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Service Manual

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1. 7 9 7 9 Installation 7 9 ECT 5 7 10 Removal 7 10 7 10 Installation 7 11 Thermostat 7 12 Removal 7 12 nspection 7 12 Installation 7 13 Water 7 14 Removal and Disassembly 7 14 Reas
2. 3 17 3 17 Foot 3 19 Brake Pedal Inspection 3 19 Brake Pedal Position Adjustment 3 19 Brake Pedal Removal 3 20 Brake Pedal Installation 3 20 Master Cylinder Removal 3 20 Master Cylinder Installation 3 21 3 1 DINLI Construction Rear Brake Assy Bolt 4pcs etes t e 5 a Front Brake Assy I Hex Socket Bok 9 Rear Bake Disc oot brake Sensor 5 umami Hex Socket Bolt 4pcs 21 Washer 17pcs Hose H tao eee _ ange Bolt ope srake BEN EON Brak
3. 10 20 Tightening Torque 10 21 10 21 ChassiS 10 22 Cooling System 10 23 Tightening Torque Chart 10 24 service Data 10 25 10 1 DINLI APPENDIX AW uu JJ L U U U Troubleshooting Guide CAUTION This is not an exhaustive list giving every possible cause for each problem listed It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties Engine Engine Doesn t Start Starting Difficulty 1 Starter motor not rotating e Starter motor trouble e Battery voltage low e Relays not contacting or operating e Starter button not contacting e Wiring open or shorted e Ignition switch trouble e Fuse blown 2 Starter motor rotating but engine doesn t turn over e Starter one way clutch trouble 3 Recoil starter not operating e Recoil starter
4. 2 4 Inspection T 2 5 2 5 ire 2 6 2 6 Installation 2 6 2 8 2 9 Front Hub Removal 2 9 Front Hub Inspection 2 9 Front Hub Installation 2 10 Rear Hub Removal 2 10 Rear Hub Inspection 2 10 Rear Hub Installation 2 11 2 1 DINEI WHEELS TIRES Specifications Tires
5. 4 19 Front Propeller Shaft 4 20 Removal and Disassembly 4 20 Inspection and Reassembly 4 21 Installation 4 23 Rear Propeller Shaft 4 24 4 24 Inspection and Reassembly 4 24 Installation 4 26 Steering 4 27 Construction 4 27 Removal and Disassembly 4 28 nspection 4 30 Reassembly Installation
6. 5 3 Front and Rear Racks Removal 5 3 Front and Rear Racks Installation 5 4 Front and Rear Fenders 5 5 Front Fender Construction 5 5 Front Fender Removal 5 6 Front Fender Installation 5 10 Rear Fender Construction 5 11 Rear Fender Removal 5 12 Rear Fender Installation 5 14 Luggage 5 15 Luggage Compartment Removal Installation 5 15 Drainage Plug Inspection 5 16 5 17 Protector Removal Installation
7. 7 12 Troubleshooting 7 12 7 13 Ignition 5 7 16 Troubleshooting 7 16 Spark Plug Removal Installation 7 17 Spark Plug Cleaning Inspection 7 17 Spark Plug 7 18 Ignition Coil Removal 7 18 Ignition Coil Installation 7 18 Ignition Coil Inspection 7 18 CDI Output 7 19 Starter Relay Inspection 7 19 Main Relay Inspection
8. 6 8 Engine Disassembly 6 10 Engine Side 6 10 Engine Bottom Side 6 14 Inspection 6 23 Camshaft and Cylinder Head 6 23 Cam Chain Tensionet 6 32 Cam Chain Guide 6 32 6 32 Timing 6 34 5 6 35 Connecting 6 37 6 38 Oil Gallery Copper Plug
9. 5 4 __ DINLI Front and Rear Fenders Front Fender Construction Front fender L Clip nut 10pcs Fixed plate 4pcs front ener He waster ast 25 Fed inte pen front fender undercover 15 Hex waster facebo epay Spring _ older over 17 Hex washer face bolt apoy Taping sew 9 Glove compartment cover 18 Machine screw 6pcs 5 5 DINLI Front Fender Removal Maintenance Compartment e Remove the front rack See 5 3 e Remove front fender decoration B by inserting the opening stick into the hole A to open it e Remove the maintenance compartment C by removing its screws and bolts e D x 4 left amp right attach to the front fender e E x 2 left amp right attach to the body decoration e Remove the lead wire of the accessory socket F 5 6 opy __ DINLI Headlight Shade e Remove the front rack See 5 3 e Remove the front fender decoration See 5 6 e Remove the headlight lead wire coupler A e Remove headlight shade by unscrew the screws B x5 e C 6 left amp right attach to the front fender Front Fender Under Cover e Remove the indicator bulb See Electrical System 5 7 e Remove under cover of front fender unscrew screws B x 4 Front Fender Left amp Right e Remove the
10. c 2 aP K d 2 5 Inspect 6 41 EINE I ENGINE oO 0 un O 4 gt O Movable and fixed drive face e Inspect each drive faces for any abnormal conditions such as If any damages ing stepped wear or discoloration caused by burn are found replace the drive faces with new ones e Install the oil seal with the special tool Reassembly e Reassemble the movable and fixed drive face in the reverse order of disassembly e Apply a small amount of GREASE to the bore and oil seal lip gt bD 3 un oO bD un un lt gt 0 gt 4 4 0 Q oO 5 un Q oO e Q 4 un bD gt O Q 0 Q 0 O E O lt 5 0 2 4 lt lt i 4 bD ing roller set make sure 5 front side is ight rollers 1 on the movable drive face faces to the r e Position the movable drive face plate 3 on the movable drive face When install e Mount on the dampers 2 on the movable drive face plate e Pos
11. 7 27 OINLI lt ELECTRICAL SYSTEM Fuel Gauge e Measure the resistance at each fuel level gauge float position If the resistance is incorrect replace the carburetor with a new one F Full Approx 100 E Empty Approx 900 Multi Circuit Tester Set Tester knob indication Resistance Speedometer e If the speedometer odometer or trip meter does not function properly inspect the speed sensor and connection of coupler e If the speed sensor and connection are functioning properly replace the speedometer with a new one 920 949 949 98 808 252 252 RO 98 RO 08 ROO 98 ROO 898 RO 5269 ROO 252 ROO 898 RO 252 252 252 252 252 252 5260 252 ROO 5269 5260 808 RO 252 808 252 ROO 808 ROO 5260 e Remove left mud guard e Disconnect speed sensor coupler 1 e Remove the speed sensor 2 by removing its mounting bolt e Connect 12 V battery resistor and the multi circuit tester as shown in the right illustration Multi Circuit Tester Set Tester knob indication Voltage DCV e Under above condition if a suitable screwdriver touching the pick up surface of the speed sensor is moved the tester reading voltage changes 0 V to 12 V or 12V to If the tester reading voltage does not change replac
12. 9 18 Drive Belt 9 18 Brakes 9 22 Brake Fluid 9 24 Brake 9 25 5 9 26 a 9 27 9 28 Shift 9 28 Reverse Shifting Switch Device 9 29 Chassis Nuts and Bolts 9 30 General Lubrication 9 32 Compression Pressure Check 9 33 Compression Test Procedure 9 33 Oil Pressure Check 9 34 Oil Pressure Test Procedure
13. BRAKE Table of Contents 3 2 Brake Fluid 3 3 Brake Fluid Recommendation 3 3 Brake Fluid Level Inspection 3 4 Brake Fluid Change 3 4 Brake Line Air Bleeding 3 5 Master Cylinder 3 6 3 6 Installation 3 7 3 8 Front Caliper Removal 3 8 Rear Caliper Removal 3 8 Parking Brake Caliper Removal 3
14. gH Fl LII E E ee LE i al 5 E zi E P Es __ il LAMP e EE HH 1 5 35 irc gm En Hh 1 RS m Den ii C n 5 3m L HI L NI EE 1 ia n EE 5 F DF zb am Ex m r P i E m E EP re ung x P ra m E 2 1 E E gt E 7 37 DINEI ELECTRICAL SYSTEM NOTE 7 38 PERIODIC MAINTENANCE PERIODIC MAINTENANCE Table of Contents Periodic Maintenance Schedule 9 2 Periodic Maintenance Chart 9 2 Maintenance and Tune Up Procedures 9 3 Air Cleaner 9 3 Exhaust Pipe Nuts and Muffler Mounting Bolts 9 4 Valv
15. jump rz 715 JUSS ei WET A LOE Gre 562 E eju ezis ullus quie uiuos PIA uar unus SINS aja ue Ed Se Q CT C102813NI8N3 208129 99161 1 562 SIHLSSNOLMOH OWE 36 I dE 020 B 50 s 65 0 Us 0 SF 0 ase os ss o5 sez oez sre are sse owe sez ose sre ure set sec oc TI sss oos see oe sez unc cc o rc sse pez o eee ec occ fcc sic vn one 00 SEC 06 srz rz THERE OFC SPC Ore spel JO 1 12 03 25 BD 0 500 982 082 deus ogc src ort s set aee 81 onc COR ot ss 9 mal FOO 000 1 1 mmm SYAM aZISWIHS devi 35v LN 31891 NOLES3 138 13de v 9 7 INES PERIODIC MAINTENANCE Exhaust Side WU NOD ezis tuis Juss ard gum PONE A Yo Ley DE gE 2 wus ezis Wys 5 pedde Oe x3 SEIS LUIYS
16. found replace stabilizer joint with a new one 4 18 SUSPENSION STEERING DRIVE SHAFT ___ _ lt Rear Stabilizer Installation e Install the stabilizer bar e Tighten the rear stabilizer bracket bolts e Tighten the rear stabilizer joint bolt nut Tightening Torque 34 N m 3 4 kgf m 24 5 Ib ft 4 19 DINLI SUSPENSION STEERING DRIVE SHAFT Front Propeller Shaft isassembly Removal and D Remove the front tire wheel e Remove the front hub by removing its cotter pin and nut e Remove the front suspension see Front Suspension e Hold the inboard joint 1 of the front propeller shaft and tug the propeller shaft horizontally If it is difficult to remove the front drive shaft by hand use the v O Q Q un Hammer Slid ing joint e Remove the boot bands of the differential side joint double offset CAUTION 2 2 un O O 5 gt O lt O e Slide boot toward center of the front propeller shaft and remove the stopper ring from the outer race CAUTION c 2 un 5 gt O lt lt e Separate outer race from the front drive shaft e Wipe off any
