Linhai LH400ATV-2B Owner'S/Operator'S Manual Download

Page: 97 / 103

17. TROUBLESHOOTING

17-4



Improperly charged battery



Faulty ignitor unit



Faulty battery



Faulty pick up coil

Fuse



Broken magneto



Burnt out, improper connection woodruff key

Spark plug Switch

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Improper plug gap



Faulty main switch



Worn electrodes



Faulty “ENGINE STOP”



Wire between terminals broken switch



Improper heat range



Faulty brake switch



Faulty spark plug cap

Wiring

Ignition coil



Loose battery terminal



Broken or shorted primary/



Loose coupler connection

secondary coil



Improperly grounded



Faulty high tension cord



Broken wireharness



Broken ignition coil body

POOR IDLE SPEED PERFORMANCE
Carburetor Air cleaner



Loose or clogged pilot jet



Clogged air cleaner element



Damaged carburetor joint

Ignition system



Improperly tightened carburetor



Faulty spark plug

joint clamp hose



Faulty high tension cord



Improperly adjusted idle speed



Faulty ignitor unit

(Pilot screw), (Throttle stop screw)



Faulty pick up coil



Improperly adjusted throttle cable



Faulty ignition coil



Flooded carburetor

Valve system



Improperly adjusted



valve clearance

POOR MEDIUM AND HIGH SPEED PERFORMANCE
Carburetor Air cleaner

Summary of Contents for LH400ATV-2B

Page 1: ...please call your dealer and request to have them sent to you Important Safety Notice Never make any modifications to the engine drive system mechanical or electrical systems of your ATV Never install...

Page 2: ...ing conditions and your experience Never attempt wheelies jumps or other stunts Always inspect your ATV each time you use it to make sure it is in safe operating condition Always follow the inspection...

Page 3: ...pt to operate over large obstacles such as large rocks or fallen trees Always follow proper procedures when operating over obstacles as described in this manual Always be careful of skidding of slidin...

Page 4: ...ON KNOW YOUR VEHICLE BEFORE YOU BEGING RIDING Read this manual thoroughly referring to the various areas which are being discussed on your machine Operating this vehicle carries with it responsibiliti...

Page 5: ...hroughout this manual to convey the following messages This is the safety alert symbol When you see this symbol on your machine or in this manual be alert to the potential for personal injury Your saf...

Page 6: ...3 1 NOTE Warning decals have been placed on the vehicle for your protection Read and follow the instructions on each decal carefully In the event any decal becomes illegible or comes off contact your...

Page 7: ...LH400ATV 2B OWNER S OPERATOR S MANUAL 08 0 3 SFETY WARNING 3 2 3...

Page 8: ...LH400ATV 2B OWNER S OPERATOR S MANUAL 08 0 3 SFETY WARNING 3 3 4 5 6 7 8...

Page 9: ...LH400ATV 2B OWNER S OPERATOR S MANUAL 08 0 3 SFETY WARNING 3 4 9...

Page 10: ...LH400ATV 2B OWNER S OPERATOR S MANUAL 08 0 3 SFETY WARNING 3 5 10 11 12...

Page 11: ...LH400ATV 2B OWNER S OPERATOR S MANUAL 08 0 3 SFETY WARNING 3 6 13 14 15...

Page 12: ...LH400ATV 2B OWNER S OPERATOR S MANUAL 08 0 3 SFETY WARNING 3 7 16 17...

Page 13: ...LH400ATV 2B OWNER S OPERATOR S MANUAL 08 0 3 SFETY WARNING 3 8 18 19...

Page 14: ...ion adjustment and fluid level includes auxiliary brake 4 Throttle check for free operation and closing 5 Headlight Taillight Brakelight check operation of all indicator lights and switches 6 Engine s...

Page 15: ...he Owner s Manual For more information about the training course contact an authorized ATV dealer WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet eye protection and prot...

Page 16: ...t your balance and perception Could result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV WARNING POTENTIAL HAZARD Operating this ATV at excessi...

Page 17: ...0 5 OPERATION WARNINGS 5 3 WARNING POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never...

Page 18: ...ection and maintenance procedures and schedules described in the Owner s Manual WARNING POTENTIAL HAZARD Removing hands from handlebars or feet from footrests during operation WHAT CAN HAPPEN Removing...

