Linhai Crossfire E5 2022 Service Manual Download

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SERVICE MANUAL

19.1

LH50DU

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.

※

General Information

※

Maintenance

※

Electrical

※

Chassis

※

Final Drive

※

Brakes

Summary of Contents for Crossfire E5 2022

Page 1: ...ent 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 General Informat...

Page 2: ...LH50DU SERVICE MANUAL 19 1 LH50DU 19 1...

Page 3: ...ig nificant changes in specifications or procedures will be forwarded to all authorized Linhai dealers and will appear in future editions of this manual where applicable NOTE Designs and specification...

Page 4: ...CONTENTS CHAPTER1 General Information CHAPTER2 Maintenance CHAPTER3 Chassis CHAPTER4 Final Drive CHAPTER5 Brakes CHAPTER6 Electrical...

Page 5: ...s It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Always keep alert and wear protection Crate of the UTV and parts in the UTV maybe have sharp edge always pa...

Page 6: ...1 GENERAL INFORMATION The parts of different types variants versions maybe un interchangeable even some parts have almost same appearance Always refer to Parts Manual of each CUV model for spare parts...

Page 7: ...ded oil and grease for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality LOCK WASHERS PLATES AND COTTER PINS Replace all lock washers plates and cotte...

Page 8: ...d reinset the terminal into the connector 6 Connect Connector NOTE The two connectors click together 7 Check for continuity with a tester NOTE If there is no continuity clean the terminals Be sure to...

Page 9: ...SION 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 0 621...

Page 10: ...CHAPTER 1 GENERALINFORMATION LH50DU SERVICE MANUAL 19 1 CHAPTER 1 GENERAL PAGE 1 5 1 2 V I N NUMBER The vehicle identification number is stamped 1 into the front of the frame tube...

Page 11: ...CHAPTER 1 GENERALINFORMATION LH50DU SERVICE MANUAL 19 1 CHAPTER 1 GENERAL PAGE 1 6 1 3 VEHICLE DIMENSIONS...

Page 12: ...CHAPTER 1 GENERALINFORMATION LH50DU SERVICE MANUAL 19 1 CHAPTER 1 GENERAL PAGE 1 7 NOTES...

Page 13: ...angeable even some parts have almost same appearance Always refer to Parts Manual of each CUV model for spare parts information and service 2 1 PERIODIC MAINTENANCE 2 2 THROTTLE PEDAL INSPECTION 2 3 C...

Page 14: ...aintenance intervals are based upon average riding conditions and an average vehicle speed of approximately 16km h 10 miles per hour Vehicles subjected to severe use such as operation in wet or dusty...

Page 15: ...Monthly C Gear case Oil 150 annually R General Lubrication all fittings pivots cables etc 25 3 months L Shift linkage 50 hrs 6 months I A R if necessary DL Transmission belt 50 hrs 6 months I R if nec...

Page 16: ...at 100 hours 4 Rear Axle Bearing on swing arm model Grease Locate fittings and grease Every 3 months or 50 hours 5 Steering system Grease Lubricate the pivoting and sliding parts Every 3 months or 50...

Page 17: ...CHAPTER 2 MAINTENANCE LH50DU SERVICE MANUAL 19 1 CHAPTER 2 MAINTENANCE PAGE 2 5...

Page 18: ...not open fully If the throttle pedal has no play the throttle may be hard to control and the idle speed may be erratic Check the throttle pedal play periodically in accordance with the Periodic Maint...

Page 19: ...on is not obtainable inspect choke cable for kinks or sharp bends in routing 2 4 TOE ALIGNMENT METHOD STRAIGHTEDGE OR STRING Be sure the steering wheel in a straight ahead position NOTE String should...

Page 20: ...and looseness Check surface condition of the disc BRAKE PAD INSPECTION Pads should be changed when friction material is worn to 3 64 1mm HOSE FITTING INSPECTION Check braking system hoses and fittings...

Page 21: ...one on the lever and apply the lever While adjusting it is important you apply the lever back and forth for operation free play and the locking of the parking position 7 Make sure the rear wheels turn...

Page 22: ...n 1 Maximum Hard position 5 2 7 WHEELS Inspect all wheels for runout of damage Check wheel nuts and ensure they are tight Do not over tighten the wheel nuts WHEEL REMOVAL 1 Stop and lock the parking b...

