Linhai MP4 Service Manual
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Linhai MP4 Service Manual

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  • Page 2 LH40DA SERVICE MANUAL 19.0 LH40DA 维修手册欧标英文 版本 19.0...
  • 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 CHAPTER1 ………………………………………………General Information ↖ CHAPTER2 ………………………………………….……………Maintenance ↖ CHAPTER3………………………………………………….….………Electrical ↖ CHAPTER4…………………………………………..…………………Chassis ↖ CHAPTER5………………………………………………….………Final Drive ↖ CHAPTER6………………………………………………………………Brakes ↖...
  • Page 5 WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Always keep alert and wear protection.. Crate of the ATV and parts in the ATV maybe have sharp edge, always pay attention and wear protection.

  • Page 6: Chapter 1 General Information

    CHAPTER 1 GENERALINFORMATION LH40DA 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 7: Preparation For Removal Procedures

    CHAPTER 1 GENERALINFORMATION LH40DA 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 8: Checking Of Connections

    CHAPTER 1 GENERALINFORMATION LH40DA 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 circlip① , make sure that the sharp-edged corner ② is positioned opposite the thrust ③...

  • Page 9: Conversion Table

    CHAPTER 1 GENERALINFORMATION LH40DA 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 Result...
  • Page 10 CHAPTER 1 GENERALINFORMATION LH40DA SERVICE MANUAL 19.0 V.I.N NUMBER PAGE. 1- 5 CHAPTER 1 GENERAL...
  • Page 11 CHAPTER 1 GENERALINFORMATION LH40DA SERVICE MANUAL 19.0 VEHICLE DIMENSIONS PAGE. 1- 6 CHAPTER 1 GENERAL...

  • Page 12: Chapter 1 Generalinformation Notes

    CHAPTER 1 GENERALINFORMATION LH40DA SERVICE MANUAL 19.0 NOTES PAGE. 1- 7 CHAPTER 1 GENERAL...

  • Page 13: Chapter 2 Maintenance

    CHAPTER 2 MAINTENANCE LH40DA 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. 2.1 PERIODIC MAINTENANCE 2.2 TOE ALIGNMENT 2.3 BRAKING SYSTEM INSPECTION...

  • Page 14: Periodic Maintenance Schedule

    CHAPTER 2 MAINTENANCE LH40DA 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 15 CHAPTER 2 MAINTENANCE LH40DA 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 Headlamp Inspection Daily apply dielectric grease to connector when replaced Tail lamp inspection Daily...
  • Page 16 CHAPTER 2 MAINTENANCE LH40DA SERVICE MANUA 19.0 Headlight Aim Adjust if necessary Required ▲ Ball joint (A arm- strut) 10 hrs monthly I, (for damage, wear, and play) R. Replace if necessary LUBRICANT AND FLUID Item Lube Rec Method Frequency 1.A-arm pivot shaft Grease Locate fittings and grease...
  • Page 17 CHAPTER 2 MAINTENANCE LH40DA SERVICE MANUA 19.0 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 18: Toe Alignment

    CHAPTER 2 MAINTENANCE LH40DA SERVICE MANUA 19.0 2.2 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 19: Brake Pad Inspection

    CHAPTER 2 MAINTENANCE LH40DA SERVICE MANUA 19.0 2.3 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 20 CHAPTER 2 MAINTENANCE LH40DA 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 21: Front Suspension

    CHAPTER 2 MAINTENANCE LH40DA SERVICE MANUA 19.0 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. Check all front suspension components for wear or damage.

  • Page 22: Wheel Removal

    CHAPTER 2 MAINTENANCE LH40DA SERVICE MANUA 19.0 WHEEL, HUB TORQUE TABLE Item LH40DA Front Wheel Nuts 69 Ft.Lbs 96 N.m Rear Wheel Nuts 69 Ft.Lbs 96 N.m Front Spindle Nut Refer to FRONT HUB INSTALLATION Rear Hub 80 Ft.Lbs 110.6 N.m Retaining Nut WHEEL REMOVAL 1.

