Linhai ATV 500-D T3 EFI Service Manual
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Linhai ATV 500-D T3 EFI Service Manual

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2019 ATV
SERVICE MANUAL
ATV 500-D T3 EFI
●
WARNING
The parts of different types/ variants/ versions maybe un-interchangeable, even some parts
have almost same appearance. Always refer to Parts Manual of each ATV model for spare
parts information and service.
EUROPE 19.0
PN. F010106A26
General Information
※
Maintenance
※
Engine
※
Chassis
※
Final Drive
※
Brakes
※
Electrical
※

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Summary of Contents for Linhai ATV 500-D T3 EFI

  • Page 1 2019 ATV SERVICE MANUAL EUROPE 19.0 PN. F010106A26 ATV 500-D T3 EFI ● WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each ATV model for spare parts information and service.
  • Page 2 Foreword This manual is designed primarily for use by the ATV factory certified service technicians in a properly equipped shop. Persons using this manual should have a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly.
  • Page 3 CONTENTS CHAPTER1 ………………………………………………General Information ↖ CHAPTER2 ………………………………………….……………Maintenance ↖ CHAPTER3……………………………………. …. ………………500 Engine ↖ CHAPTER4…………………………………………..…………………Chassis ↖ CHAPTER5………………………………………………….………Final Drive ↖ CHAPTER6………………………………………………………………Brakes ↖ CHAPTER7………………………………………………….….………Electrical ↖...
  • Page 4 WARNING Never run an engine in an enclosed area. Carbon monoxide exhaust gas is poisonous and can cause severe injury or death. Always start engines outdoors. Gasoline is extremely flammable and explosive under certain conditions. Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing.
  • Page 5 CHAPTER 1 GENERALINFORMATION LH500ATV-D T3 EFI SERVICE MANUAL 19.0 CHAPTER 1 GENERAL INFORMATION WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each ATV model for spare parts information and service.
  • Page 6 CHAPTER 1 GENERALINFORMATION LH500ATV-D T3 EFI SERVICE MANUAL 19.0 1.1 IMPORTANT INFORMATION PREPARATION FOR REMOVAL PROCEDURES 1. Remove all dirt, mud, dust and foreign material before removal and disassembly. 2. Use proper tools and cleaning equipment. 3. When disassembling the machine, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been ”mated ”through normal wear.
  • Page 7 CHAPTER 1 GENERALINFORMATION LH500ATV-D T3 EFI SERVICE MANUAL 19.0 CIRCLIPS 1. Check all circlips carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip ① , make sure that the sharp-edged corner ② is positioned opposite the thrust ③...
  • Page 8 CHAPTER 1 GENERALINFORMATION LH500ATV-D T3 EFI SERVICE MANUAL 19.0 CONVERSION TABLE How to use the CONVERSION TABLE Use this table to convert METRIC unit data to IMPERIAL unit data. METRIC MULIPLIER **mm 0. 3937 **in **cm 0.03937 **in CONVERSION TABLE METRIC TO IMP Known Multiplier...
  • Page 9 CHAPTER 1 GENERALINFORMATION LH500ATV-D T3 EFI SERVICE MANUAL 19.0 V.I.N AND ENGINE SERIAL NUMBER CHAPTER 1 GENERAL PAGE. 1- 5...
  • Page 10 CHAPTER 1 GENERALINFORMATION LH500ATV-D T3 EFI SERVICE MANUAL 19.0 STATUTORY PLATE CHAPTER 1 GENERAL PAGE. 1- 6...
  • Page 11 CHAPTER 1 GENERALINFORMATION LH500ATV-D T3 EFI SERVICE MANUAL 19.0 VEHICLE DIMENSIONS Note. The on-road equipments (rear view mirror, turn lights, etc.) are not Standard Equipment for USA. ATV 500-T3 EFI CHAPTER 1 GENERAL PAGE. 1- 7...
  • Page 12 CHAPTER 1 GENERALINFORMATION LH500ATV-D T3 EFI SERVICE MANUAL 19.0 NOTES CHAPTER 1 GENERAL PAGE. 1- 8...
  • Page 13 CHAPTER 1 GENERALINFORMATION LH500ATV-D T3 EFI SERVICE MANUAL 19.0 CHAPTER 1 GENERAL PAGE. 1- 9...
  • Page 14 CHAPTER 2 MAINTENANCE LH500ATV-D T3 EFI SERVICE MANUA 19.0 CHAPTER 2 MAINTENANCE WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each ATV model for spare parts information and service.
  • Page 15 CHAPTER 2 MAINTENANCE LH500ATV-D T3 EFI SERVICE MANUA 19.0 2.1 PERIODIC MAINTENANCE GENARAL CAUTION Mark on the following chart DL ： Due to the nature of the adjustments marked with a DL on the following chart, it is recommended that service be performed by an authorized dealer. ▲：...
  • Page 16 CHAPTER 2 MAINTENANCE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Item Hours When Remarks Service (Main) Brake Pre-ride System Auxiliary (Secondary) Brake / Pre-ride Parking Brake Pre-ride Tires Pre-ride Wheels Pre-ride Frame nuts, bolts fasteners Pre-ride Air Filter-Pre-Cleaner Daily ▲ Coolant/Level Daily Coolant Annually...
  • Page 17 CHAPTER 2 MAINTENANCE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Engine Oil Change 30 hrs 3 months Break-in Service at 1 month. Change oil more often in cold weather use. ▲ Oil Filter 50 hrs 6 months Engine breather hose 100 hrs 6 months ▲...
  • Page 18 CHAPTER 2 MAINTENANCE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Brake fluid 200 hrs 24 months Change every two years Idle Speed Required Toe adjustment Periodic inspection, adjust when parts are Required replaced Headlight Aim Adjust if necessary Required ▲ Front drive chain (and...
  • Page 19 CHAPTER 2 MAINTENANCE LH500ATV-D T3 EFI SERVICE MANUA 19.0 U-joint hours 16. Rear prop shaft Grease Locate fittings and grease Every 3 months or 50 yoke hours 17. Front prop shaft Grease Locate fittings and grease Every 3 months or 50 U-joint ( SDX300) hours 18.
  • Page 20 CHAPTER 2 MAINTENANCE LH500ATV-D T3 EFI SERVICE MANUA 19.0 2.2 FUEL SYSTEM WARNING Gasoline is extremely flammable and explosive under certain conditions. Always stop the engine and refuel outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
  • Page 21 CHAPTER 2 MAINTENANCE LH500ATV-D T3 EFI SERVICE MANUA 19.0 FUEL LINES 3. Remove fuel lines from filter. 4. Install new filter and clamps onto fuel lines Check fuel lines signs wear, with arrow pointed in direction of fuel flow. deterioration, damage or leakage. Replace if 5.
  • Page 22 CHAPTER 2 MAINTENANCE LH500ATV-D T3 EFI SERVICE MANUA 19.0 1. Fuel Pump 2. Strainer 3. Gasket, Fuel Module 4. Module Bracket 5. Module Harness 6. Fuel Tube (out pump) Fuel Pump Module Dimensions Description and Working Principle Fuel Module Cover in elliptical shape with outer Fuel Pump Module supplies fuel to engine at edge dimensions as 115mm x 65mm.
  • Page 23 CHAPTER 2 MAINTENANCE LH500ATV-D T3 EFI SERVICE MANUA 19.0 provided in this section.   D isconnect negative cable at battery.   D isconnect fuel module wire coupler.   D rain the fuel in fuel tank thru fuel filler with help of hand pump (siphon).
  • Page 24 CHAPTER 2 MAINTENANCE LH500ATV-D T3 EFI SERVICE MANUA 19.0 bolts). Use designated bolts only. METHOD: STRAIGHTEDGE OR STRING Follow the tightening torque and tightening Be sure to keep handlebars centered sequence instruction. Over torque and miss-sequence can cause unequal NOTE: String should just touch side surface compression of gasket and leakage.
  • Page 25 CHAPTER 2 MAINTENANCE LH500ATV-D T3 EFI SERVICE MANUA 19.0 The following checks are recommended to keep the braking system in good operating condition. Service life of braking system components depends on operating conditions. Inspect brakes in accordance with the maintenance schedule and before each ride. Keep fluid level in the master cylinder reservoir to the indicated level on reservoir.
  • Page 26 CHAPTER 2 MAINTENANCE LH500ATV-D T3 EFI SERVICE MANUA 19.0 1. First check foot brake effectiveness by applying a 25 kg (50 lb). (Approx) downward force on the pedal. The top of the pedal should be at least 1 inch, (25 .4m m) above the surface of the footrest.
  • Page 27 CHAPTER 2 MAINTENANCE LH500ATV-D T3 EFI SERVICE MANUA 19.0 1. With the engine off, loosen the adjustor on the lever. 2. Loosen the jam nut of the adjuster on the caliper. 3. Turn the adjuster (bolt) CW (clockwise) by hand till the pad touch the brake disc, turn the Note: burnishing procedure is also applicable adjuster bolt CCW (counterclockwise) by 1/4 for parking brake.
  • Page 28 CHAPTER 2 MAINTENANCE LH500ATV-D T3 EFI SERVICE MANUA 19.0 3. If the wheels or one wheel are/is not locked, it must be adjusted. Adjusting To adjust (set up) the mechanical drum brake, use the following procedure. ↑ adjust on the lever ATV500 1.
  • Page 29 CHAPTER 2 MAINTENANCE LH500ATV-D T3 EFI SERVICE MANUA 19.0 2.5 SUSPENSION SPRING RPELOAD ADJUSTMENT Operator weight and vehicle loading affect suspen ents. Adjust sion spring preload requirem sary. neces FRONT SUSPENSION Compress and release front suspension. Damping should be smooth throughout the range of travel.
  • Page 30 CHAPTER 2 MAINTENANCE LH500ATV-D T3 EFI SERVICE MANUA 19.0 2.6 WHEELS Inspect all wheels for runout of damage. Check wheel nuts and ensure they are tight. Do not over tighten the wheel nuts. WHEEL, HUB TORQUE TABLE Item ATV500 Front Wheel Nuts 69 Ft.Lbs 96 N.m Rear Wheel Nuts...
  • Page 31 CHAPTER 2 MAINTENANCE LH500ATV-D T3 EFI SERVICE MANUA 19.0 2.7 TIRE PRESSURE TIRE INSPECTION CAUTION : Maintain proper tire pressure. Refer to the Tire Pressure Inspection  warning tire pressure decal applied to the vehicle. Front Rear Improper tire inflation may affect ATV maneuverability.
  • Page 32 CHAPTER 2 MAINTENANCE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Periodically inspect the tightness of all fasteners in accordance with the maintenance schedule. Check that all cotter pins are in place. Refer to specific fastener torques listed in each chapter. ATV 500 Torque（Ft-Lb）...
  • Page 33 CHAPTER 2 MAINTENANCE LH500ATV-D T3 EFI SERVICE MANUA 19.0 CHAPTER 2 MAINTENANCE PAGE. 2- 20...
  • Page 34 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 CHAPTER 3 ENGINE 500 cc 3.1 Removal and Installation of Engine, Drive Train and Gearshift Unit 3.1.1 Overhaul Info 3.1.2 Engine Removal and Installation 3.1.3 R e m o v a l a n d I n s t a l l a t i o n o f F r o n t a n d R e a r A x l e 3.1.4 Removal and Installation of Gearshift Unit 3.2 Troubleshooting...
  • Page 35 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 3.1. Removal and Installation of Engine, Drive Train and Gearshift Unit Overhaul Info…..……………………………..3.1.1 Removal and Installation of Front and Rear Axle……………………………………………….3.1.3 Removal and Installation of Gearshift Unit……3.1.4 Engine Removal and Installation…………...3.1.2 3.1.1 Overhaul info Operation cautions ●Securely support the ATV with bracket when removing or installing engine.
  • Page 36 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 ●Engine Removal Remove: --Plastic(→Chapter 2) --Air Filter(→Engine service chapter) --Carburetor (→Engine service chapter) --Clamp --Water Inlet Hose Remove screw Remove gear shift rod Remove clamp Remove water outlet hose Remove Sleeve. Remove connectors of magneto, enriching device lead, pickup, water temperature transducer, gear sensor as illustrated on the right.
  • Page 37 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Remove spark plug cap from cylinder. Remove protection sleeve of starter relay. Remove Nut. Disconnect positive wire of starter relay. Remove nut. Remove negative wire of starter relay. Remove Bolt 1 and Nut 1 of upper engine hanger. CHAPTER 3 ENGINE PAGE.
  • Page 38 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Remove Bolt 1 and Nut 1 of lower engine hanger. Remove Bolt 2 and Nut 2 of lower engine hanger. CHAPTER 3 ENGINE PAGE. 3- 5...
  • Page 39 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 3.1.2 Engine Installation Put engine onto the frame，install the two lower mounting bolts and nuts. Then install the upper and lower engine hangers. Engine upper hanger bolt:35～45N.m Tightening torque: Engine lower hanger bolt:50～60N.m Install: --Water outlet and inlet hoses to engine with proper clamps.
  • Page 40 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Remove nut and bolt of front axle from frame. Remove nut and bolt of rear axle from frame. CHAPTER 3 ENGINE PAGE. 3- 7...
  • Page 41 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Remove the 18 bolts for drive shafts and front and rear axles. (Refer to P. 5-5, Bolt 3 of Part No.5) Remove: --Front and rear axles, drive shafts, rear brake disc Installation: Reverse the removal procedure for installation.
  • Page 42 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 3.2. Troubleshooting Operation Notice……………………………………………………………………..3.2.1 Starting Failure/Hard Starting……………………………………………………….3.2.1 Unstable Engine Running or Engine Stops……………………………………..…3.2.2 Poor Engine Performance in High-speed Range or Slow Speed Rising……….3.2.3 Unstable Idle Speed…………………………………………………………………3.2.4 Poor Engine Performance in Middle or High Range………..……………………3.2.5 Operating Notice This chapter is a general explanation of major troubleshooting of the whole engine.
  • Page 43 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Unstable Engine Running or Engine Stops No petrol in fuel tank Loosen drain screw, and check No fuel Clogged fuel hose the if fuel has reached carburetor Clogged float valve Clogged fuel filter Clogged fuel tank cap breather hole With Fuel Stained, damaged and color changed...
  • Page 44 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Connect fuel enrichment device wire lead with With Air current battery for 5 Minutes. Connect ethylene pipe Faulty fuel enrichment device with fuel increment loop and blow. No air current Clogged carburetor Poor Engine Performance in Hi-speed Range or Slow Speed Rising No rise of Clogged air filter...
  • Page 45 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Unstable Idle Speed Incorrect Faulty pulse generator check ignition Timing Faulty CDI unit Correct check carburetor Incorrect mixture screw Refer to fuel system (Engine Service) Correct Check if secondary air Air intake Faulty tightening of carburetor joint Faulty reed valve seal washer intake into carburetor...
  • Page 46 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Poor Engine Performance in Middle or High Range Correct Faulty pulse generator check ignition timing Faulty CDI unit Correct Clogged check carburetor Clean Normal Remove fuel enrichment device No continuity Broken starting enriching cable wire lead and check continuity Faulty fuel enrichment device Normal continuity...
  • Page 47 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 3.3．Engine Overhaul Information Item Conversion Press 1kgf/cm =98.0665KPa 1KPa=1000Pa 1mmHg=133.322Pa=0.133322KPa Torque 1kgf.m=9.80665N.m Conversion Table Volume 1ml=1cm =1cc 1l=1000 cm Force 1kgf=9.80665N Warning/Caution/Note Please read this manual and follow is instructions carefully. To emphasize special information, the symbol and the words WARNING,CAUTION and NOTE have special meanings.

