Linhai ATV 500-D T3 EFI Page 87 Service Manual Download

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CHAPTER 3 ENGINE

LH500ATV-D T3 EFI SERVICE MANUA 19.0

CHAPTER 3 ENGINE PAGE. 3- 54

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

crankcase half.

Driven Bevel Gear, Front Output Shaft

Remove bevel gear cover bolt

Remove driven bevel gear

③

Remove front output shaft nut

④

Summary of Contents for ATV 500-D T3 EFI

Page 1: ...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: ...ld use discretion as to how much disassembly is needed to correct any given condition All references to left and right side of the vehicle are from the operator s perspective when seated in a normal r...

Page 3: ...CONTENTS CHAPTER1 General Information CHAPTER2 Maintenance CHAPTER3 500 Engine CHAPTER4 Chassis CHAPTER5 Final Drive CHAPTER6 Brakes CHAPTER7 Electrical...

Page 4: ...contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Always keep alert and wear protection Exhaust system components are very hot during and after use of ATV Never s...

Page 5: ...AL 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 part...

Page 6: ...ements Use recommended oil and grease for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality GASKETS OIL SEALS AND O RINGS 1 Replace all gaskets seals...

Page 7: ...ogether 7 Check for continuity with a tester NOTE If there is no continuity clean the terminals Be sure to perform the steps 1 to 7 listed above when checking the wire harness Use the tester on the co...

Page 8: ...CONVERSION TABLE METRIC TO IMP Known Multiplier Result Torque m kg m kg cm kg cm kg 7 233 86 794 0 0723 0 8679 ft lb In lb ft lb In lb Weight kg g 2 205 0 03527 lb oz Distance km h km m m cm mm 0 6214...

Page 9: ...CHAPTER 1 GENERALINFORMATION LH500ATV D T3 EFI SERVICE MANUAL 19 0 CHAPTER 1 GENERAL PAGE 1 5 1 2 V I N AND ENGINE SERIAL NUMBER...

Page 10: ...CHAPTER 1 GENERALINFORMATION LH500ATV D T3 EFI SERVICE MANUAL 19 0 CHAPTER 1 GENERAL PAGE 1 6 VIN STATUTORY PLATE...

Page 11: ...RALINFORMATION LH500ATV D T3 EFI SERVICE MANUAL 19 0 CHAPTER 1 GENERAL PAGE 1 7 1 3 VEHICLE DIMENSIONS Note The on road equipments rear view mirror turn lights etc are not Standard Equipment for USA A...

Page 12: ...CHAPTER 1 GENERALINFORMATION LH500ATV D T3 EFI SERVICE MANUAL 19 0 CHAPTER 1 GENERAL PAGE 1 8 NOTES...

Page 13: ...CHAPTER 1 GENERALINFORMATION LH500ATV D T3 EFI SERVICE MANUAL 19 0 CHAPTER 1 GENERAL PAGE 1 9...

Page 14: ...s 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...

Page 15: ...of important components are explained in the following chart on the following pages Maintenance intervals are based upon average riding conditions and an average vehicle speed of approximately 16km h...

Page 16: ...Air Box Sediment Tube Daily D Headlamp Inspection Daily C apply dielectric grease to connector when replaced Tail lamp inspection Daily C apply dielectric grease to socket when replaced Air Filter Mai...

Page 17: ...on 50 hrs 6 months I L T if necessary Rear Suspension 50 hrs 6 months I T if necessary Spark Plug 100 hrs 12 months I R if necessary DL Ignition Timing 100 hrs 12 months I Adjust as needed DL Fuel Sys...

Page 18: ...ear Gear case oil SEA 80W 90GL5 Add to proper level Change annually or at 100 hours 5 Front Gear case oil SDX30 0 SEA 80W 90GL5 Add to proper level Change annually or at 100 hours 6 Front A arm pivot...

Page 19: ...ings and grease Every 3 months or 50 hours 19 Inner and outer CV Joints SDX300 Grease M Grease inspect and replace it if necessary Every 3 months or 50 hours 21 A arm pivot shaft Grease Locate fitting...

Page 20: ...ormed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If you get gasoline in your eyes or if you swallow gasoline see your doctor immediately If you spill gasoline on yo...

Page 21: ...and inspect for leaks 8 Reinstall fuel tank ATV 500 FUEL VALVE AND STRAINER SCREEN FOR B TYPE ATV500 NOTE After installing the fuel valve and connecting the fuel line refill the fuel tank and turn th...

Page 22: ...ns as 115mm x 65mm Identification and Markings Fuel Module Fuel Pump and Regulator are marked with batch code in Julian Date Code On Fuel Module batch code in mentioned on the label available on fuel...

Page 23: ...um 3 liters of fuel in the fuel tank Fuel Module Removal Relieve fuel pressure in fuel lines referring to the Fuel Pressure Relief Procedure provided in this section Disconnect negative cable at batte...

Page 24: ...e electrical coupler from vehicle harness Start engine and run till it stops due to lack of fuel Repeat ignition key ON and OFF for 2 3 times of about 3 seconds each time to relieve fuel pressure in l...

Page 25: ...ake fluid from a sealed container to avoid contamination to system Check brake system for fluid leaks Check brake for excessive travel or spongy feel Check friction pads for wear damage and looseness...

Page 26: ...system in a conventional manner following the procedure outlined in the Brake chapter MECHANICS PARKING BRAKE FOR EUROPE ATV 500 Foot control brake is only for ATV 260 300 If the push rod joint is re...

Page 27: ...lay at the end of the parking lever 4 Tighten the jam nuts securely against the adjusters 5 Make sure the rear wheels turns freely without dragging 6 Turn the adjustor the one on the lever and apply t...

Page 28: ...ved at the brake lever rake shoes as a set either is worn to the limit NOTE While adjusting free play it is important you apply the lever back and forth 3 Tighten the jam nuts securely against the adj...

Page 29: ...ension Damping should be smooth throughout the range of travel Check all front suspension components for wear or damage Inspect from strut cartridges for leakage Shock spring preload can not be adjust...

Page 30: ...L INSTALLATION 1 With the transmission in gear and the parking Brake locked place the wheel in the correct Position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on...

Page 31: ...irs especially in SDX300 model The use of non standard size or type tires may affect ATV handling and cause machine damage especially in SDX300 model TIRE TREAD DEPTH Always replace tires when tread d...

Page 32: ...rson 8 11 LT SwingArmPivotLeft 14 19 SwingArmPivotRight 120 165 ThreadedPivotNut forswingarm 120 165 RefertoSWING ARM ASSEMBLY INSTALLATION 4 2SWING ARM CHAPTER4A CHASSIS NutM14X1 5AttachingFrontAbsor...

Page 33: ...CHAPTER 2 MAINTENANCE LH500ATV D T3 EFI SERVICE MANUA 19 0 CHAPTER 2 MAINTENANCE PAGE 2 20...

Page 34: ...shift Unit 3 1 1 Overhaul Info 3 1 2 Engine Removal and Installation 3 1 3 Removal and Installation of Front and Rear Axle 3 1 4 Removal and Installation of Gearshift Unit 3 2 Troubleshooting 3 3 Engi...

Page 35: ...e Take care not to damage frame engine body bolts and cables Wrap the frame to avoid any possible damage when removing or installing the engine Following operation doesn t require removal of engine fr...

Page 36: ...apter 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 connect...

Page 37: ...CHAPTER 3 ENGINE PAGE 3 4 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...