17. Y 1 Bore CF 8 1041 TUVH2 sIHI e EY 365 06 Jc OH DO 969 sez 084 560 180 06 0 989 980 180 OSes 320 SO bed 9907190 090 9390 SFE ba 07 Srt FO OF 09 88 0 SET oet 60 570 601 520 00 000 tu 124471 iZlsWiHSdNdJSdud 0 Uxx s000813 ON 23138 WHS Ide t 9 8 PERIODIC MAINTENANCE 7 Spark Plug Inspect every 2000 km 100 hours 6 months Replace every 6000km e Remove the front fender e Disconnect the high voltage cable 1 and remove the spark plug Cold Type 31 e Check to see if there are carbon deposits on spark plug If carbon is deposited remove it with a spark plug cleaner machine or carefully use a tool with a pointed end e Measure the spark plug gap with a thickness gauge If the spark plug gap is out of specification adjust the gap Spark Plug Gap 0 7 0 8 mm 0 7 0 8 mm Wire Gauge e Check condition of electrode e If the electrode is extremely worn or burnt replace the spark plug with a new one e Also replace the spark plug if it has a broken insulator damaged threads etc CA
18. lt un e e Remove the thermostat cover 1 e Remove the thermostat Cam Chain Tensioner Thermostat Inspection smoothly when releasing stopper e If it does not slide smoothly replace the cam chain tensioner with a new one 6 32 DINLI ENGINE e Check the contacting surface of the cam chain guide for wear and Cam Chain Guide Inspection damage If the largest reading at every position of the straightedge exceeds the straightedge and thickness gauge taking a clearance reading at Check the gasketed surface of the cylinder for distortion with a several places as indicated e If it is found to be damaged replace it with a new one Cylinder distortion Cylinder t replace the cylinder limi Cylinder Distortion 0 05 mm Service Limit Thickness Gauge inder e Different color on the cover of outside cylinder water pipe Recognize Cyl Yellow means A level Pink means B level e A Piston has to be matched with A cylinder B Piston has to be matched with B cylinder Check for damage or wear on bore surface Cylinder bore N N N Q D E gt e Measure cylinder bore at total 6 positions top middle and bottom positions and perpendicular to each other Service limit Cylinder Gauge Set 6 33 I ENGINE i
19. 4 s 0 N un K 4 5 S 5 0 oO Q ea 1 the original pos put them 6 55 DINEI ENGINE e Install the pin e Install the gear position indicator 1 face ixed dr e Install the f Degrease the fixed drive face Use nonflammable cleaning solvent ipe off oily or greasy matter and make its surfaces completely tow dry e Install the drive belt as low as possible between the movable driven face and fixed driven face by using the special tool CAUTION o The drive belt contact surface of the dr iven face should be thoroughly cleaned Movable Driven Face Spring Compressor e The other way is using the same size bolts which at least 70 mm long to install the drive belt e Install the movable driven face assembly CAUTION 0 un Q 0 un Q 5 oO 0 0 Q 4 5 bD Xx z O in lt gt Nar lt 6 56 ENGINE e Tighten the movable driven face bolt to the specified torque with Tightening Torque 110 N m 11 0 kgf m 79 5 Ib ft the special tool e Install the movable drive face assembly
20. 5 17 5 1 DINLI Seat Removal e To remove seat insert the key to the main switch e Push inward the key and turn it counter clockwise to seat open position gt z lt 2 gt e Align catch A at back of the seat with the receiver B on 3 gt Mer E wi p S i is Q e Un into lock D e Slip the seat hook C under seat e Push front of the seat until you hear the click sound to lock the seat 5 2 __ DINLI Front and Rear Racks Front and Rear Racks Removal e Remove the front rack by removing its bolts A x 4 left amp right e B x 2 left amp right e Remove the rear rack by removing its bolts C x 2 left amp right e D x 2 e E x 2 left amp right 5 3 OINLI lt BODY Front and Rear Racks Installation e Install the front and rear rack in the reverse order of removal NOTE When installing the racks notice that the difference between front and rear rack X
21. e Remove radiator e Remove the cooling fan mounting bolts and collars ing Remount e Install the cooling fan in the reverse order of removal 5 o 5 i un lt E O Q bD S gum 5 bD O Q E Ka 20 5 p 4 nt 5 Z Le 3 p om imd Ke E 7 8 COOLING AND LUBRICATION SYSTEM Cooling Fan Thermo Switch Removal e Remove the left headlight e Drain engine coolant e Disconnect the cooling fan thermo switch lead wire coupler 1 e Remove the cooling fan thermo switch 2 Inspection e Check the thermo switch closing or opening temperatures by testing it at the bench as shown in the figure Connect the thermo switch 1 to a circuit tester and place it in the water contained in a pan which is placed on a stove e Heat the water to raise its temperature slowly and read the column thermometer 2 when the switch closes or opens Multi circuit tester set Tester knob indication Continuity test Cooling Fan Thermo Switch Operating Temperature Standard OFF to ON Approx 96 C 205 F Standard ON to OFF Approx 86 187 CAUTION o Take special care when handling the thermo switch It may cause damage if it gets a sharp impact o Do not contact the cooling fan thermo switc
22. wal Pl gt gt 2 06074 _ 1 e When installing actuator assembly tighten its bolts to specified torque Tightening Torque 22 N m 2 2 kgf m 15 9 Ib ft 7 21 DIMNE ELECTRICAL SYSTEM Combination Meter Description e This combination meter mainly consist of LCD Liquid Crystal Display and LED Light Emitting Diode This combination meter is light thin and of high response compared to those currently in use because of this composition 1 Engine oitindicator 8 _ ModeButn 2 Cem Temperature Indicar _ Pa Hazard ightindiator Poston Indico Setting Button Speedometer _____ 6 HighBeam Indicator _ 13 __ u 7 22 ELECTRICAL SYSTEM oe OINLI Functions and Operating Procedure Functions 1 7 Hazard Light Indicator High beam indicator light Engine indicator When engine oil level is low this indicator lights up When the ignition switch is turned on it lights up until the engine starts Coolant Temperature Indicator i This indicator lights up when the coolant temperature becomes high When the main switch in ON if the light comes on automatically you must stop the vehicle immediately and contact an authorized Dinli dealer This indicator light
23. I neda 377 5 18 Usperhendkerdamp U 9 Rearview miror 4 35 INES SUSPENSION STEERING DRIVE SHAFT Removal Remove the handlebar holder cover 1 e Remove the brake hose 0 Mar Q 0 oO 4 2 0 un un ps Q 0 un 0 4 4 0 gt O x e Remove throttle w e Remove the right switch assembly ts cap 1 ing i e Remove the choke cable by remov e Remove the parking brake cable 2 o o ing i by remov e Remove the left lever assembly 3 4 36 SUSPENSION STEERING DRIVE _ e Remove the handlebar clamp bolts A e Remove the upper clamps e Remove the handlebar Installation e Install the handlebar in the reverse order of removal Pay attention to the following point e Install the handlebar so that the angle of the handlebar matches the angle of the steering stem as shown e Install the handlebar upper clamps as shown e First tighten the bolts 1 to the specified torque and then tighten the bolts 2 to the specified torque Tightening Torque 26 N m 2 6 kgf m 19 0 Ib ft e Make sure the cable harness and brake hose are routing properly CAUTION When installing the h
24. 6 39 Movable Drive Face and Driven 6 40 Drive Belt 6 47 6 47 Transmissi0Nn 6 48 Gearshift 6 50 Generator 6 51 Reassembly 6 53 Engine Bottom Side 6 53 Engine Top Side 6 62 6 1 EINE I ENGINE Removal and Installation 552 Engine Removal e Thoroughly clean the ATV engine and chassis in coolant and engine oil e Clean work area e Dra e Remove the seat e Remove the side fenders e Remove the rear propeller shaft e Disconnect the battery lead wires CAUTION Q Q 5 un 0 gi 0 5 z oO gt 0 gt
25. 7 20 Transfer selecting system 7 21 7 21 Combination Meter 7 22 7 22 Functions and Operating Procedure 7 23 Removal and Installation 7 26 7 26 Lighting System 7 29 Headlight Bulb and Assembly Replacement 7 29 Taillight Bulb and Assembly Replacement 7 29 Indicator Bulb and Assembly Replacement 7 29 7 1 DIMNE ELECTRICAL SYSTEM 7 30 Main Fuse 7
26. lt D D amp 4 bD 5 amp C m 2 5 C Te cam drive sprocket e Install the cam chain guide 1 e Fit the dowel pins 2 and new cylinder head gasket 3 CAUTION bD oO ES un oO bD O gt 0 4 4 un oO bD z un Install the cylinder head Tighten the cylinder head bolts M10 1 in ascending order of numbers to the specified torque Tightening Torque Initial 25 N m 2 5 kgf m 18 0 Ib ft Final 37 N m 3 7kgf m 27 0 Ib ft 5 5 lt un cU un Ts lt te io w oo T on 4 FS E Z 3 ing Tighten 6 65 E 2 E D U gt z c Z z 2 5 2 4 35 5 O O ge lt 5 v 2 8 o 58 gt 5 k G c 2 E ES E 5 12 gt ERE C g E D He 2 62 mM 5 EE B U lt gt 5 5 s g SE s MS H 5 9 5D 60 o0 9 5
27. 5 O gt e Remove the cylinder head bolts M6 1 e Remove the cylinder head bolts M10 2 and washers Remove the cylinder head 6 12 22INL ENGINE e Remove the dowel pins 1 and cylinder head gasket 2 52 S 3 bp z 5 gs gt 0 Ss aP gt gt gt O aP x x ins 1 and gasket 2 1115 e Remove dowel p un lt lt lt lt 8 D 2 O O gt lt i Q ea iston by removing the piston pin circlip 1 e Remove the p Place a clean rag under the piston so as not to drop the piston pin un oO Q Q 4 Mar 4 om 6 13 DINEI ENGINE 9209929 Q lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt QQ 92029929 10101010101010 QOO QOO OO OO OO OO Engine Bottom Side 970191010191619101019161016 with the special tool f i e Remove the o e Remove the water pump cover 1 NGO OOOO OOO OOOO OAM