Page 23: ...a tire always use original equipment size and type and replace in pairs especially in 4X4 model The use of non standard size or type tires may affect CUV handling and cause machine damage especially i...

Page 24: ...TER 2 MAINTENANCE PAGE 2 12 2 9 FRAME NUTS BOLTS FASTENERS Periodically inspect the tightness of all fasteners in accordance with the maintenance schedule Check that all cotter pins are in place Refer...

Page 25: ...CHAPTER 2 MAINTENANCE LH50DU SERVICE MANUAL 19 1 CHAPTER 2 MAINTENANCE PAGE 2 13 NOTES...

Page 26: ...even some parts have almost same appearance Always refer to Parts Manual of each CUV model for spare parts information and service 3 1 FRONT A ARM REPLACEMENT 3 2 REAR A ARM REPLACEMENT 3 3 REAR STABI...

Page 27: ...nuts NOTE 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 DO NOT reuse old bolts Ser...

Page 28: ...CHAPTER 3 CHASSIS LH50DU SERVICE MANUAL19 1 CHAPTER 3 CHASSIS PAGE 3 3 3 2 REAR A ARM REPLACEMENT...

Page 29: ...e and safely support vehicle with weight removed from the rear wheel s 2 Remove the wheel nuts and wheel NOTE To ease the removal of the spindle bolt remove the hub cap and loosen the spindle bolts be...

Page 30: ...off of the axle 6 Remove the bolt that secures the shock and coil to the lower A arm 7 Loosen two bolts that secure the A arm to frame by alternating each about 1 3 of the way until A arm can be remo...

Page 31: ...to 44 ft lbs 60 Nm DO NOT reuse old bolts Serious injury or death could result if fasteners come loose during operation 13 Attach A arm to rear knuckle Tighten upper and lower bolts to 44 ft lbs 60 Nm...

Page 32: ...STALLATION 1 Elevate and safely support vehicle with weight removed from the rear wheel s 2 Remove the rear wheel to gain access to the stabilizer bar each side 3 Remove the stabilizer bar nut from th...

Page 33: ...bilizer bar Inspect the bushings and replace if needed 7 Inspect the stabilizer joint and replace if needed 8 Reverse the procedure for installation Torque the stabilizer bolts to 23 ft lbs 32 Nm 3 4...

Page 34: ...e sure CUV is secure before beginning this service procedure 3 Remove wheel nuts and wheels 4 Remove cotter pin from ball joint 5 Remove castle nut and separate A arm from ball joint stud 6 Remove scr...

Page 35: ...ing the rest of the removal process The box is not as stable with the hinge pin removed 7 With the hinge pins removed remov the box from the frame Two people maybe needed to remove the bed from the fr...

Page 36: ...CHAPTER 3 CHASSIS LH50DU SERVICE MANUAL19 1 CHAPTER 3 CHASSIS PAGE 3 11 3 7 STEERING ASSEMBLY REMOVAL INSTALLATION...

Page 37: ...ring wheel 2 With the steering wheel holder nut removed remove the steering wheel holder 3 Remove the steering column bolts 4 Remove the upper of the steering column 5 Remove the cotter pins and the t...

Page 38: ...CHAPTER 3 CHASSIS LH50DU SERVICE MANUAL19 1 CHAPTER 3 CHASSIS PAGE 3 13 NOTES...

Page 39: ...TORQUE TABLE 4 2 FRONT HUB EXPLODED VIEW 4 3 FRONT HUB REMOVAL INSPECTION 4 4 FRONT HUB INSTALLATION 4 5 FRONT HUB BEARING REPLACEMENT 4 6 FRONT DRIVE AXLE REMOVAL INSPECTION 4X4 4 7 FRONT DRIVE AXLE...

Page 40: ...other fasteners CAUTION Locking nuts and bolts with pre applied locking agent should be replaced if removed The self locking properties of the nut or bolt are reduced or destroyed during removal 4 2...

Page 41: ...hub cap cotter pin front spindle nut and washer 7 Rotate each bearing by hand and check for smooth rotation Visually inspect bearing for moisture dirt or corrosion or roughness is evident 4 4 FRONT H...