  • Page 48: Table Of Contents

    CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 General Precautions ………………………………..…………………………..3.3.2 Fuel, Oil and Coolant……………………………………………………………3.3.3 Brake-in ………………………………………………………………………….. 3.3.3 Engine Exterior and Engine No…………………………………………………3.3.4 Engine Specification………………………………………………..……………3.3.5 Overhaul Data……………………………………………………………………. 3.3.6 Tightening Torque Table………………………………………………………….. 3.3.10 Tools……………………………………………………………………………….. 3.3.12 Materials for Operation and Fixing ……………….……………………….……. 3.3.14 CHAPTER 3 ENGINE PAGE.

  • Page 49: General Precautions

    Do not dispose used oil, coolant or defective parts optionally for environmental purpose. CAUTION: Use genuine LINHAI MOTO parts or their equivalent. Place and store the disassembled parts separately in order for correct assemble. Use special tools according to service manual.

  • Page 50: Fuel, Oil And Coolant

    CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 FUEL, OIL, COOLANT Fuel Use unleaded gasoline with octane number over 90. Use a premium quality 4-stroke motor oil to ensure longer service life of your vehicle. Use only oils that meet API service classifications SN and that have a viscosity rating of SAE10W/50.

  • Page 51: Engine Exterior And Engine

    CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Engine Exterior and Engine No CHAPTER 3 ENGINE PAGE. 3- 18...

  • Page 52: Engine Specification

    CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Engine Specification REF. ITEM Type/SPECIFICATION Type Single Cylinder, 4-Storke, Liquid-cooled, 4 Valve, SOHC Bore and stroke 87.5mm×82.0mm Displacement 493ml Compression ratio 10.2: 1 Lowest continuous idle speed with load 1400r/min±100r/min Starting type Electrical starting Ignition / CDI Magneto ignition/BTDC10°1500r/min...

  • Page 53: Overhaul Data

    CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Overhaul Data Item Standard Service Limit Remark Valve Head Diameter 30.6 ----------- Valve Head Diameter 27.0 ----------- 0.05-0.10 Valve Clearance ------------ 0.010-0.037 Valve Clearance ------------ Clearance Between Valve 0.010-0.037 ------------ Guide and Valve Stem Clearance Between Valve 0.030-0.057 ------------...
  • Page 54 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Cylinder + Piston + Piston Ring + Connecting Rod Item Standard Service Limit Remark Cylinder Pressure 1000KPa ------------ Cylinder-Piston Clearance 0.030-0.051 0.15 Piston Skirt Diameter 87.460-87.480 87.380 (10mm form skirt end) Inner Diameter of Cylinder 87.500-87.522 ------------...
  • Page 55 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Clutch + Transfer Item Standard Service Limit Remark Clutch Plate Inner diameter 140.00-140.15 140.50 Clutch Engagement Speed 1800-2400r/min --------- Clutch Lock Speed 3300-3900r/min --------- Drive Belt Width 35.2 33.5 Free length of Secondary Sheave Spring Shift Fork to Groove 0.10-0.40...
  • Page 56 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Carburetor Item Standard Remark Carburetor Type MIKUNI BSR36-129 I.D. Mark 07G0 Carburetor Barrel Size 36mm Engine Idle Speed 1400r/min+100r/min Main Jet (MJ) N10221-137.5# Main Air Jet (MAJ) MD13/24-35# Jet Needle (JN) J8-5DH77 Needle Jet (NJ) 785-401011-P-OM...
  • Page 57 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Tightening Torques Item Quantities Thread Size (mm) Tightening Torque Remark (N.m) Reverse Gear Sensor M10*1.25 Spark Plug M12*1.25 Water-temperature Rc1/8 Apply Thread Locker Sensor Adjusting Nut, Valve Clearance Nut, Primary Sheave M20*1.5 Nut, Secondary...
  • Page 58 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Tightening Torques Item Quantiti Thread Size Tightening Torque Remark (mm) (N.m) Bolt, Crankcase Bolt, Driven Sector Gear Bolt, Oil Filter M20×1.5 Bolt, Oil Starter Motor Bolt, Cylinder Head Bolt, Cylinder Head Bolt, Cylinder (Upper &...
  • Page 59 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Maintenance Tools Measurement Tools Description Specification Purpose Vernier Caliper 0-150mm For measuring the length and thickness Micrometer 0-25mm For measuring outer diameters of rocker arm, valve stem and camshaft Micrometer 25-50mm For measuring the max.

  • Page 60: Tools

    CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Special Tools Description Specifications Purpose Spark Plug Wrench Removal and installation of spark plug Clutch Holder For removing/installing clutch carrier nuts Oil Filter Wrench Removal and installation of oil filter cartridge Piston Pin Puller For removal of piston pin Flywheel Puller...

  • Page 61: Materials For Operation And Fixing

    CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Materials for Operation and Fixing Materials for engine operation engine oil, grease and coolant. Fixing materials include sealant, thread locker, etc. Description Type Application Area Remark capacity 10W-50 SN Cylinder bore 1900ml Crankcase (for changing oil)
  • Page 62 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 3.4. Checks & Adjustment Periodic Maintenance ……………………………………………………….3.4.2 Procedures of Maintenance and Adjustment…………….……………….. 3.4.3 Valve Clearance……………………………………………………………... 3.4.3 Engine Idle Speed…………………………………………….…….……….. 3.4.4 Spark Plug………………………………………………………...…….……. 3.4.4 Air Filter……………………………………………………………………….. 3.4.5 Fuel Hose, Carburetor………………………………………………………..3.4.6 Drive Belt……………………………………………………...………………. 3.4.7 Inspection of Lubrication System……………………………………..……..

  • Page 63: Periodic Maintenance

    CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Periodic Maintenance Table The table below lists the recommended intervals for all the required periodic maintenance work necessary to keep the vehicle at its best performance and economy. Maintenance intervals are expressed in terms of kilometer, miles and hours, whichever occurs first.

  • Page 64: Procedures Of Maintenance And Adjustment

    CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Procedures of Maintenance & Adjustment This section describes the maintenance procedures for each item mentioned in the Periodic Maintenance Chart. VALVE CLEARANCE Inspect initially at 20-hour break-in and every 40 hours or every 1000km thereafter.
  • Page 65 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 CHAPTER 3 ENGINE PAGE. 3- 32...

  • Page 66: Engine Idle Speed

    CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Take out the feeler gauge, measure the clearance. If the clearance is incorrect, repeat the above steps until the proper clearance is obtained. Locknut: 10 N.m Caution: Securely tighten the locknut after completing adjustment Install: 2 valve adjusting cover;...

  • Page 67: Air Filter

    CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 In case of carbon deposit, clean with a proper tool. SPARK PLUG GAP Measure the spark plug gap with a feeler gauge. Out of specification: → Adjust Spark plug gap: 0.8-0.9mm Caution: Check the thread size and reach when replacing the spark plug.

  • Page 68: Fuel Hose, Carburetor

    CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 A--Non-flammable cleaning solvent B—Engine oil SAE#30 or SAE10W/40. Warning: Never use with gasoline or low flash point solvents to clean the filter element Inspect the filter element for tears. torn element must be replaced.
  • Page 69 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Inspection: Inspect drive belt for wear and damage. If any cracks or damages are found, replace drive belt with a new one. Inspect drive belt for width, if width is out of service limit, replace drive belt with a new one.

