Linhai M565L EURO IV Page 2 Owner'S Manual Download

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CONTENTS

1. INTRODUCTION ················································ 3

2. UNDERSTANDING WARNINGS ····························· 6

3. SAFETY WARNING ·············································· 8

4. DAILY PRE-RIDE INSPECTION ·························15

5. OPERATION WARNINGS ······························· 16
6. V.I.N ································································· 31

7. CONTROL AND PARTS FUNCTIONS ··················· 32

8. STARTING THE ENGINE ································· 45

9. VEHICLE BREAK-IN PERIOD ···························· 46

10. RIDING GEAR ·················································· 47
11. CARRYING LOADS ········································· 48

12. RIDING ························································· 51

13. CVT SYSTEM ·············································· 63

14. BATTERY ························································· 65

15. EXHAUST SYSTEM ······································ 68

16. MAINTENANCE ············································ 69

17. TROUBLESHOOTING ··································· 92
18. TOOLS ························································ 97

19. SPECIFICATIONS ··········································· 98

Summary of Contents for M565L EURO IV

Page 1: ...OWNER S OPERATOR S MANUAL FOR LINHAI M565L EPS T3b E4...

Page 2: ...5 5 OPERATION WARNINGS 16 6 V I N 31 7 CONTROL AND PARTS FUNCTIONS 32 8 STARTING THE ENGINE 45 9 VEHICLE BREAK IN PERIOD 46 10 RIDING GEAR 47 11 CARRYING LOADS 48 12 RIDING 51 13 CVT SYSTEM 63 14 BATT...

Page 3: ...f your ATV Never install aftermarket parts or accessories intended to increase the speed or power of your ATV Failure to follow these warnings increases the possibility of accidents leading to DEATH o...

Page 4: ...ction and maintenance procedures and schedules described in this manual Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation Always go slowly and be extr...

Page 5: ...s or fallen trees Always follow proper procedures when operating over obstacles as described in this manual Always be careful of skidding of sliding On slippery surfaces such as ice go slowly and be v...

Page 6: ...AND UNDERSTAND WARNINGS AND OWNER S MANUAL BEFORE OPERATION Read this manual thoroughly Operating this ATV carries with it responsibilities for your personal safety safety of others and the protection...

Page 7: ...hazard which could result in severe injury or death Indicates a potential hazard which may result in minor personal injury or damage to the ATV Indicates a situation that can result in damage to the m...

Page 8: ...your protection Read and follow the instructions on each label carefully If any label becomes illegible or comes off contact your dealer for a replacement Attention There is a risk of fire from drivi...

Page 9: ...M565LiOWNER S OPERATOR SMANUAL 3 SAFETY WARNING 9 2 3 4...

Page 10: ...M565LiOWNER S OPERATOR SMANUAL 3 SAFETY WARNING 10 6 7...

Page 11: ...M565LiOWNER S OPERATOR SMANUAL 3 SAFETY WARNING 11 9 10 11...

Page 12: ...M565LiOWNER S OPERATOR SMANUAL 3 SAFETY WARNING 12 13 14...

Page 13: ...M565LiOWNER S OPERATOR SMANUAL 3 SAFETY WARNING 13 16...

Page 14: ...M565LiOWNER S OPERATOR SMANUAL 3 SAFETY WARNING 14 18 19...

Page 15: ...luid level including auxiliary brake 4 Throttle check for free operation and closing 5 Headlight Taillight Brake light check operation of all lights indicator lights and switches 6 Engine stop switch...

Page 16: ...ng and inexperienced operators should complete the certified training course They should then regularly techniques described in the Owner s Manual For more information about the training course contac...

Page 17: ...and perception Could result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV POTENTIAL HAZARD Operating this ATV at excessive speeds WHAT CAN HAPP...

Page 18: ...PERATION WARNINGS 18 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 attempt stunts...

Page 19: ...tenance procedures and schedules described in the Owner s Manual POTENTIAL HAZARD Removing hands from handlebars or feet from footrests during operation WHAT CAN HAPPEN Removing even one hand or foot...

Page 20: ...ar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react This could result in ATV overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and...

Page 21: ...in Always be especially cautious on these kinds of terrain POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn HOW TO AVOID THE HAZARD Alway...

Page 22: ...ing at low speeds before attempting to turn at faster speeds Do not turn at excessive speeds POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn more easily...

Page 23: ...angle which would cause the vehicle to lean sharply to one side Go straight down the hill where possible POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause los...

Page 24: ...d Keep weight uphill Apply the brakes Lock parking brake after you are stopped If you begin rolling backwards Keep your weight uphill never apply throttle Never apply the rear brake while rolling back...

Page 25: ...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 POTENTIAL HAZARD Skidding or slid...

