Linhai 2004 ATV 260 User manual

2009 ATV
SERVICE MANUALEUROPE 09.0
PN. F010102A01
● ATV 260/300
Model ：2004
2005
Special Edition - Anniversary
2x4
4x4
● Mini 50/80/100/150
● B-Type 150/200, 2x4
260/300, 2x4/ 4x4
● ATV520
● ATV400-2
● ATV400-2B
● Attachment : Delphi Small Engine Management System Service
Manual
WARNING
The parts of different types/ variants/ versions maybe un-interchangeable, even some parts
have almost same appearance. Always refer to Parts Manual of each ATV model for spare
parts information and service.
※General Information
※Maintenance
※Engine
※Chassis
※Final Drive
※Transmission
※Brakes
※Electrical

Foreword
This manual is designed primarily for use by the ATV factory certified service technicians in
a properly equipped shop. Persons using this manual should have a sound knowledge of
mechanical theory, tool use, and shop procedures in order to perform the work safely and
correctly. The technician should read the text and be familiar with service procedures
before starting the work. Certain procedures require the use of special tools. Use only the
proper tools, as specified. Cleanliness of parts and tools as well as the work area is of
primary importance.
This manual is divided into sections. Each section covers a specific ATV component or
system and, in addition to the standard service procedures. Keep this manual available for
reference in the shop area. When using this manual as a guide, the technician should use
discretion as to how much disassembly is needed to correct any given condition.
All references to left and right side of the vehicle are from the operator's perspective when
seated in a normal riding position.
At the time of publication all information contained in this manual was technically correct.
Some photographs used in this manual are used for clarity purposes only and are not
designed to depict actual conditions. We constantly refine and improve its products, all
materials and specifications are subject to change without notice.
This ATV’s publications and decals display the words Warning, Caution, Note, and At This
Point to emphasize important information:
WARNING
Indicates a potential hazard which will result in severe injury or death to the operator,
bystander or person inspecting or servicing the ATV..
CAUTION
Indicates a potential hazard which may result in personal injury or death or damage to the
machine.
NOTE
The word “NOTE” in this manual will alert you to key information or instructions.

CONTENTS
CHAPTER1 ………………………………………………General Information ↖
CHAPTER2 ………………………………………….……………Maintenance
↖
CHAPTER3A…………………………………….……….260 300 400 Engine
↖
CHAPTER3B…………………………………….……….…….…50 80 Engine
↖
CHAPTER3C……………………………………. …. 100 125 150 200Engine
↖
CHAPTER4A…………………………………………..…………………Chassis
↖
CHAPTER4B………………………..……………Chassis (Youth/ mini ATV)
↖
CHAPTER5………………………………………………….………Final Drive
↖
CHAPTER6……………………………………………….………Transmission
↖
CHAPTER7………………………………………………………………Brakes
↖
CHAPTER8………………………………………………….….………Electrical
↖
CHAPTER9………………………………………………….520 Maintenance
↖
Attachment: Delphi Small Engine Management System Service Manual

WARNING
Never run an engine in an enclosed area. Carbon monoxide exhaust gas is
poisonous and can cause severe injury or death. Always start engines outdoors.
Gasoline is extremely flammable and explosive under certain conditions. Battery
electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with
skin, eyes or clothing. Always keep alert and wear protection..
Exhaust system components are very hot during and after use of ATV. Never service
when the engine is warm or hot. Escaping steam from cooling system or hot oil from the
machine can cause severe burns. The engine must be cool before service.
Crate of the ATV and parts in the ATV maybe have sharp edge, always pay attention
and wear protection.

CHAPTER 1 GENERALINFORMATION ATVSERVICEMANUAL09.0
CHAPTER1 GENERAL PAGE.1-
1
CHAPTER 1 GENERAL INFORMATION
WARNING
The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have
almost same appearance. Always refer to Parts Manual of each ATV model for spare parts
information and service.
1.1 IMPORTANT INFORMATION
1.2 V.I.N AND ENGINE SERIAL NUMBER
1.3 VEHICLE DIMENSIONS

CHAPTER 1 GENERALINFORMATION ATVSERVICEMANUAL09.0
CHAPTER1 GENERAL PAGE.1-
2
1.1 IMPORTANT INFORMATION
PREPARATION FOR REMOVAL PROCEDURES
1. Remove all dirt, mud, dust and foreign material before removal and disassembly.
2. Use proper tools and cleaning equipment.
3. When disassembling the machine, always keep mated parts together. This includes gears,
cylinders, pistons and other parts that have been ”mated ”through normal wear. Mated part must
always be reused or replaced as an assembly.
4. During machine disassembly, clean all parts and place them in trays in the order of disassembly.
This will speed up assembly and allow for the correct installation of all parts.
5. Keep all parts away from any source of fire.
REPLACEMENT PARTS
Use only genuine parts for all replacements. Use recommended oil and grease for all lubrication
jobs. Other brands may be similar in function and appearance, but inferior in quality.
GASKETS,OIL SEALS AND O-RINGS
1. Replace all gaskets seals and O-rings when overhauling the engine. All gasket surfaces, oil seal
lips and O-rings must be cleaned.
2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips.
LOCK WASHERS/PLATES AND COTTER PINS
Replace all lock washers/plates and cotter pins
after removal. Bend lock tabs along the bolt or
nut flats after the bolt or nut has been tightened
to specification.
BEARINGS AND OIL SEALS
Install bearings and oil seals so that the
manufacturer’s marks or numbers are visible.
When installing oil seals, apply a light coating of
lightweight lithium base grease to the seal lips.
Oil bearings liberally when installing, if
appropriate.
①oil seal
CAUTION:
Do not use compressed air to spin the bearings
dry. This will damage the bearing surfaces.
①Bearing
CIRCLIPS
1. Check all circlips carefully before reassembly.

