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Linhai LH500ATV-D, Owner'S/Operator'S Manual

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Linhai LH500ATV-D Owner'S/Operator'S Manual Download Page 74

                        LH500ATV-D 

OWNER’S/OPERATOR’S

 

MANUAL

14.0   

16. MAINTENANCE 

                                                                                       16-6 

 

2.Brake 
Fluid 

DOT 3 Only 

Maintain level 
Between fill lines. 
See “7.CONTROL” 

As require; 
change 
every two 
years or 200 
hours   

 

4.Rear Gear 
case oil   

SAE   
GL-4 85W/90 

See “16.MAI- 
NTENANCE/Rear   
Gear 

case 

Lubrication” 

Change 
annually or   
at 100 hours 

 

5.Front  Gear 
case oil   

SAE   
GL-4 85W/90 

See “16.MAI- 
NTENANCE/Rear   
Gear case 
Lubrication” 

Change 
annually or   
at 100 hours 

 

 

 

 

Summary of Contents for LH500ATV-D

Page 1: ...D FOR USE ON RENTAL TRACKS OR RACING OWNER S OPERATOR S MANUAL Europe 14 0 LH500ATV D 4X4 BEFORE OPERATING THIS VEHICLE THE OWNER AND EACH OPERATOR MUST HAVE READ AND HAVE AN UNDERSTANDING OF ALL THE...

Page 2: ...ntities to cause cancer birth defects or other reproductive harm NOTE A storage area toolbox has been provided on the ATV for storage of this manual and addendums Please keep this manual and addendums...

Page 3: ...N ENGINE SERIAL NUMBER AND KEY 6 1 7 CONTROL AND FUNCTIONS 7 1 8 STARTING THE ENGINE 8 1 9 VEHICLE BREAK IN PERIOD 9 1 10 RIDING GEAR 10 1 11 CARRYING LOADS 11 1 12 RIDING 12 1 13 CVT SYSTEM 13 1 14 B...

Page 4: ...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 5: ...ng 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 6: ...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 7: ...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 8: ...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 9: ...SFETY WARNING 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 of...

Page 10: ...LH500ATV D OWNER S OPERATOR S MANUAL 14 0 3 SFETY WARNING 3 2 3 4 5...

Page 11: ...LH500ATV D OWNER S OPERATOR S MANUAL 14 0 3 SFETY WARNING 3 3 6 7 8...

Page 12: ...LH500ATV D OWNER S OPERATOR S MANUAL 14 0 3 SFETY WARNING 3 4 9 10...

Page 13: ...LH500ATV D OWNER S OPERATOR S MANUAL 14 0 3 SFETY WARNING 3 5 11 12 13...

Page 14: ...LH500ATV D OWNER S OPERATOR S MANUAL 14 0 3 SFETY WARNING 3 6 14 15 16...

Page 15: ...LH500ATV D OWNER S OPERATOR S MANUAL 14 0 3 SFETY WARNING 3 7 17 18 19...

Page 16: ...on 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 st...

Page 17: ...e 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 prote...

Page 18: ...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 excessiv...

Page 19: ...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 a...

Page 20: ...ction 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 21: ...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 22: ...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 23: ...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 24: ...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 25: ...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 26: ...me 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 HAZAR...

Page 27: ...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 28: ...s 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 access...

Page 29: ...d 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 POTENTIA...

Page 30: ...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 31: ...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 numbe...

Page 32: ...3 Power Indicator 14 Gear position indicator Throttle WARNING Do not start or operate an ATV with sticking or improperly operation throttle controls A stuck or improperly operating throttle could caus...

Page 33: ...o continue to run and result in loss of control 7 CONTROL AND PARTS FUNCTIONS Front and Rear Brakes The brake fluid level should be checked before each ride The reservoir of hand brake is located on t...

Page 34: ...RNING Never operate the ATV with a spongy feeling brake pedal operating the ATV with a spongy brake pedal can result in loss of braking Loss of braking could cause an accident Setting the Parking Brak...

Page 35: ...aggressively 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 a...

Page 36: ...models there is a side window the fluid level can be seen through it and should be maintained between the indicated max and min marks on the reservoir Automatic Transmission Gear Selector Operation T...

Page 37: ...o assure proper transmission function Should you experience any shifting problem see your dealer WARNING POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high WHAT CAN HAPPEN The wh...

Page 38: ...pressure cap and into the recovery bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the tank past the pressure cap and into the radiator NOTE Some co...

Page 39: ...spected and coolant added if necessary NOTE Use of a non standard pressure cap will not allow the recovery system to function properly If the cap should need replacement contact your dealer for the co...

Page 40: ...fueling is performed or where gasoline is stored Do not over fill the tank Do not fill the tank neck If you get gasoline on your skin or clothing immediately wash it off with soap and water and change...

Page 41: ...front fender and has three positions OFF For vehicle storage and whenever transporting ON For normal operation RES For reserve supply in the event of main supply exhaustion NOTE here is about a 6 mile...

Page 42: ...conds 3 Stop the engine remove dipstick 1 and wipe dry with a clean cloth 4 Put dipstick into the oil tank don t screw in it remove it and read the oil level 5 Remove dipstick and check to see that th...

Page 43: ...mechanics would finally disengaged engaged when rides on a hard surface or rides in reverse CAUTION Do not switch on 4WD if the rear wheels are spining This may cause severe machine damage When switch...

Page 44: ...heavy steering is a symptom of malfunction of one side inner or outer CV joints loss of control could result even in 2WD position If you experience any symptoms from the steering take the ATV to your...

Page 45: ...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 46: ...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 respond...

Page 47: ...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 48: ...ost 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 prote...