Page 26: ...owly 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 Remember that wet brakes...

Page 27: ...intain proper tire pressure a described in this Manual POTENTIAL HAZARD Operating this ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of this ATV...

Page 28: ...hed Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking Always follow the instructions in this Manual for carrying cargo or pulling a trailer POTENTIAL HAZARD Ridi...

Page 29: ...rottle and steering for possible damage Safe operation of this rider active vehicle requires good judgment and physical skills Persons with cognitive or physical disabilities who operate this vehicle...

Page 30: ...up 2 Hook up the towing equipment or trailer according to the operating manual Before safe hooking up the towing equipment or trailer it is forbidden to operate the ATV with installed equipment or co...

Page 31: ...l Number on the left rear side of engine crankcase Remove the spare key and store it in a safe place Your key can be duplicated only by obtaining a key blank and having it cut by mating it with your e...

Page 32: ...uits and remove the key ON In this position the ATV electrical system is connected the engine can be started and the key cannot be removed HEADLIGHT In this position the headlights are on Never turn t...

Page 33: ...4WD and diff lock indicator 3 Turn indicator light 12 Fuel gauge Indicator 4 Reverse indicator light 13 Engine Malfunction indicator 5 Speedometer 14 Odometer 6 Coolant temperature meter 15 Parking i...

Page 34: ...speed returns to idle when the lever is released Washing or operating the ATV in freezing temperatures can result in water freezing in the throttle cable conduit and or on the throttle mechanism This...

Page 35: ...he ATV with a spongy feeling in brake pedal Operating the ATV with a spongy brake pedal can result in loss of braking Loss of braking could cause an accident Engaging the Parking Brake 1 Squeeze the r...

Page 36: ...iliary brake aggressively when going forward or the rear wheels may skid and slide sideways causing loss of control Auxiliary brake lever Your ATV is equipped with an auxiliary brake as a safety featu...

Page 37: ...e side of the master cylinder Fluid level can be seen through it and should be maintained between the max and min marks NOTE When checking the fluid level the ATV must be on level ground and the handl...

Page 38: ...ar Shifting gears with the engine speed above idle or while the ATV is moving could cause transmission damage Always place the transmission in gear with the parking brake locked whenever the ATV is le...

Page 39: ...ry bottle As engine coolant temperature decreases cooled coolant is drawn back up from the tank past the pressure cap and into the radiator Recommended coolant MAXIMA COOLANOL or another quality antif...

Page 40: ...ever if the recovery bottle has run dry the coolant level in the radiator should be inspected and coolant added if necessary NOTE Use of a non standard pressure cap will not allow the recovery system...

Page 41: ...cap securely If you get gasoline on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Gasoline engines exh...

Page 42: ...only SAE 10W 40 SL OIL Never substitute or mix oil brands Serious engine damage and voiding of warranty can result Recommended engine oil MAXIMA ATV PREMIUM 4T 10W40 Synthetic engine oil EPS Power St...

Page 43: ...ifferential lock Open the cover and press the yellow button When pressed the button slides out CAUTION Always shift only when ATV doesn t move NOTE When shift 2WD 4WD or Diff Lock the mechanics in the...

Page 44: ...ng 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 dealer for i...

Page 45: ...rm up before riding or engine damage could result 1 Shift the transmission to neutral and release the parking brake 2 Sit on the ATV 3 Turn the engine stop switch to RUN 4 Turn the ignition key to ON...

Page 46: ...rottle limiter to half throttle during the break in period 1 Lock nut 2 Adjuster 1 Fill the fuel tank 2 Check oil reservoir level indicated on dipstick Add oil ifnecessary 3 Warm up engine before you...

Page 47: ...tant piece of protective gear for safe riding A helmet can prevent a severe head injury Select an approved helmet 2 Eye Protection Pair of motocross goggles or helmet with face shield offers the best...

Page 48: ...ront rack can obstruct the headlight beam reducing night visibility Do not obstruct the headlight beam with cargo Use of Low gear is recommended when pulling heavy loads to extend belt life Proper loa...

Page 49: ...igh on the racks raises the center or gravity of the ATV 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 maintai...

Page 50: ...ailer will not detach from the towing vehicle Use a chain with the strength rating equal to or greater than the gross weight of the towed equipment Attach the chain to the ATV s trailer coupler or ano...

Page 51: ...d have it serviced by authorized dealer Inspect your ATV every time before riding to ensure it is in proper working order If proper inspection is not done severe injury or death could result See 4 DAI...

Page 52: ...is needed when in four wheel drive and the differential is locked Never exceed 16 km h with the differential in the LOCK position To turn slow down and steer in the direction of the turn leaning your...

Page 53: ...d the trail and avoid quick sharp turns which can cause skidding 3 Correct a skid by turning the handlebars in the direction of the slide and shifting your body weight forward 4 Never apply brakes dur...

