance by yourself. However, when in need of parts or major service, be sure to see your dealer. For service, contact the dealership from ① Vehicle serial number. which you purchased your vehicle or your local dealer.
Specifications SPECIFICATION TABLE Engine Make Specification Type 1-cylinder, 4-cycle, gasoline, SOHC, liquid cooled Displacement CC Horsepower Kw(HP) Rated revolution Low idling revolution Fuel Capacity 471cm 19.44 HP rpm 7000 rpm 1350 to 1500 L(U.S.gas) 29(7.
Specifications Model Cargo bed Width mm (in.) 1066 (42) Length mm (in.) 787(31) Depth mm (in.) 279(11) Volume Bed height (unloaded) Cargo bed capacity (1 row/2 row) Sound level, operator ear Tire Specification cu.ft. 8.28 mm (in.) 927(36.50) kg (lbs.) 159(350) db (A) 85 Front 26×9-12 Rear 26×10-12 Body color Camo NOTE: The values in “Ground clearance” and “Weight” are those of the machine equipped with the tires in the table above.
Specifications VEHICLE LIMITATIONS The Vehicle has been thoroughly tested for proper performance with implements sold or approved by manufacturer.
Pre-Operation DAILY CHECK To better prevent troubles, it is important to know condition of the vehicle well. Check it before starting. CAUTION: To avoid personal injury: Be sure to check and service the vehicle on a level surface with the engine shut off and the parking brake “ON” and implement lowered to the ground if equipped.
Operating the Engine NOTE: CAUTION:Section The parking brake warning lamp (P) comes on To avoid personal injury: while parking brake is applied and goes off when it is released. Read "SAFE OPERATION" in front of this manual. Read the danger, warning and caution labels located on the vehicle. To avoid the danger of exhaust fume poisoning, do not operate the engine in closed buildings without proper ventilation. Start engine only from operator’s seat.
Operating the Engine 3. Insert the key into the key switch and turn it “START”. OFF (Stop the Engine) (L) Low Range ON (Engine runs or headlights on) (H) High Range START ① Range gear shift lever. (N) Neutral position (R) REVERS (Start the Engine) IMPORTANT : It is not sufficient to do daily checks on dash board only. Always conduct daily checks carefully by referring to “DAILY CHECK“ in “PERIODIC SERVICE” section. 2. Push the accelerator pedal down slowly. 4.
Operating the Engine WARMING UP CAUTION: To avoid personal injury: Be sure to set the parking brake during warm-up. Be sure to set the shift lever to the “NEUTRAL” position during warm-up. For 5 minutes after engine start-up, allow the engine to warm up without applying any load. This is to allow oil to reach every engine part. If load is applied to the engine without warming-up, engine damage may occur.
Operating the Vehicle OPERATING NEW VEHICLE ■ Changing Lubricating Oil for New Vehicles How a new vehicle is handled and maintained The lubricating oil is especially important for a determines the life of vehicle. new vehicle. Various parts need time to wear A new vehicle just off the factory production line and has been, of course, tested, but the various parts operating clearances.
Operating the Vehicle NOTE: Turning the head light switch to the “ON” position causes the following lamps to light simultaneously. 1. Tail lights (lamps at the rear portions of the vehicle) ① Seat belt 2. Selecting light switch position. Lamp built in the coolant temperature gauge 3. Lamp built in the fuel gauge 4. Lamp built in the speedometer 5.
Operating the Vehicle activated, the indicated turning light will flash and other will stay on. The brake pedal is the left pedal on the foot Be sure to return switch to center position board. Depress the pedal to slow or stop the after turning. vehicle. control. Reduce the speed. ① Brake pedal 4. Selecting the travel speed. ■ Range Gear Shift Lever CAUTION: To avoid personal injury: ① Head light descending a slope.
Operating the Vehicle 3. 4. Select proper gear and engine speed NOTE: depending on the type of job. When range gear shift lever is hard to Before exiting vehicle, shift the gear shift engage, do not force the lever. Set the lever to the “NEUTRAL” position and set parking parking brake. accelerator pedal and release it to neutral brake, slightly depress the position, then shift the lever. FOR HS450UTV When the lever is hard to disengage, do not force the lever.
