Name: Linhai LH400CUV-2
Brand: Linhai
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LH400CUV-2

SERVICE MANUAL

Important Information2
Table of Contents3
General Information5
Important Information6
Preparation for Removal Procedures6
Replacement Parts6
Gaskets,Oil Seals and O-Rings6
Checking of Connections7
Conversion Table8
Metric to Imp8
V.I.n and Engine Serial Number9
Vehicle Dimensions10
Maintenance12
Periodic Maintenance Schedule13
Periodic Maintenance13
Engine14
Transmission15
Lubricant and Fluid16
Brakes16
Lubrication Recommendations18
Throttle Pedal Inspection18
Throttle Freeplay18
Throttle Freeplay Inspection18
Choke Adjustment19
Fuel System19
Fuel Lines19
Toe Alignment20
Vent Lines and Roll over Valve20
Fuel Filter20
Braking System Inspection21
Brake Pad Inspection21
Hose/Fitting Inspection21
Adjusting the Brake Pedal21
Adjusting the Parking Brake22
Suspension Spring Rpeload Adjustment23
Front Suspension23
Rear Suspension23
Wheels23
Tire Inspection24
Tire Pressure24
Wheel Nut Torque Specifications24
Wheel Installation24
Frame , Nuts, Bolts, Fasteners25
Tire Tread Depth25
CHAPTER 3 ENGINE ATV SERVICE MANUAL 2005/ Version Number27
Maintenance Specifications28
Parts Inspection and Service34
Valve Clearance Adjustment34
Valve Clearance34
Idling Speed Adjustment35
Spark Plug Inspection36
Compression Pressure Measurement37
Recommended Engine Oil38
Engine Oil Level Inspection38
Engine Oil Replacement39
Engine Oil Pressure Inspection39
Coolant Level Inspection40
Coolantre Placement40
Radiator41
Handling Notes for Coolant42
Cylinder Head43
Cylinder Head Removal45
Cylinder Head Inspection45
Cyinder Head Installation46
Camshaft and Rocker Arms48
Cam Lobes Length49
Cam Shaft Inspection49
Rocker Arm and Rocker Arm Shaft Removal49
Rocker Arms and Rocker Arm Shafts Inspection50
Camshaft and Rocker Arm Installation50
Valves and Valve Springs52
Valves and Valve Springs Removal53
Valve and Valve Springs Inspection53
Valve Seats Inspection54
Valves and Valve Springs Installation56
Cylinder and Piston58
Piston and Piston Rings Removal59
Cylinder Inspection59
Piston and Piston Pin Inspection60
Piston Rings Inspection61
Piston Rings, Piston and Cylinder Installation61
Engine Oil63
Primary Sheave65
Secondary Sheave66
Primary Sheave Removal67
Secondary Sheave and V-Belt Removal67
Secondary Sheave Disassembly68
Clutch Inspection68
V-Belt Inspection68
Weight Inspection69
Secondary Sheave Inspection69
Primary Sheave Assembly69
Secondary Sheave Installation70
A.C. Magneto and Starter Clutch72
Magneto Cover and Stator Coil72
A. C. Magneto and Starter Clutch73
A.C. Magneto Rotor Removal74
Starter Drive Gear Inspection74
A.C. Magneto Rotor Installation75
Oil Pump76
Oil Pump Inspection77
Crankcase and Crankshaft78
Crankcase and Crankshaft Removal79
Crankshaft Removal80
Crankshaft Inspection80
Crankcase Installation81
Cooling System82
Water Pump84
Thermostat88
Chassis96
Front A-Arm Replacement97
Rear A-Arm Replacement98
Rear Stabilizer Bar Removal/Installation101
Front Strut Replacement103
Front Strut Ball Joint Replacement104
Box Removal105
Box Installating105
Steering Assembly Removal/Installation106
Final Drive108
Front Hub Removal/Inspection109
Front Hub Exploded View109
Wheel, Hub, and Spindle Torque Table109
Front Hub Bearing Replacement111
Front Drive Axle Removal/Inspection (4X4)112
Front Drive Axle Installation (4X4)113
Chapter1113
Chapter2113
- Front Drive Axle Disassembly/ Inspection(4X4)114
- Inner CV Joint Inspection114
- Front Drive Axle Assembly (4X4)116
- Rear Hub Exploded View117
- Rear Hub and Knuckle Removal/ Inspection118
- Rear Hub and Knuckle Installation118
- Rear Drive Shaft Removal119
- Rear Drive Shaft Installation119
- Rear Gear Case Exploded View121
- Rear Gearcase Disassembly122
- Rear Gearcase Assembly122
- Backlash Inspection123
- Front Gearcase Slip Limit Torque Test123
- Front Gearcase Disassembly/ Inspection124
- Front Gearcase Assembly127
- Front Diffrential Disassembly/ Inspection129
- Front Diffrential Assembly131
- Front Gearcase Exploded View133
- Rear, Front Prop Shaft Removal134
- Transmission136
- Gear Shifter Removal137
- Shifter Disassembly137
- Shifter Assembly138
- Shifter Installation139
- Shift Linkage Adjustment139
- Engine and Transmission Removal140
Chapter3140
- Engine and Transmssion Install142
- Transmission Disassembly143
- Transmission Assembly144
Chapter4146
Chapter5146
Trouble Shooting Checklist147
Chapter6147
- 2X4 Transmission Exploded View148
- 4X4 Transmission Exploded View149
- Brakes151
- Burnishing Procedure153
- Brake Bleeding-Fluid Change153
- Parking Brake and Brake Line Inspection155
Chapter7155
- Parking Brake Adjustment156
- Parking Brake Inspection156
- Parking Brake Rear Caliper Removal / Install157
- Front Pad Removal / Inspection / Installation157
- Front Disc Inspection159
- Front Caliper Removal/ Inspection / Installation160
- Rear Brake Pad Removal/ Inspection / Installation161
- Rear Caliper Removal/ Inspection/ Installation162
- Rear Brake Disc Inspection163
- Electrical166
- Headlight Adjustment167
- Taillight / Brakelight Lamp Replacement168
Chapter8168
- Battery169
- Battery Inspection / Removal169
- Open Circuit Voltage Test170
- Load Test170
- Battery Testing170
- Battery Installation170
- Ignition System Troubleshooting171
- No Spark, Weak or Intermittent Spark171
- Circuit Diagram172
- If the Ignition System Fails to Operate173
- Charging System177
- Charging System Circuit Diagram177
- Current Draw - Key off177
- Electrics Starting System180
- If the Starter Motor Fails to Operate181
- If the Fan Motor Fails to Turn184
- If the Heat Alarm Unit Working187
- Lighting System189
- Light System Check192
- The Taillight Fails to Come on193
- Reverse Limit System194
- Gear Position Indicator Switch Test195
- Switch Table195
- Switch Schematic196
- Speedmeter System197
- Operation of Spped Sensor197
- Main Technical Parameter：198
- Main Switch and Handle Switch200
- Fuel Gauge/ Fuel Level Sensor201
- The Operation Principle of the Electric 4Wd Shift203
- Wiring Diagram206

Brand	Linhai
Model	LH400CUV-2
Category	Offroad Vehicle
Language	English

Linhai LH400CUV-2 User Manual

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Linhai LH400CUV-2 Specifications

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