User Manuals: Linhai ATV520-B HY560 Offroad Vehicle

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Linhai ATV520-B HY560 Service Manual

Linhai ATV520-B HY560 Service Manual (363 pages)

Linhai ATV 2004-2005, 2009

Brand: Linhai | Category: Offroad Vehicle | Size: 45 MB

Table of Contents

Contents
3
Chapter 1 General Page

5
- General Information
  5
- Bearings and Oil Seals
  6
- Important Information
  6
- Preparation for Removal Procedures
  6
- Replacement Parts
  6
- Checking of Connections
  7
- Conversion Table
  8
- Mini / Youth
  9
- V.I.N. and Engine Serial Number
  9
- Vehicle Dimensions
  10
- Demon ATV 260 / 300 Europe
  12
- B-Type 260/ 300
  13
- Special Edition - Anniversary
  13
- Atv 400-2
  14
- B-Type 150/ 200
  14
- Atv 400-2B
  15
- Atv 520
  15
- Atv 520-B
  16
- Maintenance
  18
- Periodic Maintenance
  19
- Periodic Maintenance Schedule
  19
- Fuel System
  24
- Lubrication Recommendations
  24
- Fuel Filter
  26
- Fuel Lines
  26
- Vent Lines and Roll over Valve
  27
- Toe Alignment
  28
- Brake Pad Inspection
  29
- Braking System Inspection
  29
- Foot Brake Adjustment
  29
- Hose/Fitting Inspection
  29
- Bleeding
  30
- Controls
  30
- Foot Brake Testing
  30
- To Adjust (Set Up) the Mechanical Parking Brake
  31
- Brake Drum
  32
- Brake Shoes
  32
- Drum Brake Checking
  32
- Drum Brake for ATV 50-150
  32
- Front Suspension
  34
- Rear Suspension
  34
- Suspension Spring Preload Adjustment
  34
- Wheel Installation
  35
- Wheel Removal
  35
- Wheel, Hub Torque Table
  35
- Wheels
  35
- Tire Inspection
  36
- Tire Pressure
  36
- Tire Pressure Inspection
  36
- Tire Tread Depth
  36
- Frame, Nuts, Bolts, Fasteners
  37
Chapter 3 Engine Page. 3A

40
- Maintenance Specifications
  41
- Tightening Torques
  46
- Chapter 3 Engine Page
  48
- Parts Inspection and Service
  48
- Valve Clearance Adjustment
  48
- Idling Speed Adjustment
  49
- Spark Plug Inspection
  50
- Compression Pressure Measurement
  51
- Compression Pressure
  52
- Engine Oil Level Inspection
  52
- Engine Oil Replacement
  53
- Recommended Engine Oil
  53
- Coolant Level Inspection
  54
- Engine Oil Pressure Inspection
  54
- Coolant Replacement
  55
- Recommended Coolant
  56
- Handling Notes for Coolant
  57
- Cylinder Head
  58
  - Cylinder Head Removal
    60
  - Cyinder Head Installation
    61
  - Cylinder Head Inspection
    61
  - Camshaft and Rocker Arms
    64
  - Cam Shaft Inspection
    65
  - Rocker Arm and Rocker Arm Shaft Removal
    65
  - Rocker Arms and Rocker Arm Shafts Inspection
    65
  - Camshaft and Rocker Arm Installation
    66
  - Valves and Valve Springs
    68
  - Valve and Valve Springs Inspection
    69
  - Valves and Valve Springs Removal
    69
  - Valve Seats Inspection
    70
  - Valves and Valve Springs Installation
    72
  - Cylinder and Piston
    74
  - Cylinder Inspection
    75
  - Piston and Piston Rings Removal
    75
  - Piston and Piston Pin Inspection
    76
  - Piston Rings Inspection
    77
  - Piston Rings, Piston and Cylinder Installation
    77
  - V-Belt,Clutch and Secondary/Primary Sheave Crankcase Cover (Left)
    80
  - Primary Sheave
    81
  - Secondary Sheave
    82
  - Primary Sheave Removal
    83
  - Secondary Sheave and V-Belt Removal
    83
  - Clutch Inspection
    84
  - Secondary Sheave Disassembly
    84
  - V-Belt Inspection
    84
  - Primary Sheave Assembly
    85
  - Secondary Sheave Inspection
    85
  - Weight Inspection
    85
  - Secondary Sheave Installation
    86
  - A.C. Magneto and Starter Clutch
    89
  - Magneto Cover and Stator Coil
    89
  - Magneto Rotor Removal
    91
  - Magneto Rotor Installation
    92
  - Oil Pump
    94
  - Oil Pump Inspection
    95
  - Crankcase and Crankshaft
    96
  - Crankshaft Inspection
    98
  - Crankshaft Removal
    98
  - Crankcase Installation
    99
  - Cooling System
    100
  - Radiator
    100
  - Inspection
    101
  - Water Pump
    103
  - Thermostat
    106
  - Carburetor
    108
  - Carburetor Removel
    108
  - Carburetor Disassembly/Inspection
    109
  - Float and Jets
    110
  - Vacuum Chamber
    110
  - Accererating Pump
    112
  - Air Cut-Off Valve
    112
  - Table of Contents
    119
  - 50Cc/80Cc
    119
  - Air Filter Replacement
    120
  - Replacing Frequency
    120
- Scheduled Maintenance
  120
  - Spark Plug
    120
  - Valve Adjustment
    121
  - Carburetor Idle Speed
    122
  - Cylinder Pressure
    122
  - Ignition Time
    122
  - Changing Gear Oil
    123
  - Final Reduction Gear Oil Checking
    123
  - Gear Oil Recommended
    123
  - Transmission Belt
    123
  - Cylinder Head, Valve
    124
  - Important Information
    124
    
