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. 01031701 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 Coolant temperature gauge 8-5 Hour Meter and Fuel gauge 8-6 Safe Operation 1-1 Winch mount plate 9-1 Children safety Instruction 1-2 Service interval chart 10-1 Driving on a slope/high speeds 1-3 Periodic Service 11-1 Parking and Transportation 1-4 How to open the front hood and seat 11-1 Warning labels 1-5 Front hood cover 11-1 Servicing of Vehicle ID Numbers 2-1 Operator’s seat 11-1 Specifications 3-1 How to raise the cargo bed 11-1 Vehicle
200 Hour Maintenance 11-11 Replacing brake master cylinder (inner 11-17 Changing the oil 11-11 parts) Replacing the oil 11-11 Replacing front brake seal 11-17 Replacing transmission oil 11-12 Replacing rear brake cylinder seal 11-17 Checking brake pedal 11-12 Replacing intake air line 11-17 Checking brake hose and pipe 11-13 Every 4 years 11-17 Checking brake light switch 11-13 Replacing brake hose 11-17 Checking radiator hose and clamp 11-13 Replacing slow-blow fuses 11-17 Che
SAFE OPERATION 1-1 SAFE OPERATION operation, as these can be drawn into All operators, including experienced UTV drivers moving parts on the vehicle and could cause or passengers, should carefully read and fully a severe injury to occur. understand this User’s Manual, and operate You should wear protective devices, such as strictly as the manual states in order to achieve helmet, boots, eye protection, ear protection, best performance and avoid accidents. Others gloves, and etc.
SAFE OPERATION this UTV. This may affect vehicle performance and cause injury. 1-2 speeds and the vehicle is less maneuverable 9. Never drive over terrain such as a ditch, a 10. This UTV is designed and manufactured for hole, dams, excessive mud, or the vehicle off-road use only, so never drive on paved can get stuck because of the vehicles roadways. weight. 10. Always pay close attention to your 2. Operation surroundings, and check for streets, trail 1.
SAFE OPERATION protective equipment. When parking the vehicle, park the on a firm, flat surface. If parking on a slope, you should use the 4. Driver should slow down according to road conditions, terrain, visibility conditions. parking brake, remove the key, and place a wedge 5. under the tires. 1-3 Be cautious when driving over a ditch, stone road or hidden obstacles. 4. Driving on a slope 6. Avoid operating in any unknown depth of Be cautious when riding on a slope, as this is the water.
SAFE OPERATION before securing and locking the cargo bed. or steam blown out. 3. 8. Parking 1. 2. 1-4 No smoking when adding electrolyte or refueling. Fuel tank and battery should be Set the gear shift to the “N” position and to kept away from sparks. Battery produces release the parking brake, depress the hydrogen and oxygen during charging and brake pedal. this could accelerate the risk of explosion. Avoid stopping the vehicle on a slope. If 4.
SAFE OPERATION 11.
SAFE OPERATION ⑹ ⑺ ⑻ ⑽ ⑼ 1-6
SAFE OPERATION ⑾ ⑿ ⒀ ⒁ ⒂ 1-7
SERVICING OF VEHICLE 2-1 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.
SPECIFICATIONS 3-1 SPECIFICATIONS SPECIFICATION TABLE Model Engine Vector Make H-L forward, Neutral, Reverse Type 4-stroke, Water cooled Displacement 471cm3 Horsepower Kw(HP) Rated revolution Low idling revolution Fuel Capacity 16 rpm 7000 rpm 1350 to 1500 L(U.S.gas) 29(7.
SPECIFICATIONS Model Cargo bed Worksite/Orange Worksite/Camo Width mm (in.) 1305 (51.37) Length (row) mm (in.) 775 (30.52) Depth mm (in.) 285 (11.22) m3 (cu.ft.) 0.23 (8.11) mm (in.) 927 (36.49) kg (lbs.
VEHICLE LIMITATIONS 4-1 VEHICLE LIMITATIONS The Vehicle has been thoroughly tested for proper performance with implements sold or approved by manufacturer.
INSTRUMENT PANEL AND CONTROLS 5-1 INSTRUMENT PANEL AND CONTROLS LOCATION OF PARTS
INSTRUMENT PANEL AND CONTROLS ILLUSTRATED CONTENTS 5-2
INSTRUMENT PANEL AND CONTROLS 5-3
PRE-OPERATION CHECK PRE-OPERATION CHECK 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 7-1 OPERATING THE ENGINE STARTING THE ENGINE CAUTION: To avoid personal injury: 1. Make sure the parking brake is set. Read "SAFE OPERATION" in front of this manual. Read the danger, warning and caution labels located on the vehicle. To avoid the danger of exhaust fume poisoning, do not operate the engine in closed buildings without proper ventilation. Start engine only from operator’s seat. Never start engine while standing on ① Parking brake lever ground.