Page 38: ...CHAPTER 3 ENGINE LH500ATV D T3 EFI SERVICE MANUA 19 0 CHAPTER 3 ENGINE PAGE 3 5 Remove Bolt 1 and Nut 1 of lower engine hanger Remove Bolt 2 and Nut 2 of lower engine hanger...

Page 39: ...to engine Connect all the connectors Spark plug cap Gearshift rod to engine Air filter carburetor and removed parts 3 1 3 Removal and Installation of Front and Rear Axle Support the vehicle with jack...

Page 40: ...CHAPTER 3 ENGINE LH500ATV D T3 EFI SERVICE MANUA 19 0 CHAPTER 3 ENGINE PAGE 3 7 Remove nut and bolt of front axle from frame Remove nut and bolt of rear axle from frame...

Page 41: ...oval procedure for installation Tightening torque Bolt front axle 40 50N m Bolt rear axle 40 50N m Bolt front and rear drive shafts 40 50N m Gearshift Unit Remove Left and right side panel Fuel tank t...

Page 42: ...ark plug cap get it earthed and check spark Normal spark Measure compression pressure No Fuel Weak spark or No spark Low or no Compression No fuel in fuel tank Clogged fuel hose Clogged float valve Cl...

Page 43: ...pressure with pressure meter Weak spark or No spark Low or no compression Faulty spark plug or stained spark plug Faulty Ignition coil Faulty high tension coil or short circuit Faulty ignition switch...

Page 44: ...r Engine speed rises Check ignition timing Incorrect Faulty pickup coil Faulty CDI unit Correct Measure compression pressure with pressure meter Normal compression pressure Low or no Compression Press...

Page 45: ...move spark plug and mount it to spark plug cap get it earthed and check spark Normal spark Remove fuel enrichment device wire lead and check continuity Normal Continuity Connect fuel enrichment device...

Page 46: ...unit Correct check carburetor Clogged Clean Normal Remove fuel enrichment device wire lead and check continuity Normal continuity Connect fuel enrichment device wire lead with No continuity Broken sta...

Page 47: ...es highlighted by these signal words Warning Indicates a potential hazard that could result in injury or death Caution indicates a potential hazard that could be result in vehicle damage Note provides...

Page 48: ...ER 3 ENGINE PAGE 3 15 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...

Page 49: ...r leakages after repairing fuel cooling lubricating or exhaust system Do not dispose used oil coolant or defective parts optionally for environmental purpose CAUTION Use genuine LINHAI MOTO parts or t...

Page 50: ...on DO NOT mix coolant with that of other engines BREAK IN PROCEDURES During manufacturing only the best possible material are used and all machined parts are finished to a very high standard It is sti...

Page 51: ...CHAPTER 3 ENGINE LH500ATV D T3 EFI SERVICE MANUA 19 0 CHAPTER 3 ENGINE PAGE 3 18 Engine Exterior and Engine No...

Page 52: ...r Gasoline RQ 90 9 Valve System Valve Type SOHC Chain Drive 10 Lubrication System Lubrication Type Pressure Splash Oil Pump Rotor Type Filter Type Full Flow Filter Screen Oil Type SAE10W 50 SN 11 Cool...

Page 53: ...EX 0 5 Play of Valve Head Seal IN EX 0 03 Width of Valve Seat Seal IN EX 0 9 1 1 Valve Spring Free Length IN EX 40 38 8 Valve Spring Tension IN EX 182 210N when compressed to 31 5mm Cam Height IN 33...

Page 54: ...Ring 0 97 0 99 2ND Ring 1 17 1 19 Piston Ring Groove Width Top Ring 1 03 1 05 2ND Ring 1 22 1 24 Oil Ring 2 51 2 53 Inner Diameter of Piston Pin Hole 23 002 23 008 23 030 Outer Diameter of Piston Pin...

Page 55: ...16 2 Functioning Temperature of Thermoswitch OFF ON 88 ON OFF 82 Coolant Type 35 antifreeze corrosion resistant high boiling point coolant Item Standard Service Limit Remark Clutch Plate Inner diamete...

Page 56: ...5000r min Regulated Voltage 13 5V 15 0V 5000r min Primary Peak Voltage of Ignition Coil 150W Starter Relay Coil Resistance 120W Starter Relay Coil Resistance 3 5 Auxiliary Starter Relay Coil Resistan...

Page 57: ...ut Driven Bevel Gear 1 M16 1 5 150 Fixing Nut Clutch 1 M18 1 5 70 Counter Clockwise Limit Nut Drive Bevel Gear Bearing 1 M60 110 Apply Thread Locker Nut Universal Joint Yoke 1 M55 80 Counter Clockwise...

Page 58: ...lt Oil Starter Motor 2 M6 10 Bolt Cylinder Head 4 M10 42 Bolt Cylinder Head 2 M6 10 1 M8 25 Bolt Cylinder Upper Lower 4 M6 10 Bolt Cylinder Head Cover 12 M6 10 Bolt Chain Tensioner 2 M6 10 Bolt Chain...

Page 59: ...Gauge For measuring the clearance 12 Spring Balance For measuring the spring tension 13 Tachometer For measuring engine speed 14 Oil Pressure Gauge For measuring oil pressure 15 Compression Gauge Ada...

Page 60: ...nkcase 8 Crankshaft Installation Set For installing crankshaft to left crankshaft 9 Valve Spring Compressor For removal and installation of valve spring 10 Valve Seat Cutter For valve seating 11 Ring...

Page 61: ...ubricating Grease 3 MoS2 Lithium Base Grease Oil seal lip O ring and sealing faces of other rubber seal materials bearings with seals CVT bearing and collar Coolant 35 antifreeze corrosion resistant h...

Page 62: ...nance 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...

Page 63: ...rburetor I Replace every 4 years Clutch I Drive Belt I R Engine Oil R R Oil Filter R R Coolant Level I I I Water Hose Pipes I I I Coolant Replace every 2 years Periodic Maintenance Table The table bel...

Page 64: ...y Remove cover Remove inspection cap on left crankcase Remove 2 valve adjusting cover Turn the crankshaft until the line of T D C on rotor is aligned with mark of inspection hole on left crankcase Ins...

Page 65: ...CHAPTER 3 ENGINE LH500ATV D T3 EFI SERVICE MANUA 19 0 CHAPTER 3 ENGINE PAGE 3 32...

Page 66: ...ENGINE IDLE SPEED Inspect initially at 20 hours run in and every 40 hours or 1000km thereafter Start the engine and warm it up for several minutes measure engine speed with a tachometer Set the engine...

Page 67: ...auge Air Filter Inspect every 40 hours or 1000 km clean it if necessary If the air cleaner is clogged with dust intake resistance will be increased with a resultant decrease in power output and an inc...

Page 68: ...h torn element Make sure that the air filter element is in good condition at all times Remove the drain plug of air box to drain out any water Fuel Hose Inspect every 80 hours or 2000 km replace every...

Page 69: ...e between secondary sliding sheave and primary fixed sheave Hold secondary sheave with a special tool and tighten the nut to the specified torque Nut Secondary Sheave 115 N m Install primary sheave an...

Page 70: ...not tighten it Take out oil dip rod and check if oil is between upper and lower limit If the engine oil is insufficient fill more oil until the sufficient oil is obtained Engine Oil SAE10W 50SN Note...

Page 71: ...oil should be changed when the engine is warm If the oil filter should be replaced replace engine oil at the same time Replacing Oil Filter Remove relative parts see Replacing Engine Oil Remove oil f...

