Linhai HY510S Service Manual
  1. Manuals
  2. Brands
  3. Linhai Manuals
  4. Offroad Vehicle
  5. HY510S
  6. Service manual

Linhai HY510S Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

2014 ATV
SERVICE MANUAL
ATV 500-D
●
493cc
Cette revue concerne les modèles suivants :
HY510S - HY500 60ème - HY500T - HY510IS - HY500IS - HY540ST - HY540STL
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 14.0
PN.
F010102A14
General Information
※
Maintenance
※
Engine
※
Chassis
※
Final Drive
※
Transmission
※
Brakes
※
Electrical
※

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the HY510S and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Linhai HY510S

Summary of Contents for Linhai HY510S

  • Page 1 ● 493cc Cette revue concerne les modèles suivants : HY510S - HY500 60ème - HY500T - HY510IS - HY500IS - HY540ST - HY540STL 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 ATV SERVICE MANUAL EUROPE 14.0 F010102A14 LH500ATV-D 维修手册欧标英文 版本 14.0 零件代号 F010102A14...
  • Page 3 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 4 CONTENTS ↖ ………………………………………………General Information CHAPTER1 ↖ CHAPTER2 ………………………………………….……………Maintenance ↖ ………………500 Engine CHAPTER3……………………………………. …. ↖ CHAPTER4…………………………………………..…………………Chassis ↖ CHAPTER5………………………………………………….………Final Drive ↖ CHAPTER6………………………………………………………………Brakes ↖ CHAPTER7………………………………………………….….………Electrical...
  • Page 5 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 6 CHAPTER 1 GENERALINFORMATION LH500ATV-D SERVICE MANUAL 14.0 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 7 CHAPTER 1 GENERALINFORMATION LH500ATV-D SERVICE MANUAL 14.0 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 8 CHAPTER 1 GENERALINFORMATION LH500ATV-D SERVICE MANUAL 14.0 CIRCLIPS 1. Check all circlips carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip①, make sure that the sharp-edged corner ② is positioned opposite the thrust ③...
  • Page 9 CHAPTER 1 GENERALINFORMATION LH500ATV-D SERVICE MANUAL 14.0 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 Result...
  • Page 10 CHAPTER 1 GENERALINFORMATION LH500ATV-D SERVICE MANUAL 14.0 V.I.N AND ENGINE SERIAL NUMBER CHAPTER 1 GENERAL PAGE. 1- 5...
  • Page 11 CHAPTER 1 GENERALINFORMATION LH500ATV-D SERVICE MANUAL 14.0 CHAPTER 1 GENERAL PAGE. 1- 6...
  • Page 12 CHAPTER 1 GENERALINFORMATION LH500ATV-D SERVICE MANUAL 14.0 VEHICLE DIMENSIONS Note. The on-road equipments (rear view mirror, turn lights, etc.) are not Standard Equipment for USA. ATV 500 CHAPTER 1 GENERAL PAGE. 1- 7...
  • Page 13 CHAPTER 1 GENERALINFORMATION LH500ATV-D SERVICE MANUAL 14.0 NOTES CHAPTER 1 GENERAL PAGE. 1- 8...
  • Page 14 CHAPTER 2 MAINTENANCE LH500ATV-D SERVICE MANUA 14.0 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. 2.1 PERIODIC MAINTENANCE 2.2 FUEL SYSTEM 2.3 TOE ALIGNMENT...
  • Page 15 CHAPTER 2 MAINTENANCE LH500ATV-D SERVICE MANUA 14.0 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 SERVICE MANUA 14.0 Coolant strength 25 hrs 3 months Inspect strength seasonally ▲ Air Box Sediment Tube Daily Headlamp Inspection Daily apply dielectric grease to connector when replaced Tail lamp inspection Daily apply dielectric grease to socket when replaced ▲...
  • Page 17 CHAPTER 2 MAINTENANCE LH500ATV-D SERVICE MANUA 14.0 ▲ Front Suspension 50 hrs 6 months T if necessary ▲ Rear Suspension 50 hrs 6 months T if necessary Spark Plug 100 hrs 12 months R if necessary Ignition Timing 100 hrs 12 months Adjust as needed Fuel System...
  • Page 18 CHAPTER 2 MAINTENANCE LH500ATV-D SERVICE MANUA 14.0 LUBRICANT AND FLUID Item Lube Rec Method Frequency 1. Engine Oil SAE 15W/40 SE Add to proper Check level daily level on dipstick 2. Brake Fluid DOT 3 Only Maintain level As require; change Between fill lines.
  • Page 19 CHAPTER 2 MAINTENANCE LH500ATV-D SERVICE MANUA 14.0 LUBRICATION RECOMMENDATIONS NOTE: More often under severe use, such as wet or dusty conditions. Grease: Light weight lithium-soap grease. Grease M：Molybdenum disulfide (MoS ) grease (water resistant). When suspension action becomes stiff or after washing. Hours are based on 10 mph(16Km/h) average.