Page 19: ...ATV on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV overturning or going out of control HOW TO AVOID THE HAZARD...

Page 20: ...on such terrain Always be especially cautious on these kinds of terrain WARNING POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn HOW TO...

Page 21: ...nual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speed WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle...

Page 22: ...ll at an angle which would cause the vehicle to lean sharply to one side Go straight down the hill where possible WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN...

Page 23: ...se all forward speed Keep weight uphill Apply the brakes Lock parking brake after you are stopped If you begin rolling backwards Keep weight uphill never apply engine power Never apply the rear brake...

Page 24: ...eme caution when riding over large obstacles such as large rocks or fallen trees If you cannot avoid obstacles always follow proper procedures as described in the Owner s Manual WARNING POTENTIAL HAZA...

Page 25: ...avoid water go slowly balance your weight carefully avoiding sudden movement maintain a slow and steady forward motion do not make sudden turns or stops and do not make sudden throttle changes Remembe...

Page 26: ...is vehicle Always maintain proper tire pressure a described in the Owner s Manual WARNING POTENTIAL HAZARD Operating this ATV with improper modifications WHAT CAN HAPPEN Improper installation of acces...

Page 27: ...ed Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking Always follow the instructions in the Owner s Manual for carrying cargo or pulling a trailer WARNING POTENTI...

Page 28: ...brakes throttle and steering for possible damage WARNING Safe operation of this rider active vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who op...

Page 29: ...key and store in a safe place Your key can be duplicated only by obtaining a key blank and having it cut by mating it with your existing key Record Key Number The vehicle frame and engine serial numb...

Page 30: ...2 Fuel gauge Indicator Throttle WARNING Do not start or operate an ATV with sticking or improperly operation throttle controls A stuck or improperly operating throttle could cause an accident resultin...

Page 31: ...l should be checked before each ride The reservoir of hand brake is located on the left side of the handlebar The reservoir of foot brake is located under the seat The fluid should be kept between the...

Page 32: ...oss of braking Loss of braking could cause an accident Setting the Parking Brake On independent suspension models 1 Squeeze the right hand brake lever two or three times and hold it 2 Push the park br...

Page 33: ...ively apply the auxiliary brake when going forward or the rear wheels may skid and slide sideways causing loss of control Auxiliary brake lever Your ATV has an auxiliary brake provided brake as a safe...

Page 34: ...level ground and the handlebars must be straight If the fluid level is low add DOT 3 only On some models there is a side window the fluid level can be seen through it and should be maintained between...

Page 35: ...hicle is left unattended Maintaining shift linkage adjustment is important to assure proper transmission function Should you experience any shifting problem see your dealer WARNING POTENTIAL HAZARD En...

Page 36: ...ant is drawn back up from the tank past the pressure cap and into the radiator NOTE Some coolant level drop on new machines is normal as the system is purging itself of trapped air Observe coolant lev...

Page 37: ...a funnel slowly add coolant as necessary through the radiator filler neck Fuel and Oil system WARNING Gasoline is highly flammable and explosive under certain conditions Always exercise extreme cautio...

Page 38: ...oduct contains chemicals known in certain quantities to cause cancer birth defects or other reproductive harm Fuel and Oil System Fuel System The fuel tank filler cap 1 is located directly behind the...

Page 39: ...ank as soon as possible after having used reserve supply Always return valve to on position after refueling machine Fuel filter The filter should be replaced by your dealer every 100 hours of operatio...

Page 40: ...d the oil level 5 Remove dipstick and check to see that the oil level is between the full and add marks 2 Add oil as indicated by the level on the dipstick Do not overfill CAUTION Use only SAE 15W 40...

Page 41: ...r CAUTION Do not switch on 4WD if the rear wheels are spining This may cause severe machine damage When switch on 4WD the button will stay in 4WD position but 4WD mechanics maybe still disengaged Alwa...

Page 42: ...position If you experience any symptoms from the steering take the ATV to your dealer for inspection and service WARNING You must inspect your ATV each time before riding to ensure it is in proper wo...