Page 72: ...quid or vapor Engine coolant is harmful If coolant splashes in your eyes or clothes thoroughly wash it away with water and consult a doctor If coolant is swallowed induce vomiting and get immediate me...

Page 73: ...linder Wear of piston or piston ring Piston ring jam in groove Poor closure of valve seat Damaged cylinder gasket or other defects Note When cylinder pressure too low check the above items Testing Cyl...

Page 74: ...Combination of above items Oil pressure is too high Oil viscosity is too high Clogged oil passage Combination of above items Testing Oil Pressure Install hose and hose Connect tachometer with ignition...

Page 75: ...n 2400r min If the engagement speed is out of the above range check the following Clutch shoes Clutch shoe wheel Primary and secondary sheave Refer to Chapter 12 for inspection of clutch II Clutch Loc...

Page 76: ...15 48 15 59 Oil Pump Sprocket and Chain 15 8 15 59 Engine Right Side CVT Cover 15 9 15 51 15 58 Drive Belt 15 9 15 36 15 57 Primary Sheave Secondary Sheave 15 9 15 30 15 57 CVT Housing Clutch Outer F...

Page 77: ...l 11 8 Drain up coolant 11 10 Engine Periphery Water Hose Pipe Remove water hose clamp and Remove water hose Remove screw and water hose Left Side Cover Remove 4 bolts M6X12 of left side cover Remove...

Page 78: ...bolts of cylinder head cover Remove cylinder head cover Timing Chain Tensioner Remove screw plug insert a flat screwdriver into slot of timing chain tensioner adjuster turn it clockwise to lock tensio...

Page 79: ...e 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 cylind...

Page 80: ...case Piston Remove piston pin circlip with long nosed pliers Note Put a clean rag under piston so as not to drop piston pin circlip into crankcase Remove piston pin and piston Notes When installing pi...

Page 81: ...er Remove 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 d...

Page 82: ...ump Remove water pump SPLINED SPACER MODEL1 Remove bolt and washer Remove splined spacer Left Crankcase Cover Remove bolts Remove left crankcase cover Remove dowel pin and gasket Magneto Rotor Install...

Page 83: ...3 ENGINE LH500ATV D T3 EFI SERVICE MANUA 19 0 CHAPTER 3 ENGINE PAGE 3 50 Remove left crankcase cover 1 MODEL2 Remove nut nstall special tool to rotor thread Remove rotor and woodruff key Tool Rotor R...

Page 84: ...ENGINE PAGE 3 51 Starting Motor Gear Remove driven gear and needle bearing Remove spacer Remove dual gear and shaft Remove idle gear and shaft Oil Pump Sprocket and Chain Remove drive sprocket nut Rem...

Page 85: ...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 Re...

Page 86: ...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 R...

Page 87: ...ht 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...

Page 88: ...55 Remove Oil seal Bearing limit nut Remove Bearing Front Output Shaft Shift Cam Fork Shaft Remove Shift Cam Fork Shaft Drive Bevel Gear Remove left crankcase from driven bevel gear Drive Shaft Drive...

Page 89: ...E LH500ATV D T3 EFI SERVICE MANUA 19 0 CHAPTER 3 ENGINE PAGE 3 56 Crankshaft Separate crankshaft from left crankcase with special tool Tool Crankshaft Separator Oil bump Relief Valve Remove oil bump a...

Page 90: ...m shaft bolts A Remove rocker arm shaft by using M6 bolts B Cylinder Head Cover Distortion Clean off sealant from the fitting surface of cylinder head cover place cylinder head cover on a surface plat...

Page 91: ...ar 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 Install rocker arms a...

Page 92: ...GINE PAGE 3 59 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 fro...

Page 93: ...valve lapper to hold the valve head The ring like dye impression on the valve face should be continuous without any break The width of the dye ring which is the visualized seat width should be within...

Page 94: ...ial run out as illustrated on the right Valve head Radial Run out out of range Replace Service Limit 0 03mm Tool Dial Gauge 1 100 Magnetic Stand V Block Valve Face Wear Check each valve face for wear...

Page 95: ...force to compress the spring to the specified length Valve spring tension out of range Replace Service Limit IN EX 182N 210N 31 5mm Tool Spring Scale Measure valve spring incline Spring incline out of...

Page 96: ...the two cotter halves to the stem end and release compressor to allow the cotter to wedge in between seat and stem Make sure that the rounded lip of the cotter fits into the groove in the stem end Too...

Page 97: ...he 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 pro...

Page 98: ...urnal Wear Check whether each journal is worn to the limit by measuring camshaft journal oil clearance with the camshaft installed Camshaft journal oil clearance Service limit 0 15mm Check according t...

Page 99: ...0mm Other end 17 466mm 17 484mm Tool micrometer 0 25mm Camshaft Run out Measure the run out with a micrometer Replace camshaft is the run out is out of range Service limit 0 10mm Timing Sprocket and C...

Page 100: ...chain tensioner with a new one Cylinder Cylinder Distortion Check the gasket face of cylinder for distortion with a straightedge and thickness gauge and take clearance readings at 7 points as illustra...

Page 101: ...clearance according to the above measurement If the clearance is more than 0 15mm replace the cylinder or piston or both Piston Ring to Groove Clearance Use a thickness gauge to measure the side clea...

Page 102: ...ton ring Piston ring free end gap limit Top ring 8 9mm 2nd ring 9 5mm Piston ring end gap limit Top Ring 0 60mm 2nd ring 0 60mm Tool Vernier caliper Thickness gauge Piston Pin and Pin Bore Use a bore...

Page 103: ...od is also applicable to check and inspection of big end Connecting Rod Deflection 3 0mm Tools Dial Gauge Magnetic stand V block Connecting Rod Big End Side Clearance Push the big end to one side and...

Page 104: ...lutch should be replaced as a set Clutch Wheel Check the inner clutch wheel for scratches scuffs or blue discoloration or uneven wear If any damage is found replace the clutch wheel with a new one Che...

Page 105: ...CHAPTER 3 ENGINE LH500ATV D T3 EFI SERVICE MANUA 19 0 CHAPTER 3 ENGINE PAGE 3 72 Primary and Secondary Sheave...

Page 106: ...ary Sliding Sheave Disassembly Remove spacer Remove Cam and Roller Roller Check each roller and sliding face for wear and damage Wear and damage Replace Note rollers should be replaced as a set Oil Se...

Page 107: ...removal procedure of primary sliding and fixed sheave for installation Pay attention to the following Apply grease to inner bore and oil seal lip Note Wipe off any excessive grease thoroughly Take ca...

Page 108: ...spring compressor Tool Nut Wrench Sheave Holder Attach special tool to the secondary sliding sheave and compress it by turning in the tool handle Note Make sure that spring end A is inserted into slo...

Page 109: ...MANUA 19 0 CHAPTER 3 ENGINE PAGE 3 76 Remove spring Remove spring seat Remove guide pin and spacer Remove secondary sliding sheave O ring and Oil Seal Check the O ring and oil seal for wear and damag...

Page 110: ...r 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 cond...

Page 111: ...bly 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 Insert spring end into the hole Compress spring with special tool Align...

Page 112: ...g 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 Check belt width with vernier caliper Damage w...

Page 113: ...RANGE 1 2 SHIFT CAM 1 11 DRIVEN GEAR LOW RANGE 1 3 RIGHT CRANKCASE 1 12 SPRING SHIFT FORK 1 4 LEFT CRANKCASE 1 13 RIGHT SHIFT FORK 1 5 DRIVEN SECTOR GEAR 1 14 GUIDE BAR 1 6 SPROCKET REVERSE GEAR 1 15...

