Hey folks. I recently acquired a pre-owned Hisun 500, carburated. And surprise... it has issues.
When cold, it typically starts without any issues, but once it warms up it tends to sputter and stall out. When accelerating, you can also feel it hesitating occasionally, and when you stop or put her into reverse, she will often stall. The fuel is clean, I installed a new fuel filter, and the air filter is clean. Though the fuel pump appears to be working ok, it makes a strange knocking sound whenever power is put to it. I've never heard anything like it, and I'm not sure if its shot or just a cheap Chinese pump thing. I have an aftermarket pump coming, and I've ordered a new ignition coil as well on the off chance that it is faulty. I am hoping replacing these two parts will solve the issue, and if it does I will post the results here.
If not, anyone have any other ideas? Also, I've noticed it is very difficult to find parts for this make... any suggestions on a good source for Hisun parts? I appreciate any comments or insights.
Dealers - - - also see http://www.utvboard....dpost__p__16044 & http://www.utvboard....dpost__p__16045
No Limits Powersports in Arlington Texas - Contact Jarrad (Snowman6479). (817)695-1151 http://www.joyner-atv-utv.com/
Silver Bullet Motorsports in Yuma Arizona - Contact (silverbullet). (928) 344-2117 http://www.silverbul...otorsports.net/
Thin Air Powersports in Spring Creek Nevada - Contacts Tim (Anylizer) or Amanda (Long Track Lady) (775)753-8223 http://www.thinairpowersports.com/
McCoy Motorsports in Pikeville Kentucky - Contact Art (Art) (606)432-1556 http://www.tobefast....sa-c-63727.html
Mudslingers Motorsports, Alberta, Canada, Trevor Carson (780) 576-2860 cell: (780) 984-2711 http://www.mudslinge...website_006.htm
Joyner USA In Phoenix Arizona - Contact Brandon Deruiter Office (480) 882-9612 Email [email protected] Web site Joyner-usa.com
I also take suggestions for any and everyone!!
parts & pieces from dealer in Germany
AIR FILTER K&N RU-1000, RC-4160, and another link
If you have the new 09 filter box, w/ Fram # CA-7764
ALTERNATOR BELT 14mmx 755mm replacement that works....Carquest #K040292
Alternator Belt - Checkers Auto Parts KO40292 - Exact Match
Battery, according to 2 scoops, Duralast 51-DL is the correct size.
Troopers with Thread Size 20X1.5 MM can use:
WIX 51347, 51334 --- Napa 1347, 1334, PS1334 --- Fram PH6010A, PH3593A
Troopers with Thread Size 3/4X16 " can use:
Fram PH4967, Napa 1394 & Wix 5194 (slightly longer than original, Wix 51396 (even longer yet).
OIL COOLER See thread, http://www.utvboard....768-oil-cooler/
Oil Pressure Gauge Replacement
Zorro found some at his Local Marine Supply store
Sending Unit -- TeleFlex Morse Part # IA15001 0-80 psi, 240-33 ohm
Gauge -- TeleFlex Morse Part # 57903P 0-80 psi, 240-33 ohm
Manufactured by Veethree Elec. & Marine LLC
together cost aprox $80.00
Says it fits the existing hole perfectly Thanks Zorro
Plumber added this reference; http://www.spydertal...pressure-gauge/ which Crosses over to a Sierra part# 01858990
IMHO--I would move the the sender away from the exhaust manifold.
FUEL FILTER replacement, Fram Fuel Filter G4777
FUEL PUMP replacement, Bosch 0 580 254 910 According to Brostar, (Thank You!!)
http://www.ebay.com/itm/Hayg-OEM-Inline-Fuel-Pump-0-580-254-910-0580254910-New-/230568738342#vi-content (updated 05-2015)
PRE FILTER KNN-RC-4160-DK prefilter
HEAD LIGHT REPLACEMENT Sylvania H5006 replaces the whole bulb, It works sooooo much better than the original.
SPARK PLUGS NGK Iridium BKR5EIX-11, NGK 2387, NGK BKR7ES-11, Bosh 3311, Denso Iridium plug 5310 IK22
CV Boot Kit There appears to be a difference between inner and outer boots, I used a NAPA CVB6862340 for my outer rear, fit good but not tightly on the CV end, I held it on with Tyraps
Autozone part # 03606. Comes with bands and grease for $11.99, quick/split boot. K2181 95 Geo Metro $15.99
NAPA #686-2149 fits for the Troopers inner CV. It's a speck tight but only about 1/16".(Lenny)
Napa 686-2181 CV Boot from a 95 Geo Metro.