Page 49: ...o not obstruct the headlight beam with cargo Use of low forward gear is recommended in heavy pulling situations to extend belt life WARNING Correct loading of this vehicle is necessary to maintain pro...

Page 50: ...ity 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 stable operating conditions OPERATE...

Page 51: ...it 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 resu...

Page 52: ...an 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 wei...

Page 53: ...ding 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 d...

Page 54: ...le 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 footr...

Page 55: ...nto 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 56: ...eight 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 brak...

Page 57: ...hill 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...

Page 58: ...s 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 throu...

Page 59: ...ot 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 o...

Page 60: ...rn 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 T...

Page 61: ...reverse 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 62: ...e 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...

Page 63: ...nge while operating at low ground speeds the air temperature in the clutch will be reduced Reducing the temperature inside the clutch cover extends the life of the CVT components belt cover etc When T...

Page 64: ...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 65: ...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 66: ...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 67: ...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 68: ...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 69: ...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 70: ...Air Filter Pre Cleaner Daily Daily Inspect Clean Coolant Level Inspection Daily Daily Replace engine coolant Every one year Air Box Sediment Tube Daily Daily Drain deposits whenever visible Headlamp...

Page 71: ...d 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 72: ...Inspect daily lubricate Front Suspension 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 n...

Page 73: ...nts 25 hrs 3 months Inspect D Valve clearance 100 hrs 12 months Inspect adjust D Shift selector box H L R N 200 hrs 24 months Change grease every two years D Brake fluid 200 hrs 24 months Change every...

Page 74: ...n fill lines See 7 CONTROL As require change every two years or 200 hours 4 Rear Gear case oil SAE GL 4 85W 90 See 16 MAI NTENANCE Rear Gear case Lubrication Change annually or at 100 hours 5 Front Ge...

Page 75: ...se with grease gun Every 3 months or 50 hours 7 Steering Post Bushings Grease Locate fitting on pivot shaft and grease with grease gun Every 3 months or 50 hours 8 Front Rear Wheel bearings Grease Ins...

Page 76: ...aft Shaft Yoke Grease Locate fitting and Grease Semi annually 13 Throttle Cable Grease M Grease inspect and replace it if necessary Monthly or 20 hours 14 Rear Axle Bearing on swing arm model Grease L...

Page 77: ...LH500ATV D OWNER S OPERATOR S MANUAL14 0 16 MAINTENANCE 16 9...

Page 78: ...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 char...

Page 79: ...ght 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 block to 10 12 ft Ibs 14 16Nm NOTE Tighten bolts so there is an e...

Page 80: ...tapered side against wheel Air Filter Service 1 Remove seat 2 Release clips and remove cover 3 Loosen clamp and remove Filter 4 Reinstall filter Replace filter as required 5 Reinstall filter into air...

Page 81: ...s position 2 Measure A and B A minus B should be 1 16 to 1 8 1 5 to 3mm 3 If this measurement needs to be adjusted contact your dealer for service Front Brake WARNING Once a bottle of brake fluid is o...

Page 82: ...y and surface condition of the disc Pads should be changed whenfriction material is worn to 3 64 1mm A Rear and Auxiliary Brake Rear Brake The rear brake is a hydraulic disc type brake which is activa...

Page 83: ...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 the lever While adjusting it is...

Page 84: ...retor 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 85: ...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 chang...

Page 86: ...il may be hot Do not allow hot oil to come into contact with skin as severe burns may result 1 Place vehicle on a level surface 2 Run engine two or three minutes until warm Stop engine 3 Clean area ar...

Page 87: ...to the bottom of the fill plug threads The correct gearcase lubricant to use is SAE GL 4 85W 90 Weight Gear Lube Oil Changing Procedure 1 Remove the drain plug Catch and discard used oil properly 2 Cl...

Page 88: ...to the bottom of the fill plug threads The correct gearcase lubricant to use is SAE GL 4 85W 90 Weight Gear Lube Oil Changing Procedure 6 Remove the drain plug Catch and discard used oil properly 7 Cl...

Page 89: ...alled properly If wheels are improperly installed it could affect vehicle handling and tire wear Wheel Removal Procedure 1 Stop the engine place the transmission in gear and lock the parking brake 2 L...

Page 90: ...3mm 1 or less Please refer to your Owner s Manual for tire specifications Headlight Lamp Replacement WARNING Keep your headlights and taillights clean Poor light while riding can result in an acciden...

Page 91: ...e bulb 16 MAINTENANCE Taillight Brake light Lamp Replacement If the taillight brake light does not work the lamp may need to be replaced 1 Remove the lens 2 Remove lamp and replace it with recommended...

Page 92: ...adjusting bolt counterclockwise is to lower the beam area The dipper headlight adjustment is the same to the High beam Headlight Cleaning Your ATV Keeping your ATV clean will extend the life of vario...

Page 93: ...ect the following fluid levels and change if necessary transmission brake fluid change every two years or as required if fluid looks dark or contaminated Fog the Engine Spray a light oil into the cyli...

Page 94: ...measures should be taken 1 Turn off the engine and remove the key 2 Turn the fuel valve to off 3 Be certain the fuel cap oil cap and seat are installed correctly 4 Always tie the frame of the ATV to t...

Page 95: ...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 96: ...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 97: ...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 98: ...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 99: ...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 100: ...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 101: ...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 102: ...18 TOOL 18 1...

Page 103: ...ch Turn diameters 6500mm 256 inch Dry Weight 355kg 782lbs 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 4...

Page 104: ...87 5mmX82mm Displacement 493cm Starter System Electric Starter Engine Cooling Liquid Cooled Lubrication System Wet Sump Carburetor BSR36 Ignitions CDI Spark Plug Type DPR7EA 9 NGK Electrical Equipmen...

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