Linhai HY510S User manual

2014 ATV
SERVICE MANUALEUROPE 14.0
PN. F010102A14
● ATV 500-D
493cc
Cette revue concerne les modèles suivants :
HY510S - HY500 60ème - HY500T - HY510IS - HY500IS - HY540ST - HY540STL
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

ATV SERVICE MANUAL EUROPE 14.0
PN. F010102A14
LH500ATV-D 维修手册欧标英文 版本 14.0 零件代号 F010102A14

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
↖
CHAPTER3……………………………………. …. ………………500 Engine
↖
CHAPTER4…………………………………………..…………………Chassis
↖
CHAPTER5………………………………………………….………Final Drive
↖
CHAPTER6………………………………………………………………Brakes
↖
CHAPTER7………………………………………………….….………Electrical
↖

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 ofATV. 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 LH500ATV-DSERVICEMANUAL14.0
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 LH500ATV-DSERVICEMANUAL14.0
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.
 oil seal
CAUTION:
Do not use compressed air to spin the bearings
dry. This will damage the bearing surfaces.
 Bearing

CHAPTER 1 GENERALINFORMATION LH500ATV-DSERVICEMANUAL14.0
CHAPTER1 GENERAL PAGE.1-
3
CIRCLIPS
1. Check all circlips carefully before reassembly.
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 the ATV maybe have sharp edge, always pay attention and wear
protection.

CHAPTER 1 GENERALINFORMATION LH500ATV-DSERVICEMANUAL14.0
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(cm
3
)
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 LH500ATV-DSERVICEMANUAL14.0
CHAPTER1 GENERAL PAGE.1-
5
1.2 V.I.N AND ENGINE SERIAL NUMBER

CHAPTER 1 GENERALINFORMATION LH500ATV-DSERVICEMANUAL14.0
CHAPTER1 GENERAL PAGE.1-
6

CHAPTER 1 GENERALINFORMATION LH500ATV-DSERVICEMANUAL14.0
CHAPTER1 GENERAL PAGE.1-
7
1.3 VEHICLE DIMENSIONS
Note.
The on-road equipments (rear view mirror, turn lights, etc.) are not Standard Equipment for USA.
ATV 500

CHAPTER 1 GENERALINFORMATION LH500ATV-DSERVICEMANUAL14.0
CHAPTER1 GENERAL PAGE.1-
8
NOTES

CHAPTER 2 MAINTENANCE LH500ATV-DSERVICEMANUA14.0
CHAPTER 2 MAINTENANCE PAGE. 2- 1
CHAPTER 2 MAINTENANCE
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.
2.1 PERIODIC MAINTENANCE
2.2 FUEL SYSTEM
2.3 TOE ALIGNMENT
2.4 BRAKING SYSTEM INSPECTION
2.5 SUSPENSION SPRING RPELOAD ADJUSTMENT
2.6 WHEELS
2.7 TIRE PRESSURE
2.8 FRAME, NUTS, BOLTS, FASTENERS

CHAPTER 2 MAINTENANCE LH500ATV-DSERVICEMANUA14.0
CHAPTER 2 MAINTENANCE PAGE. 2- 2
2.1 PERIODIC MAINTENANCE
GENARAL
CAUTION
Mark on the following chart
DL ：Due to the nature of the adjustments marked with a DL on the following chart, it is
recommended that service be performed by an authorized dealer.
▲：Service/Inspect more frequently when operating in adverse conditions.
PERIODIC MAINTENANCE SCHEDULE
Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition.
Inspection, adjustment and lubrication intervals of important components are explained in the
following chart on the following pages.
Maintenance intervals are based upon average riding conditions and an average vehicle
speed of approximately 16km/h (10 miles per hour). 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.
A = Adjust I = Inspect
C = Clean L = Lubricate
D = Drain R = Replace
T =Tighten to Correct Torque
Item Hours When Remarks
Service (Main) Brake
System
/ Pre-ride
I
Auxiliary (Secondary) Brake / Pre-ride I
Parking Brake / Pre-ride I
Tires / Pre-ride I
Wheels / Pre-ride I
Frame nuts, bolts fasteners / Pre-ride I
▲Air Filter-Pre-Cleaner / Daily I C
Coolant/Level / Daily I
Coolant 150 Annually R

CHAPTER 2 MAINTENANCE LH500ATV-DSERVICEMANUA14.0
CHAPTER 2 MAINTENANCE PAGE. 2- 3
Coolant strength 25 hrs 3 months I Inspect strength seasonally
▲Air Box Sediment Tube / Daily D
Headlamp Inspection / Daily C
apply dielectric grease to connector when
replaced
Tail lamp inspection / Daily C
apply dielectric grease to socket when
replaced
▲Air Filter-Main Element 2 Weekly I C
Replace if necessary
▲Transmission Oil Level 10 Monthly I
change annually
Battery Terminals 10 Monthly I C
Battery fluid level 10 Monthly I
DL Brake pad wear 2 Weekly I
▲Gear case Oil 10 Monthly C
150 annually R
Engine Cylinder Head and
Cylinder Base Fasteners
25 3 months I
(re-torque required at first service only)
▲General Lubrication
all fittings, pivots, cables,
etc.
25 3 months L
Engine Oil-Level / Daily I
Engine Oil Change 30 hrs 3 months R
Break-in Service at 1 month. Change oil more
often in cold weather use.
▲Oil Filter 50 hrs 6 months I C
▲Engine breather hose 100 hrs 6 months I
Carburetor Float Bowl 50 hrs 6 months Drain bowl periodically and prior to storage
Throttle Cable / Pre-ride I
DL Throttle Cable 50 hrs 6 months A L (Grease M) R if necessary
Shift linkage 50 hrs 6 months I A R if necessary
DL Transmission belt 50 hrs 6 months I
R if necessary
▲Steering 50 hrs 6 months I L T if necessary
▲Rear Axle ( and Bearings) 50 hrs 6 months I L

