User Manuals: Linhai T-Boss 550 Off Road Vehicle

Manuals and User Guides for Linhai T-Boss 550 Off Road Vehicle. We have 1 Linhai T-Boss 550 Off Road Vehicle manual available for free PDF download: Service Manual

Linhai T-Boss 550 Service Manual

Linhai T-Boss 550 Service Manual (259 pages)

Brand: Linhai | Category: Utility Vehicle | Size: 13.99 MB

Table of Contents

Table of Contents
3
Warning
4
General Information
5
Bearings and Oil Seals
6
Gaskets, Oil Seals and O-Rings
6
Preparation for Removal Procedures
6
Replacement Parts
6
Checking of Connections
7
Circlips
7
Conversion Table
8
VIN and Engine Serial Number
9
Vehicle Dimensions
10
Maintenance
12
Periodic Maintenance Schedule
13
Lubricant and Fluid
16
Choke Adjustment
18
Throttle Freeplay
18
Throttle Pedal Inspection
18
Fuel Lines
19
Fuel System
19
Vent Lines and Roll over Valve
19
Braking System Inspection
20
To Alignment
20
Adjusting the Brake Pedal
21
Adjusting the Parking Brake
21
Brake Pad Inspection
21
Hose/Fitting Inspection
21
Suspension Spring Preload Adjustment
22
Wheel Installation
23
Wheel Removal
23
Frame, Nuts, Bolts, Fasteners
24
Tire Inspection
24
Tire Pressure
24
Tire Tread Depth
24
Chapter 1

26
Chapter2

26
- Engine
  26
- Engine Removal
  28
- Engine Installation
  31
- Engine Overhaul Information
  32
- Fuel, Oil and Coolant
  34
- General Precautions
  34
  - Break-In Procedures
    35
  - Engine Exterior and Engine no
    36
  - Engine Specification
    37
    
    Engine Overhaul Data
    38
    
    Tightening Torques (Engine)
    42
    
    Maintenance Tools
    44
  - Tools
    45
  - Materials for Operation and Fixing
    46
    
    Engine Checks and Adjustments
    47
    
    Periodic Maintenance Table (Engine)
    48
    
    Procedures of Engine Maintenance & Adjustment
    49
  - Valve Clearance
    49
  - Engine Idle Speed
    50
  - Spark Plug
    50
  - Air Filter
    51
  - Drive Belt
    52
  - Fuel Hose
    52
  - Check Engine Oil Level
    54
  - Inspection of Lubrication System
    54
    
    Replacing Engine Oil
    54
    
    Replacing Oil Filter
    55
  - Inspection of Cooling System
    56
  - Inspection of Cylinder Pressure
    57
  - Inspection of Oil Pressure
    58
  - Inspection of Clutch Engagement and Lock-Up
    59
    