  • Page 23: Tire Tread Depth

    CHAPTER 2 MAINTENANCE LH40DA SERVICE MANUA 19.0 pairs. Front Rear  The use of non- standard size or type tires may affect ATV handling and cause machine damage. （ recommen 5PSI 5PSI TIRE TREAD DEPTH d） Always replace tires when tread depth is (35±0.5KPa) (35 ±0.5KPa) worn to 1/8"...
  • Page 24 CHAPTER 2 MAINTENANCE LH40DA SERVICE MANUA 19.0 EARLY DESIGN* Handlebar Clamp Nut M6 Handlebar Clamp Nut M8 26-30 Nut M10X1.25 Attaching Tie Rod to Steering column 35-41 Nut M10X1.25 Attaching Tie Rod to Front Absorber Strut body 26-30 35-41 Tie Rod Jam Nut M12 37-44 MANTENANCE-FREE PIVOT DESIGN Bolt M12 Attaching 50-60...
  • Page 25 CHAPTER 2 MAINTENANCE LH40DA SERVICE MANUA 19.0 CHAPTER 2 MAINTENANCE PAGE. 2- 13...

  • Page 26: Chapter 3 Electrical

    CHAPTER 3 ELECTRICAL LH40DA SERVICE MANUAL 19.0 CHAPTER 3 ELECTRICAL PARTS INSPECTION AND SERVICE BATTERY Vehicle travel system CHARGING SYSTEM LIGHTING SYSTEM SPEEDOMETER SYSTEM MAIN SWITCH AND HANDLE SWITCH WIRING DIAGRAM CHAPTER 8 ELECTRICAL CTRICAL PAGE 8-...

  • Page 27: Headlight Lamp Replacement

    CHAPTER 3 ELECTRICAL LH40DA SERVICE MANUAL 19.0 HEADLIGHT LAMP REPLACEMENT LH40DA 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. Fit a new bulb into the socket, sitting properly in the three slots, install the clip as shown in the fig.

  • Page 28: Battery Installation

    CHAPTER 3 ELECTRICAL LH40DA 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 29 CHAPTER 3 ELECTRICAL LH40DA SERVICE MANUAL 19.0 7.3 Vehicle travel system Procedure Check: 1. Fuse (Main) 7.Motor 2. Battery 8.Main switch 9. accelerator DC-DC Voltage Converter 4.Charger DC contactor 5. Emergency stop switch 11.Wiring connection 6. Motor controller 1、Fuse NO CONTINUITY Replace the fuse.
  • Page 30 CHAPTER 3 ELECTRICAL LH40DA SERVICE MANUAL 19.0 Connect the three-hole plug-in to the 48V power supply as shown in the figure above ，there is a 12 V-13.8V voltage between Ⅳ terminal and Ⅴ terminal(Measuring with a multimeter)。 CORRECT 4、 Charger ...
  • Page 31 CHAPTER 3 ELECTRICAL LH40DA SERVICE MANUAL 19.0 Normal working state State of emergency note: When a vehicle is in danger, the user should press the emergency stop switch at the first time. The vehicle will not be able to drive or charge after pressing the emergency stop switch When the emergency stop switch is in normal working state, the terminals A and B are connected。...
  • Page 32 CHAPTER 3 ELECTRICAL LH40DA SERVICE MANUAL 19.0  Check the temperature sensor On 0.25 sec，Off 1 sec Motor temperature connection ¤ ¤ ¤ Slow twinkle 3 times，Off 2 sec， fault  Make sure thermistor Repeat 1 works On 0.25 sec，Off 0.25 sec Motor hall signal...
  • Page 33 CHAPTER 3 ELECTRICAL LH40DA SERVICE MANUAL 19.0 Connections with the controller are normal, and when you tap the accelerator, you find that the car doesn't move, or it jitters at a very slow speed. The motor encoder is normal, but the motor phase sequence is not correct. It needs to change the U V or V W phases of the motor .
  • Page 34 CHAPTER 3 ELECTRICAL LH40DA SERVICE MANUAL 19.0 1、Accelerator power supply negative pole 2、Acceleration control signal 3、Accelerator power supply positive pole Inspection methods and procedures Connect the terminal 3 of the accelerator with 5V DC power supply according to the figure above, press the pedal to the termination position lightly, and check the voltage value of terminal 1 and 3 with the multimeter.
  • Page 35 CHAPTER 3 ELECTRICAL LH40DA SERVICE MANUAL 19.0 DC contactor The DC contactor terminal C and terminal D connected with 12V(DC) voltage, then A and B terminals are interconnection(Measuring with a multimeter)。 11.Wiring connection Check the connection of the entire system POOR CONNECTIONS correct Travel system CIRCUIT DIAGRAM...