    Standards
    124
    
    Abnormal Noise
    125
    
    Slow Speed Hitch
    125
    
    Tools
    125
    
    Torque Value
    125
    
    Trouble Diagnosis
    125
  - Disassembling of Camshaft
    126
    
    Disassembly of Camshaft Seat and Rocker Arm Assembly
    127
    
    Checking of Camshaft Bearing Rocker Arm
    128
    
    Disassembly of Cylinder Head
    128
    
    Breaking down Cylinder Head
    129
    
    Remove Carbon Deposit from Valve Guide
    130
    
    Valve and Valve Guide
    130
    
    Valve Guide Replacement
    130
    
    Valve Seat Chamfer Cutting Tools
    131
    
    Valve Seat Checking and Correcting
    131
    
    Valve Seat Cutting
    132
    
    Build up Spring Seat
    133
    
    Building-Up of Cylinder Head
    133
    
    Camshaft Assembly
    134
    
    Installing Cylinder Head
    134
    
    Camshaft Chain Regulator Assembling
    135
    
    Important Points
    136
    
    Tech Criterion
    136
    
    Low Compression Pressure
    137
  - Removing the Cylinder
    137
  - Removing the Piston
    137
    
    Max Service Allowance
    138
    
    Checking the Cylinder
    139
  - Assembling the Piston
    140
  - Assembling the Cylinder
    141
    
    Driving Belt Device & the Starting Lever
    142
    
    Removing the Starting Pivot
    143
  - The Left Crankcase Cover Detaching
    143
  - Checking the Starting Pivot
    144
  - Installing the Starting Assembly
    145
  - The Driving Belt
    146
    
    Assembling the Driving Belt
    147
    
    Taking the Driving Pulley Apart
    147
  - The Driving Pulley Dismounting
    147
  - Assembling the Driving Pulley
    148
    
    The Overrunning Clutch
    148
    
    Disassembling the Clutch/Transmission Pulley
    149
    
    Removing the Clutch/Transmission Pulley
    149
    
    Checking the Clutch Transmission Pulley
    150
    
    The Clutch / Transmission Pulley Assembly
    152
    
    Assembling the Clutch/Transmission Pulley
    153
    
    Assembly the Clutch Housing
    153
    
    The Final Transmission Assembly
    154
  - Dismantling the Final Transmission
    155
  - Detach the Final Transmission Gearbox Cover
    156
  - Assembling the Final Gear Set
    157
    
    Oil Leakage
    157
    
    Replacing the Bearing
    157
    
    The Crankcase & the Crankshaft
    158
  - Important Points
    159
  - Dismantling the Crankcase
    160
  - The Crankshaft
    161
  - Assembling the Crankcase
    162
- The Cylinder and the Piston
  136
- Lubricating System
  164
  - Over All Engine Requirements
    165
  - Engine Oil / Filter Screen
    166
    
