Table Of Contents - Linhai T-Boss 550 Service Manual

Table of Contents

Table Of Contents3
Warning4
General Information5
Preparation For Removal Procedures6
Replacement Parts6
Gaskets, Oil Seals And O-Rings6
Bearings And Oil Seals6
Circlips7
Checking Of Connections7
Conversion Table8
Vin And Engine Serial Number9
Vehicle Dimensions10
Maintenance12
Periodic Maintenance Schedule13
Lubricant And Fluid16
Throttle Pedal Inspection18
Choke Adjustment18
Throttle Freeplay18
Fuel System19
Fuel Lines19
Vent Lines And Roll Over Valve19
To Alignment20
Braking System Inspection20
Brake Pad Inspection21
Hose/Fitting Inspection21
Adjusting The Brake Pedal21
Adjusting The Parking Brake21
Suspension Spring Preload Adjustment22
Wheel Removal23
Wheel Installation23
Tire Pressure24
Frame, Nuts, Bolts, Fasteners24
Tire Inspection24
Tire Tread Depth24
Engine26
Chapter226
Engine Removal28
Engine Installation31
Engine Overhaul Information32
Fuel, Oil And Coolant34
General Precautions34
Break-In Procedures35
Engine Exterior And Engine No36
Engine Specification37
Engine Overhaul Data38
Tightening Torques (Engine)42
Maintenance Tools44
Tools45
Materials For Operation And Fixing46
Engine Checks And Adjustments47
Periodic Maintenance Table (Engine)48
Procedures Of Engine Maintenance & Adjustment49
Valve Clearance49
Engine Idle Speed50
Spark Plug50
Air Filter51
Fuel Hose52
Drive Belt52
Inspection Of Lubrication System54
Check Engine Oil Level54
Replacing Engine Oil54
Replacing Oil Filter55
Inspection Of Cooling System56
Inspection Of Cylinder Pressure57
Inspection Of Oil Pressure58
Inspection Of Clutch Engagement And Lock-Up59
Engine Removal, Inspection & Installation60
Oil Filter64
Water Pump65
Starting Motor Gear66
Oil Pump Sprocket And Chain66
Engine Components Inspection72
Cylinder Head Cover Check72
Rocker Arm Check73
Cylinder Head Check73
Cylinder Head Distortion75
Valve Seat Width75
Valve Stem And Valve Guide75
Valve Stem Deflection75
Valve Face Wear76
Valve Stem End76
Valve Head Radial Run-Out76
Valve Stem Run-Out76
Valve Spring77
Assembly Of Cylinder Head77
Install Thermostat79
Camshaft79
Automatic Decompression80
Cam Wear80
Camshaft Journal Wear80
Camshaft Journal O.d.81
Camshaft Run-Out81
Chain Tensioner Check82
Cylinder Check82
Piston Check83
Connecting Rod/Crankshaft Check85
Clutch Check86
Primary And Secondary Sheave Diagram87
Primary Sliding Sheave Disassembly88
Primary Sliding Sheave And Fixed Sheave Check89
Primary Sliding Sheave Assembly92
Drive Belt Check94
Transmission Diagram95
Transmission Inspection96
Oil Pump Disassembly And Checks99
Front Output Shaft Check101
Driven Bevel Gear Check101
Bevel Gear Washer Adjustment101
Bevel Gear Check102
Balancer Shaft Inspection104
Magneto Rotor104
Electric Starter Gear Check106
Cvt Cover107
Cvt Case107
Crankcase Diagram108
Oil Pump And Relief Valve109
Connecting Rod110
Sector Gear117
Starting Motor118
Chain Tensioner123
Engine Periphery124
Water Pipe And Hose125
Fuel Injection System126
Ecu Description And Handling128
Injector129
Ecu - Power Requirements129
Injector Installation130
Injector Replacement131
Throttle Body Assembly Description132
Throttle Body Removal132
Engine Coolant Temperature Sensor133
Throttle Body Installation133
Intake Airpressure And Temperature Sensor (Map & Mat)133
Oxygen Sensor134
Ignition Coil135
Fuel Pump Module138
Fuel Module Diagnosis140
Fuel Module Removal140
Fuel Module Installation140
Motor Scanner141
Fuel Pressure Relief Procedure141
Fuel Leakage Check Procedure141
Mt05 Ecu Malf Code147
Cooling And Lubrication System148
Engine Coolant149
Inspection Of Cooling Circuit149
Inspection And Cleaning Of Radiator And Water Hoses150
Inspection Of Fan Motor151
Inspection Of Water Temperature Sensor152
Inspection Of Thermostat152
Water Pump Removal And Disassembly153
Inspection Of Water Pump155
Assembly And Installation Of Water Pump156
Lubrication System Illustration160
Engine Troubleshooting161
Faulty Drive Train162
Faulty Gear Shifting163
Faulty Clutch164
Overheating164
Overcooling165
Poor Braking Performance165
Unstable Handing165
Faulty Lighting Or Signaling System165
Chassis167
Front A-Arm Replacement168
Rear A-Arm Replacement170
Rear Stabilizer Bar Removal/Installation173
Box Removal/Installation174
Steering Assembly Removal/Installation175
Final Drive177
Wheel, Hub And Spindle Torque Table178
Front Hub Exploded View178
Front Hub Removal/Inspection178
Front Hub Installation179
Front Hub Bearing Replacement180
Front Drive Axle Removal/Inspection180
Front Drive Axle Installation182
Front Drive Axle Disassembly/Inspection182
Chapter3182
Inner Cv Joint Inspection183
Front Drive Axle Assembly184
Chapter4185
Rear Hub Exploded View186
Rear Hub Knuckle Removal/Inspection186
Rear Hub And Knuckle Installation187
Rear Drive Shaft Removal188
Rear Drive Shaft Installation188
Chapter5189
Rear Carcase Exploded View190
Rear Gearcase Assembly195
Front Gearcase Exploded View198
Front Gearcase Disassembly200
Front Gearcase Assembly204
Brakes210
Brakes Specifications211
Brake System Service Notes211
Burnishing Procedure212
Brake Bleeding Fluid Change212
Parking Brake And Brake Line Inspection214
Chapter6214
Parking Brake Adjustment215
Parking Brake Rear Caliper Removal/Installation216
Front Pad Removal/Inspection/Installation216
Front Disc Inspection/Removal/Replacement218
Front Caliper Removal/Inspection/Installation219
Rear Brake Pad Removal/Inspection/Installation220
Rear Caliper Removal/Inspection/Installation221
Rear Brake Disc Inspection/Removal/Replacement222
Electrical225
Chapter7225
Headlight Lamp Replacement226
Headlight Adjustment226
Battery227
Ignition System Troubleshooting229
If The Ignition System Fails To Operate230
Charging System234
Electrics Starting System237
Cooling System240
If The Fan Motor Fails To Turn240
If The Heat Alarm Unit Working243
Lighting System245
Light System Check247
Gear Shift Switch Test249
Switch Table250
Speedmeter Systm251
Operation Of Speed Sensor251
Switches254
Fuel Gauge/Fuel Level Sensor255
The Operation Principle Of The Electric 4Wd Shift257
Wiring Diagram258