Linhai ARCHON 400 User manual

SERVICE MANUAL
ARCHON 400

NOTICE
This manual was produced by the Linhai Group primarily for use by Linhai dealers
and their qualified mechanics. It is not possible to include all the knowledge of a
mechanic in one manual, so it is assumed that anyone who uses this book to perform
maintenance and repairs on Linhai vehicle has a basic understanding of the
mechanical ideas and the procedures of vehicle repair. Repairs attempted by anyone
without this knowledge are likely to render the vehicle unsafe and unfit for use.
Linhai Group is continually striving to improve all its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized
Linhai dealers and will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following
notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT!
YOUR SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe
injury or death to the vehicle operator, passenger, a bystander, or
a person checking or repairing the vehicle.
CAUTION: A CAUTION indicates special precautions that must be taken to
avoid damage to the vehicle.
NOTE: A NOTE provides key information to make procedures easier or
clearer.

CONTENTS
CHAPTER1 ……………………………………………………….General Information
CHAPTER2 ………………………………………….……………………Maintenance
CHAPTER3…………………………………….……….….…………………….Engine
CHAPTER4…………………………………………..…………………………Chassis
CHAPTER5………………………………………………….……………….Final Drive
CHAPTER6……………………………………………….………………Transmission
CHAPTER7………………………………………………………………………Brakes
CHAPTER8………………………………………………….….……………..Electrical

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 UTV. 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 UTV and parts in the UTV maybe have sharp edge, always pay attention
and wear protection.

CHAPTER 1 GENERALINFORMATION BUCK 450 SERVICE MANUAL 20.0
CHAPTER 1 GENERAL INFORMATION PAGE. 1-
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CHAPTER 1 GENERAL INFORMATION
The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have
almost same appearance. Always refer to Parts Manual of each UTV 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 BUCK 450 SERVICE MANUAL 20.0
CHAPTER 1 GENERAL INFORMATION PAGE. 1-
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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

CHAPTER 1 GENERALINFORMATION BUCK 450 SERVICE MANUAL 20.0
CHAPTER 1 GENERAL INFORMATION PAGE. 1-
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CIRCLIPS
1. Check all circlips carefully before reassembly.
Always replace piston pin clips after one use.
Replace distorted circlips. When installing a
circlip ①, make sure that the sharp-edged
corner ②is positioned opposite the thrust ③
it receives. See sectional view ④Shaft.
CHECKING OF CONNECTIONS
Dealing with stains, rust, moisture, etc. on the
connector.
1. Disconnect:
Connector
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 reinsert the terminal into the connector.
6. Connect:
Connector
NOTE:
The two connectors ” click ” together.
7. Check for continuity with a tester.
NOTE:
If there is no continuity, clean the terminals.
Be sure to perform the steps 1 to 7 listed
above when checking the wire harness.
Use the tester on the connector as shown.
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 CUV. 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 CUV and parts in the CUV maybe have sharp edge, always pay attention and wear
protection.

CHAPTER 1 GENERALINFORMATION BUCK 450 SERVICE MANUAL 20.0
CHAPTER 1 GENERAL INFORMATION PAGE. 1-
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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 BUCK 450 SERVICE MANUAL 20.0
CHAPTER 1 GENERAL INFORMATION PAGE. 1-
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1.2 V.I.N AND ENGINE SERIAL NUMBER
The vehicle identification number
○
1
is stamped into the front of the frame tube.
The engine serial number
○
1
is stamped into left side of engine crankcase.