Page 114: ...rocket 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 Check ea...

Page 115: ...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 verni...

Page 116: ...ce Check shift cam groove for scratches damage Scratch or damage Replace Assembly Reverse the removal procedure for assembly Pay attention to the following Use new retainers Pay attention to the direc...

Page 117: ...OIL PUMP Disassembly oil pump as illustrated 1 Oil pump housing 2 Dowel pin 3 Oil pump shaft 4 Straight pin 5 Inner rotor oil pump 6 Outer rotor oil pump 7 Oil pump cover Check oil pump housing and c...

Page 118: ...oosen drive bevel gear nut 3 remove the drive bevel gear 4 and adjust washer 5 Check the drive bevel gear 4 and output driven gear 2 Output driven gear 6 Drive bevel gear shaft 3 Drive bevel gear nut...

Page 119: ...press out driven bevel gear Place a clean rag under bevel gear cover Remove bearing limit nut 10 with special tool and remove bearing Check driven bevel gear 8 surface for scratches wear Scratch or w...

Page 120: ...driven gears to the crankcase Wrap a screwdriver with a rag and insert it into the speed sensor hole of left crankcase to fix the drive bevel gear Install special tool and micrometer Tool Bevel gear s...

Page 121: ...turns in both directions Remove drive and driven bevel gear shafts and check the coated teeth of the drive bevel gear Refer to the illustration on the right for tooth contact pattern and Incorrect co...

Page 122: ...GINE PAGE 3 89 Balancer Shaft Remove the parts as illustrated on the right Check each part for abnormal wear or damage Wear or damage Replace Balancer shaft gear Woodruff key Balancer shaft Balancer s...

Page 123: ...e Apply engine oil to starter clutch Apply thread locker to bolt and tighten to the specified torque Tightening torque of starter clutch bolt 30N m Material Thread Locker Install the starter driven ge...

Page 124: ...burn or short circuit if any replace with new one Check bearing 4 for smooth turning If it is stuck replace with a new one Check oil seal 5 for damage Replace it if it s damaged Apply thread locker t...

Page 125: ...Note Use a new oil seal Install oil seal limitator and tighten screw after applying thread locker Tool Bearing Remover Oil Seal Remover Bearing Installer CVT Case Check bearing 5 for smooth turning I...

Page 126: ...7 Oil Drainage Bolt Clean and grease the bearings turn the inner race of bearing and check the play noise and smooth turning In case of any abnormal remove bearing with special tool and replace Check...

Page 127: ...Drain bolt tightening torque 30N m Tool Bearing Remover Bearing Installer Multimeter III Engine Assembly Reverse the engine removal procedure for installation Caution Clean all the parts before assem...

Page 128: ...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 Caut...

Page 129: ...y adequate engine oil to each part Drive Bevel Gear Install drive bevel gear and tighten to the specified torque Drive bevel gear tightening torque 32N m Material Thread Locker Right Crankcase Driven...

Page 130: ...erly fitted Install bolt and tighten to the specified torque Crankcase bolt tightening torque M6 10N m M8 25N m Note Crankcase bolts should be tightened diagonally in several steps Place the steel bal...

Page 131: ...l CVT case assembly to right crankcase Install bolt and nut Note Tighten bolt nut diagonally Use a new gasket Install air guide plate and screw Primary Sheave Secondary Sheave Drive Belt Install prima...

Page 132: ...ed torque Primary sheave nut tightening torque 115 N m Tool Rotor Holder Tighten secondary sheave nut with special tool to the specified torque Secondary sheave tightening torque 115 N m Tool Rotor Ho...

Page 133: ...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 L...

Page 134: ...LH500ATV D T3 EFI SERVICE MANUA 19 0 CHAPTER 3 ENGINE PAGE 3 101 Install starting driven gear Magneto Rotor MODEL1 Install Splined Spacer 1 Install Bolt Bolt tightening torque 60N m 2 Remove Bolt Remo...

Page 135: ...over Install dowel pin2 and gasket 3 Note Use a new gasket Apply Lubricant grease to oil sea lip Install left crankcase cover 1 Install bolts Install Splined Spacer 2 Install Bolt Bolt tightening torq...

Page 136: ...CHAPTER 3 ENGINE LH500ATV D T3 EFI SERVICE MANUA 19 0 CHAPTER 3 ENGINE PAGE 3 103 Install left crankcase cover 1 Install end cap 2...

Page 137: ...il 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 4 driven sector gear 5 driven sec...

Page 138: ...ecified torque Tool Oil Filter Wrench Starting Motor Apply engine oil to new O ring Install starting motor Install bolt and tighten to the specified torque Tightening torque 10N m Engine Top Side Pist...

Page 139: ...r check that the gaps are so located Apply a light coat of moly oil to the piston pin Install piston pin into holes of piston and conrod small end Note When installing the piston the IN mark on piston...

Page 140: ...ht between sprocket and crankcase Install chain guide Fit the dowel pin and new cylinder cover gasket Note Use a new cylinder cover gasket to prevent oil leakage Cylinder Head Install the cylinder cov...

Page 141: ...ill be caught between sprocket and crankcase Align the mark A on the camshaft so that they are parallel with the mating surface of the cylinder head Note Do not rotate the magneto rotor while doing th...

Page 142: ...que 15 N m Bend up the lock washer to lock the bolts Cylinder Head Cover Clean the mating surface of cylinder head and cylinder head cover Install dowel pin to the cylinder head Apply sealant to the m...

Page 143: ...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 t...

Page 144: ...d apply grease Install Valve Inspection Cap Install valve inspection cap bolt Spark Plug Install spark plug with special tool and tighten to the specified torque Note To avoid damage to the cylinder h...

Page 145: ...CHAPTER 3 ENGINE LH500ATV D T3 EFI SERVICE MANUA 19 0 CHAPTER 3 ENGINE PAGE 3 112 Water Pipe and Hose Install water hose 5 Install bolt 4 Install water hose 3 Install clamp 1 and 2...

Page 146: ...SERVICE MANUA 19 0 CHAPTER 3 ENGINE PAGE 3 113 3 6 1 Carburetor Carburetor Removal 3 6 1 1 Inspection 3 6 1 2 Measurement and Adjustment 3 6 1 3 Carburetor Assembly 3 6 1 4 Carburetor Installation 3 6...

Page 147: ...Vacuum Chamber Cover 1 11 Float Chamber 1 3 Spring 1 12 Float 1 4 Jet Needle Holder 1 13 Needle Valve Set 1 5 Spring 1 14 Main Jet MJ 1 6 Jet Needle Set 1 15 Needle Jet NJ 1 7 Vacuum Diaphragm 1 16 Pi...

Page 148: ...these parts Check float float tang for damage Damage Replace Check valve seat needle valve O ring for damage abnormal wear or dirt Damage or wear or dirty Replace Note Valve set needle valve should b...

Page 149: ...ds Wear or bends Replace Check above jets for clog Blow out the jets with compressed air Insert piston valve into carburetor body and check the free movement Check free movement of throttle valve Repl...

Page 150: ...retor on a level surface Connect fuel level gauge with drain pipe Tool Fuel Level Gauge Loosen drain screw Keep fuel level gauge vertical next to the float chamber line and read the fuel level a Fuel...

Page 151: ...lter carburetor Note Align the installation mark of carburetor and carburetor joint 6 Carburetor Parameters Type Aperture No MIKUNI BSR36 129 07G0 Throat size Pilot Float height Fuel level Main jet Ma...