  • Page 20 CHAPTER 2 MAINTENANCE LH500ATV-D SERVICE MANUA 14.0 ATV 500 FUEL LINES FUEL FILTER The fuel filter should be replaced in Check fuel lines signs wear, accordance with the Periodic Maintenance deterioration, damage or leakage. Replace if Chart or whenever sediment is visible in the necessary.
  • Page 21 CHAPTER 2 MAINTENANCE LH500ATV-D SERVICE MANUA 14.0 6. Turn fuel valve ON. ATV 500 7. Start engine and inspect for leaks. 8. Reinstall fuel tank. ATV 500 routed properly toward the ground and FUEL VALVE AND STRAINER SCREEN secured with cable ties. CAUTION: Make FOR B-TYPE ATV500 sure lines are not kinked or pinched NOTE...
  • Page 22 CHAPTER 2 MAINTENANCE LH500ATV-D SERVICE MANUA 14.0 2.3 TOE ALIGNMENT METHOD: STRAIGHTEDGE OR STRING Be sure to keep handlebars centered NOTE: String should just touch side surface of rear tire on each side of the ATV. Measure from string to rim at front and rear of rim.
  • Page 23 CHAPTER 2 MAINTENANCE LH500ATV-D SERVICE MANUA 14.0 2.4 BRAKING SYSTEM INSPECTION 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.
  • Page 24 CHAPTER 2 MAINTENANCE LH500ATV-D SERVICE MANUA 14.0 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 25 CHAPTER 2 MAINTENANCE LH500ATV-D SERVICE MANUA 14.0 1. With the engine off, apply the parking brake lever and attempt to move the ATV. 2. If the rear wheels are locked, it is adjusted properly. 3. If the wheels are not locked, it must be adjusted.
  • Page 26 CHAPTER 2 MAINTENANCE LH500ATV-D SERVICE MANUA 14.0 adjuster jam nuts. NOTE: Apply the front brake a number of times to ensure the wheels lock and the brake light illuminate properly. 4. Make sure the right and left brake are balance after the adjustment of the front brakes by test at low speed.
  • Page 27 CHAPTER 2 MAINTENANCE LH500ATV-D SERVICE MANUA 14.0 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 28 CHAPTER 2 MAINTENANCE LH500ATV-D SERVICE MANUA 14.0 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 29 CHAPTER 2 MAINTENANCE LH500ATV-D SERVICE MANUA 14.0 2.7 TIRE PRESSURE TIRE INSPECTION CAUTION : Tire Pressure Inspection Maintain proper tire pressure. Refer to the warning tire pressure decal applied to the Front Rear vehicle. Improper tire inflation may affect ATV maneuverability.
  • Page 30 CHAPTER 2 MAINTENANCE LH500ATV-D SERVICE MANUA 14.0 2.8 FRAME , NUTS, BOLTS, FASTENERS 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 31 CHAPTER 2 MAINTENANCE LH500ATV-D SERVICE MANUA 14.0 NOTES CHAPTER 2 MAINTENANCE PAGE. 2- 18...
  • Page 32 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 ta 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 33 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 34 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 ●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 35 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 36 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 37 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 38 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 39 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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. Tightening torque: Bolt, front axle：40-50N.m Bolt, rear axle：40-50N.m...
  • Page 40 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 41 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 With Fuel Clogged fuel filter Clogged fuel tank cap breather hole Stained, damaged and color changed Remove spark...
  • Page 42 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 Run vehicle at high engine speed...
  • Page 43 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 Unstable Idle Speed check ignition Timing Incorrect Faulty pulse generator Faulty CDI unit Correct Incorrect check carburetor mixture screw Refer to fuel system (Engine Service) Correct Air intake Faulty tightening of carburetor joint Check if secondary air Faulty reed valve seal washer intake into carburetor joint...
  • Page 44 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 45 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 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 46: Table Of Contents

    CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 47: General Precautions

    CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 GENERAL PRECAUTIONS Warning ! Proper service and repair procedures are important for the safety of operator and the safety and reliability of the vehicle. When two or more persons work together, keep reminding each other for safety purpose. When start the engine indoors, make sure that the exhaust gas is forced outdoors.

  • Page 48: Fuel, Oil And Coolant

    CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 SF or SG and that have a viscosity rating of SAE10W/40.

  • Page 49: Engine Exterior And Engine

    CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 Engine Exterior and Engine No CHAPTER 3 ENGINE PAGE. 3- 18...

  • Page 50: Engine Specification

    CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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/ Recoil Starting Ignition / CDI Magneto ignition/BTDC10°1500r/min Ignition Timing...

  • Page 51: Overhaul Data

    CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 Overhaul Data Item Standard Service Limit Remark Valve Head Diameter 30.6 ----------- 27.0 0.05-0.10 Valve Clearance ------------ 0.010-0.037 Clearance Between Valve 0.010-0.037 ------------ Guide and Valve Stem 0.030-0.057 Inner Diameter of Valve IN & EX 5.000-5.012 ------------- Guide...
  • Page 52 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 ------------ Cylinder Joint Face Distortion...
  • Page 53 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 0.50...
  • Page 54 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 Pilot Jet (PJ) N224103-22.5#...
  • Page 55 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 M20*1.5 Sheave Ring Nut, Secondary...
  • Page 56 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 & Lower) Bolt, Cylinder Head Cover...
  • Page 57 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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. lift of camshaft Micrometer 75-100mm For measuring piston skirt...

  • Page 58: Tools

    CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 For removal of magneto rotor...

  • Page 59: Materials For Operation And Fixing

    CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 SAE10W-30 Cylinder bore 1900ml Lubricating or SAE15W-40 Crankcase (for changing oil) or SAE20W-50...
  • Page 60 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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……………………………………..…….. 3.4.8 Inspection of Cooling System………………………………………………..

  • Page 61: Periodic Maintenance

    CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 62: Procedures Of Maintenance And Adjustment

    CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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. Inspect the clearance after removing cylinder head.

  • Page 63: Engine Idle Speed

    CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 64: Air Filter

    CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 65: Fuel Hose, Carburetor

    CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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. Note: If driving under dusty conditions, clean the air filter element more frequently.
  • Page 66 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 67: Inspection Of Lubrication System

    CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 68 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 69: Inspection Of Cooling System

    CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 70: Inspection Of Cylinder Pressure

    CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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. Leakage or Damage: →Replace Inspection of cylinder pressure Check cylinder pressure is necessary.

  • Page 71: Inspection Of Oil Pressure

    CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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; Oil pump failure; Combination of above items;...