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CHAPTER 1 GENERAL INFORMATION PAGE. 1-
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1.3 VEHICLE DIMENSIONS

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CHAPTER 1 GENERAL INFORMATION PAGE. 1-
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NOTES

CHAPTER 2 MAINTENANCE BUCK 450 SERVICE MANUAL 20.0
CHAPTER 2 MAINTENANCE
The parts of different types/ variants/ versions maybe un-interchangeable, even some parts
have almost same appearance. Always refer to Parts Manual of each UTV model for spare
parts information and service.
2.1 PERIODIC MAINTENANCE
2.2 THROTTLE PEDAL INSPECTION
2.3 FUEL SYSTEM
2.4 TOE ALIGNMENT
2.5 BRAKING SYSTEM INSPECTION
2.6 SUSPENSION SPRING RPELOAD ADJUSTMENT
2.7 WHEELS
2.8 TIRE PRESSURE
2.9 FRAME, NUTS, BOLTS, FASTENERS
CHAPTER 2 MAINTENANCE PAGE. 2-
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CHAPTER 2 MAINTENANCE BUCK 450 SERVICE MANUAL 20.0
2.1 PERIODIC MAINTENANCE
GENARAL
CAUTION
Mark on the following chart
D ：Due to the nature of the adjustments marked with a D on the f
ollowing chart, it is
recommended that service be performed by an authorized dealer.
More often under severe use, such as dirty or wet conditions
to purge water or dirt
contamination from grease fittings and other critical components.
PERIODIC MAINTENANCE SCHEDULE
Careful periodic maintenance will help keep your vehicle in t
he safest, most reliable condition.
Inspection, adjustment and lubrication
intervals of important components are explained in the
following chart on the following pages.
NOTE:
Maintenance intervals are based upon average riding conditions and an average vehicle
speed of approximately 16 km/ 10 miles per hour. However, keep in mind that if the vehicle isn’t
used for a long period of time, the month maintenance intervals should be followed.
Vehicles subjected to severe use, such as operation 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 use genuine parts
available from your dealer.
Service and adjustments are critical. If you are not familiar with safe service and adjustment
procedures, have a qualified dealer perform these operations.
Item
Hours
When
Remarks

Brake System
Pre-ride
Pre-ride
Pre-ride inspection item
Accelerator pedal
Pre-ride Pre-ride Inspect –
adjust, lubricate,
replace if necessary; pre-ride
inspection item
Fuel System Pre-ride Pre-ride Check for leaks at tank cap,
lines, fuel valve and filter

Tires Pre-ride Pre-ride Inspect daily, pre-ride
inspection
item

Front and Rear Wheels/
Hubs
Pre-ride
Pre-ride
Pre-ride inspection item

Steering Pre-ride Pre-ride Inspect daily, lubricate
D Wheels bearings 10 hrs Monthly Check for looseness/ damage.
Replace if damaged.
Frame nuts, bolts
fasteners
Pre-ride Pre-ride Pre-ride inspection item

Air Filter-Pre-Cleaner Daily Daily Inspect-Clean
CHAPTER 2 MAINTENANCE PAGE. 2-
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CHAPTER 2 MAINTENANCE BUCK 450 SERVICE MANUAL 20.0
Item
Hours
When
Remarks
Coolant/Level Inspection Daily Daily Replace engine coolant every
one year

Air Box Sediment Tube
Daily
Daily
Drain deposits whenever visible
Headlamp Inspection Daily Daily Check operation daily; apply
dielectric grease
to connector
when replaced
Tail/ indicator lamp
inspection Daily Daily Check operation daily; apply dielectric grease to socket when
replaced

Air Filter-Main Element
Weekly
Weekly
Inspect –Replace if necessary
Battery 20 hrs Monthly Check/clean Terminals; check
fluid level
D
Brake pad wear 10 hrs Monthly Inspect periodically

Rear Gear case Oil 100 hrs Monthly Check monthly and change
annually

Front Gear case Oil 100 hrs Monthly Check monthly and change
annually
Engine Cylinder Head
and Cylinder Base
Fasteners
25 hrs 3 months Inspect (re-
torque required at
first service only)

General Lubrication 50 hrs 3 months Lubricate all fittings,
pivots, cables, etc.