  • Page 70: Inspection Of Lubrication System

    CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Inspection of Lubrication System Replace engine oil and oil filter initially at 20 hours or 200km and every 80 hours or 2000km thereafter. Check Engine Oil Level Keep the engine in a plan position. Remove oil dip rod 1 Clean oil dip rod, insert oil dip rod but do not tighten Take out oil dip rod and check if oil is between upper...
  • Page 71 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Install oil dip rod, start the engine and allow it to run for several minutes at idling speed. Turn off the engine and wait for about 3 minutes, and then check the oil level on the dipstick. Caution: The engine oil should be changed when the engine is warm.

  • Page 72: Inspection Of Cooling System

    CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Inspection of Cooling System Check initially at 40 hours or 1000km, replace coolant every 2 years. Check radiator, reservoir tank and water hoses. Leakage or Damage: → Replace Check coolant level by observing the upper and the lower limit on the reservoir tank.

  • Page 73: Inspection Of Cylinder Pressure

    CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Fill coolant into the reservoir tank till between upper and lower limit. Install reservoir tank cap. Warning: Never mix with other brand Inspection of Radiator Hose Perform inspection every 40 hours or Check radiator hose and clamp.

  • Page 74: Inspection Of Oil Pressure

    CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Inspection of Oil Pressure Oil Pressure: 130～170kpa at 3000r/min Lower or higher oil pressure may be caused by: Ⅰ Oil pressure is too low Clogged oil filter; Leakage from oil passage; Damaged O-ring;...