Operating the Vehicle ① Parking brake ■ Accelerator Pedal The accelerator pedal is used to increase the engine and vehicle speed. Push down on it for higher speed. ①Fuel gauge ■ Coolant Temperature Gauge CAUTION: ① Accelerator pedal To avoid personal injury: STOPPING Do not remove radiator cap until coolant ■ STOPPING temperature is well below its boiling 1. Release the accelerator pedal point. Then loosen cap slightly to relieve 2. Step on the brake pedal. pressure 1.
Operating the Vehicle ① Coolant temperature gauge The hour meter indicates in five digits the hours the vehicle has been used; the last digit indicates 1/10 of an hour. ① Hourmeter The speedometer indicates the traveling speed.
Maintenance and Adjustment WINCH MOUNT PLATE Always read and follow the instructions in the winch owner’s manual before attempting to install or use a winch. ① Winch mount plate ■ Transporting Vehicle Pay attention to the following points when transporting the vehicle. 1. Use a suitable truck or trailer. 2. Apply the parking brake and place chocks against the front and rear tires.
Maintenance and Adjustment CAUTION: To avoid personal injury and vehicle damage: Be sure you have sufficient knowledge, experience, the proper replacement parts and tools before you attempt any vehicle maintenance task. If you don’t have the knowledge and equipment which are necessary to perform the maintenance task, consult your local dealer. Have your local dealer perform inspection items which are marked *4 in the chart below.
Maintenance and Adjustment Indication of No.
Maintenance and Adjustment Indication of No. Items 50 100 150 200 250 300 350 400 450 500 550 600 650 700 31 Coolant Change 32 Fuel system Bleed 33 Fuse Replace 34 Light bulb Replace After 700 hrs Every 2 years Service as required NOTE: ◆Engine Oil:(10W/40SL) Oil used in the engine should have an American Petroleum Institute (API) service classification and Proper SAE Engine Oil according to the ambient temperatures as shown above.
Periodic Service ① Turn switch ② Front hood cover CAUTION: ■ Operator’s Seat To avoid personal injury: To open the seat, raise the seat to the forward HOW TO OPEN THE FRONT HOOD COVER AND SEAT position. CAUTION To avoid personal injury from contact with moving parts: Never open operator’s seat while the engine is running. ■ Front hood cover To open the hood, turn the switch as the direction ① Operator’s seat in below picture to release the latch and lift the hood off.
Periodic Service ■ Front End NOTE: Pull up the cargo bed handle to raise the cargo Jack up at the front frame tube only. bed with the gas spring elasticity. ① Jack ② Front frame tube ① Cargo bed handle ② UP ■ Rear End ③ DOWN Jack the rear only after placing a wooden block under the right and left frame tubes for securing the engine and then supporting it. Do not apply jack pressure on the steel plate directly under the engine.
Periodic Service IMPORTANT CAUTION If oil level is low, do not run engine. To avoid personal injury: Checking engine oil level 1. Be sure to park the vehicle on a flat Park the vehicle on a flat surface with surface with the engine off and the parking engine off, raise the cargo bed, mount the brake "ON". safety support. 2.
Periodic Service IMPORTANT ■ Checking Coolant Level follow the cautions above and securely CAUTION retighten the cap. TO avoid personal injury If the radiator cap has to be removed, Do not remove radiator cap while coolant is hot, when cool, slowly rotate to the first stop and allow sufficient time for excess the recovery tank. If water should leak, consult your local HSUN Dealer. pressure to escape removing the cap completely.
Periodic Service ■ Checking brake fluid level ■ Checking brake pedal CAUTION CAUTION TO avoid personal injury: TO avoid personal injury: Never operate the vehicle if the brake fluid is below the minimum mark. Stop the engine and chock the wheels before checking brake pedal. Use only DOT3 from a sealed container. Other 1.Inspect the brake pedals for free play and types of brake fluid may ruin synthetic resin or smooth operation.