28. MEER TUNE TEN FR EFT ia L 1 p 1255 1 1 7 5 r 1 9 92 QS T 050 x 1 009 9 9 i QS E 9 3 4 mp 5260 9 T I4 5 SE 1 ex 929 I 9 ro r 50 92 QS Li bii rre Hin i 1 LLL 3 Radiator Remounting e Install the radiator in the reverse order of removal e Pay attention to the following points e Connect the radiator hoses e Install the drain plug e engine coolant e Bleed air from the cooling circuit 7 5 COOLING AND LUBRICATION SYSTEM Radiator Reservoir Tank Removal Installation e Remove the reservoir tank mounting bolts and disconnect the siphon hose from the reservoir tank and drain engine coolant e Install the reservoir tank in the reverse order of removal e Fill the reservoir tank to the upper level line Radiator Cap Inspection e Remove the radiator cap lid e Fit the cap 1 to the radiator cap tester 2 e Build up pressure slowly by operating the tester Make sure that the pressure build up stops at 110 140 kPa 1 1 1 4 kef cm 15 6 19 9 psi and that with the tester held standstill the c
29. H Mn H 21 ls i Hoo os n is rt ME 7 32 ELECTRICAL SYSTEM oe DINLI Wiring Diagram Version I NTC XX TURN LIGHT R n 5 VES a TUENLIGHTL us RE LAME 7 33 DIMNE ELECTRICAL SYSTEM Wiring Diagram Version F m u H ES zi ttt i ec in i i Py a 7 34 ELECTRICAL SYSTEM C DINLI Wiring Diagram Version II TAS TIT TAIL maroo LAMP L Nw dis URN L is URN aisi zl GEAR Lo SHIFT 1 875 Sb LEVEL apes RA rl nun ui 71 ant TONDU LAOUER HETER 7 35 DIMNE ELECTRICAL SYSTEM Wiring Diagram Version II SPEED BI Vn 7 36 mi 22INL ELECTRICAL SYSTEM Wiring Diagram Version II EA 5 TM d L 25 STARTI E s 8
30. Installation e Install the front propeller shaft in the reverse order of removal 4 23 DINLI SUSPENSION STEERING DRIVE SHAFT Rear Propeller Shaft Remove the rear wheel Removal d E m bD gt v on c 5 is s S op je 2 hb 29 N F G gt 7 8 re e o 2 5 5 Q c m un 5 Q amp 5 gt bD GH amp O O o 5 U 9 2 E 8 G o tu D QU o en S gue 79 E amp gt x S S 85 v D Ba Not a gc gt 9 d G gt gt On gt Q 2 6 z T y c 8 9 uu 9 des m een bb gos E o ggg 8 So 91 4 lt 518 W 2 Ha v lt Er 654 lt 9 S s BBS 9 N 5 gt 5 a c 423 5 9 9 8 2 g Y 5 x Du m 2808585 Q 5 5 n S uw mu o Q
31. 2 side of the boot to shaft groove e Install the cage 1 on the shaft CAUTION qo un lt bp 5 Q un oN 2 oN lt lt K un A Large Diameter B Small Diameter 4 21 DINLI SUSPENSION STEERING DRIVE SHAFT e Install the new snap ring GREASE to the entire surface of the cage and the inside of t 45g Wheel side Differential side the outer race e Apply included in the wheel side boot set or The tube of joint grease is wheel side joint assembly of spare parts e Insert the cage into the outer race and install the new stopper ring to the groove of the outer race CAUTION ies bD 5 lt lt lt un z O O O un bD 5 lt lt 5 5 SG 2 not lined up e After installing the boot on the outer race insert a screw driver into the boot on the outer race side and allow air to enter the boots so that the air pressure in the boot becomes the same as the atmospheric pressure at the positions indicated in the illustration A 188 198 mm 7 4 7 8 in 4 22 SUSPENSION STEERING DRIVE SHAFT _ 7 lt gt
32. 2 amp QD 50 C aP lt Q S d C 5 ci un DD z 2 9 attention to the following points INL WHEELS TIRES o Tighten the brake disc mounting bolts A to the specified torque e Install the front hub in the reverse order of removal Pay Front Hub Installation Torque 25 N m 2 5 kgf m 18 0 Ib ft ing o Apply GREASE to the hub spline Tighten o Tighten the axle nut to the specified torque Tightening Torque 110 N m 11 0 kgf m 79 5 Ib ft o Insert the new cotter pin and bent it over the nut e Remove the wheel See wheel Removal Rear Hub Removal e Remove the cotter pin 1 CAUTION 10 damages are found replace damaged bolts with new ones 2 Es 6 Q 5 oD gt z Ke Q Q O Q e Remove axle nut 2 with washer and pull off the rear hub e Inspect the rear hub bolts A for wear or damage If any Rear Hub Inspect 2 10 WHEELS TIRES C OINLI Rear Hub Installation e Install the rear hub in the reverse order of removal Pay attention to the following points o Apply GREASE to the hub spline o Tighten the axle nut 1 to the specified torque Tightening Torque 110 N m 11 0 kgf m 79 5 lb ft Insert the new cotter pin and bent it over the nut 2 11
33. Front Brake Pad Remove the front wheels e The extent of front brake pad wear can be checked by observing the limit line 1 on the side of brake pads When the wear reaches the limit line replace the pads with new ones CAUTION Replace the brake pads as a set otherwise braking performance will be adversely affected Tightening Torque 18 N m 1 8 kgf m 13 0 lb ft Rear Brake Pad Remove the rear wheels e The extent of rear brake pad wear can be checked by observing the limit line 1 on the side of brake pads When the wear reaches the limit line replace the pads with new ones CAUTION Replace the brake pads as a set otherwise braking performance will be adversely affected Foot Brake Pedal e Check that the brake pedal A is in the correct position as shown Pedal Position B Standard 72 80 mm above footrest If it is incorrect adjust the brake pedal position NOTE First adjust the brake pedal and then adjust the brake lever e Loosen the nut A and turn the bracket B until pedal is correctly positioned e Tighten the nut A e Make sure to tighten the nut A securely 9 22 DINLI PERIODIC MAINTENANCE o Depress the brake pedal lightly by hand until the brake is applied e Check the brake pedal free play A If the free play is incorrect adjust it Pedal Free Play The brake lever play 1 as measured at the lever holder should be betwee
34. The harness of the sensor must be fastened to prevent for hitting the stator 6 52 DINLI ENGINE REASSEMBLY e Please reverse the disassembly steps to reassembly Pay attention to the following points bD 5 79 5 War lt 4A 6 i bD O lt reassembling CAUTION Always keep the drive belt drive face and driven face away from any greasy matter Engine Bottom Side e Install the crankshaft into crankcase Z lt z bee bD 5 74 H un gt 0 un oO Q Q 4 Ke 4 5 da un oO Q 4 4 dd 0 gt Z O plastic mallet e Install the crank balancer shafts 1 e Install the transmission gear shaft assembly in a certain order main counter shaft 3 and reverse idle output shaft 2 gear assembly 4 input shaft 1 e Install the spacer 5 e Install the gearshift forks 6 53 DINEI ENGINE e Install the gearshift cam drum e Install the oil sump filter Fit the thinner side of the oil sump filter in the bottom as shown e Wipe the crankcase mating surfaces both surfaces with a cleaning solvent e Fit the dowel pins onto the left half on the crankcase e Apply engine oil to the connect
35. e Inspect of the oil seal and O ring for wear or damage If any damages are found replace the oil seal or O ring with a new one e Remove the oil seal Q m Q un ze lt te oO un T SG E 6 44 DINLI ENGINE Movable driven face spring Measure the spring free length with the vernier caliper e If the length is shorter than the service limit replace the spring with new one bD 4 B un lt Es gt 150 0 Service Limit e When installing the spring shorter side is on the top Movable and fixed driven face e Inspect the driven faces for any abnormal conditions such as un bD gt bD i G 5 gt 5 un 3 oO Q c S 4 4 Q ee 4 2 5 Q un c 2 Q gt 5 gt z lt Q a 3 Reassembly e Install the new O ring e Apply GREASE to the oil seal lips and movable driven face inside grease groove e Apply GREASE to the O rings and pin grooves e Install the rollers and pins CAUTION
36. z E g E ps pn 5 SD 60 o d o E S BI N H p lt Q gt y S E E 4 0 S g 5 8 as E 8 o oc oc o o 5 la 5 5 2 56 EE s o Qc o Qc oe gt gt gt gt gt gt gt gt gt O O S E g al T G 2 e e 7 e e e 6 16 LLL AS 5 lt 22INL 49404940494 940 4040404 4 ENGINE a S B s 2 D 2 2 m gt Ka RS 2 E 5 c H Q bD gt gt bD 8 B E 2 5 E E Ss u 5 gt 4 om o gt Q 5 5 8 5 o gt gt x gt gt gt X E 5 Q 9 M 0 gt c gt c
37. E oO 0 bD 0 gt 0 Q E Q Q 4 2 O T crank balancer shaft driven gear bolts to specified torque ightening Torque 50 N m 5 0 kgf m 36 0 Ib ft T e Install the cam chain guide e Tighten the cam chain guide bolt to the specified torque 3 kgf m 16 5 Ib ft 23 N m 2 Torque ightening T e Install the starter driven gear 1 e Install the key 2 gt un un 0 bD 4 4 c D 5 0 4 un oO bD 0 iE O un lt z z un m un 5 Q O n wipe off oily and greasy matter to make these surfaces completely dry o Make sure the pin A is installed at the end of the crankshaft 6 60 DINLI ENGINE e Install the generator rotor assembly CAUTION 5 0 gt me da Q 4 Ke 4 Ke Q Q gt oO O Har 4 4 5 un 0 gt into generator rotor properly there had to have a small amount of clearance between the rotor and the starter driven e Tighten the generator rotor nut to the
38. Un CAUTION If grease or oil is present on the surface of the drive belt degrease the belt thoroughly Vernier Calipers e Rotate the oil pump by hand and check that it moves smoothly e If it does not move smoothly replace the oil pump assembly Oil Pump CAUTION un un z 5 lt E z un un z lt E un un G un E c E gt 5 O4 G 6 47 ENGINE A U Transmission Disassembly e Disassemble the transmission as shown Fee 18 Dowepm 42 Revere driven gear Plain washer Main input shaft SED Clutch Drive tevel gear 39 Retaining igs ses Comesaes Fal TM ge 1L Springwasher 23 _ Semina 35 47 Final T M shaft in 24 Bush bearing 36 Spacer 2pcs Output connector 6 48 ENGINE QINLI KC Reassembly e Assemble the transmission gear in the reverse order of disassembly Pay attention to the following points NOTE Always use new snap rings Before installing the gears coat lightly engine oil to the transmission input output shaft CAUTION o Never reuse a snap ring After a snap ring has been removed from a shaft it should be discarded