  • Page 75: Inspection Of Clutch Engagement And Lock-Up

    CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Inspection of Clutch Engagement and Lock-up Engine is equipped with a centrifugal type automatic clutch. Before checking the initial engagement and clutch lock-up two inspection checks must be performed to thoroughly check the operation of the drive train. I Initial Engagement Inspection Connect tachometer to ignition coil Start engine...
  • Page 76 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 3.5. Engine Removal, Inspection & Installation Δ Engine Removal/Installation Orders and the Relative Page Numbers Item Description Disassembly Inspection / Assembly Remarks Maintenance Engine Water Hose/Pipe 15-2 15-11 15-69 Periphery Left Side Cover 15-2 —...
  • Page 77 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Ⅰ Engine Removal ΔPreparation before engine removal Prepare a proper tray used for load of components Prepare necessary removal and assembly tools Drain up engine oil（→11-8） Drain up coolant（→ 11-10） △ Engine Periphery Water Hose/Pipe Remove water hose clamp①...
  • Page 78 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Cylinder Head Cover Remove valve adjusting cover Remove12 bolts of cylinder head cover Remove cylinder head cover Timing Chain Tensioner Remove screw plug①, insert a flat screwdriver into slot of timing chain tensioner adjuster , turn it clockwise to lock tensioner spring;...
  • Page 79 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Remove C-ring① Remove timing sprocket from camshaft, remove camshaft Note: Take care not to drop spacer, bolt, bolt lock and C-ring into crankcase. Remove tensioner plate Cylinder Head Remove cylinder head bolt Remove cylinder head bolts diagonally;...
  • Page 80 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Remove cylinder bolt Remove cylinder Note：Take care not to drop dowel pin into crankcase Remove dowel pin and cylinder gasket Note：When performing above removal process, be sure to hook up timing chain to prevent it from falling into crankcase Piston Remove piston pin circlip①...
  • Page 81 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Oil Filter emove oil filter with special tools Tool: Oil filter Remover Sector Gear Remove bolt of sector gear housing cover Remove wire clip and sector gear housing cover Remove dowel pin and gasket Remove drive sector gear 1 Remove bolt 2 of driven sector gear Remove washer3 and driven sector 4...
  • Page 82 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Water Pump Screw out bolt of water pump Remove water pump SPLINED SPACER(MODEL1) Remove bolt and washer; Remove splined spacer Left Crankcase Cover Remove bolts; Remove left crankcase cover Remove dowel pin and gasket Magneto Rotor Install attachment 1 to crankshaft end Install special tool to rotor thread;...
  • Page 83 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Remove left crankcase cover 1.(MODEL2) Remove nut. nstall special tool to rotor thread; Remove rotor and woodruff key Tool: Rotor Remover CHAPTER 3 ENGINE PAGE. 3- 50...
  • Page 84 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Starting Motor Gear Remove driven gear ① and needle bearing Remove spacer ② ·Remove dual gear and shaft ③ ·Remove idle gear and shaft ④ Oil Pump Sprocket and Chain Remove drive sprocket nut ⑤ Remove C-ring ⑥...
  • Page 85 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Δ Engine Right Side CVT Cover Remove bolt of CVT cover Remove CVT cover Remove gasket and dowel pin CVT(Continuously Variable Transmission) Remove primary sheave nut with special tool Remove primary sliding sheave Remove secondary sheave nut with special tools Remove secondary sheave Remove drive belt...
  • Page 86 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 CVT Case Remove bolt 1 of CVT case Remove bolt 2 of CVT case Remove outer clutch face and CVT case Remove dowel pin, front and rear gasket Clutch Remove one-way clutch Remove clutch shoe fixing nut with special tool Remove clutch shoe.
  • Page 87 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Engine Center Gear position bolt Remove gear position bolt 1 Remove spring and steel ball Right Crankcase Remove left crankcase bolts Remove right crankcase bolts Separate right crankcase with special tool Caution The Crankcase separator plate should be parallel with the end face...
  • Page 88 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Remove Oil seal①, Bearing limit nut② Remove Bearing③, Front Output Shaft ④ Shift Cam, Fork/Shaft Remove Shift Cam⑤, Fork /Shaft⑥ Drive Bevel Gear Remove left crankcase from driven bevel gear Drive Shaft, Drive Shaft Remove drive shaft⑦...
  • Page 89 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Crankshaft Separate crankshaft from left crankcase with special tool Tool: Crankshaft Separator Oil bump, Relief Valve Remove oil bump and relief valve CHAPTER 3 ENGINE PAGE. 3- 56...
  • Page 90 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Engine Components Inspection Cylinder Head Cover Disassembly Caution: Each removed part should be identified to its location, and the pars should be laid out in groups designated as “Exhaust”, “Intake”, so that each will be restored to the original location during assembly.
  • Page 91 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Rocker Arm When checking the rocker arm, check the inner diameter of the valve rocker arm and wear of the camshaft contact surface. Rocker Arm I.D. : .000~12.018mm Tool: Dial Calipers Assembly Note: Intake rocker arm shaft A has oil holes.
  • Page 92 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Remove thermostat Compress the valve spring and remove valve cotter with tweezers. Tools: Valve Spring Compressor Tweezers Remove valve spring upper seat and valve spring Remove valve from the other side. Remove valve stem seal ring and valve lower seat.
  • Page 93 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Cylinder Head Distortion Clean off carbon deposit from combustion chamber; Check the gasket surface of the cylinder head for distortion with a straightedge and thickness gauge. Take clearance readings from several places. If any clearance reading is out of the service limit, replace with a new cylinder head.
  • Page 94 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Valve Stem O.D Measure valve stem O.D with a micrometer Service Limit IN: 4.975-4.990mm EX: 4.955-4.970mm Tool: Micrometer (0-25mm) Valve Stem Run-out Support valve stem with V block as illustrated on the right.
  • Page 95 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Valve Spring Valve Spring keeps valve and valve seat tight. Weakened spring results in reduced engine power output and chattering noise from valve mechanism. Measure the spring free length. Spring free length out of range: →Replace Service Limit: 38.8mm Tool: Vernier Caliper.
  • Page 96 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Install valve spring with small-pitch end “b” facing cylinder head. Big-pitch end “a” is marked. Put on the valve spring retainer. Use the valve spring compressor to press down the spring. Fit the two cotter halves to the stem end and release compressor to allow the cotter ①...
  • Page 97 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Install thermostat Install thermostat cover Install water temperature sensor, apply thread locker to the thread part, tighten it to the specified torque. Water temperature sensor Tightening torque: 10 N·m Install intake pipe, apply lubricant to 0-ring. Camshaft Check camshaft for wear and run-out of cams and journals if the engines produces abnormal noise or...
  • Page 98 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Automatic Decompression Move the automatic decompression weight with hand and check if it is operating smoothly. If it is not working smoothly, replace with a new camshaft/automatic decompression assembly. Cam Wear Worn cams can often cause mistimed valve operation resulting in reduced power output.
  • Page 99 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Camshaft Journal O.D. Measure camshaft journal O.D. with a micrometer. If the O.D. is out of range, replace camshaft with a new one. Camshaft journal O.D. service limit: Sprocket end: 22.959 mm—21.980mm Other end: 17.466mm—17.484mm Tool: micrometer (0-25mm)
  • Page 100 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Chain Tensioner Inspection Check tensioner for any damage or poor function. Damage, poor function: →Replace Insert screw driver into the slotted end of adjusting screw, turn it clockwise to loosen the tension and release the screwdriver.
  • Page 101 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Piston Piston Diameter Use a micrometer to measure the diameter at the point 10mm above the piston end, as illustrated on the right. If the measurement is less that the limit, replace the piston Standard: 87.460-87.480mm Limit: 87.380mm...
  • Page 102 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Piston Ring Free End Gap and End Gap Before installing piston rings, use vernier caliper to measure the free end gap of each ring, and then fit ring into the cylinder. Use thickness gauge to measure each ring end gap, if any ring has an excess end gap, replace the piston ring.
  • Page 103 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Connecting Rod/Crankshaft Connecting rod small end I.D. Use a dial gauge to measure the I.D. of connecting rod small end. If the measurement exceeds the limit, replace the connecting rod. Connecting rod small end I.D. : 23.040mm Tool: Dial Gauge (18-35mm) Connecting Rod Deflection Check the movement of the small end of the rod and...
  • Page 104 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Clutch Clutch Shoes Check clutch for chipping, scrape, uneven wear or heat discoloration. At the same time check depth of the grooves of clutch shoes. If any of the clutch shoes has no groove, replace the clutch. Note: clutch should be replaced as a set.
  • Page 105 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Primary and Secondary Sheave CHAPTER 3 ENGINE PAGE. 3- 72...
  • Page 106 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Primary Sliding Sheave Disassembly Remove spacer Remove Cam ①and Roller② Roller Check each roller and sliding face for wear and damage. Wear and damage: →Replace Note: rollers should be replaced as a set. Oil Seal Check oil seal lip for wear and damage.
  • Page 107 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Primary Sliding Sheave and Fixed Sheave Check the drive face for any abnormal conditions such as damage or stepped wearing. Damage or wearing: → Replace Install oil seal with special tool. Tool: Bearing install set Assembly Reverse the removal procedure of primary sliding and...
  • Page 108 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Install spacer Secondary Sheave Disassembly Use special tool and holder to hold the secondary sheave. Remove secondary sheave nut with special tool. Caution: Do not remove the ring nut before attaching the clutch spring compressor.
  • Page 109 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Remove spring ① Remove spring seat ②. Remove guide pin and spacer. Remove secondary sliding sheave ③ O-ring and Oil Seal Check the O-ring and oil seal for wear and damage. Wear and Damage: →...
  • Page 110 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Install oil seal with special tool. Tool: Bearing install set Secondary Sheave Spring Use vernier caliper to check the spring free length. If the length is shorter than the service limit, replace with a new one.
  • Page 111 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Install guide pin and spacer ① Note: To avoid damage to the oil seal lip during assembly, slide the lip with a 0.1mm steel sheet as guide. Install spring seat. Align hole A with hole B. Install spring and spring plate.
  • Page 112 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Tighten the ring nut with special tool to the specified torque. Ring Nut Tightening Torque: 100N·m Tool: Ring nut wrench Sheave Holder Drive belt Check belt for any greasy substance. Check contact surface of belt for any cracks and damage.
  • Page 113 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Transmission Description Description Qty. MAIN SHAFT. GEARSHIFT DRIVEN GEAR, HIGH RANGE SHIFT CAM DRIVEN GEAR, LOW RANGE RIGHT CRANKCASE SPRING, SHIFT FORK LEFT CRANKCASE RIGHT SHIFT FORK DRIVEN SECTOR GEAR GUIDE BAR SPROCKET, REVERSE GEAR DRIVEN SHAFT CHAIN, REVERSE GEAR...
  • Page 114 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Inspection Check main shaft gear and sprocket surface for any damage or over wear. Damage or over wear: → Replace Check reverse gear chain for any damage or over wear. Damage or over wear: → Replace Disassemble driven shaft as illustrated.
  • Page 115 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Check the shift fork clearance with a thickness gauge in the groove of its gear. Clearance exceeds the limit: → Replace Shift fork to Groove clearance Standard clearance :0.10-0.30mm Service Limit :0. 50mm Measure shift fork groove width with vernier caliper Standard shift fork groove width: 6.05-6.15mm Measure shift fork thickness with vernier calipers;...
  • Page 116 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Put the guide bar on a flat plate and roll it. In case of any bend, replace with a new one. NOTE:DON NOT attempt to correct a bent guide bar. Check shift fork spring for breakage, damage Broken or damaged: →...
  • Page 117 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 When assembling the guide bar, take care not to assemble the two shift forks and springs in the opposite direction. 1. Guide bar 2. Retainer 3. Left shift fork 4. Shift fork Spring (small) 5.
  • Page 118 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Oil strainer Check oil strainer ① and O-ring ② for damage Damaged oil strainer: → Replace Clean the surface of oil strainer with engine oil Relief Valve Check the valve body ① 、valve ② and spring ③O ring④...
  • Page 119 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Front Output Shaft Check bearing 7 for smooth turning and abnormal wear. Check oil seal 5 for damage. Wear or damage: → Replace Apply lubrication oil to bearing 7 and oil seal 5 lip before assembly.
  • Page 120 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Bevel Gear Note: Proper bevel gear engagement depends on that the gear backlash and tooth contact are within the proper range. Bevel Gear Backlash Install drive and driven gears to the crankcase.
  • Page 121 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Tooth Contact After adjusting the backlash, check the tooth contact according to the following procedures: Remove drive and driven bevel gear shafts from crankcase; Clean and degrease every tooh of drive and driven bevel gear;...
  • Page 122 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Balancer Shaft Remove the parts as illustrated on the right. Check each part for abnormal wear or damage. Wear or damage: → Replace ① Balancer shaft gear ② Woodruff key ③ Balancer shaft ④...
  • Page 123 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Check starter clutch roller and holder for abnormal wear or damage. Wear or damage: → Replace Install the starter clutch in the correct direction. Note: When install the starter clutch to the magneto rotor, make sure side “A”...
  • Page 124 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Electric Starter Gear Check the gear surface for scrap or damage. Scrape or Damage: → Replace LEFT CRANKCASE COVER Check magneto stator coil 2, pickup coil 3 for damage, burn or short circuit, if any , replace with new one; Check bearing 4 for smooth turning.
  • Page 125 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 CVT Cover Remove screw 5, oil seal limitator 4. Remove oil seal 3 with special tool; Check bearing 2 for free turning. In case of any abnormal, remove with special tool and replace with a new bearing;...
  • Page 126 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Crankcase 1. Right Crankcase 10. O-ring 19. Bearing 2. Bearing 11. Gear Sensor 20. Bearing 3. Seal 12. Left Crankcase 21. Bearing 4. Bearing 13. Oil Plug 22. Oil Dip Rod 5.
  • Page 127 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Install new O-ring and apply grease; Install gear sensor; Install reverse gear sensor 9 and tighten to the specified torque. Reverse gear sensor tightening torque: 20N.m Install speed sensor 24 Install oil pipe and tighten the link bolt to the specified torque;...