CHAPTER 1 GENERALINFORMATION ATVSERVICEMANUAL09.0
CHAPTER1 GENERAL PAGE.1-
3
Always replace piston pin clips after one use.
Replace distorted circlips. When installing a
circlip①, make sure that the sharp-edged
corner ②is positioned opposite the thrust
③it receives. See sectional view.
④Shaft
CHECKING OF CONNECTIONS
Dealing with stains, rust, moisture, etc. on the
connector.
1. Disconnect:
zConnector
2. Dry each terminal with an air blower.
3. Connect and disconnect the connector two or
three.
4. Pull the lead to check that it will not come off.
5. If the terminal comes off, bend up the pin ①
and reinset the terminal into the connector.
6. Connect:
zConnector
NOTE:
The two connectors ” click ” together.
7. Check for continuity with a tester.
NOTE:
zIf there is no continuity, clean the terminals.
zBe sure to perform the steps 1 to 7 listed
above when checking the wire harness.
zUse the tester on the connector as shown.
WARNING
Never run an engine in an enclosed area. Carbon monoxide exhaust gas is poisonous and
can cause severe injury or death. Always start engines outdoors.
Gasoline is extremely flammable and explosive under certain conditions. Battery electrolyte is
poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing.
Always keep alert and wear protection..
Exhaust system components are very hot during and after use of ATV. Never service when
the engine is warm or hot. Escaping steam from cooling system or hot oil from the machine can
cause severe burns. The engine must be cool before service.
Crate of the ATV and parts in theATV maybe have sharp edge, always pay attention and wear
protection.

CHAPTER 1 GENERALINFORMATION ATVSERVICEMANUAL09.0
CHAPTER1 GENERAL PAGE.1-
4
CONVERSION TABLE
How to use the CONVERSION TABLE
Use this table to convert METRIC unit data to IMPERIAL unit data.
Ex.
METRIC MULIPLIER IMP
**mm x 0.3937 = **in
**cm x 0.03937 = **in
CONVERSION TABLE
METRIC TO IMP
Known Multiplier Result
Torque m·kg
m·kg
cm·kg
cm·kg
7.233
86.794
0.0723
0.8679
ft·lb
In·lb
ft·lb
In·lb
Weight kg
g 2.205 0.03527 lb oz
Distance km/h
km
m
m
cm
mm
0.6214
0.6214
3.281
1.094
0.3927
0.03927
mph
mi
ft
yd
in
in
Volume/
Capacity cc(cm3) cc(cm3)
lit(liter)
lit(liter)
0.03527
0.06102
0.8799
0.2199
oz(IMP liq.)
cu·in
qt (IMP liq.)
gal(IMP liq.)
Miscellaneous kg/mm
kg/cm2
Centigrade
55.997
14.2234
9/5(℃)+32
lb/in
psi(lb/in2 )
Fahrenheit(°F)

CHAPTER 1 GENERALINFORMATION ATVSERVICEMANUAL09.0
CHAPTER1 GENERAL PAGE.1-
5
1.2 V.I.N AND ENGINE SERIAL NUMBER
ATV 260 / 300 / 400-2 /400-2B
Mini / Youth

CHAPTER 1 GENERALINFORMATION ATVSERVICEMANUAL09.0
CHAPTER1 GENERAL PAGE.1-
6
1.3 VEHICLE DIMENSIONS
Note.
The on-road equipments (rear view mirror, turn lights, etc.) are not Standard Equipment for USA.
2004 2005
DEMON
Special Edition - Anniversary
Mini / Youth B-Type
ATV400-2 ATV400-2B
520ATV 520ATV-B

CHAPTER 1 GENERALINFORMATION ATVSERVICEMANUAL09.0
CHAPTER1 GENERAL PAGE.1-
7
ATV 260 / 300
’05 Model ATV 260 / 300

CHAPTER 1 GENERALINFORMATION ATVSERVICEMANUAL09.0
CHAPTER1 GENERAL PAGE.1-
8
Demon ATV 260 / 300 Europe
Mini / Youth

CHAPTER 1 GENERALINFORMATION ATVSERVICEMANUAL09.0
CHAPTER1 GENERAL PAGE.1-
9
Special Edition - Anniversary
B-Type 260/ 300

CHAPTER 1 GENERALINFORMATION ATVSERVICEMANUAL09.0
CHAPTER1 GENERAL PAGE.1-
10
B-Type 150/ 200
ATV 400-2

CHAPTER 1 GENERALINFORMATION ATVSERVICEMANUAL09.0
CHAPTER1 GENERAL PAGE.1-
11
ATV 400-2B
ATV 520

CHAPTER 1 GENERALINFORMATION ATVSERVICEMANUAL09.0
CHAPTER1 GENERAL PAGE.1-
12
ATV 520-B

CHAPTER 1 GENERALINFORMATION ATVSERVICEMANUAL09.0
CHAPTER1 GENERAL PAGE.1-
13
NOTES