    Loss of Engine Oil
    166
    
    No Oil Pressure
    166
    
    Problem Diagnosis
    166
  - General Information
    172
    
    Hard Starting Engine
    172
    
    Poor Drivability
    172
    
    Repairing Material
    172
    
    Troubleshooting
    172
- Disassembly of Carburetor
  173
  - Checking Auto Choke
    174
  - Vacuum Chamber Break-Down
    175
  - Float Bowl Disassembling
    176
  - Accelerator Pump Disassembling
    178
- Assembly of Carburetor
  178
  - Checking
    178
  - Carburetor Adjustment
    179
  - Fastener Torque Specification
    180
  - Operation Point
    180
- Starter System
  180
  - Starter Motor Does Not Turn
    181
  - Starter Motor Removal
    181
  - Starter Motor Turns over Slowly
    181
  - Starter Motor Turns- Engine Does Not Rotate
    181
  - Starter Pinion Inspection
    183
  - Starter Pinion Removal
    183
  - Magneto Dismantling
    184
  - Starter Pinion Installation
    184
  - Starter Pinion Assembling
    185
  - Universal Solid Wrench
    187
  - Ignition System Installation
    188
  - Ignition System Operating Points
    188
  - Ignition System Reference Standard
    188
  - Ignition System Troubleshooting
    188
  - CDI Inspection
    189
  - Ignition Coil
    189
  - Charging Coil Inspection
    190
  - Magneto
    190
  - Pickup Coil Inspection
    190
  - Spark Advance Angle Inspection
    190
  - 100Cc/125Cc Chain Drive
    193
  - 150Cc /200Cc Shaft Drive
    193
  - 3C Engine
    193
  - B-Type
    193
  - Gaskets, Oil Seals and O-Rings
    194
  - Preparation for Removal
    194
  - Replacement Parts
    194
  - Air Filter (for MINI ATV100/150)
    195
  - Periodic Inspection and
    195
  - Carburetor Idle Adjustment
    196
  - Transmission Oil Inspection
    196
  - Crankcase Oil Inspection
    197
  - Camshaft Removal
    198
  - Camshaft Holder Removal and Installation
    199
  - Cylinder Body, Piston and Piston Ring
    202
  - V-Belt and CVT
    204
  - Transmission (for MINI ATV100/150)
    208
  - Transmission (for B-Type 150/200)
    209
  - Transmission Disassembly
    209
  - Transmission Assembly
    211
  - Trouble Shooting Checklist
    212
  - Electric Starter
    216
  - Oil Pump
    217
    
    Carburetion
    218
    
    Tightening Torques of Engine Main Fasteners
    223
    
    Atv 260 / 300 / 400
    229
  - Atv Service Manual
    229
    
    B-Type ATV400-2 / ATV400-2B
    229
    
    Chassis
    229
    
    A-Rm Replacement
    230
    
    Mantenance-Free Pivot Design
    231
    
    Swing Arm (Except Atv400-2，Atv400-2B)
    232
    
    Swing Arm Assembly Installation
    232
    
    Front Strut Replacement Atv260/ 300 /400 /400-2 /400-2B
    233
    
    Front Strut Ball Joint Replacement
    234
    
    Steering Post Assembly
    235
    
    Front Hub Removal
    238
    
    Front Hub/ Drum/ Brake Shoe/ Brake Panel/ Brake Cam and Arm Inspection
    238
    
    Front Wheel Removal
    238
    
    Front Wheel/ Hub
    238
    
    Drum Brake Assembly
    239
    
    Drum Brake Disassembly
    239
    
    Hub Bearing Replacement
    239
    
    Drive Chain Removal
    241
    
    Final Drive
    241
    
    Rear Wheel Removal
    241
    
    Drive Chain Inspection, Installation and Adjustment
    242
    
    Final Drive Disassembly
    243
    
    Final Drive Installation
    243
    
    Final Drive Removal
    243
    
    Final Drive Inspection
    244
    
    Final Drive Assembly
    245
    
    Swing Arm
    245
  - Front Hub Disassembly/Inspection
    249
    
    Wheel Hub, and Spindle Torque Table
    249
    
    Front Hub Removal/Inspection 4X4 (ATV400-2 / ATV400-2B)
    250
    
    Front Hub Assembly (Atv150/200/260/300)
    251
    
    Front Hub Installation 4X4 (Atv400-2 / Atv400-2B)
    252
    
    Front Hub Installation (Atv150/200/260/300)
    253
Chapter 5 Final Drive

253
- Front Hub Bearing Replacement 4X4 (Atv400-2 / Atv400-2B)
  255
- Front Drive Axle (Inner and Outer CV Joint) Removal/Inspection (4X4)
  256
- Inspection (4X)
  256
- Front Drive Axle Disassembly/ Inspection (4X4)
  258
- Front Drive Axle Installation (4X)
  258
- Front Drive Axle Installation (4X4)
  258
- Inner CV Joint Inspection
  259
- Front Drive Axle Assembly (4X4)
  260
- Rear Axle Removal
  262
- Rear Hub Inspection
  262
- Rear Axle Installation
  263
  - Rear Axle Bearing Installation
    264
  - Rear Axle Bearing Removal
    264
  - Rear Gearcase Assembly
    265
  - Rear Gearcase Disassembly
    265
    