OPERATING THE ENGINE 7-2 2. Set gear shift lever to the “NEUTRAL” position. ① Range gear shift lever. (H) High Range ◆ Checking the indicator / warning lights: 1. engine oil pressure) should come on. If trouble (L) Low Range occurs at any location with engine running, the (N) “Neutral” position warning lamp corresponding to that location (R) “REVERSE” 3. Push the speed accelerator pedal down When the key is turned “START”, lamps (1 comes on. 2.
OPERATING THE ENGINE STOPPING THE ENGINE 1. After slowing the engine to idle, turn the key to “OFF”. 2. Remove the key. 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.
OPERATING THE VEHICLE 8-1 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 are not “broken-in” A new vehicle just off the factory production line and are not aligned to each other.
OPERATING THE VEHICLE CAUTION: To avoid personal injury: Always use the seat belts when operating and riding the vehicle. NOTE: Turning the head light switch to the “ON” position causes the following lamps to light simultaneously. 1. Adjust the seat belts for proper fit and connect the buckle. This seat belt is an auto-locking retractable type. 8-2 Tail lights (lamps at the rear portions of the vehicle) 2. Lamp built in the coolant temperature gauge 3. Lamp built in the fuel gauge 4.
OPERATING THE VEHICLE 8-3 If the hazard light switch is pressed to the “ON” position while the turn signal is activated, the indicated turning light will flash and other will stay on. Be sure to return switch to center position after turning. ① Brake pedal 4. Selecting the travel speed. ■ Gear Shift Lever CAUTION: To avoid personal injury: Avoid changing gear shift lever when ascending or descending a slope.
OPERATING THE VEHICLE 8-4 Accident may occur if the vehicle is suddenly stopped, as heavy towed loads could shift forward causing loss of control. The braking characteristics are different between two and four wheel drive. Be aware of the differences and use caution. IMPORTANT: 5. Unlock the parking brake and start slowly. ① Gear shift lever To release the parking brake, depress the brake pedal or push the release button and push down (L) LOW Range (H) HIGH Range parking brake lever.
OPERATING THE VEHICLE 8-5 STOPPING ■ STOPPING 1. Release the speed control pedal 2. Step on the brake pedal. CHECK DURING DRIVING ■ Immediately Stop the Engine if: The engine suddenly slows down or accelerates. Unusual noises are suddenly heard. Exhaust fumes suddenly become very white. ① Fuel gauge ■ Coolant Temperature Gauge While driving, check the following items to see if all parts are functioning normally.
OPERATING THE VEHICLE ① Hourmeter The speedometer indicates the traveling speed.
WINCH MOUNT PLATE WINCH MOUNT PLATE WINCH MOUNT PLATE Mounting the optional winch always requires reading the instruction manual included with the 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 10-1 MAINTENANCE 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. If you don’t have the knowledge and equipment which are necessary to perform the maintenance, consult your local dealer. Have your local dealer perform inspection items which are marked × in the chart below.
MAINTENANCE 10-2 Indication of No.
MAINTENANCE 10-3 NOTE: ◆Engine Oil:(15W/40SL) Oil used in the engine should have an American Petroleum Institute (API) service classification and Proper SAE Engine Oil according to the ambient temperatures as shown above. ◆Brake fluid: Always use DOT3 GENUINE BRAKE FLUID from a sealed container.
PERIODIC SERVICE 11-1 PERIODIC SERVICE CAUTION: To avoid personal injury: ■ HOW TO OPEN THE HOOD COVER Cover AND TILT THE SEAT CAUTION To avoid personal injury from contact with moving parts: Never open operator’s seat while the engine is running. Support hood with the other hand while ① HOW TO RAISE THE CARGO BED unlocking support link.
PERIODIC SERVICE 11-2 3. Lower the lever to the “DOWN” position to JACK POINT lower the bed. 4. WARNING After making sure that the bed has lowered to the lowest position, lock it by the restricting To avoid personal injury, death or vehicle damage: plate. Do not work under the vehicle unless it is secured by safe stands or suitable blocking. NOTE: Pull up the cargo bed handle to raise the cargo bed with the gas spring resistance ■ Front End Jack up at the front bumper only.