CHAPTER 2 MAINTENANCE LH500ATV-DSERVICEMANUA14.0
CHAPTER 2 MAINTENANCE PAGE. 2- 4
▲Front Suspension 50 hrs 6 months I L
T if necessary
▲Rear Suspension 50 hrs 6 months I
T if necessary
Spark Plug 100 hrs 12 months I
R if necessary
DL Ignition Timing 100 hrs 12 months I
Adjust as needed
DL Fuel System 100 hrs 12 months Check for leaks at tank, cap, lines, fuel valve,
filter, and carburetor. Replace lines every 2
years.
DL Fuel Filter 100 hrs 12 months R
Radiator 100 hrs 12 months I R
Cooling System hoses 50 hrs 6 months I
R if necessary
Spark arrestor 10 hrs monthly C
R if necessary
DL Clutches (drive and Driven) 25 hrs 3 months I R
R if necessary
Engine mounts 25 hrs 3 months I T
DL Valve clearance 100 hrs 12 months I A
DL Shift selector box
(H/L/R/N)
200 hrs 24 months Change grease every two years
DL Brake fluid Level / Pre-ride I
Brake fluid 200 hrs 24 months Change every two years
Idle Speed / As
Required
A
DL Toe adjustment / As
Required
Periodic inspection, adjust when parts are
replaced
Headlight Aim / As
Required
Adjust if necessary
▲
DL
Front drive chain (and
sprockets) in transmission
(only SDX300 );
300 hrs (full time in
4X4), or 1000 hrs ( in
2X4 alternate 4X4 )
I, Replace if necessary
▲
DL
Ball joint (A arm- strut) 10 hrs monthly I, (for damage, wear, and play)
R. Replace if necessary

CHAPTER 2 MAINTENANCE LH500ATV-DSERVICEMANUA14.0
CHAPTER 2 MAINTENANCE PAGE. 2- 5
LUBRICANT AND FLUID
Item Lube Rec Method Frequency
1. Engine Oil SAE 15W/40 SE Add to proper
level on dipstick
Check level daily
2. Brake Fluid DOT 3 Only Maintain level
Between fill lines. See
“7.CONTROL”
As require; change
every two years or 200
hours
3. Transmission Oil SEA 80W/90GL5 Add to proper
level on dipstick
Change annually or at
100 hours
4.Rear Gear case oil SEA 80W/90GL5 Add to proper
level
Change annually or
at 100 hours
5. Front Gear case
oil ( SDX30-0 )
SEA 80W/90GL5 Add to proper
level
Change annually or
at 100 hours
▲6. Front A-arm
pivot Shaft
Grease Locate fitting on pivot shaft
and grease with grease gun
Every 3 months or 50
hours
( Except
Maintenance-Free
A-arm pivot )
▲7.Steering
Post Bushings
Grease Locate fitting on
pivot shaft and
grease with grease gun
Every 3 months or 50
hours
▲8.Front Wheel
bearings
Grease
(high temperature
resist)
Inspect and replace bearings if
necessary
Semi-annually
9.Tie rods Grease Locate fittings and grease Semi-annually
10.Shift
Linkages
Grease Locate fittings and grease Semi-annually
▲11.Ball joints Inspect Inspect and replace it if
necessary
Semi-annually
▲12.Rear Axle
Bearing
Grease Locate fittings and grease Every 3 months or 50
hours
▲13.Swing Arm
Bearing
Grease Locate fittings and grease Monthly or 20 hours
▲14.Throttle
Cable
Grease M Grease, inspect and replace it
if necessary
Monthly or 20 hours
15. Rear prop shaft
U-joint
Grease Locate fittings and grease Every 3 months or 50
hours
16. Rear prop shaft
yoke
Grease Locate fittings and grease Every 3 months or 50
hours
17. Front prop shaft
U-joint ( SDX300)
Grease Locate fittings and grease Every 3 months or 50
hours
18. Front prop shaft
yoke ( SDX300)
Grease Locate fittings and grease Every 3 months or 50
hours
19. Inner and outer
CV-Joints (SDX300)
Grease M Grease, inspect and replace it
if necessary
Every 3 months or 50
hours
▲
21. A-arm pivot
shaft
Grease Locate fittings and grease Every 3 months or 50
hours

CHAPTER 2 MAINTENANCE LH500ATV-DSERVICEMANUA14.0
CHAPTER 2 MAINTENANCE PAGE. 2- 6
LUBRICATION RECOMMENDATIONS
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.
2.2 FUEL SYSTEM
WARNING
Gasoline is extremely flammable and explosive under certain conditions.
Always stop the engine and refuel outdoors or in a well ventilated 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 gasoline in your eyes or if you swallow gasoline, see your doctor immediately.
If you spill 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 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.

CHAPTER 2 MAINTENANCE LH500ATV-DSERVICEMANUA14.0
CHAPTER 2 MAINTENANCE PAGE. 2- 7
ATV 500
FUEL LINES
Check fuel lines for signs of wear,
deterioration, damage or leakage. Replace if
necessary.
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.
FUEL FILTER
The fuel filter should be replaced in
accordance with the Periodic Maintenance
Chart or whenever sediment is visible in the
filter.
1. Shut off fuel supply at fuel valve.
2. Remove line clamps at both ends of the
filter.
3. Remove fuel lines from filter.
4. Install new filter and clamps onto fuel lines
with arrow pointed in direction of fuel flow.
5. Install clamps on fuel line.