  • Page 72: Inspection Of Clutch Engagement And Lock-Up

    CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 73 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 74 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 75 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 76 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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; Remove cylinder head Note: Take care not to drop dowel pin into crankcase...
  • Page 77 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 78 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 79 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 Water Pump Screw out bolt of water pump Remove water pump SPLINED SPACER Remove bolt and washer; Remove splined spacer Left Crankcase Cover Remove bolts; Remove left crankcase cover Remove dowel pin and gasket Magneto Rotor Install the bolt M10×1.25×40 into crankshaft.
  • Page 80 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 81 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 Tool: Sheave Holder...
  • Page 82 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 83 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 of crankcase Crankshaft should remain in the left...
  • Page 84 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 85 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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- 54...
  • Page 86 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 87 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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. Apply engine oil to rocker arms and shafts;...
  • Page 88 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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. CHAPTER 3 ENGINE PAGE.
  • Page 89 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 90 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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. Check the run-out with a dial gauge. Service Limit: 0.05mm Tool: Magnetism Stand Dial Gauge (1/100)
  • Page 91 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 92 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 93 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 94 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 95 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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) Camshaft Run-out...
  • Page 96 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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. Check the push rod movement.
  • Page 97 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 Tool: Micrometer (75-100mm)
  • Page 98 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 99 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 100 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 101 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 Primary and Secondary Sheave CHAPTER 3 ENGINE PAGE. 3- 70...
  • Page 102 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 103 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 fixed sheave for installation.
  • Page 104 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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. Tool: Nut Wrench Sheave Holder Attach special tool to the secondary sliding sheave...
  • Page 105 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 Remove spring ① Remove spring seat ②. Remove guide pin and spacer. ③ Remove secondary sliding sheave O-ring and Oil Seal Check the O-ring and oil seal for wear and damage. Wear and Damage: → Replace Remove Oil Seal CHAPTER 3 ENGINE PAGE.
  • Page 106 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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. Service Limit: 145.4mm Secondary Sliding and Fixed Sheave Check drive face for any abnormal condition such...
  • Page 107 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 108 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 109 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 SPRING, SHIFT FORK...
  • Page 110 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 111 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 112 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 113 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 114 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 115 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 116 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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. Wrap a (--) screwdriver ③with a rag ②...
  • Page 117 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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; Coat the driven bevel gear with machinist’s layout dye or paste;...
  • Page 118 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 Balancer shaft sprocket ⑤...
  • Page 119 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 120 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 121 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 122 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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. Bearing 14. Oil Pipe 23.
  • Page 123 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 124 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 Caution: Balancer shaft driven gear should be aligned to...
  • Page 125 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 126 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 127 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 and gasket⑤ to the right crankcase.
  • Page 128 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 129 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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; Install sprocket retainer with a long nose pliers Tool: Long Nose Pliers Dual Gear, Idle Gear...
  • Page 130 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 Install starting driven gear; Magneto Rotor Install woodruff key into crankshaft groove; Install magneto rotor 1; Note: Degrease the tapered part of rotor and crankshaft. Use nonflammable solvent to clean off the oily or greasy matter and fully dry the surfaces.
  • Page 131 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 132 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 133 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 134 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 135 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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. Align the mark “A”...
  • Page 136 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 137 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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; Chain tensioner bolt tightening torque: 10 N·m After chain tensioner is installed, turn the (--) screwdriver counter clockwise.
  • Page 138 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 139 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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- 108...
  • Page 140 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 3.6. Carburetor Carburetor Removal…………………………………………………….…3.6.2 Inspection……………………………………………………………..….…3.6.3 Measurement and Adjustment…………………………………….………3.6.4 Carburetor Assembly………………………………………………………3.6.5 Carburetor Installation………………………………….……………….…3.6.6 Carburetor Parameters…………………… ……...…3.6.6 CHAPTER 3 ENGINE PAGE. 3- 109...
  • Page 141 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 Main Jet (MJ)
  • Page 142 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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: → Replace Check valve seat①, needle valve②, O-ring③...
  • Page 143 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 and starter plunger⑦ for wear and bends;...
  • Page 144 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 145 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 146 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 Water Pump Assembly and Installation………..……………3.7.9 Lubrication System Illustration………………………………..……3.7.13...

  • Page 147: Engine Coolant

    CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 148: Inspection And Cleaning Of Radiator And Water Hoses

    CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 149: Inspection Of Fan Motor

    CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 150: Inspection Of Water Temperature Sensor

    CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 to the circuit tester, place it in a vessel with engine oil.