Page 43: ...urn the fuel tank valve to ON 3 Sit on the vehicle 4 Turn the engine stop switch to RUN 5 Turn the ignition key to ON apply the brake lever and press the starter button 6 Do not press the throttle mor...

Page 44: ...for approximately 10 seconds before pressing it again 3 Immediately after the engine starts operate the choke knob to keep fast idle 4 Continue warming up the engine until it runs smoothly and respon...

Page 45: ...build up and cause damage to close fitted engine parts Please set a limit to half throttle during the break in periods 1 Locknut 2 Adjuster 1 Fill fuel tank 2 Check oil reservoir level indicated on di...

Page 46: ...most important piece of protective gear for safe riding A helmet can prevent a severe head injury Select an approved helmet 2 Eye Protection A pair of goggles or helmet face shield offer the best prot...

Page 47: ...ing of the front rack can obstruct the headlight beam reducing night visibility Do not obstruct the headlight beam with cargo Use of low forward gear is recommended in heavy pulling situations to exte...

Page 48: ...e racks raises the center or gravity of the vehicle and creates a less stable operating condition When cargo loads are carried high on the racks the weight of the loads must be reduced to maintain sta...

Page 49: ...t serviced by the authorized dealer WARNING You must inspect you ATV each time before riding to ensure it is in proper working order If proper inspection is not done severe injury or death could resul...

Page 50: ...n the inside wheels when turning and the inside tire must slip traction slightly To turn steer in the direction of the turn leaning your upper body to the inside of the turn while supporting your weig...

Page 51: ...ing the trail and avoiding quick sharp turns which can cause skids 3 Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward 4 Never apply brakes du...

Page 52: ...e control or overturning of the ATV could occur causing severe injury or death Whenever traveling uphill always travel straight uphill and 1 Avoid steep hills 15 maximum 2 Keep both feet on the footre...

Page 53: ...to the hill transferring your upper body weight toward the hill while keeping your feet on the footrests 3 Steer slightly into the hill to maintain vehicle directions If vehicle begins to tip quickly...

Page 54: ...ight to the rear of the vehicle 3 Slow down 4 Apply the brakes slightly to aid in slowing Familiarize yourself with the auxiliary rear brake pedal and its use in the event loss of normal service brake...

Page 55: ...ill of ATV turn handlebars full left while facing front of ATV 5 While holding service brake release parking brake lock and slowly allow ATV to roll around to your right until ATV is pointing across t...

Page 56: ...3 Proceed slowly avoiding rocks and obstacles if possible 4 After crossing dry the brakes by applying light pressure to the lever until braking action is normal CAUTION Never operating the ATV throug...

Page 57: ...t more than 8 inch 200mm Turn the fuel valve to OFF Remove the spark plug Loosen the carburetor drain screw 1 Turn the engine over several times with electric start Dry the spark plug and reinstall or...

Page 58: ...n to read the trail as you ride Stay on the right side of the trail if possible and be constantly alert for hazards such as logs rocks and low hanging branches WARNING Not all obstacles are visible Tr...

Page 59: ...everse 5 Never open the throttle suddenly while backing NOTE This ATV is equipped with a reverse speed limiter Do not operate at wide open throttle Only open the throttle enough to maintain a desired...

Page 60: ...engine off 2 Place the transmission in gear 3 Set the parking brake 4 Shut off fuel supply 5 Avoid parking on an incline If it is neceddary to park on an incline always block the rear wheels on the d...

Page 61: ...ll be reduced Reducing the temperature inside the clutch cover extends the life of the CVT components belt cover etc Adjust the center distance of the CVT 1 Remove crankcase filter cover cover protect...

Page 62: ...g lists provide a guideline for when to use low range rather than high Low Range Basic operation at speeds less than 7 MPH 11km h Heavy pulling Riding through rough terrain swamps mountains etc at low...

Page 63: ...lk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15minutes and get prompt medical attention Batteries produce explosive gases Keep spark...

Page 64: ...on always connect battery cables in the order specified Red positive cable first black negative cable last An exploding battery can cause serious injury or death Battery terminals and connections shou...

Page 65: ...Before reusing take the battery to your dealer for testing and recharging Power plug leads may need to be bent down so that battery cover may be installed When installing a new battery make certain i...