  • Page 36: Charging System Circuit Diagram

    CHAPTER 3 ELECTRICAL LH40DA SERVICE MANUAL 19.0 7.4 CHARGING SYSTEM CHARGING SYSTEM CIRCUIT DIAGRAM Connecting positive and negative poles of battery pack (Red Wire Connecting Positive Pole) 1、Charging interface： 2、Charger socket 3、Charger body 4、Charging display lamp： 5、Battery temperature sensor When the charger is connected to 220V AC power supply, the voltage at both ends of the battery pack increases by 5-25V.
  • Page 37 CHAPTER 3 ELECTRICAL LH40DA SERVICE MANUAL 19.0 Inspection methods and procedures 1、Emergency stop switch Confident that the emergency stop switch is in normal working state,If not, pull out the switch button。 Normal working state State of emergency 2.Wiring connection Check the connection of the changing system, Refer to “CIRCUIT DIAGRAM”. Charging display lamp Charging capacity <...

  • Page 38: Lighting System

    CHAPTER 3 ELECTRICAL LH40DA SERVICE MANUAL 19.0 7.5　LIGHTING SYSTEM 1. Fuse (Main) 4.Lights switch 2. Battery 5. DC-DC converters 3. Main switch Wiring connection (entire lighting system) 1、Fuse NO CONTINUITY Replace the fuse. CONTINUITY 2. Battery  Check the battery condition. INCORRECT Clean battery terminals.

  • Page 39: Main Switch

    CHAPTER 3 ELECTRICAL LH40DA SERVICE MANUAL 19.0 replace the “ DC-DC Voltage Converter” 。 Refer to " INSPECTION" DC-DC Voltage Converter 6. Wiring connection (entire lighting system) Check the connection of the entire lighting system POOR CONNECTIONS correct 7.6LCD Meter 1.
  • Page 40 CHAPTER 3 ELECTRICAL LH40DA SERVICE MANUAL 19.0 7.8　WIRING DIAGR CHAPTER 8 ELECTRICAL CTRICAL PAGE 8- 15...
  • Page 41 CHAPTER 4 CHASSIS LH40DA SERVICE MANUAL 19.0 CHAPTER 4 CHASSIS 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. 4.1 A-ARM REPLACEMENT 4.2 SWING ARM 4.3 FRONT STRUT REPLACEMENT...
  • Page 42 CHAPTER 4 CHASSIS LH40DA SERVICE MANUAL 19.0 4.1 A-ARM 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 43 CHAPTER 4 CHASSIS LH40DA 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. Remove two pinch bolts from strut body.

  • Page 44: Front Strut Ball Joint Replacement

    CHAPTER 4 CHASSIS LH40DA 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 45: Steering Post Assembly

    CHAPTER 4 CHASSIS LH40DA 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 46 CHAPTER 4 CHASSIS LH40DA SERVICE MANUAL 19.0 NOTES CHAPTER 4 CHASSIS PAGE. 4-...

  • Page 47: Chapter 5 Final Drive

    CHAPTER 5 FINAL DRIVE 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. 5.1 WHEEL, HUB, AND SPINDLE TORQUE TABLE 5.2 FRONT HUB DISASSEMBLY/INSPECTION 5.3 FRONT HUB ASSEMBLY 5.4 FRONT HUB INSTALLATION (2WD)

