Linhai LH1100U-D User manual
SERVICE MANUAL
LH1100U-D
2019.0
Foreword
This manual is designed primarily for use by the UTV 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 UTV 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 UTV’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 UTV.
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…………………………………….………. ………………Chassis
↖
CHAPTER4…………………………………………..………………Final Drive
↖
CHAPTER5………………………………………………….……………Brakes
↖
CHAPTER6……………………………………………….………Transmission
↖
CHAPTER7…………………………………………Rear and Front Gearcase
↖
CHAPTER8………………………………………………….….………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 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 UTV and parts in the UTV maybe have sharp edge, always pay attention
and wear protection.
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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 INFORMAT ION
1.2 V.I.N AND ENGINE SERIAL NUMBER
1.3 VEHICLE DIMENSIONS
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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
CIRCLIPS
1. Check all circlips carefully before reassembly.
Always replace piston pin clips after one use.
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Replace distorted circlips. When installing a
circlip ①, 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:
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 reinset 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.
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.
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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)
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1.2 V.I.N AND ENGINE SERIAL NUMBER
Record the frame VIN and the engine serial number from your UTV in the spaces provided.
Frame VIN (found on the front right side of the frame tube)
The vehicle frame is important for model identification when registering your vehicle, obtaining
insurance or whenever replacement parts are required. In the event your vehicle were stolen these
numbers are essential to the recovery and identification of your UTV.
The engine serial numbers are punched on the surface of the crankcase
Engine number
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1.3 VEHICLE DIMENSIONS
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NOTES
This manual suits for next models
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