Page 42: ...o specified torque 4 5 FRONT HUB BEARING REPLACEMENT 1 Remove outer snap ring 2 Form the back side tap on the outer bearing race with a drift punch in the reliefs as shown 3 Drive bearing out evenly b...

Page 43: ...5 Stopper Ring 6 Plunging 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 44: ...s 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 excessive wear or play 3 This inner CV joint inboard pivot j...

Page 45: ...e boot A onto the drive axle and off the inboard joint 3 Wipe out all of the molybdenum disulfide grease within the inboard joint cavity 4 Remove the stopper ring from the inboard joint 5 Remove the i...

Page 46: ...for wear or damage and replace the joint if necessary 8 Inspect the snap ring groove on the inboard joint for wear or damage 9 Inspect the splines on the inner CV joint for wear or damage 10 Check th...

Page 47: ...isassembled assemble the bearing as follows a Position the bearing race and install the race into the bearing case Align the steel ball receptacles in both parts b Install the steel balls into their r...

Page 48: ...band onto the boot Bend down the tab on the boot band and secure the tab with the locking clips and tap them with a plastic hammer Make sure they are locked in place 15 Install the large boot bands on...

Page 49: ...by the brake line Use wire to hang the caliper to prevent possible damage to the brake line 5 Remove hub cap cotter pin front spindle nut and washer 6 Remove the upper and lower control arm bolts 7 Sl...

Page 50: ...at of the steps in the REAR HUB AND KNUCKLE REMOVAL section 2 Slide the rear drive axle out of the knuckle by pulling the hub and knuckle assembly outward and down 3 Pull the rear drive axle straight...

Page 51: ...e rear drive axle into the knuckle 4 Lift knuckle into place and install bolt to upper and lower control arm Torque bolt to 44 ft lbs 60 Nm 5 Install the washer and the spindle retainer nut 6 Install...

Page 52: ...E EXPLODED VIEW 1 SOCKET HEAD BOLT M8X70 2 SEAL 25X47X7 3 SEAL 30X50X13 5 4 BOLT M8X50 5 DRAIN SCREW 6 WASHER 7 LEFT CASE 8 DOWEL PIN 9 WASHER 18 10 BOLT M18x1 5 11 VENT NOZZLE 12 CLAMPS 13 VENT PIPE...

Page 53: ...HAFT 7 MID GEAR 8 CLIP 30 9 BEARING 110 10 HEXAGON FLANGE BOLT 11 DIFF CASE 12 OUTPUT GEAR 13 BEARING 6210 14 CLUTCH GEAR 15 Shift Yoke 16 Shift Return Spring 17 Shift Bar 18 Shift Pin 19 Shift Lever...

Page 54: ...drain from the gearbox Important Clean the plug carefully and Replace the Washer B before Its assembled Fig 1 Fig 1 2 Remove the three Socket Head Bolts A and six Bolts B and Left Case C Fig 2 Fig 2 3...

Page 55: ...1 CHAPTER 4 FINAL DRIVE 4 17 4 Remove two Bearing 6205 A two Bearing 6304 B Input Gear C and Mid Gear Shaft D Fig 4 Fig 4 5 Remove the Diff Solenoid A Shift Yoke Assembly B Shift Pin C Fig 5 Fig 5 6 R...

Page 56: ...Spring A and the Shift Lever B and Shift Lever Spring C and Shift Bar D and Shift Yoke E Fig 7 Fig 7 8 Remove the Bearing 6210 A and Bearing 110 E Then remove eight Bolts D remove Output Gear B from...

Page 57: ...E MANUAL 19 1 CHAPTER 4 FINAL DRIVE 4 19 10 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 Ge...

Page 58: ...CHAPTER 4 FINAL DRIVE 4 20 4 16 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 the...

Page 59: ...f Cross Pin B Then mount the Diff Roll Pin A Fig 12 Fig 12 3 Mount Output Gear B to Diff Assembly C mount eight Bolts D Then mount the Bearing 6210 A and Bearing 110 E PS Apply Loctite 271 evenly on t...