  • Page 151: Water Pump

    CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 152 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 153 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 154 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 155 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 156 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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. Install the new O-ring Note: Use the new O-ring to prevent oil leakage;...
  • Page 157 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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.
  • Page 158 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 CHAPTER 3 ENGINE PAGE. 3- 127...
  • Page 159 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 4.
  • Page 160 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 161 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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. Worn piston 2.
  • Page 162 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 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 163 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 164 CHAPTER 3 ENGINE LH500ATV-D SERVICE MANUAL14.0 NOTES CHAPTER 3 ENGINE PAGE. 3- 133...
  • Page 165 CHAPTER 4A CHASSIS LH500ATV-D SERVICE MANUAL 14.0 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 166 CHAPTER 4A CHASSIS LH500ATV-D SERVICE MANUAL 14.0 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 167 CHAPTER 4A CHASSIS LH500ATV-D SERVICE MANUAL 14.0 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. Remove two pinch bolts from strut body.
  • Page 168 CHAPTER 4A CHASSIS LH500ATV-D SERVICE MANUAL 14.0 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 169 CHAPTER 4A CHASSIS LH500ATV-D SERVICE MANUAL 14.0 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 170 CHAPTER 4A CHASSIS LH500ATV-D SERVICE MANUAL 14.0 NOTES CHAPTER 4 CHASSIS PAGE. 4-...
  • Page 171 CHAPTER 5 FINAL DRIVE LH500ATV-D SERVICE MANUAL 14.0 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 172 CHAPTER 5 FINAL DRIVE LH500ATV-D SERVICE MANUAL 14.0 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 Rear Hub Retaining Nut...
  • Page 173 CHAPTER 5 FINAL DRIVE LH500ATV-D SERVICE MANUAL 14.0 7. Place a shop towel on hub to protect 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.
  • Page 174 CHAPTER 5 FINAL DRIVE LH500ATV-D SERVICE MANUAL 14.0 6. Rotate each bearing by hand and check smooth rotation. Visually inspect bearing for moisture, dirt, or corrosion, or roughness is evident. 5.3 b. FRONT HUB INSTALLATION 4X4 (ATV500) 1. Inspect the hub strut bearing surface for wear or damage.
  • Page 175 CHAPTER 5 FINAL DRIVE LH500ATV-D SERVICE MANUAL 14.0 10. Install wheel and wheel nuts and tighten evenly in a cross pattern to specified torque. 5.4 b. 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 176 CHAPTER 5 FINAL DRIVE LH500ATV-D SERVICE MANUAL 14.0 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 177: Inspection