Norrec Industries then Application, then UTV, then look up joyner, they have them all
Polaris CV Boot Kit # 2203438, (PR-8061)
Also see CV boot for driveline? - UTV BOARD - Side X Side and UTV Forum
Valves shims are 25mm, Joyner shims start at 2.18 and increase in increments of .02 up to 2.80, The Honda shims come out of CB450s and GL1100s, start at 2.30 and increase in increments of .05
Master Electrical Switch Key
Make your own, it's easy, I did, just in case mine breaks.
At the suggestion of one of our members, here's some info on the gas gauge sending unit.
3 ohms is full, 13 ohms is 3/4, 23 ohms is 1/2, 63 ohm is 1/2, 110 ohms is empty.
Electrical readings are: F=0.75v-98ma, 3/4=1.91v-82ma, 1/2=2.7v-71ma, 1/4=3.3v-62ma, 0=4.1v-52ma, E=5.0v-39ma
0 is top of red zone, E is bottom of red zone.
Manuals and Information
Trooper T2 weights, 380lb. on each front wheel, 480 lb. on left rear, 520 on right rear TOTAL = 1760 pounds
down load this and save it!!!!
Torque Values Select Your type of bolt at the top. http://www.engineers...bles/torque.htm
My Snorkel Made from a Sears ShopVac 7' Hose and the Extension Wand,
Oil Drain QuickOilDrainValve.com
the best way to change oil, IMHO Kinarfi
Fram Sure Drain #SD3
Paint as recommended by Brostar: http://www.zynolyte..../rustmaster.asp
Supplier of parts in General
Pegasus Auto Racing Supplies - Home Page
Discount Hydraulic Hose.com
Tie Rod Dust Boot, Checker Auto#13566
Rod End / Heim Joint Seals , http://pitstopusa.co...-end-seals.html, thanks rocmoc
Ball Joint Rod Ends AKA Heim Joints
16 x2.0mm threat, 16mm ID, 21 mm thick,
I got mine at McMaster-Carr 4483T36
PTFE/Kevlar Insert, M16 x 2.0 x 40.mm shank, 21,966 lb static radial load capacity, 23°, $25.60 ea. or $204.80 for 8
14 Inch Tires That fit our Stock Wheels Note that the stock lug bolt pattern is 4 X 115
STEEL WHEELS http://www.utvboard....dpost__p__10804
JC Whitney for all Auto parts - Car, Truck, Jeep, Motorcycle & RV Parts
Interco Tires SSR-24R - INTERCO SSR Series Tire - Quadratec
Interco Tires SAM-12 - INTERCO Super Swamper TSL Tire - Quadratec
TSL Radial | Interco Tire
Maxxis Bighorn 2.0 AT26 X 11R 14
General Grabber AT2 27x8.50 R14 95Q 6PR OWL $90.10 http://ssl.delti.com.../GRABBERAT2.jpg
National Chaparral A/P 27x8.50 R14 95Q 6PR OWL $113.80 http://ssl.delti.com...ChaparralAP.jpg
Kumho Road Venture MT-834 27x8.50 R14 95Q 6PR OWL $110.30
Mastercraft COURSER A/T 27x8.50 R14 95Q 6PR OWL $87.00 http://ssl.delti.com...t/COURSERAT.jpg
Cooper Discoverer LT 27x8.50 R14 95Q 6PR OWL $99.60 http://ssl.delti.com...iscovererlt.jpg
Laramie Performer RV 27x8.50 R14 95Q 6PR OWL $100.70 http://ssl.delti.com...PerformerRV.jpg
ITP MUD LITE XTR 27-9-14 $87.99
ITP TERRACROSS R/T 26-9-14 $144.99
15 inch Wheels [Be sure to get the correct lug nuts, 12X1.5
Vision Wheel Inc Vision Wheel
ITP has one now also, getting info. ITP TIRES - The World's #1 ATV Aftermarket Tire & Wheel Source :: Holeshot
Non Trooper Info
u joints for joyner renegade are Spicer 5-1501X and Precision 391. They are American work great. graybeard9
40 28 to Full 25 96144A227• 8.33
1100 Trooper T2 ECU Wiring Diagram.pdf
Joyner Trooper Differential Rebuild Kit .doc
Joyner 650 commando rear differentail and its parts are avaialbe now.
Qty is limited. Any one who is in need please contact [email protected]
By Dale Linton
Hey guys new to the forum! Upgraded my old 800 to a 900s and decided to part out my 800. Have a few items laying in the garage and didn’t know if they could get someone back on the trail!!!! I have..
good rear end
and good secondary clutch
all parts came from a 2011 rzr 800 with 1800 miles. Have pics of odometer and video of it running .thanks for looking