Page 60: ...VICE MANUAL 19 1 CHAPTER 4 FINAL DRIVE 4 22 4 Mount the Shift Return Spring A and the Shift Lever B and Shift Lever Spring C and Shift Bar D and Shift Yoke E as shown Fig 14 Fig 14 5 Mount the Clip A...

Page 61: ...H50DU SERVICE MANUAL 19 1 CHAPTER 4 FINAL DRIVE 4 23 6 Mount the Diff Solenoid A Shift Yoke Assembly B Shift Pin C Fig 16 Fig 16 7 Mount two Bearing 6205 A two Bearing 6304 B Input Gear C and Mid Gear...

Page 62: ...and Diff Case Assembly C and Clutch Gear D and Coupler E and Nut F Fig 18 PS Apply Loctite 271 evenly on the Bolt F screw thread Tighten the Bolt to a torque of 80 90Nm Fig 18 9 Mount the three Socket...

Page 63: ...CHAPTER 4 FINAL DRIVE LH50DU SERVICE MANUAL 19 1 CHAPTER 4 FINAL DRIVE 4 25 10 Mount the oil Drain Screw A and Washer B Add 825 25mL oil 85W 90GL 4 from C Fig 20 Fig 20...

Page 64: ...CHAPTER 5 FINAL DRIVE LH500U 2 LH500U 2A SERVICE MANUAL16 0 CHAPTER 4 FINAL DRIVE 4 26 NOTES...

Page 65: ...mation 5 1 SPECIFICATIONS 5 2 TORQUE 5 3 BRAKE SYSTEM SERVICE NOTES 5 4 BURNISHING PROCEDURE 5 5 BRAKE BLEEDING FLUID CHANGE 5 6 PARKING BRAKE AND BRAKE LINE INSPECTION 5 7 PARKING BRAKE ADJUSTMENT 5...

Page 66: ...sc Thickness 0 177 0 187 4 496 4 750m m 0 167 4 242mm Brake Disc Thickness Variance Between Measurements 0 002 0 051mm Brake Disc Run out 0 005 0 127mm 5 2 TORQUE Item Torque ft lbs except where noted...

Page 67: ...king effectiveness Braking distance will be extended until brake pads are properly burnished To properly burnish the brake pads use the following procedure 1 Choose an area large enough to safely acce...

Page 68: ...clear hose to the fitting and place the other end in a clean container Be sure the hose fits tightly on the fitting 6 Slowly pump foot pedal until pressure builds and holds 7 Hold brake pedal on to ma...

Page 69: ...servoir cover 13 Field test machine at low speed before putting into service Check for proper braking action and pedal reserve With pedal firmly applied pedal reserve should be no less than 1 2 1 3cm...

Page 70: ...ehicle should not roll while parked 3 If the vehicle moves adjustment is necessary 4 Adjust the parking brake where the cable attaches to the lever assembly on the rear brake caliper Parking Brake Adj...

Page 71: ...rly 1 Loosen the two brake caliper bolts in equal increments Remove the bolts from the bracket and lift park brake assembly out 2 Measure the thickness of the caliper parking brake pads Replace pads i...

Page 72: ...ury may occur if machine tips or falls 2 Remove the front wheel 3 Remove the two caliper bolts and caliper from mounting bracket 4 Push caliper piston into caliper bore slowly using a C clamp or locki...

Page 73: ...ing Bolts Torque 18 ft lbs 25 Nm 4 Slowly pump the brake lever until pressure has been built up Maintain at least 1 2 13 mm of brake fluid in the reservoir to prevent air from entering the brake syste...

Page 74: ...56 mm Brake Disc Thickness Variance Service Limit 0 002 0 051 mm difference between measurements 3 Mount dial indicator as shown to measure disc runout on the dial indicator Replace the disc if runout...

Page 75: ...fluid draining INSPECTION Inspect caliper body for nicks scratches or worn Replace caliper as an assembly if any problem exists INSTALLATION 1 Install caliper on hub strut Apply Loctite 242 to screw...

Page 76: ...line 4 Push caliper piston 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...

Page 77: ...ine 2 Use a wrench to remove the brake line Place a container to catch brake fluid draining from brake lines 3 After the fluid has drained into the container remove the caliper mounting bolts and remo...