Page 54: ...could occur causing severe injury or death Whenever going uphill always drive straight up the hill and 1 Avoid hills steeper than 15 2 Keep both feet on the footrests 3 Shift your weight forward to t...

Page 55: ...2 Shift all your body weight to the uphill side while keeping your feet on the footrests 3 Steer slightly into the hill to maintain vehicle direction If ATV begins to tip quickly turn the front wheels...

Page 56: ...sfer your weight to the rear of the ATV 3 Slow down 4 Lightly apply the brakes to aid in slowing Familiarize yourself with the rear brake pedal operation and its use if loss of normal brakes occurs Do...

Page 57: ...taying uphill of ATV turn handlebars all the way left while facing front of ATV 5 While holding brake lever release parking brake lock and slowly let the ATV to roll to your right side until is pointi...

Page 58: ...clines 3 Keep speed slow avoiding rocks and obstacles if possible 4 After crossing the water briefly apply the brakes to make sure they work Never operate the ATV through deep or fast flowing water NO...

Page 59: ...east to water max 20 cm deep Remove the spark plug Crank the engine several times with electric starter Dry the spark plug and reinstall it or replace it with a new plug Try to start the engine If nec...

Page 60: ...d 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 Not all obstacles are visible Ride with caution...

Page 61: ...er open the throttle suddenly while in reverse NOTE This ATV is equipped with Override system reverse speed limiter Do not operate at wide open throttle Only open the throttle enough to maintain a des...

Page 62: ...M565LiOWNER S OPERATOR SMANUAL 12 RIDING 62...

Page 63: ...urn the engine off 2 Set the parking brake Check the ATV does not move Engage PARK gear 3 Avoid parking on the hill If it is necessary to park on a hill always block the rear wheels on the downhill si...

Page 64: ...ine maintenance is the responsibility of the owner Always follow recommended maintenance procedures See you dealer The CVT housing must be securely in place during operation Failure to comply with thi...

Page 65: ...ide the clutch cover extends the life of the CVT components belt cover etc When To Use Low Range The following lists provide a guideline for when to use low range rather than high Low Range Basic oper...

Page 66: ...Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Alw...

Page 67: ...e mains 4 Connect the red terminal lead from the charger to the positive terminal of the battery the black terminal lead to the negative terminal of the battery 5 Plug the battery charger into a 230V...

Page 68: ...e cable 4 Reinstall battery cover and attach the hold down strap 5 Verify that cables are properly routed NOTE When your ATV is in storage for 1 month or more the battery should be removed charged to...

Page 69: ...e surface of the muffler pull out the arrestor mesh 2 Clean the arrestor or replace it When cleaning the spark arrestor you must follow the Safety Information below to avoid serious injury Do not perf...

Page 70: ...on in wet or dusty areas should be inspected and serviced more frequently Inspect clean lubricate adjust or replace parts as necessary NOTE Inspection may reveal the need for replacement parts Always...

Page 71: ...cessary Coolant Level Inspection Daily Daily Replace engine coolant every year Air Box Sediment Tube Daily Daily Drain deposits whenever visible Headlamp Inspection Daily Daily Check operation daily a...

Page 72: ...hrs 6 months Inspect tighten fasteners Spark Plug 100 hrs 12 months Inspect replace if necessary D Ignition Timing 100 hrs 12 months Inspect and adjust as needed D Fuel System 100 hrs 12 months Check...

Page 73: ...Maintain level between fill lines See 7 CONTROL As required change every 2 years or 20 hours 4 Rear Gear case oil T3b Rear differential oil E4 SAE 80W 90 GL 5 See 16 MAI NTENANCE Rear Gear case Lubric...

Page 74: ...t lithium soap grease 3 Grease M molybdenum disulfide MoS2 grease waterresistant 4 When suspension action becomes stiff or after washing 5 Hours are based on 16 km h average 8 Front Rear Wheel bearing...

Page 75: ...M565LiOWNER S OPERATOR SMANUAL 16 MAINTENCE 75...

Page 76: ...e handlebars do not hit fuel tank or any other part of the machine when fully turned to left or right 4 Torque handlebar adjuster block to 14 16 Nm NOTE Tighten bolts so there is an equal gap in the f...

Page 77: ...itions service the filter at the intervals specified in the Maintenance Schedule If operated in dusty wet or muddy conditions clean the filter more frequently Failure to inspect the air filter frequen...

Page 78: ...amage may occur Steering Inspection The steering assembly of the machine should be checked periodically for loose nuts and bolts If loose nuts and bolts are found have your dealer tighten them before...

Page 79: ...see 7 Controls And Parts Functions Normal functioning 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 indica...