  • Page 48: Wh E E L , H U B , And Spindle Torque Table

    5.1 WH E E L , H U B , AND SPINDLE TORQUE TABLE Item Specification heel Nuts ATV400：48 Ft.Lbs 66 N.m Front W heel Nuts ATV400：48 Ft.Lbs 66 N.m Rear W Front Hub Nut on Spindle/ outer CV joint Refer to FRONT HUB INSTALLATION Rear Hub Retaining Nut ATV400：101Ft.Lbs...
  • Page 49 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. 9. Drive other bearing out and discard. 10.
  • Page 50 bearing for moisture, dirt, or corrosion, or roughness is evident. 5.3 FRONT HUB INSTALLATION 4X4 1. Inspect the hub strut bearing surface for wear or damage. 2. Apply grease to drive axle spindle. 3. Install spindle through the backside of the hub strut.
  • Page 51 torque. 5.4 FRONT HUB BEARING REPLACEMENT 4X4 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. 3. Drive bearing out evenly by tapping on outer race only.
  • Page 52 NOTE The outer CV joint cannot be disassembled or repaired, if damage or faulty the drive axle assembly must be replace. 1. Drive axle/ outer CV joint assembly. 2. Boot band “A”. 3. Outer board boot. 4. Boot band “B”. 5.
  • Page 53 help get "leverage" and protect the casting. "pop" the in inner CV joint out from the front differential. INSPECTION NOTE The boots are subjected to a lot of abuse if the vehicle is ridden in rough terrain. If the boots are damage and left un-repaired, the driveshaft joints will fair prematurely by allowing the joint to be exposed to dirt, mud and moisture.
  • Page 54 4. Carefully install the outer CV joint (spindle) into the strut， install the front hub and wheel. 5. Install the ball joint on the A arm, the steering tie rods, the hubs and the wheels as described in this Chapter and Chapter 5.7 FRONT DRIVE AXLE DISASSEMBLY/ INSPECTION (4X4) INNER CV JOINT DISASSEMBLY NOTE...
  • Page 55 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. 2. Inspect the steel balls, bearing case and the bearing race for wear or damage. 3.
  • Page 56 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. The rubber boots are not identical and must be installed on the correct joint. The boots are marked as follows: a.
  • Page 57 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 58: Rear Hub Inspection

    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. 17. Secure all large boot bands. Bend down the tab on the boot band and secure the tab with the locking clip and tap them with a plastic hammer.
  • Page 59 5. Insta l new axle tube bolts loosely. 6. Insta l left s ing arm asm bolts and torque to 59-67 ft. lbs ( 80-90Nm). 7. Torque axle tube bolts in a cross pattern to 60 ft. lbs( 80 Nm). e- insta l skid plate and torque bolts to 25 ft.lbs (34Nm).

  • Page 60: Rear Axle Bearing Installation

    5.12 REAR AXLE BEARING INSTALLATION 1. Clean bearing surface on axle tube and install new bearing (s), retaining ring and seals reversing steps of rear axle bearing removal.. 2. Torque brake caliper, rear hub nut, and rear wheel nuts to specifications. 5.13 REAR GEAR CASE DISASSEMBLY REAR GEARCASE EXPLODED VIEW...
  • Page 61 SEAL SEAL LEFT CASE BEARING INPUT GEAR BEARING MID GEAR CASE BEARING HEXAGON FLANGE BOLT DIFF CASE OUTPUT GEAR BOLT GUARD DOWEL PIN VENT NOZZLE RIGHT CASE WASHER...
  • Page 62 BOLT DRAIN SCREW BOLT Side Gear Thrust-Washer Diff Side Gear Diff Roll Pin Diff Pinion Mate Gear Pinion Mate Thrust-Washer Diff Cross Pin...

  • Page 63: Chapter 5 Final Drive

    CHAPTER 5 FINAL DRIVE LH40DA SERVICE MANUAL19.0 1. Remove the oil Drain Screw A and let the oil drain from the gearbox. Important: Clean the plug carefully and Replace the Washer B before Its assembled. →Fig 1 Fig 1 2. Remove the ten Bolts A, Right Case B, Input Gear C, Mid Gear Case D, Diff Case Assembly E and Left Case F.
  • Page 64 CHAPTER 5 FINAL DRIVE LH40DA SERVICE MANUAL19.0 Fig 3 4. Remove the Bearing A and Bearing E. Then, remove six Bolts D , remove Output Gear B from Diff Assembly C. →Fig 4 Fig 4 5. Remove the Diff Roll Pin A. Then, remove the Diff Cross Pin B.
  • Page 65 CHAPTER 5 FINAL DRIVE LH40DA SERVICE MANUAL19.0 Fig 5 6. First turn Diff Pinion Mate Gear B 90 ° and then remove Pinion Mate Thrust-Washer A and Diff Pinion Mate Gear B and Side Gear Thrust-Washer C and Diff Side Gear D and Diff Case E. →Fig 6 Fig 6 CHAPTER 5...