Periodic Service ① Joint boot ② Drive shaft ■ Checking tire inflation pressure Though the tire pressure is factory-set to the prescribed level, it naturally drops slowly in the course of time, thus check it every day and inflate as necessary. tire sizes inflation pressure Front: 26x9-12 70kPa (10psi) Rear: 26x10-12 70kPa (10psi) ① Parking brake ■ Checking gauges meter service lamps 1. Inspect the instrument panel for broken EVERY 50 HOURS gauges meter and warning lamps. 2. Replace if broken.
Periodic Service ① Range gear shift lever pivot (spray type grease ) ① Range gear shift lever ■ Checking engine start system CAUTION ■ Checking wheel bolt torque TO avoid personal injury Do not allow anyone near the vehicle while CAUTION testing. To avoid personal injury If the vehicle does not pass the test, do not operate the vehicle. wheel bolts. ◆ Preparation before testing 1.
Periodic Service Check all bolts frequently and keep them tight. Check wheel bolts regularly especially when new if they are loose tighten them as follows: ① Air filter element ① Torque wheel bolts to 75 to 90 N.m ■ Cleaning air cleaner primary element 1. Remove the air cleaner cover and primary ① Air filter element ② Locating pad element. 2. Remove the sponge material from its frame. 3. Wash the sponge material gently but thoroughly in solvent. 4.
Periodic Service Be sure to refit the cower with the arrow (on pump entrance. Even a small amount of dust or the rear of cower ) upright if the cover is dirt cause premature wear and malfunction of improperly fitted the evacuator valve will not the fuel pump and injector components. function and dust will adhere to the element. ◆ Evacuator Valve Open the air cleaner cover once a week under ordinary conditions –or daily when used in a dusty place-to get rid of large particles of dust and dirt.
Periodic Service CAUTION To avoid personal injury When the battery is being activated, 12V32Ah 12 ◆ Direction for storage are extremely explosive. Keep open sparks 1. When storing the vehicle for a long period, and flames away from the battery at all remove the battery from the vehicle, store times, in a dry place out of direct sunlight. especially when charging the 2.
Periodic Service 2. measurement is obtained. IMPORTANT: Retighten the lock nut. Visually check the muffler for cracks or IMPORTANT holes in the body, weldment or pipes at regular intervals. Keep the equal length of the left and right tie rod. ■ Cleaning Muffler USDA approval requires clearance between spark arrester sleeve and muffler body to be no larger than 0.023”(0.584 CAUTION mm). To avoid personal injury: Replace the entire muffler if it is damaged.
Periodic Service 4. Fill with the new oil up to the upper notch on the dipstick. oil can be hot and can burn. (See “LUBRICANTS, FUEL AND COOLANT” 1. in “MAINTENANCE” section.) [Filter exchanged] Allow engine to cool down sufficiently, Park the vehicle on a flat surface, remove the seat and open the adjust hatch cover. 1.8L (1.89U.S. qts.) Oil capacity 2. Remove the oil filter. 3. Put a film of clean engine oil on the rubber [Filter non-exchanged] 1.6L (1.68U.S. qts.
Periodic Service Be sure to stop the engine before changing oil. Allow engine to cool down sufficiently, oil ■ Checking Brake Pedal can be hot and can burn. 1. CAUTION Park the vehicle on a flat surface, raise the cargo bed, and mount the safety support. before checking brake pedal. 2. Put a film of clean transmission oil; 3. Quickly tighten the filter until it contacts the brake. turn only.
Periodic Service 3. securely, if radiator hoses are swollen, hardened or cracked. Replace hoses and hose clamps every 2 years or earlier, if checked and found that hoses are swollen, hardened or cracked. ① Brake pedal ② “FREE TRAVEL” ③ “PEDAL STROKE” ■ Checking Brake Hose and Pipe 1. Check to see that brake hose and lines are not swollen, hardened or cracked. 2. 3. ① Radiator hose ◆Precaution at Overheating leaks.