Page 80: ...lowing procedure Note The adjusting on the caliper is for the wear out of the pads 1 With the engine off loosen the adjuster on the lever 2 Loosen the jam nut of the adjuster on the caliper 3 Turn the...

Page 81: ...lay Adjustment Throttle cable free play is adjusted at the handlebar 1 Side the bolts off inline cable adjuster Loosen adjuster locknut 2 Turn adjuster until 2 3 mm free play is achieved at thumb leve...

Page 82: ...3 months whichever comes first Break in oil change is at 20 hours or one month whichever comes first Severe use operation requires more frequent service Severe use includes continuous duty in dusty or...

Page 83: ...tely 6 Reinstall drain plug and torque to 25 Nm Rear Gear Case Lubrication T3b models Be sure no foreign material enters the Gear Differential case With the ATV on a level surface remove fill plug and...

Page 84: ...ll the drain plug with a new sealing washer and tighten securely 20 Nm 3 Remove the fill plug and add 250ml of SAE GL 5 85W 90 Gear Oil and inspect oil level Oil level should be kept even with the cen...

Page 85: ...ll plug threads Correct Rear Differential case oil SAE GL 5 85W 90 Recommended Rear Differential oil MAXIMA HYPOID GEAR LUBE PREMIUM 80W90 GL5 Oil Change 1 Remove the drain plug Catch and discard used...

Page 86: ...ttom of the fill plug threads Correct front differential oil SAE GL 5 85W 90 Recommended Front Differential oil MAXIMA HYPOID GEAR LUBE PREMIUM 80W90 GL5 Oil Change 1 Remove the drain plug Catch and d...

Page 87: ...rly If wheels are improperly installed it could affect handling and tire wear Wheel Removal 1 Stop the engine place the transmission in gear and lock the parking brake 2 Loosen the wheel nuts slightly...

Page 88: ...s If the ATV stopped for a long time turn off the lights Headlight Bulb Replacement Keep your headlights and taillights clean Poor lights when riding can result in accident causing severe injury or de...

Page 89: ...ange the bulb Taillight Brake light Lamp Replacement If the taillight brake light does not work the bulb may need to be replaced 1 Remove the lens 2 Remove bulb and replace it with new bulb 3 Test the...

Page 90: ...n the seat 5 To turn the two adjusting bolt 1 clockwise to heighten the beam Turn the two adjusting bolts 1 counterclockwise to lower the beam Low Beam headlight adjustment is the same as the High bea...

Page 91: ...ter Air Box Inspect clean oil or replace air filter Clean the air box and drain the sediment tube Inspect All Fluid Levels Inspect the following fluid levels and change if necessary transmission brake...

Page 92: ...talling the battery make sure the ignition switch is in the OFF position 7 Check the entire brake systems fluid level pads etc all controls headlights taillight brakelight and headlight aim adjust or...

Page 93: ...nsmission in neutral advance throttle to approx 1 8throttle in short bursts 5 7 times The belt will become more flexible and prevent belt burning Slow and easy clutch engagement Fast effective engagem...

Page 94: ...gged fuel tank breather pipe Deteriorated fuel or fuelcontaining water or foreign material fuel filter clogging the fuel pressure not correct Throttle body Air cleaner The connection is not good Clogg...

Page 95: ...Loose battery terminal Broken or shorted primary Loose coupler connection secondary coil Improperly grounded Faulty high tension cord Broken wire harness Broken ignition coil body POOR IDLE SPEED PER...

Page 96: ...lutch Refer to CLUTCHSLIPPING DRAGGING section Engine oil Improper oil level lowor over Oil level Ignition system Faulty spark plug Faulty high tension cord Faulty ignition unit Faulty pick up coil Fa...

Page 97: ...roper operation Gears primary secondary sheave Worn Damaged CLUTCH SLIPPING CVT SYSTEM Clutch weight spring Incorrect Primary ClutchPosition Worn loose Incorrect engine mount see 13 CVT system Clutch...

Page 98: ...M565LiOWNER S OPERATOR SMANUAL 18 TOOLS 98...

Page 99: ...Turning diameter 7000mm 7000mm Dry Weight 385kg 384kg Front Rack 10kg 10kg Rear Rack 20kg 20kg Load Capacity Combined Rider Payload 170kg 170kg Tongue Weight 10kg 10kg Tow Capacity 203kg 190kg Drive...

Page 100: ...specifications are subject to change without notice Engine Type LH191MR 4Stroke Single Cylinder SOHC Bore x Stroke 91 x 76 8 mm Displacement 499 5 ccm Starter System Electric Starter Engine Cooling L...

Page 101: ...n without prior notice In case of questions please contact your local dealer Copyright 2020 ASP Group s r o All rights reserved No part of this manual may be reproduced reprinted stored in data proces...

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