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Mini 80
Linhai Mini 80 User Manual
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CHAPTER 1 GENERALINFORMA
TION
A
T
V
S
E
R
V
I
C
E
M
A
N
U
A
L
0
9
.
0
C
H
A
P
T
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1
G
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E
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A
L
P
A
G
E
.
1
-
6
1.3 VEHICLE
DIMENSIONS
Note.
The on-road equipments (rear view mirror
, turn li
ghts, etc.) are not S
t
andar
d Equipment for USA.
2004 2005
DEMON
Special Edition - Anniv
ersar
y
Mini / Y
outh
B-Type
A
TV400-
2 A
TV400-
2B
520A
TV 520A
TV
-B
9
11
Table of Contents
Default Chapter
3
Contents
3
Chapter 1 General Page
5
General Information
5
Bearings and Oil Seals
6
Important Information
6
Preparation for Removal Procedures
6
Replacement Parts
6
Checking of Connections
7
Conversion Table
8
Mini / Youth
9
V.I.N. and Engine Serial Number
9
Vehicle Dimensions
10
Demon ATV 260 / 300 Europe
12
B-Type 260/ 300
13
Special Edition - Anniversary
13
Atv 400-2
14
B-Type 150/ 200
14
Atv 400-2B
15
Atv 520
15
Atv 520-B
16
Maintenance
18
Periodic Maintenance
19
Periodic Maintenance Schedule
19
Fuel System
24
Lubrication Recommendations
24
Fuel Filter
26
Fuel Lines
26
Vent Lines and Roll over Valve
27
Toe Alignment
28
Brake Pad Inspection
29
Braking System Inspection
29
Foot Brake Adjustment
29
Hose/Fitting Inspection
29
Bleeding
30
Controls
30
Foot Brake Testing
30
To Adjust (Set Up) the Mechanical Parking Brake
31
Brake Drum
32
Brake Shoes
32
Drum Brake Checking
32
Drum Brake for ATV 50-150
32
Front Suspension
34
Rear Suspension
34
Suspension Spring Preload Adjustment
34
Wheel Installation
35
Wheel Removal
35
Wheel, Hub Torque Table
35
Wheels
35
Tire Inspection
36
Tire Pressure
36
Tire Pressure Inspection
36
Tire Tread Depth
36
Frame, Nuts, Bolts, Fasteners
37
Chapter 3 Engine Page. 3A
40
Maintenance Specifications
41
Tightening Torques
46
Chapter 3 Engine Page
48
Parts Inspection and Service
48
Valve Clearance Adjustment
48
Idling Speed Adjustment
49
Spark Plug Inspection
50
Compression Pressure Measurement
51
Compression Pressure
52
Engine Oil Level Inspection
52
Engine Oil Replacement
53
Recommended Engine Oil
53
Coolant Level Inspection
54
Engine Oil Pressure Inspection
54
Coolant Replacement
55
Recommended Coolant
56
Handling Notes for Coolant
57
Cylinder Head
58
Cylinder Head Removal
60
Cyinder Head Installation
61
Cylinder Head Inspection
61
Camshaft and Rocker Arms
64
Cam Shaft Inspection
65
Rocker Arm and Rocker Arm Shaft Removal
65
Rocker Arms and Rocker Arm Shafts Inspection
65
Camshaft and Rocker Arm Installation
66
Valves and Valve Springs
68
Valve and Valve Springs Inspection
69
Valves and Valve Springs Removal
69
Valve Seats Inspection
70
Valves and Valve Springs Installation
72
Cylinder and Piston
74
Cylinder Inspection
75
Piston and Piston Rings Removal
75
Piston and Piston Pin Inspection
76
Piston Rings Inspection
77
Piston Rings, Piston and Cylinder Installation
77
V-Belt,Clutch and Secondary/Primary Sheave Crankcase Cover (Left)
80
Primary Sheave
81
Secondary Sheave
82
Primary Sheave Removal
83
Secondary Sheave and V-Belt Removal
83
Clutch Inspection
84
Secondary Sheave Disassembly