  • Page 128 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Connecting Rod Install connecting rod to left crankcase with special tool; Note: Do not hammer the conrod into crankcase with plastic mallet; Use special tool to avoid affect of conrod precision Tool: Conrod Installer Balancer Shaft Install balancer shaft...
  • Page 129 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Shift Cam, Shift For Install shift can① and shift fork② Check each part for smooth turning Install low range driven gear to counter shaft③ Spray adequate engine oil to each part. Drive Bevel Gear Install drive bevel gear and tighten to the specified torque.
  • Page 130 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Apply sealant ①to the mating face of right crankcase. Note: Apply sealant evenly in an uninterrupted thin line. Install 5 dowel pins② Assemble crankcase and tap slightly with a rubber hammer so that the crankcase is properly fitted. Install bolt and tighten to the specified torque.
  • Page 131 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Install new o-ring⑥ in spacer⑧ Install spacer onto the clutch housing shaft, then install into CVT case Note: align oil nick on spacer with oil hole on the shaft CVT Case Install dowel pin ④, gasket ②...
  • Page 132 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Install secondary sheave; Install primary sliding sheave Tighten primary sheave nut with special tool to the specified torque; Primary sheave nut tightening torque: 115 N·m Tool: Rotor Holder Tighten secondary sheave nut with special tool to the specified torque;...
  • Page 133 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Install CVT case cover bolts and tighten diagonally in several steps. Engine Left Oil Pump Sprocket and Chain Install oil pump drive sprocket; Install oil pump driven sprocket; Install oil pump drive chain; Install oil pump sprocket bolt;...
  • Page 134 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Install starting driven gear; Magneto Rotor(MODEL1) ○ Install Splined Spacer ○ Install Bolt , Bolt tightening torque: 60N.m; Remove Bolt; Remove Splined Spacer CHAPTER 3 ENGINE PAGE. 3- 101...
  • Page 135 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Left Crankcase Cover Install dowel pin2 and gasket 3 Note: Use a new gasket Apply Lubricant grease to oil sea lip; ○ Install left crankcase cover Install bolts; ○ Install Splined Spacer ○...
  • Page 136 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Install left crankcase cover Install end cap 2. CHAPTER 3 ENGINE PAGE. 3- 103...
  • Page 137 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Water Pump Install water pump; Install water pump fixing bolts; Note: Before tightening the bolts, be sure to insert oil pump shaft into groove of water pump shaft. Sector Gear Install the parts as illustrated on the right. 1- sector gear cover and gasket 2-dowel pin 3-drive sector gear...
  • Page 138 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Oil Filter Install oil filter bolt and tighten to the specified torque; Oil filter bolt tightening torque: 36 N·m Apply engine oil to O-ring; Install oil filter, turn it by hand until the filter gasket contacts the mating surface.
  • Page 139 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 1st and 2nd rings have letter “R” marked on the side. Be sure to bring the marked side to the top when fitting them to the piston. Position the gaps of the three rings as illustrated on the right.
  • Page 140 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Cylinder Apply engine oil to piston skirt and cylinder wall; Hold each piston ring with proper position, insert piston into the cylinder; Tighten the cylinder base bolts temporarily; Note: When installing the cylinder and cylinder head, pull the cam chain upward, or the chain will be caught between sprocket and crankcase.
  • Page 141 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Install chain tensioner; Camshaft Align mark “A” on magneto rotor with mark “B” on crankcase; Note: while rotating crankshaft, pull the cam chain upward, or the chain will be caught between sprocket and crankcase.
  • Page 142 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Install crankshaft C-ring ① Install lock washer so that it covers the locating pin; Apply thread locker to the bolts before installing, and tighten them to the specified torque; Sprocket bolt tightening torque: 15 N·m Bend up the lock washer to lock the bolts.
  • Page 143 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Gasket Sealant Applying Place Chain Tensioner Insert (--) screwdriver into slotted end of chain tension adjuster, turn it clockwise to lock the tensioner spring; Install the chain tensioner and the new washer 1; Install the bolt 2, tighten it to the specified torque;...
  • Page 144 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Install the new gasket 3; Install chain tensioner screw, tighten it to the specifiedTorque Chain tensioner screw tightening torque: 8 N·m Valve Adjuster Cover Refer to 11-3 for valve clearance; Use new rubber gasket and apply grease; Install Valve Inspection Cap Install valve inspection cap bolt;...
  • Page 145 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Water Pipe and Hose Install water hose 5 Install bolt 4 Install water hose 3 Install clamp 1 and 2 CHAPTER 3 ENGINE PAGE. 3- 112...
  • Page 146 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 3.6. 1 Carburetor Carburetor Removal…………………………………………………….…3.6.1.1 Inspection……………………………………………………………..….…3.6..1.2 Measurement and Adjustment…………………………………….………3.6..1.3 Carburetor Assembly………………………………………………………3.6..1.4 Carburetor Installation………………………………….……………….…3.6.1.5 Carburetor Parameters…………………… ……...…3.6..1.6 CHAPTER 3 ENGINE PAGE. 3- 113...
  • Page 147 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 1. Carburetor Removal Disassemble the carburetor in the following serial number: Serial No. Description Qty. Serial No. Description Qty. Idle Adjust Shaft Drain Screw Vacuum Chamber Cover Float Chamber Spring Float Jet Needle Holder Needle Valve Set Spring...
  • Page 148 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 2. Inspection Check carburetor body for cracks or damage. Cracks or damage:→ Replace Check carburetor float chamber, fuel passage for dirt or clog. Clean these parts. Check float①, float tang ② for damage. Damage: →...
  • Page 149 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Check the diaphragm ① for tears; Tears: → Replace Check the spring ②,cover ③ for damage and tears; Damage or tears: → Replace Check the jet needle①, mail jet②, needle jet③, pilot air jet④, pilot jet⑤, starter jet⑥...
  • Page 150 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 If float height is not within the specification, check the valve seat and needle valve; If either of valve seat or needle valve is worn, replace both; If both are fine, adjust float height by bending the float tang ①on the float;...
  • Page 151 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Carburetor Installation ①-vacuum breather hose ②-starter cable ③-carburetor joint (engine intake manifold)) ④-throttle valve cover ⑤-throttle cable ⑥-Carburetor joint (air filter) ⑦-carburetor ⑧-drain hose ⑨-fuel inlet hose Note: Align the installation mark of carburetor and carburetor joint 6.
  • Page 152 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 FUEL INJECTION SYSTEM 3.6.2 3.6.2.1 ECU 3.6.2.1.1 Description & Working Principle 3.6.2.1.2 Appearance 3.6.2.1.3 Handling – DOs & DONTs 3.6.2.1.4 Installation requirements 3.6.2.1.5 Power Requirements 3.6.2.1.6 Temperature Requirements 3.6.2.1.7 Maintenance service and Repair 3.6.2.2 INJECTOR 3.6.2.2.1 Appearance 3.6.2.2.2 Sealrings...
  • Page 153 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 3.6.2.5.6 Sample Cleaning 3.6.2.6 Oxygen Sensor 3.6.2.6.1 Description and Working Principle 3.6.2.6.2 Appearance 3.6.2.6.3 Technical Parameters 3.6.2.6.4 Fuel Quality Requirements 3.6.2.7 Ignition Coil 3.6.2.7.1Description and Working Principle 3.6.2.7.2 Appearance 3.6.2.7.3 Technical Parameters 3.6.2.7.4 Installation requirements 3.6.2.7.5 DOs a nd DONTs 3.6.2.8 Fuel Pump Module...
  • Page 154 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 3.6.2.1 ECU 3.6.2.1 .1 Description & Working Principle The ECU continuously monitors the operating conditions of the engine through the system sensors. It also provides the necessary computation, adaptability, and output control in order to minimize the tailpipe emissions and fuel consumption, while optimizing vehicle drivability for all operating conditions.
  • Page 155 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0   P ower Off: The controller will turn its power off when the ignition voltage: < 6.2 V DC. The controller prepares for entry into Power Down mode. The preparation involves storing important information into EEPROM. ...
  • Page 156 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 • Cross-section: 4.25 mm • Materials • Viton GLT (blue color). For low temperature applications • Viton A (black). All other applications. Injector to manifold • Dimensions: • ID: 9.61 mm •...
  • Page 157 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 being exposed to these ambient conditions.   N ormal Operating Temperature Range: - 30 to 125 C   E xtreme Operating Temperature Range (some performance degradation): - 40 to 150 C ...
  • Page 158 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 system leak test at engine/vehicle assembly to after shipping and handling resulting in reseat injector valves. false leakage. DO: Avoid any liquid contamination in the Coil could short circuit. injector area. DO: Use care during connection of harness to Avoid terminal damage.
  • Page 159 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0   I nstall the retaining clip after connecting the fuel line   T ighten the injector mounting to the desired torque as mentioned in the manufacturer manual   T ighten the fuel line ...
  • Page 160 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 3.6.2.3.3 Technical Parameters Throttle Position Sensor:   R eference voltage: 5±0.1VDC   R esistance between T1 and T2: 3k~12kΩ Idle Air Control Valve:   O perating voltage: 7.5~14.2 VDC ...
  • Page 161 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0   R emove air cleaner outlet hose and throttle body outlet hose 3.6.2.3.6 Cleaning Procedure If there is cover on the bottom, it may be removed and cleaned using carburetor cleaner (3M make recommended).
  • Page 162 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 negative temperature coefficient of resistance. This is a non-serviceable part. 3.6.2.4.2 Appearance 3.6.2.4.3 Installation Requirements   D ynamic Torque Requirement: The sensor shall be hand into the application and then driven by a driver with a maximum no load speed of 400 rpm or installed to the desired torque by a hand torque wrench (5/8”...
  • Page 163 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Intake AirPressure and Temperature Sensor(MAP&MAT) 3.6.2.5 3.6.2.5.1Description and Working Principle This sensor has two functions. The first is the intake manifold air temperature, it provides a resistance that varies as a function of temperature within prescribed tolerance limits.
  • Page 164 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 3.6.2.6.3 Technical Parameters   A /F ratio rich threshold: ＞750 mVDC   A /F ratio lean threshold:＜120 mVDC   H eater power: 7.0W (These parameters as above are measured basing on 450°C (engine dyno), typically on 70% duty at 10Hz and under 13.5V) ...
  • Page 165 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0   O perating temperature: -30 ~110 °C   S torage temperature: -40~155°C   M ounting Torque: 8.8~11.8Nm 3.6.2.7.4 Installation requirements   T he vehicle frame provides the mounting surface and mounting holes. ...
  • Page 166 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 output might occur possibly resulting in injury, damage the ignition component, and test equipment DO: Take care when working around the ignition The high voltage produced by the coil secondary system. circuit can cause personal injury and/or damage test equipment DO: Proper handling and shipping methods need...
  • Page 167 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 oil, water, dirt and moist residues. electrodes 2- If the firing end of spark plug has oily or wet - Cleaning & re-gapping will not restore a used deposit, brush the spark plug in an approved, spark plug to a new condition.
  • Page 168 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 1. Fuel Pump 2. Strainer 3. Gasket, Fuel Module 4. Fuel Tube (in pump) 5. Module Bracket 6. Pressure Regulator 7. Module Harness 8. Fuel Tube (out pump) 3.6.2.8.3 Dimensions Fuel Module Cover in elliptical shape with outer edge dimensions as 115mm x 70mm. 3.6.2.8.4 Identification and Markings Fuel Module, Fuel Pump and Regulator are marked with batch code in Julian Date Code.
  • Page 169 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Fuel Flow Description in vehicle fuel system 3.6.2.8.6 Service Procedure Precautions: Before attempting any service on fuel system, following cautions should be always followed for personal safety and to avoid system damages. ...
  • Page 170 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 primes for 3 seconds when the ignition noise can be heard, noise can not be key is ON. heard, go to step 2. Check for fuel pump running noise for to step 4. 3 seconds after ignition key is ON.
  • Page 171 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Bolt Tightening Torque: 3~4 Nm. Fuel module is installed with special bolts (step bolts). Use designated bolts only. Follow the tightening torque and tightening sequence instruction. Over torque and miss-sequence can cause unequal compression of gasket and leakage. ...
  • Page 172 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 OFF position. Repeat this for 3 ~ 4 times to apply fuel pressure in fuel lines.   I n this state, check to see that there are no fuel leakage from any part of fuel system (Fuel Tank, Hoses, Hose Joints, etc) Handling –...
  • Page 173 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 3.6.2.9.1 Mot or Scanner ( for MT05 EMS) 3.6.2.9.1.1 P re c a u t i o ns   M otor-Scanner is a precision instrument and should be protected from vibration and impact.
  • Page 174 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Screen: 128×64 array high definition screen with back light for displaying all the information during testing. Keyboard: There are 5 keys (one is reserved) on the main unit for selecting and controlling test steps.
  • Page 175 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Here, we take diagnostic function for demonstration. Select 1 and press key, it will display an interface for language selection, as shown below: Select ‘English’ and press key, it will display information about the diagnostic software version, press to continue, the interface will display as below: Diagnostic Function...
  • Page 176 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Press , with ‘accessing system’ fleeting on the screen, then, it will display as below: Available functions are as follows:   R ead DTC   C lear DTC   D ata Stream ...
  • Page 177 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Select ‘Data Stream’ and press , it will display as below: Press key for page up/down to view more. Press key to exit. 4. Status Stream Select ‘Status Stream’ and press , the interface will display as below: Press key for page up/down to view more.
  • Page 178 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 It’s the same way to enter month as vehicle code input. Month was input, then enter date, as below: Then, ‘Enter Year’ continues, as below: After that, ‘Enter Week’ follows, as below: Till now, the ‘date input’...
  • Page 179 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Malf code Description in MT05 P0107 MAP Circuit Low Voltage or Open P0108 MAP Circuit High Voltage P0112 IAT Circuit Low Voltage P0113 IAT Circuit High Voltage or Open P0117 Coolant/Oil Temperature Sensor Circuit Low Voltage P0118 Coolant/Oil Temperature Sensor Circuit High Voltage or Open P0122...
  • Page 180 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 3.7. Cooling and Lubrication System Engine Coolant………………………………………………………3.7.2 Inspection of Cooling Circuit……………………….………………3.7.2 Inspection and Cleaning of Radiator and Water Hoses…………3.7.3 Inspection of Fan Motor……………………………………….……3.7.4 Inspection of Water Temperature Sensor…………………………3.7.5 Inspection of Thermostat……………………………………………3.7.5 Water Pump……………………………………………………….…3.7.6 Water Pump Removal and Disassembly……………………3.7.6 Inspection………………………………………………………13.7.8...