39. Degrease the movable drive face assembly Use nonflammable cleaning solvent to wipe off oily and greasy matter and make its surfaces completely dry e Install the collar and movable drive face bolt Be careful about the direction of the collar e Tighten the movable drive face bolt to the specified torque with the special tool Tightening Torque 85 N m 8 5 kgf m 62 0 Ib ft Turn the fixed drive face until the belt is seated in and both the drive and driven faces will move together smoothly without slip e Install the dowel pins 6 57 EINE I ENGINE e Install the movable drive face cover 1 59 lt lt 4 2 E Q gt 2 D amp 9 SS 2 g 3 S 9 5 8 amp lt 0 E gt o c 6 4 Q G wm S E e e Install the pin e Install the balancer shaft drive gear e Install the cam chain drive gear with the special tool CAUTION bD O or 2 lt 5 T un 6 5 lt Q Ke Install the keys 1 6 58 DINLI ENGINE AS AS AS m F gear 2 gt Q 3 Q 0
40. E x 5 22 T gt T E x x 5 S 2b 4 5 5 5 E u x E o x U 5 x 5 p 0 5 2 5 O 8 5 P rf gt T 5 i 5 T x x 2 T gt 20 u 2 x E T x gt 55 P U 5 THE 1 x SHES 5 i x dj i D x EINE I ENGINE e Remove the oil sump filter 3 e Remove the gearshift fork shaft e Remove the gearshift forks 4 e Remove the gearshift cam drum 5 e Remove the seminal gear 6 e Remove the countershaft assembly 7 e Remove input main shaft 8 e Remove the final shaft T M assembly 9 CAUTION o Do not attempt to disassemble the output driven gear shaft o The output driven gear shaft is available only as an assembly un un lt ES lt Ke oO gt e e Remove crankshaft 6 22 ENGINE DINLI a E INSPECTION Camshaft and Cylinder Head Camshaft Identify the original position of disassembled parts with marking as necessary Place them in order on the clean table It is important that buckets are place back in original hole Visual Checking Check for wear and damage on Cam Sprocket gear teeth Check for wear and damage on decompression related parts
41. ENGINE L X 0 RR S d G Valve stem deflection e Lift the valve about 8 mm from the valve seat Measure the valve stem deflection in two directions perpendicular to each other by positioning the dial gauge e If the deflection measured exceeds the limit then determine whether the valve or the guide should be replaces with a new one Service Limit of Valve stem deflection IN amp EX 0 35 mm Dial Gauge 1 100 mm Magnetic Stand Valve stem wear e If the valve stem is worn down to the limit as measured with micrometer where the clearance is found to be in excess of the limit indicated replace the valve if the stem is within the limit then replace the guide e Measure OD of Valve Stem sliding portion at total 6 points upper middle and lower positions and X and Y directions by means of micrometer Service Limit of Valve Guide OD 5 450 5 465 mm 5 5430 5 445 mm Micrometer 0 25 mm Valve Guide Attachment Valve Guide Attachment Height Valve Seat Width e Coat the valve seat uniformly with bright color Fit the valve and tap the coated seat with the valve face in a rotating manner in order to obtain a clear impression of the seating contact In this operation use the valve lapper to hold the valve head e The ring like dye impression left on the valve face must be continuous without any break In addition the width of the dye r
42. INES 1 sPENSION STEERING DRIVE SHAFT Front Suspension Construction Ball joint 2pcs Bush 2pcs Castle nut 2pcs Driver shaft protector Cap 2pcs Spacer 2pcs Front shock absorber Hex socket bolt 2pcs 6 LowerA arm 2 16 Hex washer face bolt 5pcs C type circlip Upper A arm Hex washer face bolt C type circlip Hex washer face bo Spacer ps 9 Double row angular bearing B Hex washer face bolt 3pcs 10 Bush 2 Hex insert lock nut 5pcs 42 DINLI SUSPENSION STEERING DRIVE SHAFT Removal and Disassembly Remove the front wheels tires See Wheels Tires chapter See Body chapter Remove the front fender and the footboard m Q lt en 2 g di O oO 5 a 5 E 5 2 2 905 9 Q E 2 5 5 s ae 2 5 BB D p fa 2 Q 5 m 9 79 3 E HE Q S 8 D op 24 2 D D 9 5 Oj cx X gt 2 O ol im d Qo i 8 Oc 9 o AE gt gt 2 gt gt E O O O 2 5 E D gt Z e INES SUSPENSIO
43. Tripmeter B Hold down the MODE and setting button simultaneously for more than two seconds the display changes between mph and km h when displaying odometer as shown mph lt km h With each press of the SET button the display changes between clock hour tachometer and temperature NWARNING To avoid riding with only one hand do not operate the buttons while riding Odometer e Displays the total distance travelled lrip meter e Displays the distance travelled since the trip meter was last reset The trip meters and used independently e Hold down the MODE button over two seconds to reset the trip meter Clock e Displays the time hour and minutes on a 12 hour clock Setting the time e Hold down the SET button over two seconds and then flashing the minute display min T o Select the correct minute by pressing the MODE button e Decide the minutes by pressing the SET button and then flashing the hour display hour 7 25 7 OINLI lt ELECTRICAL SYSTEM Select correct hour by pressing the MODE button e Decide the hours by pressing the SET button Removal and Installation e Remove the screws 1 e Remove the combination meter 2 CAUTION o When disconnecting and reconnecting the combination meter coupler make sure to turn OFF the ignition switch or electronic parts may get damaged
44. cautions and detailed descriptions have been included in each chapter wherever necessary This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts Especially note the following 1 2 3 4 5 6 Dirt Before removal and disassembly clean the quad Any dirt entering the engine will shorten the life of the quad For the same reason before installing a new part clean off any dust metal fillings Battery Ground Disconnect the ground wire from the battery before performing any disassembly operations on the quad This prevents the engine from accidentally turning over while work is being carried out sparks from being generated while disconnecting the wires from electrical parts as well as damage to the electrical parts themselves For reinstallation first connect the positive wire to the positive terminal of the battery Installation Assembly Generally installation or assembly is the reverse of removal or disassembly However if installation or assembly sequence is given in this Service Manual follow it Note parts locations and cable wire and hose routing during removal or disassembly so they can be installed or assembled in the same way It is preferable to mark and record the locations and routing whenever possible Tightening Sequence When installing bolts nuts or screws for which a tight
45. direction with dial caliper gauge am am a E e Service limit ial Gauge 1 1000 mm 1mm Small Bore Gauge 18 35 mm D e Check for wear and damage on the sliding surface Piston Pin OD Piston Pin OD e Measure OD at total 3 positions both ends and middle position in the X and Y direction 22 980 mm 0 Q gt 0 Micrometer 0 25 mm 6 36 DINLI ENGINE ing Rod Connect Small end ID e Check for wear and damage on the sliding surface e Measure ID in the X and Y direction with caliper dial gauge Small end ID 23 035 mm 0 Q gt 0 Un 4 om Q w 34 10 ing rod deflect Connect e Wear of the big end of the rod can be estimated by checking the movement of the small end of the rod e This method can also check the extent of wear on the rod s big end c B Q x bD 5 4 Q Service Limit ic Stand ial Gauge 1 100 mm V block Set 100 mm Magnet D Side clearance at large end of Connecting Rod e Measure the side clearance at large end of Connecting Rod with thickness gauge clearance at large end Side 0 Q gt Q Thickness Gauge Crankshaft Runout block and m
46. z Q 9 18 ODINLI PERIODIC MAINTENANCE Remove the movable drive face cover 1 e Remove the dowel pins e Remove the movable drive face by removing its bolt 2 gt O gt O gt 2 lt gt gt O Se gt z n driven face bolt 3 lt T gt O z O 48 e Remove drive 2525252525252525252525252525252 LLL 55 55 55 55 55 55 x 55 55 55 55 55 55 55 55 e 55 55 55 e 55 x 55 55 55 55 55 55 55 55 55 55 55 55 x 10n Inspect belt for wear or damage If any cracks or e Inspect the drive it with a new one replace damages are found 9 19 DINLE 7 PERIODIC MAINTENANCE Installation e Install the drive belt in the reverse order of removal Pay attention to the following points between the movable as low as possible o Install the drive belt driven face and fixed driven face by using the special tool CAUTION 0 3 Ke un 0 Q oO 0 E 4 0 Q 5 un Q Q O O thorouehly c
47. 2 un bD 0 gt is 0 lt ic lt 4 un N N D 5 1 T D 2 pump Ol bD gt D z 5 2 EE c lt lt B gt 104949291979 9 99 99 9 9 9 9 9 9 29 9 9 9 OOOO 9 9 929 9 9 9 9 9 9 9 9 9 9 9 9 9 gt EE e Apply THREAD LOCK to the oil pump mounting bolts 1 e Install the p into the crankcase In 2 un 2 q lt ea e Install the oil pump drive gear 1 and oil pump driven gear with chain installed at the same time 0 gt oO bD 6 59 DINEI ENGINE e Install the snap ring and washer un oO Q Q 4 4 5 bD c un 4 O 5 0 oO Q 4 e Apply THREAD to balancer driven gear bolts c 0 bD D S Q 4 O un 4 4