PERIODIC SERVICE 11-3 DAILY CHECK IMPORTANT For your own safety and maximum service life of If oil level is low, do not run engine. the vehicle, make a thorough daily inspection Checking engine oil level before operating the vehicle or starting the engine. 1. Park the vehicle on a flat surface, raise the cargo bed, mount the safety support and shut CAUTION off engine. To avoid personal injury: 2.
PERIODIC SERVICE 11-4 2. Check to see that the coolant level is between the “FULL” and” LOW” marks of recovery tank. 3. When the coolant level drops due to evaporation, add water only up to the full level. In case of leakage add anti-freeze and water in the specified mixing ratio up to the full level.
PERIODIC SERVICE 11-5 Make sure the parking brake warning lampgoes off when parking brake lever is down. ① OIL CUP ② LOWER ■ Checking brake pedal CAUTION ① Parking brake pedal ■ Checking the warning lights and indicator TO avoid personal injury: Stop the engine and chock the wheels lights. 1. before checking brake pedal. 1.Inspect the brake pedals for free clearance and Inspect the instrument panel for broken warning light or indicator lights. 2. Replace if broken. smooth operation.
PERIODIC SERVICE 11-6 ① joint boot ② Drive shaft ① Parking brake pedal ① Joint boot ② Drive shaft ② Parking brake pivot(spray type grease) ■ 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 & Rear: 26x10-12 70kPa (0.
PERIODIC SERVICE 11-7 ■ Checking wheel bolt torque ◆ Preparation before testing 1. 2. CAUTION Place all control levers in the “NEUTRAL” position. To avoid personal injury Set the parking brake and stop the engine. Never operate vehicle with a loose wheel bolt. ◆ Test the range of the gear shift lever and Sit on the operators seat. 2. Shift the range gear shift lever to: “L”, “H”, “N” or REVERSE position. 3. Turn the key to “START” position. 4. The engine must not crank. 5.
PERIODIC SERVICE 11-8 11. Install the air filter element. 12. Install the air filter case cover and be sure the crankcase breather hose is connected. Do not run the engine with filter element removed. Be sure to refit the cover with the arrow (on the rear of cover) upright if the cover is improperly fitted the evacuator valve will not function and dust will adhere to the element.
PERIODIC SERVICE 11-9 IMPORTANT The factory –installed battery is non-refillable type When the fuel line is disconnected for maintenance if the battery is weak, charge the battery or or repair close both ends of the fuel line with a replace it with new one piece of clean cloth or paper to prevent dust and dirt from entering in, care must be taken not to ◆ Battery charging allow dust and dirt into the fuel pump.
PERIODIC SERVICE 11-10 Battery type Volts 12V32Ah 12 measurement is obtained. 2. Retighten the lock nut. IMPORTANT ◆ Direction for storage 1. When storing the vehicle for a long period, Keep an equal length between the left and right tie-rod. remove the battery from level vehicle, store in a dry place out of direct sunlight. 2.
PERIODIC SERVICE 11-11 IMPORTANT: Visually check the muffler for cracks or holes [Filter exchanged] 1.8L (1.89U.S. qts.) [Filter not exchanged] 1.6L (1.68U.S. qts.) Oil capacity in the body, weldment or pipes at regular intervals. USDA approval requires clearance between spark arrester sleeve and exhaust pipe to be no larger than 0.023”(0.584 mm). Replace the entire muffler if it is damaged. Do not operate the vehicle with a damaged muffler.
PERIODIC SERVICE 11-12 ① Bolt; ② Cover ③ “O” seal ring; ④ Engine oil filter Oil Leve ② Oil inlet ③ Dipstick IMPORANT: ① To prevent serious damage to the engine, use only a genuine filter. ④ Cap ■ Checking Brake Pedal CAUTION ■ Replacing Transmission Oil checking brake pedal. CAUTION To avoid personal injury: Allow engine to cool down sufficiently, oil brake. ◆Checking the brake pedal free travel can be hot and can burn. 1.
PERIODIC SERVICE 11-13 ◆ Checking the brake pedal stroke cargo bed. Check to see if radiator hoses are properly attached every 200 hours of operation or Pedal stroke Less than 120mm (4.7in.) On the pedal 1. Release the parking brake. 2. Step on the pedal and measure the pedal six months, whichever comes first. 1. tighten bands securely. 2. stroke. 3.