    CHAPTER 5 FINAL DRIVE LH500ATV-D SERVICE MANUAL 14.0 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" and protect the casting. "pop"...
  • Page 178 CHAPTER 5 FINAL DRIVE LH500ATV-D SERVICE MANUAL 14.0 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. Carefully install the outer CV joint (spindle) into the strut，...
  • Page 179 CHAPTER 5 FINAL DRIVE LH500ATV-D SERVICE MANUAL 14.0 8. If the outboard boot requires replacement, perform the following: a. Open the clamps on both boot bands “A”and“B” on the outer CV joint, then remove boot band“B”.Discard the boot band, it cannot be reused. b.
  • Page 180 CHAPTER 5 FINAL DRIVE LH500ATV-D SERVICE MANUAL 14.0 11. Inspect the exterior of the inner CV joint cracks damage, replace necessary. Check the movement of the joint for excessive play or noise by moving the drive axle in a circular and reciprocate direction.
  • Page 181 CHAPTER 5 FINAL DRIVE LH500ATV-D SERVICE MANUAL 14.0 c. Pack the bearing assembly with molybdenum disulfide grease. This will help hold the steel balls in place. 6. Position the bearing assembly with the small end of the bearing going on first and install the bearing onto the drive axle.
  • Page 182 CHAPTER 5 FINAL DRIVE LH500ATV-D SERVICE MANUAL 14.0 16. Install the large boot bands onto each boot. 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 183 CHAPTER 5 FINAL DRIVE LH500ATV-D SERVICE MANUAL 14.0 4. Remove the link, RR. Stabilizer. 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 184 CHAPTER 5 FINAL DRIVE LH500ATV-D SERVICE MANUAL 14.0 9. Remove the snap spring of the rear hub. 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.
  • Page 185 CHAPTER 5 FINAL DRIVE LH500ATV-D SERVICE MANUAL 14.0 NOTES CHAPTER 5 FINAL DRIVE. 5- 15...
  • Page 186 CHAPTER 6 BRAKES LH500ATV-D SERVICE MANUAL 14.0 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 187 CHAPTER 6 BRAKES LH500ATV-D SERVICE MANUAL 14.0 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 0.005 "/ .12 7m m...
  • Page 188 CHAPTER 6 BRAKES LH500ATV-D SERVICE MANUAL 14.0 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 189 CHAPTER 6 BRAKES LH500ATV-D SERVICE MANUAL 14.0 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 190 CHAPTER 6 BRAKES LH500ATV-D SERVICE MANUAL 14.0 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 191 CHAPTER 6 BRAKES LH500ATV-D SERVICE MANUAL 14.0 6.6 HAND BRAKE MASTER CYLINDER REMOVAL/ INSPECTION /INSTALLATION CAUTION: The master cylinder is a non-serviceable Component; it must be replaced as an assembly. NOTE: If any special service needed, contact the ATV manufacture via the agent for the parts and special instruction.
  • Page 192 CHAPTER 6 BRAKES LH500ATV-D SERVICE MANUAL 14.0 Master Cylinder Mounting Bolt Torque 55 in. lbs . (6 N m) Brake Line Banjo Bolt Torque 15 ft. lbs. (21 Nm ) 3. Fill reservoir with DOT 3 fluid. 4. Follow bleeding procedure, Check all connections for leaks and repair if necessary.
  • Page 193 CHAPTER 6 BRAKES LH500ATV-D SERVICE MANUAL 14.0 INSTALLATION 1. Lubricate mounting bracket pins with a light film of All Season Grease, and install rubber dust boots. 2. Compress mounting bracket and make sure dust boots are fully seated. Install pads with friction material facing each other.
  • Page 194 CHAPTER 6 BRAKES LH500ATV-D SERVICE MANUAL 14.0 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. Clean mating surface of disc and hub. 4.
  • Page 195 CHAPTER 6 BRAKES LH500ATV-D SERVICE MANUAL 14.0 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 196 CHAPTER 6 BRAKES LH500ATV-D SERVICE MANUAL 14.0 INSTALLATION 1. Install new pads in caliper body. Be sure to put spacer between pads. 2. Install caliper and torque mounting bolts. Brake Caliper Torque: 18 ft. lbs. (25 Nm ) 3. Slowly pump the brake lever until pressure has been built up.