48. 3 bD un 4 0 Ke un E B un bD E 5 z O 48 E T un 6 5 bD bD 2 gt Q slide the lip using a 0 1 mm steel 6 45 EINE I ENGINE lt bp 6 e gt un bp O un S ar lt T un un bp O lt bp T gt bp un Ner m 5 O un T un un 2 O 4 4 WI ing with the special tool e Compress the spr e Tighten the movable driven face ring nut temporarily ial tool from the movable driven face assembly e Remove the spec ing nut to the specified torque tool th the specia Tightening Torque 100 N m 10 0 kgf m 72 0 Ib ft Ring Nut Socket Wrench WI e Tighten the movable driven face r 6 46 22INL ENGINE e Inspect the contact surface of the drive belt for cracks or damage e Check that the drive belt is free from any greasy substance Drive Belt Inspection and measure the width of the drive belt using the vernier caliper e If any damages are found or the measurement exceeds the service limit replace the drive belt with a new one Drive belt width _ 4 Q gt
49. Apply the engine oil to the starter clutch CAUTION Q E lt lt gt 2 lt 5 T un C bD i T c O 42 Q PN 2 O 6 38 DINLI ENGINE e Apply THREAD LOCK to the bolts 5 Q O un 4 4 un Ke Q Q 0 oO un 0 C 30 aa n v 5 p 4 e 2 O N Tightening Torque Install the starter driven gear to the starter clutch gt e D Q 0 hum un 4 4 5 me bD c 2 0 oO un 4 4 4 4 Q 4 arrow mark A on rotor while holding generator motor The gear never turns in the direction of the arrow e If there is anything unusual replace the one way clutch e Check the starter driven gear bearing If there is anything unusual replacing the bearing e Remove the bearing with the special tool replace it with a new one ring e Inspect the copper plug and its O ring If any damages has found in the O e Install the bearing with the special tool Oil Gallery Coppe
50. Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub step it follows 0 3 DINLI FOREWORD INDEX CHAPTER INDEX CHAPTER 1 GENERAL INFORMATION CHAPTER 2 WHEELS TIRES CHAPTER 3 4 SUSPENSION STEERING DRIVE SHAFT CHAPTER 5 BODY CHAPTER 6 ENGINE CHAPTER 7 COOLING AND LUBRICATION SYSTEM CHAPTER 8 ELECTRICAL SYSTEM CHAPTER 9 PERIODIC MAINTENANCE CHAPTER 10 APPENDIX 0 4 GENERAL INFORMATION C wr INLI TN GENERAL INFORMATION Table of Contents Before Servicing 1 2 General Precautions 1 5 DINLI 702 1 6 Model Identifications 1 7 Fuel and Engine Coolant Recommendation 1 8 Fuel For USA and Canada 1 8 Fuel For Other Countries 1 8 Engine Oil For USA 1 8 Eng
51. e Install the steering shaft e Tighten the steering shaft bracket bolts to the specified torque Tightening Torque 23 N m 2 3 kgf m 16 5 lb ft NOTE Make sure that the wiring harness cables and brake hose routing are proper CAUTION To prevent the entry of dirt the oil seal end must face forward when installed on the steering shaft e Install the steering shaft lower nut with the washer e Tighten the steering shaft lower nut to the specified torque Tightening Torque 120 N m 12 0kgf m 87 0 lb ft NOTE After installing the steering shaft lower nut install a new cotter pin into the steering shaft Tie Rod e Tighten the tie rod end nuts to the specified torque Tightening Torque 29 2 9 kgf m 21 0 lb ft NOTE After installing the tie rod end nuts install the new cotter pins into the tie rod ends 4 32 SUSPENSION S TEERING DRIVE SHAFT e When installing the tie rods make sure the short sides 1 of the tie rods come outside NOTE The locknuts 2 have left hand threads Handlebars e When installing the handlebars on the handlebar lower clamp align the brake reservoir on the horizontal direction of the handlebar e Install the handlebar upper clamps as shown e First tighten the bolts 1 to the specified torque and then tighten the bolts 2 to the specified torque Tightening Torque 26 N m 2 6 kgf m 19 0 Ib ft e Make sure the cable harness and brake hose are r
52. e Remove the front under protector See Body chapter e Place an oil pan below the differential gear case e Drain oil by removing the oil drain plug 3 oil filler plug 2 and oil level plug 1 e Tighten the oil drain plug 3 to the specified torque and pour fresh oil through the oil filter hole until it overflows from the oil level hole e Tighten the oil level plug 1 and oil filler plug 2 to the specified torque e Install the front under protector Differential Gear Oil Specification Hypoid gear oil SAE 80W 90 API grade GL 5 Use hypoid gear oil SAE 80 API grade GL 5 if the vehicle is ridden where the ambient temperature is below 0 32 Front differential gear oil capacity 150 Tightening Torque Front differential gear oil level plug 9 N m 0 9 kgf m 6 5 ft lb Front differential gear oil drain plug 32 N m 3 2 kgf m 23 0 ft lb Front differential gear oil filler plug 35 N m 3 5 kgf m 25 5 ft Ib 9 14 PERIODIC MAINTENANCE lt Rear Driver Gear Inspect every 2000 km 100 hours 6 months Replace every year Rear Driver Gear Oil Inspection e Place the vehicle on level ground e Remove the oil level plug 1 and oil filler plug 2 and inspect the oll level If the oil level is below the level hole add fresh oil until oil flows from the level hole e Tighten the oil level plug 1 and oil filler plug 2 to the specified torque
53. gt Q O 0 4 un bD z 0 4 4 4 un ES e Install the water pump cover 1 e Install the oil filter with the special tool D003 Oil F ilter Wrench Engine Top Side e Install the piston rings in the order of oil ring second ring and first ring e The first member to go into the oil ring groove is a spacer fit the two side rails 7 After placing spacer CORRECT Q O un 5 yet yD c n 79 side rails Those can be positioned each either way CAUTION r be careful not to allow its two ends to When installing the space overlap in the groove 6 63 EINE I ENGINE e Install the second ring and first ring First Ring e Second ring has letter RN marked on the side and the first ring IR marked on the side Be sure to bring the marked side to the top when fitting it to the piston has the letter e Position the gaps of the three rings as shown Before inserting the piston into the cylinder check that the gaps are so located e First rig 9 c Q un 4 gt un bD 5 un 4 5 5 0 0 un 0 Q 0 Q Q un ring si
54. 4 un 4 Q Q un gt Q 0 4 Q QO un damages found replace caliper with a new e If any rubber parts have been removed from the caliper replace them with new ones 3 10 22INL BRAKE 3 11 DINLI pp x7 Brake Pad Removal Remove the wheels see Wheels Tires chapter Front Brake Remove the front caliper see Caliper Removal e Remove the brake pad mounting bolts A e Push the plate B remove the pads C Remove anti rattle spring Rear Brake Remove the rear caliper See Caliper Removal e Push the plate A remove the pads B Remove anti rattle spring Parking Brake e Remove the rear caliper See Caliper Removal e Remove the parking brake caliper See Caliper Removal Q Q O 4 4 4 i Q Q oO gt then remove pads 1115 e Remove 3 12 Installation e Push the caliper piston in by hand as far as it will go e sure that the anti rattle spring is in place e Install the brake pads pad B is for front brake pad C is for rear brake e Apply THREAD LOCK to the brake pad mounting bolts e Tighten the front brake pad mounting bolts to the spe
55. 7 t correct 15 e If the value clearance G E gt 8 e e l Epe eio Thickness Gauge lt 5 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 e Remove intake pipe 11 Intake Pipe e Apply GREASE to the O ring CAUTION int join through ing from suck to prevent a ing i Use the new O 311 6 EINE I ENGINE e Apply THREAD LOCK to the intake pipe bolts ass Union and Oil Pressure Gauge Water B c 5 un un Q gt 2 5 NA Q H lt L O Q lt e Remove oil pressure gauge 1 and water bypass union 2 e Apply THREAD LOCK to the oil pressure gauge 5 5 4 bz Q un 4 E 0 bD D z 2 e 3 219 E Z 5 o p pj 4 Ke 6 om un 79 T 5 un 2 Q lt lt Ke lt z lt 25 lt O un
56. Check if decompression would be operated smoothly e If any parts would be damaged or worn replace with new Camshaft Assy e Move the automatic decompression weight by hand to inspect if it is operating smoothly e If it does not operate smoothly or the spring occur elastic fatigue replace the camshaft automatic decompression assembly with a new one Camheight e Check for damage and wear on cam profile portion e Measure the height of cam profile Service Limit of cam profile height 36 150 mm 35 100 mm CAUTION Do not attempt to disassemble camshaft It is not serviceable Micrometer 25 50 mm Camshaft journal wear e Determine whether or not each journal is worn down to the limit by measuring the oil clearance with camshaft installed in place e Use the plastigauge A to read the clearance at the widest portion Oil clearance at cam journal portion NOTE Install camshaft journal holders to their original positions Plastigauge 6 23 EINE I ENGINE e Tighten the camshaft journal holder bolts evenly and diagonally to the specified torque Tightening Torque 10N m 1 0 kgf m 7 0 Ib ft Do not rotate the camshaft with the plastigauge in place e Remove the camshaft holders and read the width of the compressed plastigauge with envelope scale e This measurement should be taken at the widest part e If the camshaft journal oil clearance measured exceeds the limit measu
