Hisun 800 Problems

The Hisun 800 series of ATVs and UTVs have carved out a niche in the off-road market, offering a compelling blend of affordability and capability. However, like any machine, they're not without their quirks and potential issues. Understanding these common problems can empower owners to diagnose, troubleshoot, and ultimately keep their Hisun 800 running smoothly for years to come. This article dives deep into the most frequently encountered challenges faced by Hisun 800 owners, offering insights and potential solutions to get you back on the trail.

So, What Are the Biggest Headaches Hisun 800 Owners Face?

Let's be honest, no ATV or UTV is perfect. But knowing the common pitfalls of the Hisun 800 can save you time, money, and frustration. Here's a breakdown of the most prevalent issues:

1. Electrical Gremlins:

One of the most common complaints about the Hisun 800 revolves around its electrical system. These issues can manifest in various ways:

Battery Drain: Many owners report experiencing rapid battery drain, even when the vehicle is not in use. This can be caused by a faulty stator, a parasitic draw from an accessory, or a failing battery. Start by checking the battery voltage and load testing it. Then, systematically disconnect accessories to isolate any parasitic draws. If the battery continues to drain, the stator might be the culprit.
Starting Problems: A weak battery or a faulty starter solenoid can lead to difficulties starting the engine. Check the battery connections for corrosion and ensure they are tight. The starter solenoid is a common failure point and relatively inexpensive to replace.
Faulty Sensors: The Hisun 800 relies on various sensors to monitor engine performance. A failing sensor can trigger warning lights, cause the engine to run poorly, or even prevent it from starting. Use a diagnostic scanner to identify the faulty sensor.
Wiring Issues: The wiring harness itself can be prone to corrosion and damage, especially in harsh environments. Inspect the wiring harness for any signs of wear, tear, or corrosion. Use dielectric grease on all electrical connections to prevent corrosion.

2. Fuel System Foibles:

A properly functioning fuel system is critical for optimal engine performance. The Hisun 800 can experience fuel-related problems, including:

Fuel Pump Failure: The fuel pump is responsible for delivering fuel from the tank to the engine. A failing fuel pump can cause the engine to stall, run rough, or not start at all. Check the fuel pump relay and fuse before replacing the pump. Consider upgrading to a higher-quality aftermarket pump for increased reliability.
Clogged Fuel Injectors: Debris and contaminants in the fuel can clog the fuel injectors, restricting fuel flow and causing the engine to run lean. Use a fuel injector cleaner to try and clear the blockage. In severe cases, the injectors may need to be professionally cleaned or replaced.
Carburetor Issues (Older Models): Some older Hisun 800 models use a carburetor instead of fuel injection. Carburetors can become clogged with dirt and varnish, leading to poor engine performance. Regular cleaning and maintenance are essential.
Fuel Line Problems: Cracked or damaged fuel lines can leak fuel, creating a fire hazard and causing the engine to run poorly. Inspect the fuel lines regularly for any signs of damage and replace them as needed.

3. Drivetrain Dilemmas:

The drivetrain is responsible for transmitting power from the engine to the wheels. Common drivetrain issues in the Hisun 800 include:

CV Joint Problems: The CV joints allow the axles to articulate as the suspension moves. They are vulnerable to damage from water, dirt, and debris. Listen for clicking or popping sounds when turning, which indicates a worn CV joint. Replace damaged CV joints promptly to prevent further damage.
Differential Issues: The differentials distribute power to the wheels. They can experience wear and tear over time, leading to noise, vibration, and poor performance. Regularly check the differential fluid level and change it according to the manufacturer's recommendations.
Transmission Troubles: The transmission can experience a variety of problems, including slipping gears, difficulty shifting, and complete failure. Ensure the transmission fluid is at the correct level and in good condition. Consult a qualified mechanic for transmission repairs.
Belt Problems: Like most ATVs and UTVs, the Hisun 800 utilizes a belt drive system. A worn or damaged belt can cause slippage, loss of power, and even complete failure. Inspect the belt regularly for cracks, wear, and damage. Replace the belt as needed.

