Hisun PQV400 Quad Service Manual

[mcmoose]

Would anyone have access or a link to a workshop service manual for this vehicle?

or can answer how to align the crankshaft and balancer drive gear when there is NO Stamped dot on the crankshaft buffer boss?

 

[Mech]

I don't have a manual for that model but other 400s also say to align the dots.. Are you sure there isn't any faded dot there. Even though it says it's a punched dot, It may have been an etched grey dot which might be hard to see now it's used. If it is a hole and a punched dot then they should be easy to spot. If the marks aren't there, perhaps they decided it wasn't so crucial anyway and dispensed with the marks.

There are a few reasons they insist on aligning things like that, one is for balance and  another is critical manufacturing clearances. The other likely reason for that part having marks would be because the springs aren't exactly equally spaced. If the springs were exactly equally spaced it could get a rhythmic pulse or vibration in the drive. To prevent that they sometimes make the spacing just very slightly different as it goes around. It may be that those two parts fit together anywhere, but some places only some springs will be under a lot of tension and others will be contacting lightly. If it's put together correctly every spring will be taking equal load even though the spaces between gaps is different.. I'd check that.

 

[mcmoose]

Hi Mech, thanks for your reply!

the thing is I’ve got a brand new crank and there’s no marks on either of them where stated, but the balancer has to be in time with the crank correctly or a: it wouldn’t cancel the vibrations it’s designed to and b: it hits the crankshaft web and journal, the web is clearanced to allow the balance weight to pass . I’d assume with the crank at TDC  the balancer would be centrally in the crank web and opposed at BDC, but assuming can be dangerous  lol.

have a great day!

[Gwbarm]

I would check the old one for proper placement, if you have photos of your teardown, or the old part, strange the replacement part didnt have  a line up mark.

[Mech]

Oh. That's a pickle then. Are the parts after-market ?

And yeah the balancer will just miss the crank. That gives you some idea about where it's meant to be.

 

[Mech]

Well.. Reading around it looks like that engine is a copy of a yamaha, and the yamaha says to align the dot on the gear with the key in the shaft.  That would also mean that when installing it the key would be aligned with a dot on the other gear.