57. G c bD 9 6 Z d V oO 9 9 d 50 50 8 65 ae AS 254438 o ao 9 ca amp S 2 9 n 9 e Remove rear suspension 4 24 DINLI SUSPENSION STEERING DRIVE SHAFT e Fit a boot on the propeller shaft end fitting the small diameter side of the boot to the shaft groove fix its end with a new band on the shaft e Install the cage 1 CAUTION 85g Grease Quer 45 un lt Q un m 5 lt 2 bD lt lt T un e Apply GREASE to the entire surface of the cage and the inside of bD Eg 5 5 2 S S S A e E D PD 4 S S i 2 7 O lt un n gt 5 5 lt 6 as un bD 5 Ke wheel side joint assembly of spare parts 425 DINLI SUSPENSION STEERING DRIVE SHAFT lt e Insert the cage into the outer race and fit a stopper ring in the groove of the outer race CAUTION Locate the opening of the stopper ring 1 so that the opening is not lined up with a ball e After fitting the boot on the outer race insert a screw driver into the b
58. Piston diam 101 880 Measure at 15 mm from the skirt end Piston ring free end gap Piston ring end gap 1st 0 180 Piston ring to groove clearance 1 21 1 23 151 1 30 1 32 Piston ring groove width 1 17 1 19 Piston pin bore I D 23 002 23 008 23 030 Piston ring thickness Piston pin O D 22 992 23 000 22 980 Connecting Rod Crankshaft Unit mm Item Standard Limit Conrod small end LD 23 002 23 008 23 035 Conrod big end side clearance 0 35 0 60 Conrod big end width 3455 2500 ww cd CHR 7135 7308 Ww 10 26 APPENDIX P L Clutch Unit mm Clutch wheel I D 140 0 140 2 140 5 No groove at any Clutch shoe part Clutch engagement rpm 1800 2000 rpm Clutch lock up rpm 3800 4200 rpm m Drive Train Unit mm Automatic transmission ratio Variable change 2 670 0 787 C secondary edasine ase omnis me wo wam fs mem Drive Drivebeltwidth width 3 Movable driven face spring 158 0 150 0 free Shift fork to groove clearance fork to groove clearance 0 07 10 0 27 Shift fork groove width Reverse 5 40 5 50 oom Shift fork thickness Beverse Front differential gear oil type Hypoid gear oil SAE 80W 90 API grade GL 5 oom Rear drive gear oil type Hypoid gear oil SAE 80W 90 API grade GL 5 Front differential gear oil capacity 150 ml Rear gear box oil capacity 31
59. Step1 Check accessories which use excessive amounts of electricity Are accessories being installed YES Remove accessories NO Step2 Check the battery for current leaks Is the battery current leakage OK YES Move to Step 3 NO e Short circuit of wire harness e Faulty electrical equipment Step3 Measure the regulated voltage between the battery terminals Is the regulated voltage OK YES e Faulty battery e Abnormal driving condition NO Move to Step 4 Step4 Measure the resistance of the alternator coil Is the resistance of alternator coil OK YES Move to Step 5 NO e Faulty alternator coil e Disconnected lead wires 7 12 ELECTRICAL SYSTEM Step5 Measure the alternator no load performance Is the alternator no load performance OK YES Move to Step 6 NO Faulty alternator Step6 Inspect the regulator rectifier Is the regulator rectifier OK YES Move to Step 7 NO Faulty regulator rectifier Step7 Inspect wirings Is the wirings OK YES Faulty battery NO e Short circuit of wire harness e Poor contact of couplers Battery overcharges e Faulty regulator rectifier e Faulty battery e Poor contact of alternator lead wire coupler Inspection Battery Current Leakage e Remove the seat e Turn the ignition switch to the OFF position e Disconnect the battery lead wire 1 e Measure the current between battery termin
60. gt e e e 6 17 ive face 2 by removing bolt EINE I ENGINE e Remove the CVT cover 1 and gasket e Remove the movable drive face cover 1 e Remove the dowel pins e Remove the movable dr e Remove the movable driven face assembly by removing the bolt e Remove the drive belt 6 18 DINLI ENGINE Remove the fixed drive face e Remove the front and rear output connectors Q e un un N un 22 c gt 9 ce eU i O 9 o O v E gt Mg E BS 50 m HE 5 G ra EE Do GE E 22 o o o 2 5 5 O 5 Remove clutch housing shaft 1 6 19 e Remove output shaft 2 e Remove the collar 1 e Remove the drive bevel gear 2 e Remove the dowel pins 1 e Remove the O ring e Remove the one way clutch 6 20 lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt 2222225 lt lt lt lt 2 2 2 os p T DINLI ENGINE 6 21 E d x gt 5 E x 5 F 2 i b
61. ini Inspect e gt c 3 er e N Adjust the throttle cable play o Loosen the locknut 1 of the throttle cable in or out to obtain the correct play o Turn the adjuster 2 gt E E Q EE e te o After adjusting throttle cable play tighten locknut 1 Carburetor O gt 3 a 3 is lt gt gt Q aP 147 Q aP lud 4 dem mum z Ko 5 N e Inspect the carburetor for dirt or mud e If any dirt or mud is found clean it Idle Adjustment allow the engine to reach operating 7 e To adjust idle F Adjust the idle speed to maintain at 1300 rpm turning the temperature 70 158 adjuster clockwise to increase idle speed counterclockwise to decrease idle speed 9 11 INES PERIODIC MAINTENANCE Device t 1mi Carburetor L ing CAUTION lt E P 2 gt E un Mer 5 Q horsepower
62. o Make sure that the speedometer coupler boots is positioned properly CAUTION Do not attempt to disassemble the combination meter e Install the combination meter in the reverse order of removal Inspection e Check that the LCD immediately after turning the ignition switch ON Also check them for lighting in accordance with their switch positions e If the LCD fails in operation replace the combination meter unit with a new one after checking its wire harness coupler ELECTRICAL SYSTEM Engine Coolant Temperature Meter and Indicator e Disconnect the ECT sensor coupler 1 CAUTION When connecting and disconnecting the engine coolant temperature sensor lead wire coupler make sure to turn OFF the ignition switch or electronic parts may get damaged e Connect the variable resistor A between the terminals e Turn the ignition switch ON e Check the LED operations when the resistance is adjusted to the specified values Over 0 2 kO Approx 110 C Approx 0 11 kO 120 C and over e If either one or all indications are abnormal replace the combination meter with a new one Fuel Meter e Remove the rear fender e Connect each resistor between the terminals as shown e Turn the ignition switch ON position and wait for approx 13 seconds e Check the display of fuel meter as shown below if any abnormal is found replace the combination meter with a new one
63. wd o 7 r CYLINDER WALL STARTER amp PASTON GEAR BEARING kk ki j k u 7 21 amp JINIL COOLING AND LUBRICATION SYSTEM Engine Lubrication System 7 22 COOLING AND LUBRICATION SYSTEM ___ lt 7 23 ELECTRICAL SYSTEM DINLI ELECTRICAL SYSTEM Table of Contents Specifications 7 3 Parts 7 4 Precautions Y T 7 6 Electrical Wiring 7 8 Wiring 7 8 DBattery T U 7 9 Battery Removal 7 9 Battery Installation 7 9 Battery Charging 7 9 Charging Procedures 7 10 Battery Test Charging 7 10 Charging
64. 30 Fuse 7 30 7 31 Wiring 7 32 7 2 ELECTRICAL SYSTEM oe OINLI Specifications Item Battery Capacity 12 20Ah Alternator type Three Phase AC Ignition system DI C Charging voltage Regulator rectifier output DC 14 15 V Alternator no load output voltage AC 65 V and more at 5000 rpm Y1 Y2 0 49 Q Y2 Y3 0 49 Charge Coil Stator Y3 Y1 0 49 Xam __ Pulser Coil Bu Y G W 110 1596 Primary 020 15 Secondary 6 3 20 At 20 C Ignition Coil Gp 07 08 mm ar Cable resistance Nominal Output 0 7 kW Starter motor Reduction Ratio 28 235 7 3 DIMNE ELECTRICAL SYSTEM Parts Location Battery Ignition Coil Starter Circuit Relay z Regulator Rectifier CDI Unit Gear Position Indicator t Position Light Relay 2WD AWD Diff AWD Actuator Transfer Selecting Switch 7 4 ELECTRICAL SYSTEM OX XXXI 9 QQ OX Ignition Switch High Low Beam Switch Spark Plug Cooling Fan Temperature Sensor J itch Horn Switch Indicator Sw Hazard Lights S
65. 4 to the specified torque Caliper Mounting Bolts 25N m 2 5kg m 18 0ft Ib Brake Hose Banjo Bolt 25N m 2 5kg m 18 0ft Ib Rear brake e Install the caliper in the reverse order of removal Pay attention to the following points o Replace the washers 1 that are on each side of hose fitting with new ones o Tighten the caliper mounting bolts 2 and the brake hose banjo bolt 3 to the specified torque Caliper Mounting Bolts 25N m 2 5kg m 18 0ft Ib Brake Hose Banjo Bolt 25N m 2 5kg m 18 0ft Ib e Check the fluid level in the brake reservoir e Bleed the brake line see Brake Line Air Bleeding e Check the brake for good braking power no brake drag and no fluid leakage WARNING Do not attempt to drive vehicle until a full brake lever is obtained by pumping the brake lever until the pads are against each disc The brakes will not function on the first application of the lever if this is not done 3 9 Parking Brake e Install the parking brake caliper in the reverse order of removal Pay attention to the following points e Attach the caliper and the brake disc install the brake disc to the rear hub and tighten them to the specified torque Tightening Torque 25 N m 2 5 kgf m 18 0 Ib ft with new ones Tighten wire rope bolt 2 e Replace circlips 1 Caliper Inspection gt bD
66. 4 32 Adjustment 4 34 Handlebar 4 35 Construction 4 35 Removal 4 36 Installation 4 37 Indicator Lever 4 38 4 38 4 39 4 40 Installation 4 40 Shift 4 41 Installation 4 41 Shift Rod Adjustment 4 42 4 1