  • Page 181: Engine Coolant

    CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Engine Coolant The coolant used in cooling system is a 100% ethylene glycol antifreeze. Warning ! DO NOT open radiator cap when the engine is still hot. Or you may be injured by scalding fluid or steam;...

  • Page 182: Inspection And Cleaning Of Radiator And Water Hoses

    CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Inspection and Cleaning of Radiator and Water Hoses Radiator Cap Remove radiator cap① Install radiator cap to cap tester② Slowly increase pressure to 110-140 kPa and check if the cap can hold the pressure for at least 10 seconds.

  • Page 183: Inspection Of Fan Motor

    CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Inspection of Fan Motor Remove fan motor from radiator Turn the vanes and check if they can turn smoothly; Check fan motor: Make sure that the battery applies 12 volts to the motor and the motor will run at full speed while the ammeter shall indicate the ampere not more than 5A.

  • Page 184: Inspection Of Water Temperature Sensor

    CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Inspection of Water Temperature Sensor Place a rag under water temperature sensor① and remove it from cylinder head. Check the resistance of water temperature sensor as illustrated on the right. Connect the temperature sensor②...

  • Page 185: Water Pump

    CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Check thermostat pellet for cracks Test the thermostat in the following steps: Pass a string between thermostat flange as illustrated on the right; Immerse the thermostat in a beaker with water. Make sure that the thermostat is in the suspended position without contact to the vessel.
  • Page 186 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Remove clamps and water hoses Release bolts and remove water pump Remove O-ring Note: Do not reuse the O-ring. Remove the overflow tube Release water pump cover screws, water pump cover and gasket Remove E-ring and impeller Remove seal ring ①and rubber seal②...
  • Page 187 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Remove mechanical seal with special tool Note: The mechanical seal does not need to be removed if there is no abnormal condition. Note: Do not reuse a removed mechanical seal Put a rag on the water pump body Remove oil seal.
  • Page 188 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Oil Seal Check oil seal for damage. Pay special attention to the oil seal lip; In case of damage or leakage, replace the oil seal; Water Pump Body Check the mating mace of water pump body with bearing and mechanical seal.
  • Page 189 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Install mechanical seal with a suitable socket wrench Note: Apply sealant to side “A” of mechanical seal Install bearing with special tool Tool: Bearing Installer Note: The stamped mark on the bearing faces outside. Install seal ring to impeller Clean off the oil and grease from mechanical seal and install it into the impeller.
  • Page 190 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Install E-ring to water pump shaft; Install new gasket to water pump body; Install water pump cover and tighten the bolts and bleed bolt. Water Pump Cover Bolts Tightening Torque: 6N.m Check impeller for smooth turning.
  • Page 191 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Install water pump and tighten the bolts to the specified torque; Water pump bolts tightening torque: 10N.m Note: Set the water pump shaft slot end “B” to oil pump shaft flat side “A”. Connect water hoses Add coolant CHAPTER 3 ENGINE...
  • Page 192 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 CHAPTER 3 ENGINE PAGE. 3- 159...
  • Page 193 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 1. Engine Complaint Symptom and Possible Causes Remedy Compression is Too Low Replace 1. Worn cylinder 2. Worn piston ring Replace 3. Leakage with cylinder gasket Replace Wear valve guide or improper valve Repair or Replace seating Tighten...
  • Page 194 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 3.8. Troubleshooting Complaint Symptom and Possible Causes Remedy 1. Week valve spring Replace 2. Worn camshaft Replace 3. Fouled spark plug Clean or replace 4. Insufficient spark plug gap Adjust or replace Poor engine 5.
  • Page 195 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Complaint Symptom and Possible Causes Remedy Valve Chatter Replace 1. Excessive valve clearance 2. Worn or broken valve spring Replace 3. Worn rocker arm or camshaft Replace Noise from Piston Replace 1.
  • Page 196 CHAPTER 3 ENGINE LH500ATV-D T3 EFI SERVICE MANUA 19.0 Complaint Symptom and Possible Causes Remedy Difficulty or locked 1. Broken drive or driven bevel gear teeth Replace gearshift 2. Distorted shift fork Replace 3. Worn shift cam Replace 4. Improper gearshift rod Adjust 2.
  • Page 197 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 3. Cooling System/Radiator Complaint Symptom and Possible Causes Remedy 1. Clogged water passage or radiator Clean 2. Air in the cooling system; insufficient Discharge air and add coolant coolant Engine overheats Check and replace 3.
  • Page 198 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 NOTES CHAPTER 3 ENGINE PAGE. 3- 165...
  • Page 199 CHAPTER 4 CHASSIS LH500ATV-D T3 EFI SERVICE MANUAL 19.0 CHAPTER 4 CHASSIS ATV 500 WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each ATV model for spare parts information and service.
  • Page 200 CHAPTER 4 CHASSIS LH500ATV-D T3 EFI SERVICE MANUAL 19.0 4.1 A-RM REPLACEMENT (MacPherson) MANTENANCE-FREE PIVOT DESIGN 1. Elevate and safely support vehicle 2. Remove cotter pin from ball joint cup at wheel end of A- arm and loosen nut until it is flush with end of cup.
  • Page 201 CHAPTER 4 CHASSIS LH500ATV-D T3 EFI SERVICE MANUAL 19.0 4.3 FRONT STRUT REPLACEMENT ATV500 1. Hold strut rod with wrench and remove top 2. Compress spring. 3. Remove upper strut pivot assembly. 4. Remove coil spring and collapse strut body. 5.
  • Page 202 CHAPTER 4 CHASSIS LH500ATV-D T3 EFI SERVICE MANUAL 19.0 4.4 FRONT STRUT BALL JOINT REPLACEMENT ATV500 1. Loosen front wheel nuts. 2. Elevate and safely support ATV under footrest/frame area. . CAUTION: Serious injury may result if ATV tips or falls. Be sure ATV is secure before beginning this service procedure.
  • Page 203 CHAPTER 4 CHASSIS LH500ATV-D T3 EFI SERVICE MANUAL 19.0 4.5 STEERING POST ASSEMBLY Note: 1, Hand tighten the crown nut of the steering post. 2, Align cotter pin hole. 3, Install cotter pin. Bend both ends of cotter pin around nut in opposite directions. 4, Check steering, must move freely and easily from full left to full right without binding.
  • Page 204 CHAPTER 4 CHASSIS LH500ATV-D T3 EFI SERVICE MANUAL 19.0 NOTES CHAPTER 4 CHASSIS PAGE. 4-...
  • Page 205 CHAPTER 5 FINAL DRIVE LH500ATV-D T3 EFI SERVICE MANUAL 19.0 CHAPTER 5 FINAL DRIVE ATV500 WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each ATV model for spare parts information and service.
  • Page 206 CHAPTER 5 FINAL DRIVE LH500ATV-D T3 EFI SERVICE MANUAL 19.0 5.1 WH E E L , H U B , AND SPINDLE TORQUE TABLE Item Specification heel Nuts 69 Ft.Lbs 96 N.m Front W heel Nuts 69 Ft.Lbs 96 N.m Rear W Front Hub Nut on Spindle/ outer CV joint Refer to FRONT HUB INSTALLATION...
  • Page 207 CHAPTER 5 FINAL DRIVE LH500ATV-D T3 EFI SERVICE MANUAL 19.0 surface. Carefully pry seal out of hub. Do not damage the surface of the seal. Clean the hub. 8. Drive bearing out through opposite side of hub and discard. 9. Drive other bearing out and discard. 10.
  • Page 208 CHAPTER 5 FINAL DRIVE LH500ATV-D T3 EFI SERVICE MANUAL 19.0 bearing for moisture, dirt, or corrosion, or roughness is evident. 5.3 FRONT HUB INSTALLATION 4X4 (ATV500) 1. Inspect the hub strut bearing surface for wear or damage. 2. Apply grease to drive axle spindle. 3.
  • Page 209 CHAPTER 5 FINAL DRIVE LH500ATV-D T3 EFI SERVICE MANUAL 19.0 torque. 5.4 FRONT HUB BEARING REPLACEMENT 4X4 (ATV500) 1. Remove outer snap ring. 2. Form the back side, tap on the outer bearing race with a drift punch in the relief as shown.
  • Page 210 CHAPTER 5 FINAL DRIVE LH500ATV-D T3 EFI SERVICE MANUAL 19.0 5.5 FRONT DRIVE AXLE (INNER AND OUTER CV JOINT) REMAVAL/ INSPECTION (4X4) NOTE The outer CV joint cannot be disassembled or repaired, if damage or faulty the drive axle assembly must be replace. 1.