    Engine Removal, Inspection & Installation
    60
    
    Oil Filter
    64
    
    Water Pump
    65
    
    Oil Pump Sprocket and Chain
    66
    
    Starting Motor Gear
    66
    
    Cylinder Head Cover Check
    72
    
    Engine Components Inspection
    72
    
    Cylinder Head Check
    73
    
    Rocker Arm Check
    73
    
    Cylinder Head Distortion
    75
    
    Valve Seat Width
    75
    
    Valve Stem and Valve Guide
    75
    
    Valve Stem Deflection
    75
    
    Valve Face Wear
    76
    
    Valve Head Radial Run-Out
    76
    
    Valve Stem End
    76
    
    Valve Stem Run-Out
    76
    
    Assembly of Cylinder Head
    77
    
    Valve Spring
    77
    
    Camshaft
    79
    
    Install Thermostat
    79
    
    Automatic Decompression
    80
    
    Cam Wear
    80
    
    Camshaft Journal Wear
    80
    
    Camshaft Journal O.D.
    81
    
    Camshaft Run-Out
    81
    
    Chain Tensioner Check
    82
    
    Cylinder Check
    82
    
    Piston Check
    83
    
    Connecting Rod/Crankshaft Check
    85
    
    Clutch Check
    86
    
    Primary and Secondary Sheave Diagram
    87
    
    Primary Sliding Sheave Disassembly
    88
    
    Primary Sliding Sheave and Fixed Sheave Check
    89
    
    Primary Sliding Sheave Assembly
    92
    
    Drive Belt Check
    94
    
    Transmission Diagram
    95
    
    Transmission Inspection
    96
    
    Oil Pump Disassembly and Checks
    99
    
    Bevel Gear Washer Adjustment
    101
    
    Driven Bevel Gear Check
    101
    
    Front Output Shaft Check
    101
    
    Bevel Gear Check
    102
    
    Balancer Shaft Inspection
    104
    
    Magneto Rotor
    104
    
    Electric Starter Gear Check
    106
    
    CVT Case
    107
    
    CVT Cover
    107
    
    Crankcase Diagram
    108
    
    Oil Pump and Relief Valve
    109
    
    Connecting Rod
    110
    
    Sector Gear
    117
    
    Starting Motor
    118
    
    Chain Tensioner
    123
    
    Engine Periphery
    124
    
    Water Pipe and Hose
    125
    
    Fuel Injection System
    126
    
    ECU Description and Handling
    128
    
    ECU - Power Requirements
    129
    
    Injector
    129
    
    Injector Installation
    130
    
    Injector Replacement
    131
    
    Throttle Body Assembly Description
    132
    
    Throttle Body Removal
    132
    
    Engine Coolant Temperature Sensor
    133
    
    Intake Airpressure and Temperature Sensor (MAP & MAT)
    133
    
    Throttle Body Installation
    133
    
    Oxygen Sensor
    134
    
    Ignition Coil
    135
    
    Fuel Pump Module
    138
    
    Fuel Module Diagnosis
    140
    
    Fuel Module Installation
    140
    
    Fuel Module Removal
    140
    
    Fuel Leakage Check Procedure
    141
    
    Fuel Pressure Relief Procedure
    141
    
    Motor Scanner
    141
    
    MT05 ECU Malf Code
    147
    
    Cooling and Lubrication System
    148
  - Engine Coolant
    149
  - Inspection of Cooling Circuit
    149
  - Inspection and Cleaning of Radiator and Water Hoses
    150
  - Inspection of Fan Motor
    151
  - Inspection of Thermostat
    152
  - Inspection of Water Temperature Sensor
    152
    
    Water Pump Removal and Disassembly
    153
    
    Inspection of Water Pump
    155
    
    Assembly and Installation of Water Pump
    156
  - Lubrication System Illustration
    160
  - Engine Troubleshooting
    161
  - Faulty Drive Train
    162
  - Faulty Gear Shifting
    163
  - Faulty Clutch
    164
  - Overheating
    164
  - Faulty Lighting or Signaling System
    165
  - Overcooling
    165
  - Poor Braking Performance
    165
  - Unstable Handing
    165
  - Chassis
    167
  - Front A-Arm Replacement
    168
  - Rear A-Arm Replacement
    170
  - Rear Stabilizer Bar Removal/Installation
    173
  - Box Removal/Installation
    174
  - Steering Assembly Removal/Installation
    175
  - Final Drive
    177
  - Front Hub Exploded View
    178
  - Front Hub Removal/Inspection
    178
  - Wheel, Hub and Spindle Torque Table
    178
  - Front Hub Installation
    179
  - Front Drive Axle Removal/Inspection
    180
  - Front Hub Bearing Replacement
    180
Chapter3

182
- Front Drive Axle Disassembly/Inspection
  182
- Front Drive Axle Installation
  182
- Inner CV Joint Inspection
  183
- Front Drive Axle Assembly
  184
Chapter4

185
- Rear Hub Exploded View
  186
- Rear Hub Knuckle Removal/Inspection
  186
- Rear Hub and Knuckle Installation
  187
- Rear Drive Shaft Installation
  188
- Rear Drive Shaft Removal
  188
Chapter5

189
- Rear Carcase Exploded View
  190
- Rear Gearcase Assembly
  195
- Front Gearcase Exploded View
  198
- Front Gearcase Disassembly
  200
- Front Gearcase Assembly
  204
- Brakes
  210
- Brake System Service Notes
  211
- Brakes Specifications
  211
- Brake Bleeding Fluid Change
  212
- Burnishing Procedure
  212
Chapter6

214
Chapter7

225
- Electrical
  225
- Headlight Adjustment
  226
- Headlight Lamp Replacement
  226
- Battery
  227
- Ignition System Troubleshooting
  229
- If the Ignition System Fails to Operate
  230
- Charging System
  234
- Electrics Starting System
  237
- Cooling System
  240
- If the Fan Motor Fails to Turn
  240
- If the Heat Alarm Unit Working
  243
- Lighting System
  245
- Light System Check
  247
- Gear Shift Switch Test
  249
- Switch Table
  250
- Operation of Speed Sensor
  251
- Speedmeter Systm
  251
- Switches
  254
- Fuel Gauge/Fuel Level Sensor
  255
- The Operation Principle of the Electric 4WD Shift
  257
- Wiring Diagram
  258

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