67. 9 34 Initial Engagement and Clutch Lock Up Inspection 9 35 Initial Engagement Inspection 9 35 Clutch Lock Up Inspection 9 36 9 1 DINLI PERIODIC MAINTENANCE lt 7 Periodic Maintenance Schedule e The chart below lists the recommended intervals for all the required periodic service work necessary to keep the vehicle operating at peak performance and economy Maintenance intervals are expressed in terms of kilometers miles and months and are dependent on whichever comes first More frequent servicing may be performed on vehicles that are used under several conditions Periodic Maintenance Chart Regula Maintenance Interna Ewery 50 Ewery 100 Every Lago Syd 2000 WARME LABELS tcendition readable FRAME FUEL LINE IHROTTLE OPERATION SPARK PLUG SPEED EKHE CHL CHL FILTER fs DIFFEREN TAL GEAR OIL Replace avery b c FINAL GEAR every year SWITCHES engins stop Start tether Ignition BRAKE FLLED Pieplace every bao years BRAKE SYSTEM cables pads hosed atc ERAKE 1505 Feplace every kii LIGHTING headlight tall light
68. AMADA 1111111110 XX OOF XX OOF XX XX XX XX XX XX OOF XX XX XX OOF OOF OOF OY OY OY Remove starter cup nut with a suitable bar 1 e Remove the starter cup 2 e Remove the left crankcase cover 3 e Remove the dowel pins 4 and gasket 5 6 14 ENGINE e Remove the starter reduction gear and gearshift shaft ift shaft 1 e Remove the gearsh 60 gt gt sy C 60 a 9 te C 60 Ez gt e Remove generator rotor bolt ial tool to the crankshaft end e Install the spec Rotor Mounting Socket Wrench D006 Rotor Remover e Remove the generator rotor with the special tool 6 15 EINE I ENGINE 9004444 E ETT T P d 5 T 5 N d Q 3 5 5 S a Of D 9 amp E 5 gt 5 T z 9 9 7 2 ES O fn 5 5 gt So gt S S 22 B E x i d 2 Eb 6 9 D m
69. C 45 C 1 12 GENERAL INFORMATION oe Z INL I CHASSIS Frame Steel Wheel base Clutch type Automatic CVT wet drum Gearshift pattern Secondary reduction ratio 2 158 40 21 x E Final reduction ratio Front amp Rear 3 600 36 10 Transmission gear ratio l 1 133 30 26 1 882 32 17 Reverse _ Front suspension travel Brake fluid DOT 4 Brake disc thickness MIN Front 3 mm Rear 3 5 mm 1 13 NINES GENERAL INFORMATION Front tire AT 25 x 8 12 tubeless Recommended coil tire pressure Front Rear 35 35 kPa 5 0 psi 5 0 psi ELECTRICAL Ignition typ type Alternator output DC 14V 23A e 3000 rpm m m w weekends Mb _ Capacities Oil C NE 3300 ml May be slightly different after changed oil filter Engine oil Overhaul Differential gear oil 150 ml Rear driver gear oil 310 ml 1 14 WHEELS TIRES oe 7 WHEELS TIRES Table of Contents Specifications 2 2 2 3 Wheel Rim 2 4 2 4 Installation
70. MOLYBDENUM OIL SOLUTION to their stems without any break CAUTION take care not to damage the lip of the 7 0 gt Q bp 4 0 un oil seal e Install the valve spring with the small pitch portion 1 facing cylinder head Large pitch portion 3 Upward 2 e Install the valve spring and spring retainer with special tool CAUTION T 5 bD 4 4 0 Us gt D bD O un Q oO 0 un 5 un 4 Q g Ke Q e gt lt w gt gt AC gt pi i 38 8 He 5 shims 2 to their original position e Install the tappets 1 lt dd O O un Ner gt I bD O lt When seating shim be sure figure printed surface faces the tappet 6 30 22INL 5 55 x lt gt 297 4 4 1 1 i 1 1 1 1 1 i 1 4 4 52 22 5 62626 DROOL LL 38 04 ustment Valve Clearance e Measure the clearance between the valve and the camshaft use the tappets 1 to adjust the valve
71. Pan head bolt 4pcs 20 Hex washer face bolt 2pcs s marie Maen soe Tapping sewr amas 7 0 Cargonets 15 Rubber washer 2pcs Tapping screw 4pcs Ei Clip nut 16pcs 16 Clip nut 2pcs Reflector 2pcs 5 11 DINLI Rear Fender Removal Rear Fender e Remove the seat See 5 2 and rear rack See 5 3 e Remove the taillight lead wire coupler left amp right e Remove the rear fender by removing A x6 attach to luggage compartment e B x3 attach to luggage compartment e C x6 rightx3 leftx3 attach to footboard 5 12 Body Decoration e Remove the front fender See 5 8 e Remove the body decoration screws A x 6 left amp right e Remove the body decoration by removing screws B x 4 left amp right attach to the foot board Foot Board e Remove the foot board by removing Foot Board Bracket Bolts A x 8 left amp right 5 13 DINLI e B x12 left amp right attach to front amp rear fender e Washer bolts C x 4 attach to the body decoration See 5 13 Footrest e Remove the footboard See 5 13 e Remove the footrest mounting bolts e When installing the footrest by its mounting bolts tighten them to the specified torque Tightening Torque 55 N m 5 5 kgf m 40 0 Ib ft Rear Fender Installation e l lease reverse the Removal steps to install 5 14 opy __ DINL
72. Rear Driver Gear Oil Replacement e Place the vehicle on level ground Remove the rear under protector See Body chapter e Place an oil pan below the rear driver gear case e Drain oil by removing the oil drain plug 3 oil filler plug 2 and oil level plug 1 e Tighten the oil drain plug 3 to the specified torque and pour fresh oil through the oil filter hole until it overflows from the oil level hole Tightening Torque 23 N m 2 3 kgf m 16 5 lb ft e Tighten both the oil level plug 1 and oil filler plug 2 to the specified torque Oil level plug 23 2 3 kgf m 16 5 lb ft Oil filter plug 23 N m 2 3 kgf m 16 5 lb ft e Install the front under protector Rear driver gear oil capacity 310 ml Rear driver gear oil specification Hypoid gear oil SAE 80W 90 API grade GL 5 9 15 DINLI PERIODIC MAINTENANCE C EE EE Engine Coolant Inspect every 1000 km 50 hours 3 months Replace every two years Engine Coolant Level Check e Check the engine coolant level by observing the upper and lower lines on the engine coolant reservoir tank If the level is below the lower line add engine coolant until the level reaches the upper line Engine Coolant Replacement e Remove the front fender decoration 1 by inserting the opening stick 2 into the hole to open it e Remove the radiator cap 3 and engine coolant reservoir tank cap 4 e Remove the left footboard e Place a pan below th
73. and a new snap ring must be installed o When installing a new snap ring do not expand the end gap larger than required to slip the snap ring over the shaft o After installing a snap ring make sure that it is completely seated in its groove and securely fitted e Install the snap ring onto the transmission output shaft and position it so it fits into the groove NOTE Make sure that the snap ring is positioned properly 6 49 EINE I ENGINE Gearshift Fork Visual checking Shift Fork and Drum e Check for ware and damage e If any wear on the Fork craw portion replace with new one in Shaft and Counter Shaft Assy e After disassembling check for wear and damage on dig clutch Ma isual checking V portion gears and spline portions e If any wear and damage had found replace with new one Gearshift Fork To Groove Clearance gauge e Measure the gear fork to groove clearance by using the thickness e the clearance exceeds the limits replace the fork or its gear or both 0 Q Q gt O bD m 0 10 0 27 Standard Service Limit Thickness Gauge Width of Shift Fork Groove e Check for wear and scratch in the Fork groove e Measure the width of shift fork groove with vernier calipers LO LO gt bD L
74. e Remove the oil pressure switch e Install the oil pressure gauge into the cylinder head gallery e Start the engine e After warming up the engine maintain the engine at idle speed 1300 rpm and read the oil pressure gauge Oil Pressure Gauge 9 34 PERIODIC MAINTENANCE EE Initial Engagement and Clutch Lock Up Inspection e To insure proper performance and longevity of the clutch assemblies it is essential that the clutches engage smoothly and gradually Before checking the initial engagement and clutch lock up two inspection checks must be performed to thoroughly check the operation of drive train Perform the following o Warm up the engine Initial Engagement Inspection e Connect the tachometer or the multi circuit tester onto the spark plug high voltage cable e Start the engine e Shift the range lever to the HIGH position e Slowly open the throttle and note the engine speed rpm when the vehicle begins to move forward Tachometer or Multi Circuit Tester Engagement Speed 1800 2000 rpm e If the engagement speed does not coincide with the standard range inspect the following items for any abnormalities o Clutch shoe See Engine chapter o Clutch wheel See Engine chapter o Movable drive and driven face See Engine chapter 9 35 INES PERIODIC MAINTENANCE Clutch Lock Up Inspection e Perform this inspection to determine if the clutch is engaging fully and not
75. front rack See 5 3 e Remove the maintenance compartment See 5 6 e Remove the headlight shade See 5 7 e Remove Left and Right Fender by removing A x 6 left amp right attach to the footboard e B x 6 left amp right attach to the body decoration 5 8 __ DINLI Fuel Tank Decoration e Remove the seat e Remove the handlebar See Suspension chapter e Remove the combination meter See Electrical System e Remove the front fender left amp right e Remove the maintenance compartment See 5 6 e Remove the ignition switch decoration A and the fuel tank cap B e Remove the fuel tank decoration by removing its bolts attach to the luggage compartment Fuel Tank e Remove the fuel tank decoration See 5 9 e Disconnect the Fuel level indicator lead wire A e Remove the seat hook wire rope B e Remove the fuel hose CAUTION When removing the fuel hose place a container under the fuel hose and the fuel tank to drain off the fuel WARNING Gasoline is highly flammable and explosive Keep heat spark and flame away 5 9 lt BODY e Remove the fuel tank by removing its bolts Eront Fender Installation e Please reverse the Removal steps to install 5 10 __ DINLI EY Rear Fender Construction IL __ Right body decoration