Engine
Oil-Level/Change 30 hrs 3 months Check Level Daily; Break in Service at 1 month. Change oil
more often in cold weather use.
Engine breather hose
100 hrs
6 months
Inspect strength seasonally
D Throttle Cable/
Accelerator pedal
20 hrs monthly Inspect –
adjust, lubricate,
replace if necessary; pre-ride
inspection item
Coolant strength 100 hrs 6 months Inspect strength seasonally
Shift linkage 50 hrs 6 months Inspect, adjust
D
Drive belt 50 hrs 6 months Inspect, replace if
Necessary
CHAPTER 2 MAINTENANCE PAGE. 2-
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CHAPTER 2 MAINTENANCE BUCK 450 SERVICE MANUAL 20.0
Item
Hours
When
Remarks
D
Steering system 50 hrs 6 months
Check operation and for
looseness, worn, damage,
binding feeling / Adjust, repair,
Replace if necessary.
Check toe
alignment /Adjust if
necessary.
D
Toe adjustment
As
required
As
required
Periodic inspection,
adjust when parts are
replaced
D FrontAxle (CV Joints) 10 hrs Monthly Check for/ Axle boots/
looseness/ damage.
D
Rear Axle (CV Joints)
10 hrs
Monthly
Check for/ Axle boots/
looseness/ damage.

Front Prop Shaft＆Shaft
Yoke
50 hrs 6 months Check for looseness/ damage.

Rear Prop Shaft 50 hrs 6 months Check for looseness/ damage.

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
necessary
D Ignition Timing 100 hrs 12
months Inspect and adjust as needed
D
Fuel System 50 hrs 6 months Check for leaks at tank
cap, lines, fuel valve, filter, and
carburetor. Replace lines every
one year
D Fuel Filter 100 hrs 12
months
Replace annually
Radiator 100 hrs 12
months Inspect/clean external surface
Cooling System hoses 50 hrs 6 months Inspect/replace if
necessary
Spark arrestor 10 hrs monthly Clean out-replace if
necessary
D Clutches (drive and
driven) 25 hrs 3 months Inspect, clean
Engine mounts
25 hrs
3 months
Inspect
D
Valve clearance
100 hrs
12
months
Inspect/adjust
D Brake fluid 200 hrs 24
months Change every two years
CHAPTER 2 MAINTENANCE PAGE. 2-
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CHAPTER 2 MAINTENANCE BUCK 450 SERVICE MANUAL 20.0
Item
Hours
When
Remarks
HeadlightAim As
required
As
required
Adjust if necessary
LUBRICATION RECOMMENDATIONS
Item
Lube Rec
Method
Frequency

1. Engine
Oil SAE 15W/40SJ Add to proper level on dipstick Check level daily
2.Brake Fluid
DOT 3 Only
Add to proper level
above the minimum level
mark and replenish if
necessary
As require;
change
every two years
or 200 hours
3.Transmission Oil SAE
GL-4 85W/90 Add to proper
level on dipstick
Change annually
or at
100 hours
4
.Rear Gear case
oil SAE
GL-4 85W/90 200ml
Change annually
or
at 100 hours
5.Front
Gear case
oil SAE
GL-4 85W/90 200ml
Change annually
or
at 100 hours
CHAPTER 2 MAINTENANCE PAGE. 2-
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CHAPTER 2 MAINTENANCE BUCK 450 SERVICE MANUAL 20.0
Item
Lube Rec
Method
Frequency

6.Steering system Grease Lubricate the pivoting
and sliding parts
Every 3 months
or 50 hours

7.Tie rods
Grease
Grease
Semi-annually

8.Shift
Linkages
Grease Locate fittings
and Grease
Semi-annually

9.Front Wheel
bearings Inspect Inspect and replace bearings if
necessary
Semi-annually

10.Ball joints Grease Inspect, Locate fittings
and Grease, or replace it
if necessary
Semi-annually

11.Prop Shaft ＆Shaft
Yoke, Spline Joint
Grease Locate fitting and Grease Semi-annually

12. Front/RearA-arm
pivot Shaft Grease Locate fitting on pivot shaft and
grease with
grease gun
Every 3 months
or 50 hours

13.Throttle
Cable Grease M Grease, inspect and replace it if
necessary
Monthly or 20
hours