Page 152: ...cement Techniques 3 6 2 2 12Interchange ability 3 6 2 2 13Plugging 3 6 2 2 14Cleaning Procedure 3 6 2 3 Throttle Body As sembly with stepper motor 3 6 2 3 1 Description and Working Principle 3 6 2 3 2...

Page 153: ...Fuel Module 3 6 2 8 3 Dimensions 3 6 2 8 4 Identification and Markings 3 6 2 8 5 Operating Conditions 3 6 2 8 6 Service Procedure 3 6 2 8 7 Fuel Module Diagnosis 3 6 2 8 8 Fuel Module Removal 3 6 2 8...

Page 154: ...or other debris to accumulate on the surface of the ECU Having mud or debris accumulated on the ECU casing reduces its heat dissipation efficiency DO NOT Apply any voltage relative to any point to the...

Page 155: ...red for longer time without damage Operating The controller shall operate in the ambient temperature from 20 C to 85 C 3 6 2 1 7 Maintenance service and Repair ECU is a non serviceable part Once there...

Page 156: ...seal on the injector top flange 3 6 2 2 4 Lubricant Recommendation Lubrication should be applied to the O rings only for ease of injector installation The table 4 is a list of lubricant oils that wer...

Page 157: ...hecks Can damage injectors DO NOT Contact or apply load to the injector tip for installation Apply load to 45 deg angle on nylon over mold see DO NOT Pound injectors into manifold during assembly to e...

Page 158: ...n minor defects in the seal ring can lead to leakage Take extra care in installing seal ring over flange of injector inlet Carefully installing the harness connector will prevent terminal damage Liste...

Page 159: ...and must be controlled by the fuel supplier Increased levels of detergent additives reduce the rate of injector plugging Incase of plugging of injector follow the injector cleaning procedure mentione...

Page 160: ...g voltage 7 5 14 2 VDC Solenoid resistance 53 10 Solenoid inductance 33mH 20 3 6 2 3 4 Operating Conditions Normal Operating Temperature 30 120 C 3 6 2 3 5 Throttle Body Removal Disconnect negative te...

Page 161: ...maged or suspect material with a tag that describes the problem Only warranty cases Ensure fast and correct diagnosis of root cause DO Remove and discard protective caps just before assembling mating...

Page 162: ...withstand such an under hood environment Normal Operating Temperature 40 C 135 C continuously Relative Humidity 0 to 100 RH Typical Pressure When installed at the minimum torque the sensor shall be ca...

Page 163: ...mperature Range 40 105 C Relative Humidity 0 to 100 RH Extreme Operating Environment Maximum temperature excursion to 125 C for 2 hours 3 6 2 5 4 Storage Environment Storage temperature 50 C to 150 C...

Page 164: ...mperature range 260 850 C 3 6 2 6 4 Fuel Quality Requirements Pb 0 005g L P 0 0002g L S 0 04 weight proportion x MMT 0 0085g L Si 4ppm 3 6 2 7 Ignition Coil 3 6 2 7 1Description and Working Principle...

Page 165: ...ith a tool or other object This can lead to physical damage which can cause a system malfunction or failure DO NOT Permit paint or other sprayed materials to be sprayed onto the electrical connectors...

Page 166: ...DO The electrical wiring to the ignition system should be routed so that the conductors are protected from excessive heat damage and wear Helps prevent electrical intermittent open or shorted operatin...

Page 167: ...and spark plug threads are clean Make sure the spark plug thread is free of dings and burrs If necessary use a thread chaser and seat cleaning tool 2 Make sure the spark plug gasket seat is clean then...

Page 168: ...e label available on fuel module cover On Fuel Pump Batch code is engraved on pump body shell On Fuel Pressure Regulator batch code is engraved on regulator dome area 3 6 2 8 5 Operating Conditions Fu...

Page 169: ...or disconnecting fuel line will cause dangerous spout of fuel Before loosening disconnecting fuel lines please follow the Fuel Pressure Relief Procedure described in this section Small amount of fuel...

Page 170: ...o the Fuel Pressure Relief Procedure provided in this section Disconnect negative cable at battery Disconnect fuel module wire coupler Drain the fuel in fuel tank thru fuel filler with help of hand pu...

Page 171: ...gger diameter the other is smaller diameter are assembled in pressure regulator Place the pressure regulator on module at regulator pod Push the regulator gently in the pod Do not hit damage on the re...

Page 172: ...icing fuel module Damaged terminals will cause intermittent No contact for power supply DO NOT Force hand pump towards fuel module while draining fuel from tank To avoid any damages on fuel module DO...

Page 173: ...ectrical signals that exceed the limit of specifications Test cannot be performed by the person who is driving the car This unit should be used and stored in the following conditions Ambient temperatu...

Page 174: ...gnostic socket on the motor Connect one end of the diagnostic main cable to the main unit and the other end to diagnostic socket on the motor tighten the screws Normal Powe r on Display When power is...

Page 175: ...below Select English and press key it will display information about the diagnostic software version press to continue the interface will display as below Diagnostic Function Here we take diagnostic...

Page 176: ...Data Stream Status Stream Record Data Press or key to select function you needed 1 Read DTC Select Read DTC and press it will display fault code as below Press or key to move icon and select fault cod...

Page 177: ...Press key to exit 5 Record Data Select Record Data and press it will display Press or key to enter code when the first number of the code was set press to confirm and continue to input the sequent nu...

Page 178: ...ay to enter month as vehicle code input Month was input then enter date as below Then Enter Year continues as below After that Enter Week follows as below Till now the date input was completed and it...

Page 179: ...igh Voltage P0131 O2A Circuit Low Voltage P0132 O2A Circuit High Voltage P0031 O2A Heater Circuit High Voltage P0032 O2A Heater Circuit Low Voltage P0201 Injector 1 Circuit Malfunction P0202 Injector...

Page 180: ...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...

Page 181: ...ly Keep coolant away from reach of children Inspection of Cooling Circuit Remove radiator cap and connect tester to filler Warning Do not open the radiator cap when the engine is still hot Give a pres...

Page 182: ...cannot meet the pressure requirement replace it Radiator Cap Valve Opening Pressure Standard 110 140 kPa Tool Radiator Cap Tester Radiator Inspection and Cleaning Remove dirt or trash from radiator wi...

Page 183: ...m Inspection of Thermoswitch Remove thermoswitch Check the thermoswitch for closing or opening by testing it at the bench as illustrated Connect the thermoswitch to the circuit tester place it in a ve...

Page 184: ...n a vessel with engine oil Place the vessel above a stove Heat the oil to raise the temperature slowly and take the reading from thermometer and ohmmeter Water Temperature and Resistance Installation...

Page 185: ...ng from thermometer when the thermostat valve opens Thermostat Valve Opening Temperature 68 74 Keep heating the water to raise the water temperature Just when the water temperature reaches the specifi...

Page 186: ...NE PAGE 3 153 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...

Page 187: ...not reuse a removed oil seal Remove bearing with special tool Note The bearing does not need to be removed if there is no abnormal noise Note Do not reuse a removed bearing Inspection of Water Pump Be...

Page 188: ...ge replace the oil seal Water Pump Body Check the mating mace of water pump body with bearing and mechanical seal Damage Replace Impeller Check the impeller and shaft for damage Damage Replace Assembl...

Page 189: ...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 mechan...

Page 190: ...g 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 turnin...

Page 191: ...NUA 19 0 CHAPTER 3 ENGINE PAGE 3 158 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 shaf...