  • Page 211: Inspection

    CHAPTER 5 FINAL DRIVE LH500ATV-D T3 EFI SERVICE MANUAL 19.0 3. Hold the drive shaft straight out. 4. Place a tire lever between the inner CV joint and the differential housing, with a small piece of wood against the housing to help get "leverage"...
  • Page 212 CHAPTER 5 FINAL DRIVE LH500ATV-D T3 EFI SERVICE MANUAL 19.0 3. After the drive shaft is installed, pull the inner CV joint a little to make sure the drive shaft stopper ring has locked into the front differential side gear groove. 4.
  • Page 213 CHAPTER 5 FINAL DRIVE LH500ATV-D T3 EFI SERVICE MANUAL 19.0 axle and discard the boot band“A”, it cannot be reused. 9. Inspect the drive axle as described in this chapter. INNER CV JOINT INSPECTION 1. Clean the bearing assembly in solvent and thoroughly dry.
  • Page 214 CHAPTER 5 FINAL DRIVE LH500ATV-D T3 EFI SERVICE MANUAL 19.0 hole for wear or damage. If any of these areas are worn or damaged, replace the drive axle. NOTE. Inner CV joint must be replaced with the bearing as an assembly. 5.8 FRONT DRIVE AXLE ASSEMBLY (4X4) 1.
  • Page 215 CHAPTER 5 FINAL DRIVE LH500ATV-D T3 EFI SERVICE MANUAL 19.0 6. Position the bearing assembly with the small end of the bearing going on first and install the bearing onto the drive axle. 7. Push the bearing assembly on until it stops, then install the circlip, Make sure the circlip seats correctly in the drive axle groove.
  • Page 216 CHAPTER 5 FINAL DRIVE LH500ATV-D T3 EFI SERVICE MANUAL 19.0 CAUTION It is critical to avoid undue stress on the rubber boots after the drive axle is installed and the vehicle is run. Don’t twist the boot, and always set the both ends in designed position.
  • Page 217 CHAPTER 5 FINAL DRIVE LH500ATV-D T3 EFI SERVICE MANUAL 19.0 5. Remove the mounting bolt of rear shock absorber and upper and lower A-arm. Takedown the A-arm components. 6. Remove the mounting bolt of the rear hub, after that inspect bushes, A-arms and collar. Replace if worn.
  • Page 218 CHAPTER 5 FINAL DRIVE LH500ATV-D T3 EFI SERVICE MANUAL 19.0 10. Using bearing extractor to take down the hub bearing. Notice: when reassembling hub bearing that were removed and rear hub, which are need replaced. (The method is in accordance with removing steering knuckle.) 5.5 REAR GEAR CASE COMPONENT IDENTIFICATION REAR GEARCASE EXPLODED VIEW DRIVE BEVEL GEAR ASSEMBLY, RA...
  • Page 219 CHAPTER 5 FINAL DRIVE LH500ATV-D T3 EFI SERVICE MANUAL 19.0 ADJUST SHIM(2) 0.4 WASHER 14 RING GEAR BEARING HOUSING NEEDLE BEARING 55BTM6720A BOLT M8×25 OIL SEAL 65×90×9 BOLT M10×1.25×25 WIRE CLAMP A7 BOLT M8×35 NUT M8 INNER & OUTER RACE 34-1 ADJUST SHIM(0.40) BEVEL GEAR COMP.
  • Page 220 CHAPTER 5 FINAL DRIVE LH500ATV-D T3 EFI SERVICE MANUAL 19.0 Fig 3 4. Remove the bevel gear-driving Ⅰ ， the adjust shim J and the O-ring K. Remove the bearing retainer L with the special tool. Remove the bearing M and the oil seal P from the bevel gear bearing housing N.
  • Page 221 CHAPTER 5 FINAL DRIVE LH500ATV-D T3 EFI SERVICE MANUAL 19.0 the rear gear case S. →Fig 5 Fig 5 Fig 7 8. Remove the O-ring Z，the oil seal 65×90×9 6. Remove the oil seal 65×90×9 U from the rear a and the bearing b from the ring gear gear case S.
  • Page 222 CHAPTER 5 FINAL DRIVE LH500ATV-D T3 EFI SERVICE MANUAL 19.0 5.7 REAR GEAR CASE ASSEMBLY 3. Mount the needle bearing H and the Important: Before staring any operation needle bearing Ⅰ into the suited hole of on the gearbox ，to ensure that the surface of the rear gear case G.
  • Page 223 CHAPTER 5 FINAL DRIVE LH500ATV-D T3 EFI SERVICE MANUAL 19.0 6. Mount the shaft neck of the bevel gear comp.-driven E in the suited hole of the needle bearing H. Make the ring gear bearing housing C and the rear gear case G together →Fig 6 Fig 6 7.
  • Page 224 CHAPTER 5 FINAL DRIVE LH500ATV-D T3 EFI SERVICE MANUAL 19.0 8. Mount the axle sleeve U of the inner & outer of the bearing W. race in the neck of the bevel gear-driving V. →Fig 10 →Fig 8 Fig 10 11.
  • Page 225 CHAPTER 5 FINAL DRIVE LH500ATV-D T3 EFI SERVICE MANUAL 19.0 Fig 13 13. Mount the coupler of the rear axle f with 14. Mount the oil seal 65×90×9 j in the ring the bevel gear-driving V. gear bearing housing C on the right. Mount the washer 12.5×30×4 g.
  • Page 226 CHAPTER 5 FINAL DRIVE LH500ATV-D T3 EFI SERVICE MANUAL 19.0 5.8 FRONT GEAR CASE DISASSEMBLY FRONT GEARCASE EXPLODED VIEW CHAPTER 5 FINAL DRIVE. 5- 22...
  • Page 227 CHAPTER 5 FINAL DRIVE LH500ATV-D T3 EFI SERVICE MANUAL 19.0 BOLT BEARING RETAINER GEAR MOTOR OIL SEAL O-RING φ81.2×1.9 BEARING 6007 SCREW DRIVE PINION GEAR&DIFFERENTIAL GEAR SCREW PIN SHAFT NUT WASHER SHIFT FORK O-RING GEAR CASE ASSY, FRONT AXLE NEEDLE BEARING DRIVE CLUTCH BOLT ADJUST SHIM...
  • Page 228 CHAPTER 5 FINAL DRIVE LH500ATV-D T3 EFI SERVICE MANUAL 19.0 DRIVE CLUTCH COVER GEAR CASE, FRONT AXLE DRIVEN GEAR JOINT, BREATHER PIPE WASHER BREATHER PIPE SHIM WIRE CLAMP A7 ADJUST SHIM DRAIN BOLT TOP BRACKET,DIFFERENTIAL GEAR WASHER 10 OIL SEAL BEARING 6007 CASE COVER, FRONT AXLE WEARING RING...
  • Page 229 CHAPTER 5 FINAL DRIVE LH500ATV-D T3 EFI SERVICE MANUAL 19.0 Fig 3 4. Remove the COUPLER A. Fig 5 →Fig 4. 6. Remove the four SCREW A. →Fig 6. Fig 4 Fig 6 5. Remove the OIL SEAL A. →Fig 5. 7.
  • Page 230 CHAPTER 5 FINAL DRIVE LH500ATV-D T3 EFI SERVICE MANUAL 19.0 →Fig 9. Fig 9 10. Remove the DIFFERENTIAL GEAR ASSY →Fig 10 Fig 7 8. Remove the six bolts H（M8 L28）. →Fig 8. Fig 8 9. Remove the GEAR CASE ASSY, FRONT Fig 10 AXLE A and CASE COVER ASSY, 11.
  • Page 231 CHAPTER 5 FINAL DRIVE LH500ATV-D T3 EFI SERVICE MANUAL 19.0 Fig 11 12. Remove the SCREW A. Fig 13 →Fig 12. 14．Remove the DRIVE CLUTCH A. →Fig 14. Fig 12 13. Remove the PIN SHAFT A, SHIFT FORK B. →Fig 13. Fig 14 15．Remove the RETAINER 62 B .
  • Page 232 CHAPTER 5 FINAL DRIVE LH500ATV-D T3 EFI SERVICE MANUAL 19.0 Fig 17 Fig 15 18．Remove the OIL SEAL A. 16．Remove the DRIVE CLUTCH COVER A. →Fig 18. →Fig 16. Fig 18 Fig 16 17．Remove the ADJUST SHIM A. →Fig 17.. CHAPTER 5 FINAL DRIVE.
  • Page 233 CHAPTER 5 FINAL DRIVE LH500ATV-D T3 EFI SERVICE MANUAL 19.0 21. Remove the BEARING 61912 A . ． Remove the BEARING RETAINER A with tool B. →Fig 21. →Fig 19. Fig 19 Fig 21 20. Remove the DRIVE PINION GEAR A. 22.
  • Page 234 CHAPTER 5 FINAL DRIVE LH500ATV-D T3 EFI SERVICE MANUAL 19.0 Fig 24 25. Remove the DRIVEN GEAR A and washer B and SHIM C and ADJUST SHIM D and DIFFERENTIAL GEAR E. →Fig 25. Fig 23 24. Remove the DRIVE GEAR A and WEARING RING B and GEAR(CENTER), DIFFERENTIAL C and GEAR SHAFT(CENTER),...
  • Page 235 CHAPTER 5 FINAL DRIVE LH500ATV-D T3 EFI SERVICE MANUAL 19.0 5.10 FRONT GEARCASE ASSEMBLY 1. Mount the the drive gear A and wearing ring B and gear(center), differential C and gear shaft(center), differential D and pin E and bracket,differential F,then mount pin T →Fig 1 Fig 1 2.
  • Page 236 CHAPTER 5 FINAL DRIVE LH500ATV-D T3 EFI SERVICE MANUAL 19.0 3. Mount the differential gear assy, then apply 5. Mount the retainer 62 A . Loctite 263 evenly on the screw thread.Tighten →Fig 5. the six bolts A with the spring lock washer and the washer to a torque of 90~100Nm.
  • Page 237 CHAPTER 5 FINAL DRIVE LH500ATV-D T3 EFI SERVICE MANUAL 19.0 6. Mount the drive clutch A. →Fig 6. 8.Mount the screw A . →Fig 8. Fig 6 Fig 8 7.Mount the pin shaft A and the shift fork B . →Fig 7.
  • Page 238 CHAPTER 5 FINAL DRIVE LH500ATV-D T3 EFI SERVICE MANUAL 19.0 10. Mount the differential gear assy A to the gear case assy C ,do not forget put adjust shim I to the case cover assy B, then make B and C together →Fig 10 Fig 10 11.
  • Page 239 CHAPTER 5 FINAL DRIVE LH500ATV-D T3 EFI SERVICE MANUAL 19.0 Fig 11 12. Mount the gear motor A. Important: Before assemble the gear motor, make sure that the shift fork S is in their correct position as shown. →Fig 12. Fig 12 13.
  • Page 240 CHAPTER 5 FINAL DRIVE LH500ATV-D T3 EFI SERVICE MANUAL 19.0 Fig 13 Fig 15 14. Mount the oil seal A. →Fig 14. 、 16. Mount the O-ring A. →Fig 16. Fig 16 Fig 14 17. Apply some Loctite 263 thread locker on 15.
  • Page 241 CHAPTER 5 FINAL DRIVE LH500ATV-D T3 EFI SERVICE MANUAL 19.0 →Fig 17. Fig 1 NOTES CHAPTER 5 FINAL DRIVE. 5- 37...
  • Page 242 CHAPTER 5 FINAL DRIVE LH500ATV-D SERVICE MANUAL 14.0 CHAPTER 5 FINAL DRIVE. 5- 38...
  • Page 243 CHAPTER 6 BRAKES LH500ATV-D T3 EFI SERVICE MANUAL 19.0 CHAPTER 6 BRAKES NOTE Also See Chapter 2 for Maintenance Information. 6.1 SPECIFICATIONS 6.2 TORQUE 6.3 BRAKE SYSTEM SERVICE NOTES 6.4 BURNISHING PROCEDURE 6.5 FLUID REPLACEMENT/BLEEDING PROCEDURE 6.6 HAND BRAKE MASTER CYLINDER REMOVAL/ INSPECTION /INSTALLATION 6.7 FRONT PAD REMOVAL / INSPECTION / INSTALLATION 6.8 FRONT DISC INSPECTION / REMOVAL / REPLACEMENT 6.9 FRONT CALIPER REMOVAL/ INSPECTION / INSTALLATION...
  • Page 244 CHAPTER 6 BRAKES LH500ATV-D T3 EFI SERVICE MANUAL 19.0 6.1 SPECIFICATIONS Front Brake Caliper Item Standard Service Limit Brake Pad Friction material 0.157"/ 4mm 0.04"/ 1mm Thickness 0.150- 0.164"/3.810- 4.166m B rake Disc Thickness 0.140"/3 .556m m Brake Disc Thickness Variance 0.002 "/ .051m m Between Measurements Brake Disc Runout...
  • Page 245 CHAPTER 6 BRAKES LH500ATV-D T3 EFI SERVICE MANUAL 19.0 Check and adjust master cylinder reservoir fluid level after pad service. Make sure atmospheric vent on reservoir is unobstructed. Adjust foot brake after pad service. Test for brake drag after any brake system service and investigate cause if brake drag is evident.
  • Page 246 CHAPTER 6 BRAKES LH500ATV-D T3 EFI SERVICE MANUAL 19.0 BRAKE BLEEDING-FLUID CHANGE This procedure should be used to change fluid or bleed brakes during regular maintenance. 1. Clean reservoir cover thoroughly. 2. Remove screws, cover and diaphragm from reservoir. 3. Inspect vent slots in cover and remove any debris or blockage.
  • Page 247 CHAPTER 6 BRAKES LH500ATV-D T3 EFI SERVICE MANUAL 19.0 9. Repeat procedure until clean fluid appears in bleeder hose and al air has been purged. Add fluid as necessary to maintain level in reservoir. CAUTION: Maintain at least 1/2 " (13mm of brake fluid in the reservoir to prevent air from entering the master cylinder.
  • Page 248 CHAPTER 6 BRAKES LH500ATV-D T3 EFI SERVICE MANUAL 19.0 NOTE: If any special service needed, contact the ATV manufacture via the agent for the parts and special instruction. REMOVAL 1. Clean master cylinder and reservoir assembly. Make sure you have a clean work area to disassemble brake components.
  • Page 249 CHAPTER 6 BRAKES LH500ATV-D T3 EFI SERVICE MANUAL 19.0 connections leaks repair necessary. 6.7 FRONT PAD REMOVAL / INSPECTION / INSTALLATION NOTE: The brake pads should be replaced as a set. REMOVAL 1. Elevate and support front of ATV safely. CAUT ION: Use care w hen supporting vehicle so that it does not tip or fall.
  • Page 250 CHAPTER 6 BRAKES LH500ATV-D T3 EFI SERVICE MANUAL 19.0 dust boots. 2. Compress mounting bracket and make sure dust boots are fully seated. Install pads with friction material facing each other. Be sure pads and disc are free of dirt or grease. Front Caliper Mounting Bolts Torque 18 ft.
  • Page 251 CHAPTER 6 BRAKES LH500ATV-D T3 EFI SERVICE MANUAL 19.0 REMOVAL/ REPLACEMENT 1. Removal caliper and hub. Apply heat to the hub in the area of the brake disc mounting bolts to soften the bolt locking agent. 2. Remove bolts and disc. 3.