14. Accelerator pedal
and brake pedal Grease Grease, inspect
Monthly or 20
hours

15.Rear Wheel
Bearing Inspect
Inspect and replace
bearings if
necessary
Semi-annually
NOTE:
1. More often under severe use, such as wet or dusty conditions .
2. Grease: Light weight lithium-soap grease.
3. Grease 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.
CHAPTER 2 MAINTENANCE PAGE. 2-
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CHAPTER 2 MAINTENANCE BUCK 450 SERVICE MANUAL 20.0
2.2 THROTTLE PEDAL INSPECTION
THROTTLE FREEPLAY
If the throttle pedal has excessive play due to cable
stretch or cable misadjustment, it will cause a delay
in throttle speed.Also, the throttle may not open fully.
If the throttle pedal has no play, the throttle may be
hard to control, and the idle speed may be erratic.
Check the throttle pedal play periodically in
accordance with the Periodic Maintenance Chart
and adjust the play if necessary.
THROTTLE FREEPLAY INSPECTION
1. Apply the parking brake.
2. Put the gear shift lever in the N(Neutral) position.
3. Start the engine, and warm it up thoroughly.
4. Measure the distance the throttle pedal moves
before the engine begins to pick up speed. Free
play should be 1.5 – 3 mm.
Adjustment
1. Slide the boot off inline cable adjuster sleeve.
Loosen adjuster locknut.
2. Turn adjuster until 1.5 to 3 mm, freeplay is
achieved pedal. NOTE: While adjusting freeplay,
it is important you flip the throttle lever back and
forth.
3. Tighten locknut.
CHAPTER 2 MAINTENANCE PAGE. 2-
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CHAPTER 2 MAINTENANCE BUCK 450 SERVICE MANUAL 20.0
2.3 FUEL SYSTEM
EFI
Always stop the engine and refuel
outdoors or in a well venltilated area.
Do not smoke or allow open flames or
sparks in or near the area where
refueling is performed or where gasoline
is stored.
Do not overfill the tank. Do not fill the tank neck.
If you get fuel in your eyes or if you swallow gasoline, see your doctor immediately.
If you spill fuel 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. Fuel powered engine exhaust
fumes are poisonous and can cause loss of consciousness and death in a short time.
Never drain the float bowl when the engine is hot. Severe burns may result.
FUEL LINES
1. Check fuel lines for signs of wear,
deterioration, damage or leakage.
Replace if necessary.
2. Be sure fuel lines are routed
properly and secured with cable
ties.
CAUTION:
Make sure lines are not kinked or
pinched.
Replace all fuel lines every two years.
VENT LINES AND ROLL OVER VALVE
1. Check fuel tank, oil tank, battery and
transmission vent lines for signs of wear,
deterioration, damage of leakage. Replace every
two years.
2. Be sure vent lines are routed properly and
secured with cable ties.
CHAPTER 2 MAINTENANCE PAGE. 2-
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CHAPTER 2 MAINTENANCE BUCK 450 SERVICE MANUAL 20.0
CAUTION: Make sure lines are not kinked or
pinched.
NOTE: Make sure the↑mark on the roll over valve is
upwards.
2.4 TOE ALIGNMENT
METHOD: STRAIGHTEDGE OR STRING
Be sure the steering wheel in a straight ahead
position.
NOTE: String should just touch side surface of rear
tire on each side of the UTV.
Measure from string to rim at front and rear of rim.
Rear rim measurement (A) should be 1/8" to 1/4" (3
to 6 mm) more than front rim measurement (B).
Always pay attention to tie rods assembly, Both ends
must screw in same and enough threads length.
2.5 BRAKING SYSTEM INSPECTION
The following checks are recommended to keep the
braking system in good operating condition. Service life of
braking system components depends on operating
conditions. Inspect brakes in accordance with the
maintenance schedule and before each ride.
Keep fluid level in the master cylinder reservoir to the
indicated level on reservoir.
Use DOT 3 brake fluid.
NOTE: Use new brake fluid or brake fluid from a sealed
container to avoid contamination to system.
Check brake system for fluid leaks.
Check brake for excessive travel or spongy feel.
Check friction pads for wear, damage and looseness.
Check surface condition of the disc.
CHAPTER 2 MAINTENANCE PAGE. 2-
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