Page 78: ...pad contact surface using a 0 1 micrometer and a dial indicator Replace disc if worn beyond service limit Brake Disc Thickness New 0 150 0 164 3 810 4 166 mm Service Limit 0 140 3 556 mm Brake Disc Th...

Page 79: ...CHAPTER5 BRAKES LH50DU SERVICE MANUAL19 1 CHAPTER 5 BRAKES PAGE 5 15 NOTES...

Page 80: ...CHAPTER5 BRAKES LH50DU SERVICE MANUAL19 1 CHAPTER 5 BRAKES PAGE 5 15...

Page 81: ...CHAPTER 6 ELECTRICAL CTRICAL PAGE6 1 CHAPTER 6 ELECTRICAL 6 1 PARTS INSPECTION AND SERVICE 6 2 BATTERY 6 3 Vehicle travel system 6 4 CHARGING SYSTEM 6 5 LIGHTING SYSTEM 6 6 SPEEDOMETER SYSTEM 6 7 MAI...

Page 82: ...tally except the light on handlebar 2 Place the vehicle on a 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...

Page 83: ...produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEER OUT OF REACH OF CHILDREN WARNIN...

Page 84: ...contactor 5 Emergency stop switch 11 Wiring connection 6 Motor controller 1 Fuse NO CONTINUITY Replace the fuse CONTINUITY replace the DC DC Voltage Converter Refer to DC DC Voltage Converter INSPECT...

Page 85: ...o the 60V power supply as shown in the figure above there is a 12 V 13 8V voltage between terminal and terminal Measuring with a multimeter CORRECT 4 Charger Check the charger Confirm the Charger Char...

Page 86: ...switch 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...

Page 87: ...tor encoder Check whether the encoder wiring is correct 4 sounds one long and four short Motor Controller Overheating Turn off the Main switch Cooling Controller 5 sounds one long and five short The r...

Page 88: ...Motor check 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...

Page 89: ...HAPTER 6 ELECTRICAL CTRICAL PAGE6 9 8 Main switch check 9 accelerator 1 Accelerator switching signal 2 Acceleration control signal 3 Accelerator power supply negative pole 4 Accelerator power supply p...

Page 90: ...ove press the pedal to the termination position lightly and check the voltage value of terminal 2 and 3 with the multimeter It fits the figure below 10 DC contactor The DC contactor terminal C and ter...

Page 91: ...CHAPTER 6 ELECTRICAL LH50DUSERVICE MANUAL19 1 CHAPTER 6 ELECTRICAL CTRICAL PAGE6 11 Travel system CIRCUIT DIAGRAM...

Page 92: ...CHAPTER 6 ELECTRICAL LH50DUSERVICE MANUAL19 1 CHAPTER 6 ELECTRICAL CTRICAL PAGE6 12...

Page 93: ...UIT 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...

Page 94: ...on Normal working state State of emergency 2 Wiring connection Check the connection of the changing system Refer to CIRCUIT DIAGRAM 3 Charging display lamp Charging capacity 80 flashing interval of re...

Page 95: ...ing system 1 Fuse NO CONTINUITY Replace the fuse CONTINUITY 2 Battery Check the battery condition INCORRECT Clean battery terminals Recharge or replace the battery Refer to BATTERY INSPECTION CORRECT...

Page 96: ...re lighting system POOR CONNECTIONS correct 6 6 LCD Meter 1 Engine working hour counter and The odometer 7 Turn indicator light L 8 Turn indicator light R 2 Voltmeter 9 Reverse indicator light 3 gear...

Page 97: ...CHAPTER 6 ELECTRICAL LH50DUSERVICE MANUAL19 1 CHAPTER 6 ELECTRICAL CTRICAL PAGE6 17 6 8 WIRING DIAGR...

Page 98: ...CHAPTER 6 ELECTRICAL LH50DUSERVICE MANUAL19 1 CHAPTER 6 ELECTRICAL CTRICAL PAGE6 18 NOTES...

Page 99: ...CHAPTER 6 ELECTRICAL LH50DUSERVICE MANUAL19 1 CHAPTER 6 ELECTRICAL CTRICAL PAGE6 19...

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Linhai Crossfire E5 2022, Service Manual

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Summary of Contents for Crossfire E5 2022

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