Page 66: ...periodically purged of accumulated carbon as follows 1 Remove the arrestor screw located on the bottom of the muffler and remove the temperature detector located on the surface of the muffler pull ou...

Page 67: ...ome U S models WARNING The engine rpm limiter will work at 7500rpm this may cause excessive fuel to build in the exhaust and ignited by the catalyst in the muffler MAY RESULT IN THE MUFFLERS OVERHEATI...

Page 68: ...n adjustment and lubrication intervals of important components are explained in the following chart on the following pages Maintenance intervals are based upon average riding conditions and an average...

Page 69: ...y Inspect Clean Coolant Level Inspection Daily Daily Replace engine coolant Every one year Air Box Sediment Tube Daily Daily Drain deposits whenever visible Headlamp Inspection Daily Daily Check opera...

Page 70: ...ed at first service only General Lubrication 50 hrs 3 months Lubricate all fittings pivots cables etc Item Hours When Remarks Engine Oil Level Change 30 hrs 3 months Check Level Daily Break in Service...

Page 71: ...nsion 50 hrs 6 months Inspect lubricate tighten fasteners Rear Suspension 50 hrs 6 months Inspect tighten fasteners Spark Plug 100 hrs 12 months Inspect replace if necessary D Ignition Timing 100 hrs...

Page 72: ...box H L R N 200 hrs 24 months Change grease every two years D Brake fluid 200 hrs 24 months Change every two years Idle Speed As required As required Adjust D Toe adjustment As required As required Pe...

Page 73: ...or at 100 hours 4 Rear Gear case oil SAE 80W 90GL5 See 16 MAI NTENANCE Rear Gear case Lubrication Change annually or at 100 hours 5 Front Gear case oil SAE 80W 90GL5 See 16 MAI NTENANCE Rear Gear cas...

Page 74: ...earings if necessary Semi annually 9 Tie rods Grease Locate fittings and Grease Semi annually 10 Front Rear Prop Shaft Shaft Yoke Grease Locate fittings and Grease Semi annually 11 Ball joints Inspect...

Page 75: ...LH400ATV 2B OWNER S OPERATOR S MANUAL 08 0 16 MAINTENANCE 16 8 15 Swing Arm Bearing on swing arm model Grease Locate fittings and grease Monthly or 20 hours...

Page 76: ...LH400ATV 2B OWNER S OPERATOR S MANUAL 08 0 16 MAINTENANCE 16 9...

Page 77: ...M molybdenum disulfide MoS2 grease water resistant 4 When suspension action becomes stiff or after washing 5 Hours are based on 10 mph 16Km h average Periodic Maintenance Record Use the following cha...

Page 78: ...ar cover 2 Loosen the four bolts 3 Adjust handlebar to desired height Be sure handlebars do not hit gas tank or any other part of machine when turned fully to left or right 4 Torque handlebar adjuster...

Page 79: ...tightness and spindle nut retention are critical component operations Service work must be performed by an authorized dealer Tapered nuts install with tapered side against wheel Air Filter Service Air...

Page 80: ...vehicle Camber and Caster The camber and caster are non adjustable WARNING Do not attempt to adjust the tie rod for toe alignment Severe injury or death can result from improper adjustment Contact you...

Page 81: ...nctioning of the diaphragm is to extend into the reservoir as fluid lever drops If the fluid lever is low and the diaphragm is not extended a leak is indicated and the diaphragm should be replaced Alw...

Page 82: ...adjuster on the caliper 3 Turn the adjuster bolt CW clockwise by hand till the pad touch the brake disc turn the adjuster bolt CCW counterclockwise by 1 4 to one turn for 10 to 20mm free play at the...

Page 83: ...uretor idle screw in or out until the desired idle RPM is reached Turning the screw in clockwise will raise RPM Turning the screw out counterclockwise will lower RPM 4 The standard idle RPM is 1500 10...

Page 84: ...urn you causing severe injury Remove the spark plug by rotating counterclockwise Reverse the procedure for spark plug installation Torque to 17ft Ibs 23N m Oil and Filter Change The recommended oil ch...

Page 85: ...ankcase and remove drain plug 5 Allow oil to drain completely 6 Replace sealing washer O ring of drain plug 7 Reinstall drain plug and torque to 14ft Ibs 19N m Transmission Lubrication The transmissio...

