User manual HSUN 500ATV SERVICE MANUAL

[. . . ] BRIEF INTRODUCTION TO FOUR-WHEELED CROSS-COUNTRY VEHICLE MODEL 500ATV Four-wheeled cross -country vehicle, model 500ATV is a full road condition vehicle which can be driven on every kinds of road conditions such as sand beach, grassland, forest, village, construction site country road , This maintenance manual of four-wheeled vehicle model 500ATV (Hereafter called cross -country vehicle for short) compiled by Chongqing Industries Co. , Ltd is specially provided for saler and technical staff of our Group. This manual mainly introduce the maintenance, removing and repairing method of cross-country vehicle and provide some relative technology and performance data. Because this manual can't collect the whole content of cross-country vehicle, it can only help maintainer of our group and it's saler have a basic understanding on working principle, maintenance procedure and repairing technology of cross-country vehicle. If you don't have this knowledge, when repairing cross-country vehicle, the condition of improper assembling and danger occurs after assembling are easily happened. [. . . ] G. Small foreign objects lodged between the moving parts. NOTE: Areas A, B, and C above may be extremely difficult to diagnose. The symptoms are quite subtle and difficult to distinguish from normal machine operating noise. If there is reason to believe these components are damaged, remove the components and inspect them. The following "noises" may indicate a mechanical defect: a. A "rolling rumble" noise during coast, acceleration, or deceleration. The noise increases with front and/or rear wheel speed, but it does not increase with higher engine or transmission speeds. b. A "whining" noise that varies with acceleration and deceleration. CAUTION Too little gear lash is extremely destructive to the gear teeth. If a test ride following reassembly indicates this condition, stop riding immediately to minimize gear damage. -72- c. A slight "thunk" evident at low speed operation. This condition could result in the shaft drive assembly locking up, causing loss of control of the machine and possible injury to the rider. (2)Inspect v Drained oil Drained oil shows large amounts of metal particles ]Check the bearing for seizure. v Oil leakage Inspection steps: tClean the entire machine thoroughly, then dry it. tApply a leak-localizing compound or dry powder spray to the shaft drive. t Road test the machine for the distance necessary to locate the leak. Leakage ]Inspect the component housing, gasket, and/or seal for damage. NOTE: tAn apparent oil leak on a new or nearly new machine may be the result of a rust-preventative coating or excessive seal lubrication. tAlways clean the machine and recheck the suspected location of an apparent leakage. -73- Troubleshooting chart When basic condition "a" and "b" exist, check the following points: YES Replace the wheel bearing. Elevate and spin both wheels. NO Check the wheel nuts and hub nuts for tightness. NO Torque to specification. YES NO Check the front constant velocity joint. YES Constant velocity joint bearings and differential gear bearings are probably not damaged. Repeat the test or remove the individual components. NO Check the rear brake adjustment. Adjust per instructions. YES Constant velocity joint bearings and final drive gear bearings are probably not damaged. Repeat the test or remove the individual components. Check the rear constant velocity joint. YES NO Remove the drive shaft components. -74- II. Front constant velocity joints and differential gear Constant velocity joint Gear motor coupler/on-command four-wheel drive switch and differential gear lock switch coupler Differential gear case breather hose Differential gear Drive shaft Front arms(upper) -75- ()Remove the front constant velocity joint in the order below 1. Removal Front wheels WARNING Securely support the machine so there is no danger of it falling over. 2. Removal (1)Tie rods (2)Front brakes/Front wheel hub 3. Removal (1)Front arm (lower)¢Ù (2)Constant velocity joint 4. Removal Gear motor coupler/on-command fourwheel drive switch and differential gear lock switch coupler -76- 5. Removal Differential gear 6. Removal Drive shaft -77- ()Removal steps of Differential gear Disassembling the differential gear in the order below. [. . . ] Recharge or replace the battery Incorrect Correct Replace the main switch. 4. Wiring connection . Refet to "WIRING DIAGRAM" Correct Properly connect the signal system. Check the connections of the lighting system's circuits. Refer to "CHECKING THE SIGNAL SYSTEM". -196- If the brake light fails to come on: 1. Bulb and bulb socket. . Check the bulb and bulb socket for continuity No continuity Continuity Replace the bulb and/or bulb socket. 2. Brake light switches Refer to "CHECKING THE SWITCH" No continuity Continuity Replace the brake light switch. 2. Voltage . [. . . ]