4. Suspension Setbacks:

A well-maintained suspension is crucial for a comfortable ride and optimal handling. Common suspension problems in the Hisun 800 include:

Worn Bushings: The suspension bushings can wear out over time, leading to excessive play and a noisy ride. Inspect the bushings regularly for wear and tear. Replace worn bushings to restore proper suspension performance.
Leaking Shocks: The shocks are responsible for damping the suspension movement. Leaking shocks indicate a loss of damping ability and should be replaced.
Broken Springs: Broken springs can cause the vehicle to sit unevenly and handle poorly. Replace broken springs to restore proper suspension performance.
Ball Joint Issues: Ball joints connect the suspension components and allow for articulation. They can wear out over time, leading to excessive play and a dangerous situation. Inspect the ball joints regularly for wear and tear. Replace worn ball joints promptly.

5. Overheating Overload:

Overheating can cause serious engine damage. Preventing overheating is crucial for the longevity of your Hisun 800.

Coolant Leaks: Leaks in the cooling system can lead to a loss of coolant and cause the engine to overheat. Inspect the hoses, radiator, and water pump for leaks. Repair any leaks promptly.
Radiator Clogging: The radiator can become clogged with dirt, mud, and debris, restricting airflow and reducing cooling efficiency. Clean the radiator regularly.
Faulty Thermostat: The thermostat regulates the engine temperature. A faulty thermostat can cause the engine to overheat or run too cold. Replace the thermostat if it is not functioning properly.
Water Pump Failure: The water pump circulates coolant through the engine. A failing water pump can cause the engine to overheat. Replace the water pump if it is not functioning properly.

Digging Deeper: Troubleshooting Tips and Tricks

Now that we've identified the common problems, let's discuss some troubleshooting tips and tricks to help you diagnose and resolve these issues:

Start with the Basics: Before diving into complex repairs, always start with the basics. Check the battery voltage, fuel level, and fluid levels. Ensure all connections are clean and tight.
Use a Diagnostic Scanner: A diagnostic scanner can help you identify the source of many electrical and engine-related problems.
Consult the Service Manual: The service manual contains detailed information about the Hisun 800, including wiring diagrams, troubleshooting procedures, and repair instructions.
Utilize Online Forums and Communities: Online forums and communities are a great resource for finding information and getting advice from other Hisun 800 owners.
Don't Be Afraid to Ask for Help: If you're not comfortable performing a particular repair, don't hesitate to ask for help from a qualified mechanic.

Preventative Maintenance: The Key to Longevity

The best way to avoid problems with your Hisun 800 is to perform regular preventative maintenance. Here are some essential maintenance tasks:

Change the Oil Regularly: Change the engine oil and filter according to the manufacturer's recommendations.
Check and Change the Fluids: Check and change the coolant, transmission fluid, and differential fluid according to the manufacturer's recommendations.
Grease the Fittings: Grease the suspension and steering components regularly to prevent wear and tear.
Inspect the Tires: Inspect the tires for wear and damage. Maintain proper tire pressure.
Clean the Air Filter: Clean or replace the air filter regularly to ensure proper engine performance.
Inspect the Brakes: Inspect the brakes regularly for wear and damage. Replace brake pads and rotors as needed.
Store Your Hisun 800 Properly: When storing your Hisun 800 for an extended period, take steps to protect it from the elements. Use a fuel stabilizer to prevent fuel degradation. Disconnect the battery to prevent battery drain.

Frequently Asked Questions

Why is my Hisun 800 battery draining so quickly? A parasitic draw, faulty stator, or old battery are prime suspects. Disconnect accessories one by one to check for draws.
My Hisun 800 won't start. What should I do? Check the battery voltage, fuel level, and spark plug. A faulty starter solenoid is another common culprit.
How often should I change the oil in my Hisun 800? Consult your owner's manual, but typically every 50-100 hours of use. More frequent changes are recommended for heavy use.
My Hisun 800 is overheating. What could be the cause? Check for coolant leaks, a clogged radiator, or a faulty thermostat.
Where can I find parts for my Hisun 800? Many online retailers and local ATV/UTV shops carry Hisun parts.

The Road Ahead: Keeping Your Hisun 800 Running Strong

While the Hisun 800 might have its share of common issues, understanding these problems and implementing preventative maintenance can significantly extend the life of your machine. By addressing potential issues early and performing regular upkeep, you can minimize downtime and maximize your enjoyment of your Hisun 800. Regular maintenance is the key to a long and happy relationship with your Hisun.