Page 86: ...s 2 Remove fill plug 3 Remove transmission drain plug located on the bottom left hand side and drain the oil Catch and discard used oil properly 4 Clean and reinstall the drain plug torque to 14 ft lb...

Page 87: ...cant should be kept even with the center of the drill point approximately below the top of the fill hole NOTE Do not add lubricant to the bottom of the fill plug threads The correct gearcase lubricant...

Page 88: ...ury or death Follow the safeguards listed below to prevent this type of situation Important Safeguards Maintain proper tire pressure according to charts below Improper tire inflation may affect ATV ma...

Page 89: ...NCE Wheel Nut Torque Tire Inspection When replacing a tire always use original equipment size and type Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3mm 1 or less Please refer...

Page 90: ...brake light does not work the lamp may need to be replaced 1 Remove the lens 2 Remove lamp and replace it with recommended lamp 3 Test the taillight brake light to see that it s working 4 Reinstall t...

Page 91: ...nt is the same to the High beam Headlight 16 MAINTENANCE Cleaning Your ATV Keeping your ATV clean will extend the life of various components Washing Never use a high pressure type car wash system it c...

Page 92: ...nge every two years or as required if fluid looks dark or contaminated Fog the Engine Spray a light oil into the cylinder through the spark plug hole Check and Lubricate Cables Grease Inspect all cabl...

Page 93: ...INTENANCE 16 26 3 Be certain the fuel cap oil cap and seat are installed correctly 4 Always tie the frame of the ATV to the transporting until securely using suitable straps or rope 5 Always place the...

Page 94: ...ent life Insufficient warm up of ATV s exposed to low ambient temperatures Warm engine at least 5 min they with transmission in neutral advance throttle to approx 1 8throttle in short bursts 5 to 7 ti...

Page 95: ...d check the fuel air ignition compression system Let the main switch key on while parking the ATV When stopping the engine turn off the main switch key off at once WARNING This ATV is equipped with a...

Page 96: ...leaner Water or foreign material element Clogged pilot jet Improper air cleaner Clogged air passage setting Improperly set pilot air s crew Clogged pilot air passage Improperly sealed valve seat Impro...

Page 97: ...onnection secondary coil Improperly grounded Faulty high tension cord Broken wireharness Broken ignition coil body POOR IDLE SPEED PERFORMANCE Carburetor Air cleaner Loose or clogged pilot jet Clogged...

Page 98: ...posit buildup Clogged fuel tank breather hole Improper adjusted valve Clogged air cleaner element clearance Clogged jet Improper contacted Improperly adjusted fuel level valve and valve seat Improper...

Page 99: ...eposit build up Improperly adjusted valve timing Improperly adjusted valve clearance Engine oil Incorrect engine oil level Improper engine oil quality High viscosity Low engine oil quality Brakes Drag...

Page 100: ...nt Clutch shoe see 13 CVT system Worn damaged Primary sliding sheave Seized POORSTARTING FAULTY BRAKE PERFORMANCE POOR BRAKING EFFECT V belt Worn front hub bearing Slipping oily V belt Worn brake pad...

Page 101: ...Turn Radius 3277mm 129 inch Dry Weight 315kg 694 5lbs Front Rack 18kg 40 lbs Rear Rack 36kg 80 lbs Load Capacity Combined Rider Payload 150kg 350 lbs Tongue Weight 11kg 25 lbs Tow Capacity 200kg 450...

Page 102: ...inder SOHC Bore x Stroke 80mmX70mm Displacement 352cm Starter System Electric Starter Engine Cooling Liquid Cooled Lubrication System Wet Sump Carburetor CVK32 Ignitions T C I Spark Plug Type DR8EA NG...

Page 103: ...NTAL TRACKS OR RACING OWNER S OPERATOR S MANUAL Europe 08 0 LH400ATV 2B IRS INDEPENDENT REAR SUSPENSION BEFORE OPERATING THIS VEHICLE THE OWNER AND EACH OPERATOR MUST HAVE READ AND HAVE AN UNDERSTANDI...

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Linhai LH400ATV-2B, Owner'S/Operator'S Manual

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