84
V-Belt Inspection
84
Primary Sheave Assembly
85
Secondary Sheave Inspection
85
Weight Inspection
85
Secondary Sheave Installation
86
A.C. Magneto and Starter Clutch
89
Magneto Cover and Stator Coil
89
Magneto Rotor Removal
91
Magneto Rotor Installation
92
Oil Pump
94
Oil Pump Inspection
95
Crankcase and Crankshaft
96
Crankshaft Inspection
98
Crankshaft Removal
98
Crankcase Installation
99
Cooling System
100
Radiator
100
Inspection
101
Water Pump
103
Thermostat
106
Carburetor
108
Carburetor Removel
108
Carburetor Disassembly/Inspection
109
Float and Jets
110
Vacuum Chamber
110
Accererating Pump
112
Air Cut-Off Valve
112
Table of Contents
119
50Cc/80Cc
119
Air Filter Replacement
120
Replacing Frequency
120
Scheduled Maintenance
120
Spark Plug
120
Valve Adjustment
121
Carburetor Idle Speed
122
Cylinder Pressure
122
Ignition Time
122
Changing Gear Oil
123
Final Reduction Gear Oil Checking
123
Gear Oil Recommended
123
Transmission Belt
123
Cylinder Head, Valve
124
Important Information
124
Standards
124
Abnormal Noise
125
Slow Speed Hitch
125
Tools
125
Torque Value
125
Trouble Diagnosis
125
Disassembling of Camshaft
126
Disassembly of Camshaft Seat and Rocker Arm Assembly
127
Checking of Camshaft Bearing Rocker Arm
128
Disassembly of Cylinder Head
128
Breaking down Cylinder Head
129
Remove Carbon Deposit from Valve Guide
130
Valve and Valve Guide
130
Valve Guide Replacement
130
Valve Seat Chamfer Cutting Tools
131
Valve Seat Checking and Correcting
131
Valve Seat Cutting
132
Build up Spring Seat
133
Building-Up of Cylinder Head
133
Camshaft Assembly
134
Installing Cylinder Head
134
Camshaft Chain Regulator Assembling
135
Important Points
136
Tech Criterion
136
Low Compression Pressure
137
Removing the Cylinder
137
Removing the Piston
137
Max Service Allowance
138
Checking the Cylinder
139
Assembling the Piston
140
Assembling the Cylinder
141
Driving Belt Device & the Starting Lever
142
Removing the Starting Pivot
143
The Left Crankcase Cover Detaching
143
Checking the Starting Pivot
144
Installing the Starting Assembly
145
The Driving Belt
146
Assembling the Driving Belt
147
Taking the Driving Pulley Apart
147
The Driving Pulley Dismounting
147
Assembling the Driving Pulley
148
The Overrunning Clutch
148
Disassembling the Clutch/Transmission Pulley
149
Removing the Clutch/Transmission Pulley
149
Checking the Clutch Transmission Pulley
150
The Clutch / Transmission Pulley Assembly
152
Assembling the Clutch/Transmission Pulley
153
Assembly the Clutch Housing
153
The Final Transmission Assembly
154
Dismantling the Final Transmission
155
Detach the Final Transmission Gearbox Cover
156
Assembling the Final Gear Set
157
Oil Leakage
157
Replacing the Bearing
157
The Crankcase & the Crankshaft
158
Important Points
159
Dismantling the Crankcase
160
The Crankshaft
161
Assembling the Crankcase
162
The Cylinder and the Piston
136
Lubricating System
164
Over All Engine Requirements
165
Engine Oil / Filter Screen
166
Loss of Engine Oil
166
No Oil Pressure
166
Problem Diagnosis
166
General Information
172
Hard Starting Engine
172
Poor Drivability
172
Repairing Material
172
Troubleshooting
172
Disassembly of Carburetor
173
Checking Auto Choke
174
Vacuum Chamber Break-Down
175