Page 192: ...CHAPTER 3 ENGINE LH500ATV D T3 EFI SERVICE MANUA 19 0 CHAPTER 3 ENGINE PAGE 3 159...

Page 193: ...retor needle valve 4 Clogged fuel hose 5 Clogged fuel filter Transfer is not in Neutral position Replace Replace Replace Repair or Replace Tighten Check electrical part Adjust Adjust Clean or Replace...

Page 194: ...ace Replace Replace Engine lacks power 1 Improper valve clearance 2 Weak valve spring 3 Improper valve timing 4 Worn cylinder 5 Worn piston ring 6 Improper valve seating 7 Fouled spark plug 8 Improper...

Page 195: ...lty chain tensioner Replace chain sprocket Replace chain sprocket Repair or replace Noise from Clutch 1 Worn or damaged crankshaft spline 2 Worn inner race spline Replace crankshaft Replace inner race...

Page 196: ...er float height Clean Clean Clean Clean Adjust Adjust Adjust Medium or high speed trouble 1 Clogged main jet 2 Clogged main air jet 3 Clogged needle jet 4 Faulty throttle valve 5 Clogged fuel filter 6...

Page 197: ...coolant Check and replace Replace Replace Check and or replace Engine coolant overcools 1 Faulty thermoswitch 2 Extremely cold weather 3 Faulty thermostat Replace Put on radiator cover Replace Complai...

Page 198: ...CHAPTER 3 ENGINE LH500ATV D SERVICE MANUAL14 0 CHAPTER 3 ENGINE PAGE 3 165 NOTES...

Page 199: ...ts 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...

Page 200: ...E Tighten the nuts only finger tighten at this time They will be tightened to the final torque after the front wheels are installed and the vehicle is on the ground WARNING DO NOT reuse old bolts Seri...

Page 201: ...il spring and collapse strut body 5 Remove two pinch bolts from strut body 6 Remove strut body 7 Install front shock cartridge until bottomed in strut casting 8 Install pinch bolts with clamp s Torque...

Page 202: ...int mounting bracket 7 Using ball joint cup removal installation toolkit remove ball joint cup from strut housing Refer to photos at right Install puller guide 1 Thread bolt 2 with nut 3 onto bal join...

Page 203: ...5 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...

Page 204: ...CHAPTER 4 CHASSIS LH500ATV D T3 EFI SERVICE MANUAL 19 0 CHAPTER 4 CHASSIS PAGE 4 6 NOTES...

Page 205: ...h ATV model for spare parts information and service PLEASE SEE CHARPTER 4B IN THIS MANUAL FOR THE WHEEL HUB AND DRIVE CHAIN OF MINE YOUTH ATV 5 1 WHEEL HUB AND SPINDLE TORQUE TABLE 5 2 FRONT HUB DISAS...

Page 206: ...4x4 ATV500 1 Elevate front end and safely support machine under footrest frame area CAUTION Serious injury may result if machine tips or falls Be sure machine is secure before beginning this service...

Page 207: ...achine tips or falls Be sure machine is secure before beginning this service procedure Wear eye protection when removing bearings and seals 2 Check bearings for side play by grasping the tire Wheel fi...

Page 208: ...ication 5 Install a new cotter pin Tighten nut slightly if necessary to align cotter pin holes 6 Rotate wheel and check for smooth operation Bend both ends of cotter pin around end of Spindle in diffe...

Page 209: ...outer race only Once bearing is at bottom of casting support casting on outer edges so bearing can be removed 4 Inspect bearing NOTE Due to extremely close tolerances and minimal wear the bearings mu...

Page 210: ...5 Stopper ring 6 Outer CV joint 7 Circlip 8 Bearing 9 stopper ring 10 Inboard boot NOTE Always order and replace 6 and 8 together REMOVAL 1 Place the vehicle on level ground and set the parking brake...

Page 211: ...s described under the Disassembly Assembly procedure in this chapter 2 Move each end of the drive shaft in a circular motion and also a reciprocate for inner one and check the drive shaft joints for e...

Page 212: ...eplace 1 Open the clamps on both boot band A and B on the inner CV joint then remove boot band B Discard the boot band it cannot be reused 2 Carefully slide the boot A onto the drive axle and off the...

Page 213: ...sembly as no replacement parts are available 6 Clean the inner CV joint in solvent and thoroughly dry 7 Inspect the interior of the inboard joint where the steel balls ride Check for wear or damage an...

Page 214: ...time NOTE Position the new boot bands with their tabs facing toward the rear of the vehicle 3 Install 2 new small boot bands onto the drive axle 4 Install the inboard boot and move the small boot band...

Page 215: ...the inboard joint over the bearing assembly and install the stopper ring Make sure it is seated correctly in the inboard joint groove 11 After the stopper ring is in place fill the inboard joint cavit...

Page 216: ...t bands Bend down the tab on the boot band and secure the tab with the locking clip and tap them with a plastic hammer Make sure they are locked in place 18 If removed install the stopper ring and mak...

Page 217: ...olt 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 Discard hardwa...

Page 218: ...th removing steering knuckle 5 5 REAR GEAR CASE COMPONENT IDENTIFICATION REAR GEARCASE EXPLODED VIEW 1 DRIVE BEVEL GEAR ASSEMBLY RA 19 COUPLER REAR AXLE 2 REAR GEAR CASE 20 REAR GEAR CASE 3 1 ADJUST S...

Page 219: ...BEARING HOUSING 14 BEARING RETAINER 36 BEARING 16017 C2 15 BEVEL GEAR BEARING HOUSING 37 O RING 151 3 16 OIL SEAL 35 61 9 38 OIL SEAL 65 90 9 17 WASHER 12 5 30 4 39 GASKET 8 2 15 1 5 18 NUT M12 1 25...

Page 220: ...y G and the adjust shim H Fig 3 Fig 3 4 Remove the bevel gear driving the adjust shim J and the O ring K Remove the bearing retainer L with the special tool Remove the bearing M and the oil seal P fro...

Page 221: ...move the needle bearing V from the rear gear case S Fig 6 Fig 6 7 Remove the adjust shim W from the bevel gear comp driven X Remove the bevel gear comp driven X from the ring gear bearing housing T Re...

Page 222: ...neck of the bevel gear comp driven E Mount the bevel gear comp driven E in the bore of bearing A Mount the adjust shim F in the other neck of the bevel gear comp driven E Fig 2 Fig 2 3 Mount the needl...

Page 223: ...hole of the rear gear case G Fig 5 Fig 5 6 Mount the shaft neck of the bevel gear comp driven E in the suited hole of the needle bearing H Make the ring gear bearing housing C and the rear gear case G...

Page 224: ...O ring a into the groove of the ring gear bearing housing Z Mount the oil seal Y into the suited hole of the bevel gear bearing housing Z Fig 9 Fig 9 10 Mount the adjust shim b in the shaft neck of th...

Page 225: ...g Apply some Loctite 242 threadlocker on screw thread Tighten the nut M12 1 25 h to a torque of 50 60N m Fig 13 Fig 13 14 Mount the oil seal 65 90 9 j in the ring gear bearing housing C on the right...

Page 226: ...CHAPTER 5 FINAL DRIVE LH500ATV D T3 EFI SERVICE MANUAL 19 0 CHAPTER 5 FINAL DRIVE 5 22 5 8 FRONT GEAR CASE DISASSEMBLY FRONT GEARCASE EXPLODED VIEW...