  • Page 252 CHAPTER 6 BRAKES LH500ATV-D T3 EFI SERVICE MANUAL 19.0 PROCEDURE, And field test unit for proper braking action before putting into service. Inspect for fluid leaks and firm brakes. Make sure the brake is not dragging when lever is released. If the brake drags, recheck assembly and installation.
  • Page 253 CHAPTER 6 BRAKES LH500ATV-D T3 EFI SERVICE MANUAL 19.0 Hand and (or) Foot Brake Master Cylinder(s) Fluid Level: Between MIN and MAX lines 4. Install wheels, burnishing procedure should be performed. See BURNISHING PROCEDURE, And field test unit for proper braking action before putting into service.
  • Page 254 CHAPTER 6 BRAKES LH500ATV-D T3 EFI SERVICE MANUAL 19.0 not dragging when lever is released. If the brake drags, recheck assembly installation. REMOVAL / REPLACEMENT 6.12 REAR BRAKE DISC INSPECTION / INSPECTION 1. Visually inspect the brake disc for nicks, scratches, or damage.
  • Page 255 CHAPTER 6 BRAKES LH500ATV-D T3 EFI SERVICE MANUAL 19.0 6.13 FOOT BRAKE PEDAL FOR B-TYPE ADJUSTING If the push rod joint is reinstalled, adjust the push rod length so that the distance between the centers of the master cylinder lower mounting bolt hole and joint pin hole is 80±1mm.After adjustment, tighten the joint nut.
  • Page 256 CHAPTER 6 BRAKES LH500ATV-D T3 EFI SERVICE MANUAL 19.0 NOTES CHAPTER 6 BRAKES PAGE. 6- 14...
  • Page 257 CHAPTER 6 BRAKES LH500ATV-D T3 EFI SERVICE MANUAL 19.0 CHAPTER 6 BRAKES PAGE. 6- 14...
  • Page 258 CHAPTER 7 ELECTRICAL LH500ATV-D T3 EFI SERVICE MANUAL 19.0 CHAPTER 7 ELECTRICAL PARTS INSPECTION AND SERVICE BATTERY IGNITION SYSTEM CHARGING SYSTEM ELECTRICS STARTING SYSTEM COOLING SYSTEM LIGHTING SYSTEM GEAR SHIFT SWITCH TEST SPEEDOMETER SYSTEM 7.10 MAIN SWITCH AND HANDLE SWITCH 7.11 FUEL GAUGE/ FUEL LEVEL SENSOR 7.12 THE OPERATION PRINCIPLE OF THE ELECTRIC 4WD SHIFT 7.13 WIRING DIAGRAM...
  • Page 259 CHAPTER 7 ELECTRICAL LH500ATV-D T3 EFI SERVICE MANUAL 19.0 7.1　PARTS INSPECTION AND SERVICE HEADLIGHT LAMP REPLACEMENT 1. Use bulb 12V 55W/55W. 2. Pull the cable plug off the conducting strip in the socket, remove the clip ① before dismounting the bulb. 3.
  • Page 260 CHAPTER 7 ELECTRICAL LH500ATV-D T3 EFI SERVICE MANUAL 19.0 7.2 BATTERY Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing Antidote: External: Flush with water. lnternal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil.
  • Page 261 CHAPTER 7 ELECTRICAL LH500ATV-D T3 EFI SERVICE MANUAL 19.0 level. Do not overfill the battery. To refill use only distilled water. Tap water contains minerals which are harmful to a battery. Do not allow cleaning solution or tap water to enter the battery. It will shorten the life of the battery.
  • Page 262 CHAPTER 7 ELECTRICAL LH500ATV-D T3 EFI SERVICE MANUAL 19.0 7.3 IGNITION SYSTEM IGNITION SYSTEM TROUBLESHOOTING No Spark, Weak or Intermittent Spark  Spark plug gap incorrect  Fouled spark plug  Faulty spark plug cap or poor connection to high tension lead ...
  • Page 263 CHAPTER 7 ELECTRICAL LH500ATV-D T3 EFI SERVICE MANUAL 19.0 IF THE IGNITION SYSTEM FAILS TO OPERATE Procedure Check: 1. Fuse (Main) 7.Pickup coil resistance 2. Battery 8.Main switch 3. Spark plug 9. Wiring connection(entire ignition system) 4. lgnition spark gap 5.
  • Page 264 CHAPTER 7 ELECTRICAL LH500ATV-D T3 EFI SERVICE MANUAL 19.0 4.lgnition spark gap  Disconnect the spark plug cap from the spark plug Connect the ignition tester 1 as shown. 2 Spark plug Turn the main switch to "ON". Check the ignition spark gap . Check the spark by pushing the MEETS SPECIFICATION starter switch, and increase the spark...
  • Page 265 CHAPTER 7 ELECTRICAL LH500ATV-D T3 EFI SERVICE MANUAL 19.0 Tester (+) lead B/Y Terminal Tester ( -) lead Green 6. Ignition coil resistance Terminal Disconnect the ignition coil connector from the wire harness. Connect the pocket tester (1) to the ignition coil. ...
  • Page 266 CHAPTER 7 ELECTRICAL LH500ATV-D T3 EFI SERVICE MANUAL 19.0 7. Pickup coil resistance  Disconnect the pickup coil coupler from the wire harness. Connect the pocket tester (Ω 100) to the pickup coil coupler. Tester (+) lead → BI/Y Terminal  Tester (- ) lead→...
  • Page 267 CHAPTER 8 ELECTRICAL 500ATV T3 EFI SERVICE MANUAL 16.0 7.4 CHARGING SYSTEM CHARGING SYSTEM CIRCUIT DIAGRAM CURRENT DRAW KEY OFF CAUTION: Do not connect or disconnect the battery cable or ammeter with the engine running. Damage will occur to light bulbs and speed limiter. Connect an ammeter in series with the negative battery cable.
  • Page 268 CHAPTER 8 ELECTRICAL 500ATV T3 EFI SERVICE MANUAL 16.0 CHARGING SYSTEM Proce dure Check: 1. Fuse (Main) 4.Stator coil resistance 2. Battery 5.Wiring system (entire charging system) 3.Charging voltage 1. fuse NO CONTINUITY Replace the fuse 2. Battery Check the battery condition. INCORRECT Refer to "BATTERY INSPECTION"...
  • Page 269 CHAPTER 8 ELECTRICAL 500ATV T3 EFI SERVICE MANUAL 16.0 OUT OF SPECICATION 4. Starter coil resistance Remove the A.C. magneto coupler from wire harness Connect the pocket tester (ΩX1) 　 to the stator coil Tester (+) lead –yellow terminal Tester (-) lead –yellow terminal OUT OF SPECITICATION 　　...
  • Page 270 CHAPTER 8 ELECTRICAL 500ATV T3 EFI SERVICE MANUAL 16.0 7.5 ELECTRICS STARTING SYSTEM D I A G R A M CHAPTER 7 ELECTRICAL CTRICAL PAGE 7- 13...
  • Page 271 CHAPTER 8 ELECTRICAL 500ATV T3 EFI SERVICE MANUAL 16.0 TROUBLESHOOTING THE STARTER MOTOR OPERATES WHEN GEAR SHIFT SWITCH IS IN NEUTRAL OR THE FRONT/REAR SWITCH IS ON IF THE STARTER MOTOR FAILS TO OPERATE Procedure Check: 7. starter switch 1. Fuse (Main) 8.
  • Page 272 CHAPTER 8 ELECTRICAL 500ATV T3 EFI SERVICE MANUAL 16.0 motor WARNING 4.Starter relay A wire used as a jumper lead Disconnect the relay unit coupler from must have the equivalent the wire harness. capacity as that of the battery Connect the pocket tester (Ωx1) and lead or more, otherwise it battery (12V) to the relay unit coupler may burn.
  • Page 273 CHAPTER 8 ELECTRICAL 500ATV T3 EFI SERVICE MANUAL 16.0 Replace the handlebar switch 8. Wiring connection POOR CONNECTION Check the connections of the entire starting system. Refer to “CIRCUIT DIAGRAM Correct 7.6　COOLING SYSTEM CHAPTER 7 ELECTRICAL CTRICAL PAGE 7- 16...
  • Page 274 CHAPTER 8 ELECTRICAL 500ATV T3 EFI SERVICE MANUAL 16.0 IF THE FAN MOTOR FAILS TO TURN Procedure Check: 1. Fuse (Main, Fan) 2. Battery 4. Fan motor (inspection) 3. Main switch 5. Thermo switch 6. relay 7. Wiring connection (entire cooling system) 1.　fuse CHECK SWITCHES NO CONTINUITY...
  • Page 275 CHAPTER 8 ELECTRICAL 500ATV T3 EFI SERVICE MANUAL 16.0 4.2 Fan motor (inspection 2) Turn the main switch to off. Remove the thermo switch lead from DOES　NOT　MOVE thermo switch. Connect jumper lead to thermo switch leads. Turn the main switch to on The wiring circuit from battery to fan motor is faulty.
  • Page 276 CHAPTER 8 ELECTRICAL 500ATV T3 EFI SERVICE MANUAL 16.0 6.Relay Disconnect the starting circuit cut-off relay coupler from the wireharness. Connect the pocket tester (Ωx1) and battery (12V) to the starting circuit cut-off relay coupler terminals. Battery (+) lead→ terminal  Battery (-) lead→...
  • Page 277 CHAPTER 8 ELECTRICAL 500ATV T3 EFI SERVICE MANUAL 16.0 2. Battery INCORRECT Check the battery condition. Refer to "BATTERY INSPECTION" Clean battery terminals Recharge or replace the battery 3.Main switch CHECKING SWITCHES NO CONTINUITY Replace the main switch Handle the thermo unit with 4.Thermo unit special care.
  • Page 278 CHAPTER 8 ELECTRICAL 500ATV T3 EFI SERVICE MANUAL 16.0 Temperature gauge couple. Tester (+) lead→Green/Blue terminal Tester (-) lead→Green ground Turn the main switch to on. OUT OF SPECIFICATION Check voltage (12V) temperature gauge lead. The wiring circuit from main switch to temperature gauge is faulty.
  • Page 279 CHAPTER 8 ELECTRICAL 500ATV T3 EFI SERVICE MANUAL 16.0 7.7　LIGHTING SYSTEM CHAPTER 7 ELECTRICAL CTRICAL PAGE 7- 22...
  • Page 280 CHAPTER 8 ELECTRICAL 500ATV T3 EFI SERVICE MANUAL 16.0 TROUBLESHOOTING Procedure Check: 1. Fuse (Main) 4.Lights switch 2. Battery 5.Dimmer switch Main switch 6. Wiring connection (entire lighting system) 1.fuse refer “CHECKING SWITCHES” NO CONTINUITY section Replace the fuse 2. Battery Check the battery condition.
  • Page 281 CHAPTER 8 ELECTRICAL 500ATV T3 EFI SERVICE MANUAL 16.0 POOR CONNECTIONS 6. Wiring connection Check the connection of the entire lighting system correct 7. check the condition of each of the lighting system’s circuits Refer to “LIGHTING SYSTEM CHECK” LIGHT SYSTEM CHECK 1.
  • Page 282 CHAPTER 8 ELECTRICAL 500ATV T3 EFI SERVICE MANUAL 16.0 2. the taillight fails to come on 1. Bulb and bulb socket NO CONTINUITY CHECK SWITCHES Replace the bulb and /or bulb socket CONTINUITY 2. Voltage Connect the pocket tester (DC20V) to the bulb socket connector.
  • Page 283 CHAPTER 8 ELECTRICAL 500ATV T3 EFI SERVICE MANUAL 16.0 7.8 GEAR SHIFT SWITCH TEST D I A G R A M CHAPTER 7 ELECTRICAL CTRICAL PAGE 7- 26...
  • Page 284 CHAPTER 8 ELECTRICAL 500ATV T3 EFI SERVICE MANUAL 16.0 Switch table CHAPTER 7 ELECTRICAL CTRICAL PAGE 7- 27...
  • Page 285 CHAPTER 8 ELECTRICAL 500ATV T3 EFI SERVICE MANUAL 16.0 7.9　SPEEDMETER SYSTEM OPERATION OF SPPED SENSOR Speed Sensor is on the engine Operation Instructions of Electric Dial Meter and Speed Sensor/ Operation Instructions of LCD Meter and Speed Sensor Hall Sensor is a new type sensor used to measure speed, angle, revolution and length, etc by means of voltage pulse signals converted from sensing gear ratio of black metal gear or gear rack.
  • Page 286 CHAPTER 8 ELECTRICAL 500ATV T3 EFI SERVICE MANUAL 16.0 METER Dial Meter Item Vol value Unit Operating voltage 10V~18V Operating current ≤ 500mA Operating Environmental temperature -10℃~65℃ ℃ Battery warning voltage ≤11.5V LCD Meter 1.Neutral indicator light 10.Engineworkinghour counter 2. High beam indicator light 11.
  • Page 287 CHAPTER 8 ELECTRICAL 500ATV T3 EFI SERVICE MANUAL 16.0 7.10 MAIN SWITCH AND HANDLE SWITCH CHAPTER 7 ELECTRICAL CTRICAL PAGE 7- 30...
  • Page 288 CHAPTER 8 ELECTRICAL 500ATV T3 EFI SERVICE MANUAL 16.0 7.11 FUEL GAUGE/ FUEL LEVEL SENSOR Remove the fuel level sensor from the fuel tank. Measure the resistance with an ohmmeter across the sensor terminal and its body. If the reference values are not indicated, the sensor is faulty Resistanc Reference...
  • Page 289 CHAPTER 8 ELECTRICAL 500ATV T3 EFI SERVICE MANUAL 16.0 7.12 THE OPERATION PRINCIPLE OF THE ELECTRIC 4WD SHIFT (Fig 1) 1, The rider shifts 2WD to 4WD by the Switch on handlebar. 2. When shift 2WD/ 4WD or Diff Lock, the mechanics in the front gear box maybe still engaged/ disengaged, the mechanics would finally disengaged/ engaged when rides on a hard surface or rides in reverse.
  • Page 290 CHAPTER 8 ELECTRICAL 500ATV T3 EFI SERVICE MANUAL 16.0 7.13　WIRING DIAGR CHAPTER 7 ELECTRICAL CTRICAL PAGE 7- 33...
  • Page 291 ATV SERVICE MANUAL EUROPE 19.0 F010106A26 LH500ATV-DT3 EFI 维修手册欧标英文 版本 19.0 零件代号 F010106A26...

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