  • Page 66: Rear Gear Case Assembly

    CHAPTER 5 FINAL DRIVE LH40DA SERVICE MANUAL19.0 5.14 REAR GEAR CASE ASSEMBLY 1. Mount Pinion Mate Thrust-Washer A and Diff Pinion Mate Gear B and Side Gear Thrust-Washer C and Diff Side Gear D and Diff Case E as shown, then turn Diff Pinion Mate Gear B 90 °.
  • Page 67 CHAPTER 5 FINAL DRIVE LH40DA SERVICE MANUAL19.0 3. Mount Output Gear B to Diff Assembly C, mount six Bolts D. Then, mount the Bearing A and Bearing E. PS: Apply Loctite 271 evenly on the six Bolts D screw thread. Tighten the eight Bolts to a torque of 90~100Nm →Fig 9 Fig 9...
  • Page 68 CHAPTER 5 FINAL DRIVE LH40DA SERVICE MANUAL19.0 Fig 11 NOTES CHAPTER 5 FINAL DRIVE. 5- 22...
  • Page 69 CHAPTER 5 FINAL DRIVE LH40DA SERVICE MANUAL19.0 CHAPTER 5 FINAL DRIVE. 5- 23...

  • Page 70: Chapter 6 Brakes

    CHAPTER 6 BRAKES LH40DA 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 71: Specifications

    CHAPTER 6 BRAKES LH40DA 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 0.005 "/ .12 7m m...
  • Page 72 CHAPTER 6 BRAKES LH40DA 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 73: Fluid Replacement/Bleeding Procedure

    CHAPTER 6 BRAKES LH40DA SERVICE MANUAL 19.0 6.5 FLUID REPLACEMENT/BLEEDING PROCEDURE NOTE : When bleeding the brakes or replacing the fluid always start with the caliper farthest from the master cylinder. CAUTION Always wear safety glasses. CAUTION Brake fluid is highly corrosive. Do not spill brake fluid on any surface of the ATV.
  • Page 74 CHAPTER 6 BRAKES LH40DA SERVICE MANUAL 19.0 Reservoir Cover Torque 5 in. lbs. (.6 Nm ) 7. Slowly pump brake lever (D) until pressure builds and holds. 8. While maintaining lever pressure, open bleeder screw. Close bleeder screw and release brake lever. NOTE: Do not release lever before bleeder screw is tight or air m ay be draw n into caliper.

  • Page 75: Installation

    CHAPTER 6 BRAKES LH40DA SERVICE MANUAL 19.0 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 76 CHAPTER 6 BRAKES LH40DA SERVICE MANUAL 19.0 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 77 CHAPTER 6 BRAKES LH40DA SERVICE MANUAL 19.0 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 78: Removal/ Replacement

    CHAPTER 6 BRAKES LH40DA 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. Clean mating surface of disc and hub. 4.

  • Page 79: Removal And Inspection

    CHAPTER 6 BRAKES LH40DA SERVICE MANUAL 19.0 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. 6.10 REAR BRAKE PAD REMOVAL/ INSPECTION / INSTALLATION NOTE: The brake pads should be replaced as a set.
  • Page 80 CHAPTER 6 BRAKES LH40DA SERVICE MANUAL 19.0 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. Inspect for fluid leaks and firm brakes. Make sure the brake is not dragging when lever is released.
  • Page 81 CHAPTER 6 BRAKES LH40DA SERVICE MANUAL 19.0 installation. REMOVAL / REPLACEMENT 6.12 REAR BRAKE DISC INSPECTION / INSPECTION 1. Visually inspect the brake disc for nicks, scratches, or damage. 2. Measure the disc thickness at 8 different points around the pad contact surface using a 0-1"...
  • Page 82 CHAPTER 6 BRAKES LH40DA 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 83 CHAPTER 6 BRAKES LH40DA SERVICE MANUAL 19.0 NOTES CHAPTER 6 BRAKES PAGE. 6- 14...

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