    Rear Gearcase Exploded View
    266
    
    Front Gearcase Slip Limit Torque Test
    267
    
    Front Gearcase Disassembly/ Inspection
    268
    
    Front Gearcase Assembly
    271
    
    Front Diffrential Disassembly/ Inspection
    272
    
    Front Diffrential Assembly
    274
    
    Front Gearcase Exploded View
    277
    
    Gears Won’t Stay in Position When Shift 2WD/ 4WD
    277
    
    Differential Centre Exploded View
    278
  - Rear, Front Prop Shaft Removal
    278
  - Transmission
    280
  - Shifter Disassembly
    281
  - Shifter Removal
    281
  - Shifter Assembly
    282
  - Shift Linkage Adjustment
    283
  - Shifter Installation
    283
  - Engine and Transmission Removal
    284
  - Engine and Transmission Install
    285
  - Transmission Disassembly
    287
  - Transmission Assembly
    289
  - 2X4 Transmission Exploded View
    292
  - 4X4 Transmission Exploded View
    293
  - Brakes
    295
  - Brake System Service Notes
    296
  - Brakes Specifications
    296
  - Brakes Torque
    296
  - Brake Bleeding-Fluid Change
    297
  - Burnishing Procedure
    297
  - Fluid Replacement/Bleeding Procedure
    297
  - Master Cylinder Fluid Level
    299
  - Front Pad Removal / Inspection / Installation
    301
  - Front Disc Inspection/Removal/Replacement
    302
  - Front Caliper Removal/ Inspection / Installation
    303
  - Rear Brake Pad Removal/ Inspection / Installation
    304
  - Rear Caliper Removal/ Inspection/ Installation
    305
  - Foot Brake Pedal for B-Type
    306
  - Rear Brake Disc Inspection/Removal/Replacement
    306
  - Electrical
    308
  - Headlight Lamp Replacement
    309
  - Headlight on Handlebar
    309
  - Headlight Adjustment
    310
  - Taillight / Brakelight Lamp Replacement
    311
  - Battery
    312
  - Indicator Lamp Replacement
    312
  - Battery Inspection / Removal
    313
  - Battery Installation
    313
  - Battery Testing
    313
  - Open Circuit Voltage Test
    313
  - Ignition System
    314
  - Load Test
    314
  - No Spark, Weak or Intermittent Spark
    314
  - Electrical Circuit Diagram
    315
  - If the Ignition System Fails to Operate
    316
  - Minimum Spark Gap
    317
  - Charging System Circuit Diagram
    320
  - Charging Voltage
    321
  - Starter Coil Resistance
    322
  - Wiring Connection
    322
  - Electrics Starting System
    323
  - If the Starter Motor Fails to Operate
    324
  - Starter Relay
    325
  - Starting Circuit Cut-Off Relay
    325
  - Main Switch
    326
  - Cooling System
    327
  - If the Fan Motor Fails to Turn
    327
  - Thermo Switch
    329
  - If the Heat Alarm Unit Working
    330
  - Lighting System
    332
  - Light System Check
    335
  - Reverse Limit System
    337
  - Gear Position Indicator Switch Test
    338
  - Switch Table
    338
  - Switch Schematic
    339
  - Operation of Speed Sensor
    340
  - Speedometer System
    340
  - Dial Meter
    341
  - Lcd Meter
    342
  - Main Switch and Handle Switch
    342
  - Handle Switch Schematic for Europe Model
    343
  - Handle Switch Schematic for Usa Model
    343
  - 400Atv-2 / 400Atv-2B Handle Switch Schematic for Europe Model
    344
  - 400Atv-2 / 400Atv-2B Handle Switch Schematic for Usa Model
    344
  - Fuel Gauge/ Fuel Level Sensor
    345
  - Fuel Level Sensor Inspection
    346
  - The Operation Principle of the Electric 4Wd Shift
    347
  - Wiring Diagram for L-150/100/80/150ATV
    351
  - Wiring Diagram for LH50/80ATV/LH100/125/150ATV off Road Europe Model
    352
  - Wiring Diagram 2X4 for LH200ATV-B/LH150ATV-B Europe Model
    353
  - Wiring Diagram 2X4 for LH200/150ATV-B
    354
  - Wiring Diagram 2X4 for LH26ATV-B/ATV260/300
    355
  - Wiring Diagram 2X4 for LH260ATV-B/LH260/300
    356
  - Wiring Diagram 4X4 for LH260ATV-B/ATV260/300
    357

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