Float Bowl Disassembling
176
Accelerator Pump Disassembling
178
Assembly of Carburetor
178
Checking
178
Carburetor Adjustment
179
Fastener Torque Specification
180
Operation Point
180
Starter System
180
Starter Motor Does Not Turn
181
Starter Motor Removal
181
Starter Motor Turns over Slowly
181
Starter Motor Turns- Engine Does Not Rotate
181
Starter Pinion Inspection
183
Starter Pinion Removal
183
Magneto Dismantling
184
Starter Pinion Installation
184
Starter Pinion Assembling
185
Universal Solid Wrench
187
Ignition System Installation
188
Ignition System Operating Points
188
Ignition System Reference Standard
188
Ignition System Troubleshooting
188
CDI Inspection
189
Ignition Coil
189
Charging Coil Inspection
190
Magneto
190
Pickup Coil Inspection
190
Spark Advance Angle Inspection
190
100Cc/125Cc Chain Drive
193
150Cc /200Cc Shaft Drive
193
3C Engine
193
B-Type
193
Gaskets, Oil Seals and O-Rings
194
Preparation for Removal
194
Replacement Parts
194
Air Filter (for MINI ATV100/150)
195
Periodic Inspection and
195
Carburetor Idle Adjustment
196
Transmission Oil Inspection
196
Crankcase Oil Inspection
197
Camshaft Removal
198
Camshaft Holder Removal and Installation
199
Cylinder Body, Piston and Piston Ring
202
V-Belt and CVT
204
Transmission (for MINI ATV100/150)
208
Transmission (for B-Type 150/200)
209
Transmission Disassembly
209
Transmission Assembly
211
Trouble Shooting Checklist
212
Electric Starter
216
Oil Pump
217
Carburetion
218
Tightening Torques of Engine Main Fasteners
223
Atv 260 / 300 / 400
229
Atv Service Manual
229
B-Type ATV400-2 / ATV400-2B
229
Chassis
229
A-Rm Replacement
230
Mantenance-Free Pivot Design
231
Swing Arm (Except Atv400-2，Atv400-2B)
232
Swing Arm Assembly Installation
232
Front Strut Replacement Atv260/ 300 /400 /400-2 /400-2B
233
Front Strut Ball Joint Replacement
234
Steering Post Assembly
235
Front Hub Removal
238
Front Hub/ Drum/ Brake Shoe/ Brake Panel/ Brake Cam and Arm Inspection
238
Front Wheel Removal
238
Front Wheel/ Hub
238
Drum Brake Assembly
239
Drum Brake Disassembly
239
Hub Bearing Replacement
239
Drive Chain Removal
241
Final Drive
241
Rear Wheel Removal
241
Drive Chain Inspection, Installation and Adjustment
242
Final Drive Disassembly
243
Final Drive Installation
243
Final Drive Removal
243
Final Drive Inspection
244
Final Drive Assembly
245
Swing Arm
245
Front Hub Disassembly/Inspection
249
Wheel Hub, and Spindle Torque Table
249
Front Hub Removal/Inspection 4X4 (ATV400-2 / ATV400-2B)
250
Front Hub Assembly (Atv150/200/260/300)
251
Front Hub Installation 4X4 (Atv400-2 / Atv400-2B)
252
Front Hub Installation (Atv150/200/260/300)
253
Chapter 5 Final Drive
253
Front Hub Bearing Replacement 4X4 (Atv400-2 / Atv400-2B)
255
Front Drive Axle (Inner and Outer CV Joint) Removal/Inspection (4X4)
256
Inspection (4X)
256
Front Drive Axle Disassembly/ Inspection (4X4)
258
Front Drive Axle Installation (4X)
258
Front Drive Axle Installation (4X4)
258
Inner CV Joint Inspection
259
Front Drive Axle Assembly (4X4)
260
Rear Axle Removal
262
Rear Hub Inspection
262
Rear Axle Installation
263
Rear Axle Bearing Installation
264
Rear Axle Bearing Removal
264
Rear Gearcase Assembly
265
Rear Gearcase Disassembly
265
Rear Gearcase Exploded View
266