Periodic Service Allow engine to cool down sufficiently, oil can be hot and can burn. 1. Park the vehicle on a flat surface, raise the cargo bed, mount the safety support. 2. To drain the used oil, remove the drain plug at the bottom of the transmission case and drain the oil completely into the oil pan. ① Hose ② Hose joint 3. After draining, reinstall the drain plug. 4.
Periodic Service ■ Replacing Air Cleaner Primary Element Oil capacity for front axle case Oil capacity for rear axle case and Secondary Element 0.28L(0.072U.S.gals.) (See “Cleaning Element” 0.20L(0.052U.S.gals.) in Air “every Cleaner 100 Primary HOURS” in “PERIODIC SERVICE” section.) EVERY 2 YEARS ■ Changing Brake Fluid Consult your local Dealer for this service. (See “Checking Brake Fluid Level” in “DAILY CHECK” in “PERIODIC SERVICE” section.
Periodic Service on the recovery tank. once and take medical attention. 8. Start and operate the engine for few minutes. 9. Stop the engine and let cool. skin or clothing, wash it off immediately.。 10. Check coolant level of recovery tank and coolant if necessary. Coolant capacity When antifreeze comes in contact with the Do not mix different types of Antifreeze. The mixture can produce chemical reaction causing harmful substances. 1.8L (1.89 U.S.qts.
Periodic Service Refer to SEA J1034 standard, more coolant every 2 years. specifically also to SAE J814c. NOTE: IMPORTANT: above data represent industry standards that necessitate a minimum glycol When the antifreeze is mixed with water, the content in the concentrated antifreeze. antifreeze mixing ratio must be less than 50%.
Periodic Service electrical cabling. If any of them have blown out, STORAGE be sure to pinpoint the cause. CAUTION ◆Replacing procedure To avoid personal injury: 1) Disconnect the negative cable of the battery. 2) Open the slow-blow fuse box cover. 3) Pull out the slow-blow fuse. 4) Insert a new slow-blow fuse into the box. 5) Close the slow-blow fuse box cover. 6) Connect the negative battery cable. Do not clean the vehicle when the engine is running.
Periodic Service the battery following the battery storage 5. Start the engine. Observe all gauges. If all 8. procedures. gauges are functioning properly and reading 9. Keep the vehicle in a dry place where the normal, move the vehicle outside. Once vehicle is sheltered from the elements. outside, park the vehicle and let the engine Cover the vehicle. idle for at least five minutes. Shut the engine 10.
Troubleshooting ENGINE TROUBLESHOOTING If something is wrong with the engine, refer to the table below for the cause and its corrective countermeasure. Trouble Cause In winter, oil viscosity increases, and Engine revolution is slow. Battery becomes weak and the engine does not turn over quick enough. Clean or replace the air cleaner. Clean or replace the spark plug. Replace the ignition coil. Insufficient fuel. The injector is clogged. Crankshaft position sensor is bad..
Troubleshooting Diagnostic Trouble Code Table MT05 ECU Malf Code Table:23 Malf code in MT05 Description P0107 MAP Circuit Low Voltage or Open P0108 MAP Circuit High Voltage P0112 IAT Circuit Low Voltage P0113 IAT Circuit High Voltage or Open P0117 Coolant/Oil Temperature Sensor Circuit Low Voltage P0118 Coolant/Oil Temperature Sensor Circuit High Voltage or Open P0122 TPS Circuit Low Voltage or Open P0123 TPS Circuit High Voltage P0131 O2A Circuit Low Voltage P0132 O2A Circuit High Volt
Troubleshooting BATTERY TROUBLESHOOTING Trouble Cause Battery Preventive measure overused until lights are dim. Countermeasure Battery has Charge the battery sufficiently. not Charge the battery properly. been recharged.
Troubleshooting MACHINE TROUBLESHOOTING Trouble Cause High idling speed of engine High rotary speed for clutch connection. Gearshift cable adjustment. Trouble shifting gears Transmission noise is out of Gear abrasion Poor clearance for the inner and outside gears of transmission shaft Poor clearance of transmission gears.
TM HISUN MOTORS 310 East University Dr McKinney, Texas 75069 PH (972) 446-0760 TF (877) 838-6188 hisunmotors.