PERIODIC SERVICE 11-14 ■ Checking Intake Air Line 1. Check to see if the hoses and hose clamps are tight and not damaged. 2. CAUTION To avoid personal injury: If hoses and clamps are found to be worn or damaged, replace or repair them at once. Park the vehicle on a flat surface, raise the cargo bed, and mount the safety support. 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, and mount the safety support. 2.
PERIODIC SERVICE 11-15 the dipstick. (See “LUBRICANTS, FUEL AND COOLANT” ■ Flushing Cooling System and Changing in “MAINTENANCE” section.) 4. Coolant After filling, reinstall the filling plug. CAUTION Oil capacity 0.6L(0.6U.S.gals.) To avoid personal injury: Do not remove the radiator cap while coolant is hot. When cool, slowly rotate cap to the first stop and allow sufficient time for excess pressure to escape before removing the cap completely. 1. Stop the engine and let cool down. 2.
PERIODIC SERVICE 11-16 container underneath the engine body. Do not pour waste onto the ground, down a drain, or into any water source. Also, observe environmental protection regulations when disposing of antifreeze. If it freezes, coolant can damage the cylinders and radiator.
PERIODIC SERVICE 11-17 ■ Replacing Brake Master Cylinder (Inner 4. Adding the LLC parts) 1) Add only water if the mixture reduces in Consult your local dealer for this service. amount by evaporation. 2) If there is a mixture leak, add the LLC of the ■ Replacing Front Brake Seal same manufacturer and type in the same Consult your local dealer for this service. mixture percentage. * Never add any long-life coolant of different manufacturer.
PERIODIC SERVICE 11-18 ① Slow-blow fuse box cover ■ Replacing Light Bulb Head lights Take the bulb out of the light body and replace it with a new one.
STORAGE 12-1 STORAGE 7. STORAGE Remove the battery from the vehicle. Store the battery following the battery storage procedures. CAUTION 8. Keep the vehicle in a dry place where the To avoid personal injury: vehicle is sheltered from the elements. Cover the vehicle. Do not clean the vehicle when the engine is running. 9. Keep the vehicle indoors in a dry area that is To avoid the danger of exhaust fume protected from sunlight and excessive heat.
STORAGE gauges are functioning properly and reading normal, move the vehicle outside. Once outside, park the vehicle and let the engine idle for at least five minutes. Shut the engine off and walk around vehicle and make a visual inspection looking for evidence of oil or water leaks. 6). With the engine fully warm up, release the parking brake and test the brakes for proper adjustment as you move forward. Adjust the brake as necessary.
TROUBLESHOOTING 13-1 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.
TROUBLESHOOTING 13-2 Check malf code meaning by reading the below table.
TROUBLESHOOTING 13-3 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 13-4 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.
OPTIONS OPTIONS Consult your local dealer for further details. 1. Head rest; 2. Plastic Canopy; 3. Rear Trailer Hitch & Pin(2〞); 4. Windshield; 5. Steel Cab; 6.
2017 VECTOR WARRANTY HISUN MOTORS CORP., 301 E. University Drive, McKinney, TX 75069 (HISUN) gives the below LIMITED WARRANTY on all components of your HISUN vehicle against defects in material or workmanship.
2017 VECTOR WARRANTY Limitations of Warranties and Remedies This warranty excludes damages or failures caused by abuse, accident, fire, or any other cause other than a defect in materials or workmanship and provides no coverage for consumable components, general wear items, or any parts exposed to friction surfaces, stresses, environmental conditions and/or contamination for which they were not designed or not intended, including but not limited to the following items: Wheels and Tires Circuit breakers/
2017 VECTOR WARRANTY How to Obtain Warranty Service If your vehicle requires warranty service, you must take it to a HISUN Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registration Form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). HISUN suggests that you use your original selling dealer; however, you may use any HISUN Servicing Dealer to perform warranty service.
2017 VECTOR WARRANTY U.S.A. EPA Emissions Limited Warranty This emissions limited warranty is in addition to the HISUN standard limited warranty for your vehicle. HISUN Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms to applicable U.S. Environmental Protection Agency emission regulations.
2017 VECTOR WARRANTY Emission-related components also include any other part whose only purpose is to reduce emissions or whose failure will increase emissions without significantly degrading engine/equipment performance. The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of HISUN, repair or replacement of any defective materials, components or products.
2017 VECTOR WARRANTY MAINTENANCE LOG Use the following chart to record periodic maintenance.
TM HISUN MOTORS 310 East University Dr McKinney, Texas 75069 PH (972) 446-0760 hisunmotors.