Front Gearcase Slip Limit Torque Test
267
Front Gearcase Disassembly/ Inspection
268
Front Gearcase Assembly
271
Front Diffrential Disassembly/ Inspection
272
Front Diffrential Assembly
274
Front Gearcase Exploded View
277
Gears Won’t Stay in Position When Shift 2WD/ 4WD
277
Differential Centre Exploded View
278
Rear, Front Prop Shaft Removal
278
Transmission
280
Shifter Disassembly
281
Shifter Removal
281
Shifter Assembly
282
Shift Linkage Adjustment
283
Shifter Installation
283
Engine and Transmission Removal
284
Engine and Transmission Install
285
Transmission Disassembly
287
Transmission Assembly
289
2X4 Transmission Exploded View
292
4X4 Transmission Exploded View
293
Brakes
295
Brake System Service Notes
296
Brakes Specifications
296
Brakes Torque
296
Brake Bleeding-Fluid Change
297
Burnishing Procedure
297
Fluid Replacement/Bleeding Procedure
297
Master Cylinder Fluid Level
299
Front Pad Removal / Inspection / Installation
301
Front Disc Inspection/Removal/Replacement
302
Front Caliper Removal/ Inspection / Installation
303
Rear Brake Pad Removal/ Inspection / Installation
304
Rear Caliper Removal/ Inspection/ Installation
305
Foot Brake Pedal for B-Type
306
Rear Brake Disc Inspection/Removal/Replacement
306
Electrical
308
Headlight Lamp Replacement
309
Headlight on Handlebar
309
Headlight Adjustment
310
Taillight / Brakelight Lamp Replacement
311
Battery
312
Indicator Lamp Replacement
312
Battery Inspection / Removal
313
Battery Installation
313
Battery Testing
313
Open Circuit Voltage Test
313
Ignition System
314
Load Test
314
No Spark, Weak or Intermittent Spark
314
Electrical Circuit Diagram
315
If the Ignition System Fails to Operate
316
Minimum Spark Gap
317
Charging System Circuit Diagram
320
Charging Voltage
321
Starter Coil Resistance
322
Wiring Connection
322
Electrics Starting System
323
If the Starter Motor Fails to Operate
324
Starter Relay
325
Starting Circuit Cut-Off Relay
325
Main Switch
326
Cooling System
327
If the Fan Motor Fails to Turn
327
Thermo Switch
329
If the Heat Alarm Unit Working
330
Lighting System
332
Light System Check
335
Reverse Limit System
337
Gear Position Indicator Switch Test
338
Switch Table
338
Switch Schematic
339
Operation of Speed Sensor
340
Speedometer System
340
Dial Meter
341
Lcd Meter
342
Main Switch and Handle Switch
342
Handle Switch Schematic for Europe Model
343
Handle Switch Schematic for Usa Model
343
400Atv-2 / 400Atv-2B Handle Switch Schematic for Europe Model
344
400Atv-2 / 400Atv-2B Handle Switch Schematic for Usa Model
344
Fuel Gauge/ Fuel Level Sensor
345
Fuel Level Sensor Inspection
346
The Operation Principle of the Electric 4Wd Shift
347
Wiring Diagram for L-150/100/80/150ATV
351
Wiring Diagram for LH50/80ATV/LH100/125/150ATV off Road Europe Model
352
Wiring Diagram 2X4 for LH200ATV-B/LH150ATV-B Europe Model
353
Wiring Diagram 2X4 for LH200/150ATV-B
354
Wiring Diagram 2X4 for LH26ATV-B/ATV260/300
355
Wiring Diagram 2X4 for LH260ATV-B/LH260/300
356
Wiring Diagram 4X4 for LH260ATV-B/ATV260/300
357
4
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Linhai Mini 80 Specifications
General
Brand
Linhai
Model
Mini 80
Category
Offroad Vehicle
Language
English
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