Target Audience:
HISUN HS500 4x4 ATV owners seeking to perform their own repairs and maintenance
Value Proposition:
Significant cost savings on service, repair, and maintenance expenses
Alternative Sources:
Dealership service departments, independent mechanics, potentially limited manufacturer-provided resources
Accessibility:
Instant download via email link
Usability:
Easy to use, no special technical knowledge required, printable pages
Support:
Technical assistance available via email
Licensing:
Unlimited use, no restrictions
Scope:
All diagnostic and repair procedures, maintenance, rebuilding, refurbishing, restoration
Level Of Detail:
Professional Technician and Mechanic level information
Estimate:
Not explicitly stated, but implied to be comprehensive (A-Z coverage)
Classification:
Service Repair Workshop Manual
Primary Language:
English
Delivery Format:
PDF Download
Platform Compatibility:
PC & MAC Computers
Operating System Compatibility:
Windows 95, 98, 98SE, 2000, NT, ME, XP, Vista, Windows 7 & 8
Engine:
Complete engine disassembly, assembly, diagnostics, and repair
Transmission:
Service and repair procedures for the transmission system
Drivetrain:
4x4 system, differentials, drive shafts, hub assemblies
Suspension:
Front and rear suspension components, alignment, shock absorbers
Brakes:
Brake system diagnostics, repair, fluid replacement, pad/shoe service
Electrical:
Wiring diagrams, component testing, battery, starter, alternator, lighting, ignition system
Fuel System:
Fuel pump, carburetor/fuel injection system, fuel lines, fuel tank service
Cooling System:
Radiator, fan, thermostat, water pump, coolant replacement
Exhaust System:
Muffler, exhaust pipes, catalytic converter (if applicable) inspection and service
Steering:
Steering column, tie rods, steering linkages, wheel alignment
Body And Frame:
Frame inspection, body panel removal/installation, plastics, seats
Wheels And Tires:
Tire inspection, pressure, rotation, wheel removal/installation
Maintenance:
Scheduled maintenance, oil changes, filter replacements, lubrication
Troubleshooting:
Diagnostic flowcharts and problem-solving guides for common issues
Repair:
Step-by-step instructions for all repairable components and systems
Rebuilding:
Detailed procedures for engine, transmission, and component rebuilding
Refurbishing:
Guidance on restoring worn or damaged components
Restoration:
Procedures for bringing the ATV back to original specifications
Diagnostics:
Comprehensive diagnostic procedures for all major vehicle systems
Depth:
Full A-Z coverage, from basic maintenance to complete overhaul
User Skill Level:
Suitable for DIY owners with no prior technical knowledge, as well as professional mechanics
Searchability:
Likely text-searchable within the PDF
Printability:
Printable pages for convenience
Diagram Resolution:
Highly detailed, printable diagrams
Binding:
Not applicable (digital download)
Paper Type:
Not applicable (digital download)
Engine Type:
Not explicitly stated in product information, but typically a single-cylinder 4-stroke for ATVs of this displacement.
Displacement:
500cc (as indicated by model name)
Configuration:
Likely Single Cylinder, 4-Stroke, SOHC (Single Overhead Camshaft) - common for this class.
Horsepower:
Not explicitly stated. Typical for a 500cc ATV is in the 30-40 HP range.
Torque:
Not explicitly stated. Expected to provide strong low-end torque for off-road use.
Fuel Delivery:
Likely Fuel Injection (FI) or Carburetor, depending on the specific model year and region. Manual would cover either.
Fuel Type:
Unleaded Gasoline
Cooling Method:
Likely Liquid Cooled (Radiator and Fan)
Ignition System:
Electronic Ignition (CDI or similar)
Length:
Not specified, but typically around 80-90 inches for this class.
Width:
Not specified, typically around 45-50 inches.
Height:
Not specified, typically around 45-50 inches.
Curb Weight:
Not specified, generally in the 550-650 lbs range for 500cc ATVs.
Towing Capacity:
Not specified, but typically rated for around 1000-1200 lbs.
Rack Capacity Front:
Not specified, typically around 75-100 lbs.
Rack Capacity Rear:
Not specified, typically around 150-175 lbs.
Crash Test Results:
Not applicable to ATVs in the same way as passenger vehicles.
Braking System:
Disc brakes (likely front and rear), with integrated braking or separate controls.
4Wd Engagement:
Switch-activated 4WD system for enhanced traction.
Lighting:
Headlights, taillights, brake lights for visibility.
Throttle Limiter:
Often included for beginners or specific modes.
Parking Brake:
Essential safety feature for securing the vehicle.
Display:
Likely a basic digital instrument cluster displaying speed, RPM, odometer, trip meter, fuel level, and indicator lights.
Traction Control:
Not typically found on ATVs of this class, focus is on mechanical 4WD.
Usb Charging:
Some models may offer a 12V accessory outlet for charging devices, but USB ports are less common as standard.
Oil Change Interval:
Typically every 1,000-2,000 miles or 6-12 months. The manual will specify the exact interval and type of oil.
Air Filter Inspection:
Recommended at frequent intervals, especially in dusty conditions. Manual will provide specifics.
Spark Plug Replacement:
Typically every 6,000-10,000 miles. Manual will provide correct plug type and gap.
Valve Clearance Adjustment:
Usually required at intervals like 5,000-10,000 miles. Manual will provide exact procedure and specifications.
Engine Oil Type:
Not specified, but likely SAE 10W-40 or 20W-50 motorcycle-specific oil with JASO MA rating. Manual will be definitive.
Engine Oil Capacity:
Not specified, typically around 1.5-2.5 liters. Manual will specify exact capacity.
Coolant Type:
Not specified, but typically a permanent type antifreeze/coolant (e.g., ethylene glycol based) for liquid-cooled engines. Manual will specify mixture ratio and type.
Brake Fluid Type:
Not specified, but commonly DOT 3 or DOT 4. Manual will be definitive.
Gear Oil Type:
For final drives or gearboxes, if separate. Manual will specify viscosity and type.
Common Wear Items:
Brake pads, tires, suspension bushings, drive belts (CVT), spark plugs.
Potential Electrical Gremlins:
As with many powersports vehicles, proper maintenance of battery terminals and connections is crucial to prevent electrical issues. The manual's wiring diagrams are key.
Cv Joint Boots:
Inspection and replacement of CV joint boots is vital to prevent premature wear of the joints, especially in off-road conditions.
Manufacturer:
HISUN (Qingdao HISUN Motor Co., Ltd.) is a Chinese manufacturer known for powersports vehicles and utility vehicles.
Model Line:
The HS500 is part of HISUN's line of mid-size ATVs, offering a balance of capability and affordability.
Production Years:
Specific production years for the HS500 are not provided, but ATVs of this class are generally produced continuously with minor updates.