Page 227: ...EW 31 NUT 6 PIN SHAFT 32 NUT WASHER 7 SHIFT FORK 33 O RING 8 GEAR CASE ASSY FRONT AXLE 34 NEEDLE BEARING 9 DRIVE CLUTCH 35 BOLT 10 ADJUST SHIM 36 WASHER 14 11 O RING 141 2 4 37 COUPLER 12 DIFFERENTIAL...

Page 228: ...HER 10 50 25 OIL SEAL 51 BEARING 6007 26 CASE COVER FRONT AXLE 52 WEARING RING 5 9 FRONT GEARCASE DISASSEMBLY Important Before staring any operation On the gearbox make sure GEAR MOTOR A is protected...

Page 229: ...RIVE LH500ATV D T3 EFI SERVICE MANUAL 19 0 CHAPTER 5 FINAL DRIVE 5 25 Fig 3 4 Remove the COUPLER A Fig 4 Fig 4 5 Remove the OIL SEAL A Fig 5 Fig 5 6 Remove the four SCREW A Fig 6 Fig 6 7 Remove the GE...

Page 230: ...L 19 0 CHAPTER 5 FINAL DRIVE 5 26 Fig 7 8 Remove the six bolts H M8 L28 Fig 8 Fig 8 9 Remove the GEAR CASE ASSY FRONT AXLE A and CASE COVER ASSY FRONT AXLE B Fig 9 Fig 9 10 Remove the DIFFERENTIAL GEA...

Page 231: ...D T3 EFI SERVICE MANUAL 19 0 CHAPTER 5 FINAL DRIVE 5 27 Fig 11 12 Remove the SCREW A Fig 12 Fig 12 13 Remove the PIN SHAFT A SHIFT FORK B Fig 13 Fig 13 14 Remove the DRIVE CLUTCH A Fig 14 Fig 14 15 R...

Page 232: ...NAL DRIVE LH500ATV D T3 EFI SERVICE MANUAL 19 0 CHAPTER 5 FINAL DRIVE 5 28 Fig 15 16 Remove the DRIVE CLUTCH COVER A Fig 16 Fig 16 17 Remove the ADJUST SHIM A Fig 17 Fig 17 18 Remove the OIL SEAL A Fi...

Page 233: ...AL 19 0 CHAPTER 5 FINAL DRIVE 5 29 19 Remove the BEARING RETAINER A with tool B Fig 19 Fig 19 20 Remove the DRIVE PINION GEAR A Fig 20 Fig 20 21 Remove the BEARING 61912 A Fig 21 Fig 21 22 Remove the...

Page 234: ...30 Fig 23 24 Remove the DRIVE GEAR A and WEARING RING B and GEAR CENTER DIFFERENTIAL C and GEAR SHAFT CENTER DIFFERENTIAL D and PIN E and BRACKET DIFFERENTIAL F Fig 24 Fig 24 25 Remove the DRIVEN GEA...

Page 235: ...CASE ASSEMBLY 1 Mount the the drive gear A and wearing ring B and gear center differential C and gear shaft center differential D and pin E and bracket differential F then mount pin T Fig 1 Fig 1 2 Pu...

Page 236: ...VE 5 32 3 Mount the differential gear assy then apply Loctite 263 evenly on the screw thread Tighten the six bolts A with the spring lock washer and the washer to a torque of 90 100Nm Fig 3 Fig 3 4 Mo...

Page 237: ...0ATV D T3 EFI SERVICE MANUAL 19 0 CHAPTER 5 FINAL DRIVE 5 33 6 Mount the drive clutch A Fig 6 Fig 6 7 Mount the pin shaft A and the shift fork B Fig 7 Fig 7 8 Mount the screw A Fig 8 Fig 8 9 Mount the...

Page 238: ...NUAL 19 0 CHAPTER 5 FINAL DRIVE 5 34 10 Mount the differential gear assy A to the gear case assy C do not forget put adjust shim I to the case cover assy B then make B and C together Fig 10 Fig 10 11...

Page 239: ...SERVICE MANUAL 19 0 CHAPTER 5 FINAL DRIVE 5 35 Fig 11 12 Mount the gear motor A Important Before assemble the gear motor make sure that the shift fork S is in their correct position as shown Fig 12 F...

Page 240: ...19 0 CHAPTER 5 FINAL DRIVE 5 36 Fig 13 14 Mount the oil seal A Fig 14 Fig 14 15 Mount the coupler A Fig 15 Fig 15 16 Mount the O ring A Fig 16 Fig 16 17 Apply some Loctite 263 thread locker on screw t...

Page 241: ...CHAPTER 5 FINAL DRIVE LH500ATV D T3 EFI SERVICE MANUAL 19 0 CHAPTER 5 FINAL DRIVE 5 37 Fig 17 Fig 1 NOTES...

Page 242: ...CHAPTER 5 FINAL DRIVE LH500ATV D SERVICE MANUAL 14 0 CHAPTER 5 FINAL DRIVE 5 38...

Page 243: ...NISHING 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 REMOVA...

Page 244: ...m 0 167 4 242mm Brake Disc Thickness Variance Between Measurements 0 002 0 051m m Brake Disc Run out 0 005 0 12 7m m 6 2 TORQUE Item Torque ft lbs except where noted Torque Nm Front Caliper Mounting B...

Page 245: ...pads are properly burnished To properly burnish the brake pads use the following procedure 1 Choose an area large enough to safely accelerate the ATV to 50 km h 30 mph and to brake to a stop 2 Using...

Page 246: ...at is farthest from the m aster cylinder Install a box end wrench on the caliper bleeder screw Attach a clean clear hose to the fitting and place the other end in a clean container Be sure the hose fi...

Page 247: ...on reservoir Master Cylinder Fluid Level MAX level or Sight glass must look dark if sight glass is clear fluid level is too low 13 Install diaphragm cover and screws Tighten screws to specification 14...

Page 248: ...wear If teeth or locking cam are worn replace lever and test the parking performance if any locking problem exists Replace the master cylinder as an assembly NOTE Mechanics parking brake is equipped...

Page 249: ...ston into caliper bore slowly using a C clamp or locking pliers with pads installed NOTE Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed...

Page 250: ...rn clockwise until stationary pad contacts disc then back off 1 2 turn counter clockwise 6 Install reservoir cap Hand and or Foot Brake Master Cylinder s Fluid Level Between MIN and MAX lines 7 Instal...

Page 251: ...needed contact the ATV manufacture via the agent for the parts and special instruction REMOVAL 1 Remove wheel remove caliper from the strut 2 Loosen and remove brake hose s to caliper Place a containe...

Page 252: ...nto caliper bore slowly with pads installed NOTE Brake fluid will be forced through compensating port into m aster cylinder fluid reservoir when piston is pushed back into caliper Remove excess fluid...

Page 253: ...Clean caliper area 2 Using a flare nut wrench remove hose s Place a container to catch brake fluid draining from brake hose 3 Remove caliper 4 Remove brake pad as described above 5 Inspect surface of...

Page 254: ...g a 0 1 micrometer and a dial indicator Replace disc if worn beyond service limit Brake Disc Thickness New0 177 0 187 4 496 4 750mm Service Lim it 0 167 4 242 mm Brake Disc Thickness Variance Service...

Page 255: ...AGE 6 13 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...

Page 256: ...CHAPTER 6 BRAKES LH500ATV D T3 EFI SERVICE MANUAL 19 0 CHAPTER 6 BRAKES PAGE 6 14 NOTES...