  • Page 197 CHAPTER 6 BRAKES LH500ATV-D SERVICE MANUAL 14.0 8. Install brake hose and tighten to specified torque. Banjo Bolt Torque: 15 ft. lbs. (21 Nm) NOTE: In some versions of brake, there are 2 hydraulic circulates (for foot brake and hand brake) in one caliper.
  • Page 198 CHAPTER 6 BRAKES LH500ATV-D SERVICE MANUAL 14.0 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 199 CHAPTER 6 BRAKES LH500ATV-D SERVICE MANUAL 14.0 NOTES CHAPTER 6 BRAKES PAGE. 6- 14...
  • Page 200 CHAPTER 7 ELECTRICAL LH500ATV-D SERVICE MANUAL 14.0 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 CHAPTER 7 ELECTRICAL PAGE.7-...
  • Page 201 CHAPTER 7 ELECTRICAL LH500ATV-D SERVICE MANUAL 14.0 7.1 PARTS INSPECTION AND SERVICE HEADLIGHT LAMP REPLACEMENT 1. . ‘Use bulb 12V 35W/35W. 2. Pull the cable plug off the conducting strip in the socket, remove the clip① before dismounting the bulb. 3.
  • Page 202 CHAPTER 7 ELECTRICAL LH500ATV-D SERVICE MANUAL 14.0 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 203 CHAPTER 7 ELECTRICAL LH500ATV-D SERVICE MANUAL 14.0 Remove the filler caps and add distilled water only as needed to bring each cell to the proper 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.
  • Page 204 CHAPTER 7 ELECTRICAL LH500ATV-D SERVICE MANUAL 14.0 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 Related wiring loose, disconnected, shorted, or corroded Engine stop switch or ignition switch faulty Terminal board or connections wet, corroded Poor ignition coil ground (e.g.
  • Page 205 CHAPTER 7 ELECTRICAL LH500ATV-D SERVICE MANUAL 14.0 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.Engine stop switch 4. lgnition spark gap 10.Wiring connection 5. Spark plug cap resistance (entire ignition system) 6.
  • Page 206 CHAPTER 7 ELECTRICAL LH500ATV-D SERVICE MANUAL 14.0 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 207 CHAPTER 7 ELECTRICAL LH500ATV-D SERVICE MANUAL 14.0 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. Check if the primary coil has the specified resistance.
  • Page 208 CHAPTER 7 ELECTRICAL LH500ATV-D SERVICE MANUAL 14.0 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→ B/R Terminal OUT OF SPECIFICATION Check the pickup coil has the...
  • Page 209 CHAPTER 8 ELECTRICAL LH500ATV-D SERVICE MANUAL 14.0 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 210 CHAPTER 8 ELECTRICAL LH500ATV-D SERVICE MANUAL 14.0 CHARGING SYSTEM Procedure 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 211 CHAPTER 8 ELECTRICAL LH500ATV-D SERVICE MANUAL 14.0 4. Starter coil resistance Remove the A.C. magneto coupler from wire harness Connect the pocket tester (ΩX1) the stator coil Tester (+) lead –yellow terminal Tester (-) lead –yellow terminal OUT OF SPECITICATION Measure the stator coil resistance Stator coil resistance 0.5-0.8Ω（20 ）...
  • Page 212 CHAPTER 8 ELECTRICAL LH500ATV-D SERVICE MANUAL 14.0 7.5 ELECTRICS STARTING SYSTEM D I A G R A M CHAPTER 7 ELECTRICAL PAGE.7- 13...
  • Page 213 CHAPTER 8 ELECTRICAL LH500ATV-D SERVICE MANUAL 14.0 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. gear shift switch 1. Fuse (Main) 8.
  • Page 214 CHAPTER 8 ELECTRICAL LH500ATV-D SERVICE MANUAL 14.0 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 215 CHAPTER 8 ELECTRICAL LH500ATV-D SERVICE MANUAL 14.0 6. Main switch CHECK SWITCHES NO CONTINUITY Replace the main switch 7.Gear shift switch CHECK SWITCHES NO CONTINUITY Replace the handlebar switch 8 Front /rear brake switch NO CONTINUITY CHECKING SWITCHES Replace the brake switch 9.
  • Page 216 CHAPTER 8 ELECTRICAL LH500ATV-D SERVICE MANUAL 14.0 7.6 COOLING SYSTEM 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) CHAPTER 7 ELECTRICAL PAGE.7- 17...