Page 257: ...CHAPTER 6 BRAKES LH500ATV D T3 EFI SERVICE MANUAL 19 0 CHAPTER 6 BRAKES PAGE 6 14...

Page 258: ...N AND SERVICE 7 2 BATTERY 7 3 IGNITION SYSTEM 7 4 CHARGING SYSTEM 7 5 ELECTRICS STARTING SYSTEM 7 6 COOLING SYSTEM 7 7 LIGHTING SYSTEM 7 8 GEAR SHIFT SWITCH TEST 7 9 SPEEDOMETER SYSTEM 7 10 MAIN SWITC...

Page 259: ...level surface with the headlight approximately 25 7 6m from a wall 3 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 4 Start the engi...

Page 260: ...e battery Never add electrolyte after a battery has been in service NOTE New Battery must be fully charged before use 1 Remove vent plug from vent fitting 2 Fill battery with electrolyte to upper leve...

Page 261: ...stems the battery should be checked first Following are three tests which can easily be made on a battery to determine its condition OCV Test Specific Gravity Test and Load Test MF Maintenance Free ba...

Page 262: ...y Terminal board or connections wet corroded Poor ignition coil ground e g coil mount loose or corroded Faulty stator measure resistance of all ignition related windings Incorrect wiring inspect color...

Page 263: ...ion spark gap 5 Spark plug cap resistance 6 Ignition coil 1 Fuse NO CONTINUITY Check switches Replace the fuse CONTINUITY 2 Battery INCORRECT Clean battery terminals Recharge or replace the battery Ch...

Page 264: ...pushing the starter switch and increase the spark gap until a misfire occurs The ignition system is not faulty Minimum spark gap 6mm 0 24 in OUT OF SPECIFICATION OR NO SPARK 5 Spark plug cable resist...

Page 265: ...ition coil Check if the primary coil has the specified resistance Tester lead B Y Terminal Tester lead Green Terminal Primary coil resistance 3 6 4 8 20 Tester lead Spark plug lead Tester lead Green T...

Page 266: ...ter lead BI Y Terminal Tester lead B R Terminal Check the pickup coil has the specified resistance OUT OF SPECIFICATION Replace the pickup coil Primary coil resistance 115 145 20 MEETS SPECIFICATIO N...

Page 267: ...r with the engine running Damage will occur to light bulbs and speed limiter Connect an ammeter in series with the negative battery cable Check for current draw with the key off if the draw is excessi...

Page 268: ...RY INSPECTION INCORRECT Clean battery terminals Recharge or replace the battery 3 Charging voltage Connect the engine tachometer to the spark plug lead Connect the pocket tester DC20V to the battery T...

Page 269: ...ect the pocket tester X1 to the stator coil Tester lead yellow terminal Tester lead yellow terminal Measure the stator coil resistance Stator coil resistance 0 5 0 8 20 OUT OF SPECITICATION Replace th...

Page 270: ...CHAPTER 8 ELECTRICAL 500ATV T3 EFI SERVICE MANUAL 16 0 CHAPTER 7 ELECTRICAL CTRICAL PAGE 7 13 7 5 ELECTRICS STARTING SYSTEM DIAGRAM...

Page 271: ...relay 5 main switch 6 front rear brake switch 7 starter switch 8 wiring connection entire starting system 1 fuse refer to CHECKING SWITCHES section NO CONTINUITY Replace the fuse 2 Battery Check the b...

Page 272: ...starter relay for continuity Test lead terminal Test lead terminal WARNING A wire used as a jumper lead must have the equivalent capacity as that of the battery lead or more otherwise it may burn Thi...

Page 273: ...EFI SERVICE MANUAL 16 0 CHAPTER 7 ELECTRICAL CTRICAL PAGE 7 16 Replace the handlebar switch 8 Wiring connection Check the connections of the entire starting system Refer to CIRCUIT DIAGRAM POOR CONNEC...

Page 274: ...oling system 1 fuse CHECK SWITCHES NO CONTINUITY Replace the fuse 2 Battery Check the battery condition Refer to BATTERY INSPECTION section INCORRECT Clean battery terminals Recharge or replace the ba...

Page 275: ...Remove the thermo switch from the radiator Connect the pocket tester X1 to the thermo switch Immerse the thermo switch in the water Check the thermo switch for continuity NOTE Measure temperatures wh...

Page 276: ...ooling system Refer to CIRCUIT DIAGRAM UPPER CONNECTION 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 t...

Page 277: ...o unit Drain the coolant and remove the thermo unit from the cylinder head Immerse the thermo unit in the coolant Thermometer Handle the thermo unit with special care Never subject it to strong shocks...

Page 278: ...Tester lead Green ground Turn the main switch to on Check for voltage 12V on the temperature gauge lead OUT OF SPECIFICATION The wiring circuit from main switch to temperature gauge is faulty Repair...

Page 279: ...CHAPTER 8 ELECTRICAL 500ATV T3 EFI SERVICE MANUAL 16 0 CHAPTER 7 ELECTRICAL CTRICAL PAGE 7 22 7 7 LIGHTING SYSTEM...

Page 280: ...e refer to CHECKING SWITCHES section NO CONTINUITY Replace the fuse 2 Battery Check the battery condition Refer to BATTERY INSPECTION section in CHAPTER 3 INCORRECT Clean battery terminals Recharge or...

Page 281: ...TCHES NO CONTINUITY Replace the bulb and or bulb socket 2 Voltage Connect the pocket tester DC20V to the headlight and high beam indicator light couplers A When the dimmer switch is on low beam B When...

Page 282: ...and or bulb socket CONTINUITY 2 Voltage Connect the pocket tester DC20V to the bulb socket connector Tester lead Black terminal Tester lead Green terminal Turn the main switch to on Turn the lights sw...

Page 283: ...CHAPTER 8 ELECTRICAL 500ATV T3 EFI SERVICE MANUAL 16 0 CHAPTER 7 ELECTRICAL CTRICAL PAGE 7 26 7 8 GEAR SHIFT SWITCH TEST DIAGRAM...

Page 284: ...CHAPTER 8 ELECTRICAL 500ATV T3 EFI SERVICE MANUAL 16 0 CHAPTER 7 ELECTRICAL CTRICAL PAGE 7 27 Switch table...

Page 285: ...asure speed angle revolution and length etc by means of voltage pulse signals converted from sensing gear ratio of black metal gear or gear rack B Main Technical Parameter for sensor Item Code Vol val...

Page 286: ...ature 10 65 Battery warning voltage 11 5V V LCD Meter 1 Neutral indicator light 10 Engineworkinghour counter 2 High beam indicator light 11 2WD 4WD indicator 3 Turn indicator light A km mile selector...

Page 287: ...CHAPTER 8 ELECTRICAL 500ATV T3 EFI SERVICE MANUAL 16 0 CHAPTER 7 ELECTRICAL CTRICAL PAGE 7 30 7 10 MAIN SWITCH AND HANDLE SWITCH...

Page 288: ...r from the fuel tank 2 Measure the resistance with an ohmmeter across the sensor terminal and its body 3 If the reference values are not indicated the sensor is faulty Float at upper most position A 4...

Page 289: ...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 mecha...

Page 290: ...CHAPTER 8 ELECTRICAL 500ATV T3 EFI SERVICE MANUAL 16 0 CHAPTER 7 ELECTRICAL CTRICAL PAGE 7 33 7 13 WIRING DIAGR...

Page 291: ...ATV SERVICE MANUAL EUROPE 19 0 PN F010106A26 LH500ATV DT3 EFI 19 0 F010106A26...

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