  • Page 217 CHAPTER 8 ELECTRICAL LH500ATV-D SERVICE MANUAL 14.0 1. fuse CHECK SWITCHES NO CONTINUITY Replace the fuse 2. Battery Check the battery condition. INCORRECT Refer to "BATTERY INSPECTION" section Clean battery terminals Recharge or replace the battery 3 Main switch CHECK SWITCHES NO CONTINUITY Replace the main switch 4.1 Fan motor(inspection 1)
  • Page 218 CHAPTER 8 ELECTRICAL LH500ATV-D SERVICE MANUAL 14.0 5. Thermo switch Remove the thermo switch from the radiator. Connect the pocket tester (ΩX1) to the thermo switch . Immerse the thermo switch in the water Check the thermo switch for continuity. NOTE: Measure temperatures while heating the coolant with the temperature gauge...
  • Page 219 CHAPTER 8 ELECTRICAL LH500ATV-D SERVICE MANUAL 14.0 7. Wring connection UPPER CONNECTION Check the connection of the entire cooling system. Refer to “CIRCUIT DIAGRAM” Correct IF THE HEAT ALARM UNIT WORKING When the main switch is turned on, the temperature of the engine begins to go up. As it comes to 88±3 the thermostat is connected and the fan starts to work, cooling the coolant, if the thermostat or the fan, fails to work;...
  • Page 220 CHAPTER 8 ELECTRICAL LH500ATV-D SERVICE MANUAL 14.0 Handle the thermo unit with 4.Thermo unit special care. Drain the coolant and remove the Never subject it to strong thermo unit from the cylinder head. shocks or allow it to be Immerse the thermo unit in the dropped.
  • Page 221 CHAPTER 8 ELECTRICAL LH500ATV-D SERVICE MANUAL 14.0 LIGHTING SYSTEM CHAPTER 7 ELECTRICAL PAGE.7- 22...
  • Page 222 CHAPTER 8 ELECTRICAL LH500ATV-D SERVICE MANUAL 14.0 TROUBLESHOOTING Procedure Check: 1. Fuse (Main) 4.Lights switch 2. Battery 5.Dimmer switch 3. 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 223 CHAPTER 8 ELECTRICAL LH500ATV-D SERVICE MANUAL 14.0 POOR CONNECTIONS 7. Wiring connection Check the connection of the entire lighting system correct 8. check the condition of each of the lighting system’s circuits Refer to “LIGHTING SYSTEM CHECK” LIGHT SYSTEM CHECK 1.
  • Page 224 CHAPTER 8 ELECTRICAL LH500ATV-D SERVICE MANUAL 14.0 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 225 CHAPTER 8 ELECTRICAL LH500ATV-D SERVICE MANUAL 14.0 7.8 GEAR SHIFT SWITCH TEST D I A G R A M CHAPTER 7 ELECTRICAL PAGE.7- 26...
  • Page 226 CHAPTER 8 ELECTRICAL LH500ATV-D SERVICE MANUAL 14.0 Switch table CHAPTER 7 ELECTRICAL PAGE.7- 27...
  • Page 227 CHAPTER 8 ELECTRICAL LH500ATV-D SERVICE MANUAL 14.0 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 228 CHAPTER 8 ELECTRICAL LH500ATV-D SERVICE MANUAL 14.0 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 8、9. The odometer 2. High beam indicator light 10.Engine working hour counter 3.
  • Page 229 CHAPTER 8 ELECTRICAL LH500ATV-D SERVICE MANUAL 14.0 7.10 MAIN SWITCH AND HANDLE SWITCH HANDLE SWITCH SCHEMATIC FOR EUROPE MODEL CHAPTER 7 ELECTRICAL PAGE.7- 30...
  • Page 230 CHAPTER 8 ELECTRICAL LH500ATV-D SERVICE MANUAL 14.0 7.11 FUEL GAUGE/ FUEL LEVEL SENSOR Removal Turn the ignition switch to“OFF”. Remove the fuel tank cover. Remove the four bolts, retaining plate and fuel level sensor from the fuel tank. Installation Install a new seal rubber onto the fuel level sensor.
  • Page 231 CHAPTER 8 ELECTRICAL LH500ATV-D SERVICE MANUAL 14.0 With the fuel level sensor float at the top (FULL) position, turn the ignition switch to “ON” and check the fuel gauge. All segments up to segment “F”should come on. If the fuel gauge does not function FULL properly, check the fuel level sensor If the fuel level sensor is OK, replace...
  • Page 232 CHAPTER 8 ELECTRICAL LH500ATV-D SERVICE MANUAL 14.0 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 233 CHAPTER 8 ELECTRICAL LH500ATV-D SERVICE MANUAL 14.0 7.13 WIRING DIAGRAM CHAPTER 7 ELECTRICAL PAGE.7- 34...
  • Page 234 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8- 35...

This manual is also suitable for:

Hy500Hy500tHy510isHy500isHy540stHy540stl

Table of Contents