76. front wheel hubs with brake discs e Install the front brake calipers e Install the front wheels tires Spring Pre Load Adjustment e After installing the front shock absorbers adjust the spring pre load e The spring adjusting sleeve on shock absorber has 5 positions so that the spring can be adjusted for different terrain and loading conditions If the spring action feels too soft or too stiff adjust it in accordance with the following photograph Turn the adjusting sleeve on shock absorber to the desired position with the wrench ANNE Be sure to adjust the spring pre load on the both shock absorbers equally 4 10 SUSPENSION STEERING DRIVE SHAFT ___29NLI lt gt Rear Suspension Construction 5 Upram i m sper S Rearshockabeorber 6 row angular bearing I5 ref fas _ 4 11 INES su sPENSION STEERING DRIVE SHAFT Removal e Remove the rear wheel ipe haft protector e Remove the exhaust p e Remove the driver 5 e Remove the cotter pin and rear hub nut e Remove the rear wheel hub CAUTION ith a new one 2 Q lt 5 O gt z Ke lt Q Q int lower bolt nut izer jo i
77. grease and remove the snap ring CAUTION Replace the removed snap ring with a new one 4 20 DINLI SUSPENSION STEERING DRIVE SHAFT e Remove the cage and boot from the front propeller shaft CAUTION Do not disassemble the wheel side joint ball fixed joint If any replace it with a new one 7 5 5 bD Inspection and Reassembly e Inspect the boots for wear or damage If any damages are found replace them with new ones e Inspect the axle play by using a push and pull motion given to as shown 7 the axle shaft and wheel spindle 0 lt un mar 4 Ke 4 0 Q un mar Q Q 5 0 un un un ome Ke 4 un 2 5 0 un un 0 Q Q bD un 5 p Q Q gt 0 lt Q Q b amp an oO Q 5 z Q CAUTION o Wash all parts before installation clean the inside and outside r such as gasoline or kerosene Washing in a of the boots with a cloth o Do not wash the boots in any commercially available degrease degreaser causes deterioration of the boots e Fit a boot on the propeller shaft end fitting the small diameter 2
78. lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt 6262242226000 e Position wheel so that air valve B is toward outside of the vehicle e Tighten the wheel nuts to the specified torque in a criss cross pattern Tightening Torque 60 N m 6 0 kgf m 43 5 Ib ft 2 4 22INL WHEELS TIRES Inspection e Examine both sides of the rim for dents A If rim is dented replace it e If the tire is removed inspect air sealing surfaces A of the rim for scratches or nicks Smooth the sealing surfaces with fine emery cloth if necessary Replacement e Remove the wheel see Wheel Removal e Disassemble the tire from the rim see Tire Removal o Remove the air valve and discard it CAUTION lt O P lt gt 2 gt i d lt E O x reuse the atr valve e nstall a new atr valve in the new rim o Remove the valve cap lubricate the stem with a soap and water solution and pull the stem through the rim until it positions into place CAUTION Do not use engine oil or petroleum distillates to lubricate the 4 5 0 0 0 2
79. not a This will provide a soft surface for the final seating of the valve which will occur during the first few seconds of engine operation vacuum pump gauge to cover intake and exhaust ports and check for leaks Ke 5 Q T q 5 O z O lt bD 5 Ex un 5 e highly polished or shiny finish e Clean and assemble the head and valve components Use the If any leaks occur inspect the valve seat and face for burrs or other things that could prevent the valve from sealing 2 gt 4 4 4 Q Q O 0 5 un 0 mar oO 4 un E gt 4 bD 5 gt 0 un 0 da lt clearance after cylinder head has been reinstalled D004 Vacuum Pump Gauge e Check the force required to compress the spring e If the result is not correct replace the spring e Measure the free length of Valve Spring Valve Sprin Service Limit of Valve spring free length 48 0 mm Service Limit of Valve spring free length 19 0 21 4 kgf 36 50mm Vernier Calipers 6 29 DINEI ENGINE Valve Reassembl e Install the valve spring seats 1 e Apply MOLYBDENUM OIL SOLUTION to each oil seal 2 and put them in their position CAUTION Do not reuse the removed oil seals e Insert the valves with
80. nuts and bolts not listed in the preceding page refer to this chart Bolt Diameter Conventional or 4 marked bolt 7 marked bolt A mm T eT mumr 1 1 1 A A T 1 if A len um ee CEU EE mae gt gt Conventional 4 marked 7 marked 10 24 APPENDIX L Service Data Valve Valve Guide Unit mm Item Standard Limit _ ____ __ _ _ Valve diam es Tappet clearance When cold 0 10 0 20 0 20 0 30 Valve guide to valve stem 0 010 0 037 clearance X 0 030 0 057 o Valve guide LD IN amp EX 5474 5484 Valve stem O D Vales eset width IN amp EX TET Valve head radial runout 190 214 19 0 21 4 kgf 41 8 Valve spring tension 47 2 lbs at length 36 5 mm Camshaft Cylinder Head Unit mm 30 400 36 500 36 150 height 35 350 35 450 35 100 Camshaft journal oil clearance i 0 020 0 062 we Canaan OD werd 10 25 lt APPENDIX Cylinder Piston Piston Ring nit mm Compression pressure Approx 950 kPa 9 5 135 psi Automatic decomp actuated Piston to cylinder clearance 0 030 0 050 0 120 Cylinder bore 102 000 102 020 Nicks or Scratches 101 950 101 970
81. or weak e Camshaft bearing worn e Rocker arm worn e Worn tappet or cam surface 10 7 OINLI DINLI APPENDIX 4 Water pump noise e Too much play on pump shaft bearing e Worn or damaged impeller shaft e Worn or damaged mechanical seal e Contact between pump case and impeller 5 Other noise e Connecting rod small end clearance excessive e Connecting rod big end clearance excessive e Piston ring worn broken or stuck e Piston seizure damage e Cylinder head gasket leaking e Exhaust pipe leaking at cylinder head connection e Crankshaft runout excessive e Engine mounts loose e Crankshaft bearing worn e Camshaft chain tensioner trouble e Camshaft chain sprocket guides worn e Balancer bearing worn e Balancer gear worn e Loose alternator rotor e Worn or rubbing gears e Worn splines 10 81 Radiator Cooling System Engine Overheats e Not enough engine coolant e Radiator core clogged with dirt e Faulty cooling fan e Defective cooling fan thermo switch e Clogged water passage e Air trapped in the cooling circuit e Defective water pump e Use of incorrect engine coolant e Defective thermostat Engine Overcools e Defective cooling fan thermo switch e Extremely cold weather e Defective thermostat 10 9 APPENDIX OINLI DINLI APPENDIX Transmission Gear Shifting Faulty 1 Doesn t g
82. perform the work efficiently and to avoid costly mistakes read the text thoroughly to familiarize yourself with the procedures before starting work and then do the work carefully in a clean area Precision measurements can only be made if the proper instruments are used and the use of substitute tools may adversely affect safe operation For the duration of the warranty period we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty To get the longest life out of your vehicle e Follow the Periodic Maintenance Chart in the Service Manual e De alert for problems and non scheduled maintenance e Use proper tools and genuine DINLI vehicle parts Genuine parts provided as spare parts are listed in the Parts Catalog e Follow the procedures in this manual carefully Don t take shortcuts e Remember to keep complete records of maintenance and repair with dates and any replaced parts How to Use This Manual In preparing this manual we divided the product into its major systems These systems became the manual s chapters All information for a particular system from adjustment through disassembly and inspection is located in a single chapter The Quick Reference Guide shows you all of the product s system and assists in location of their chapters Each chapter in turn has its ow
83. rumimalights BATTERY terminals EXHALIZT spark arrester SLISPENSION HUTS BOLTS FASTENERS WHEELS TIRES pressure condition waar STEERING ASSEMBLY operation LUBRICATION dealer service suggests 4 servicing uld have Ihe pi m als service data ani d be me har ally qu alifi l Operational safety 3 The should be performed hy a dealer more frequency IF operation industry sandy andaa area 9 2 PERIODIC MAINTENANCE DIMLI lt Maintenance and Tune Up Procedures e this section describes the servicing procedures for the items mentioned in periodic maintenance chart or the other important parts that may influence the engine performance e Before performing the servicing procedures mentioned in the periodic maintenance chart remove following parts to ease servicing work seat o Front rack o Rear rack o Front fender o Rear fender o Left footboard o Right footboard Air cleaner Clean every 1000 km 50 hours 3 months e If the air cleaner element is clogged with dust intake resistance will be increased which results decrease in power output and increase in fuel consumption Check and clean the air cleaner element in the following manner o Remove the seat o Remove the air cleaner cover 1 o Remove the air cleaner e Using wa
84. specified torque Tightening Torque 160 N m 16 0 kgf m 115 Ib ft e Install the gearshift cam stopper the stopper 1 bolts 2 and return spring 3 e Install the gearshift cam stopper 1 and cam driven gear 2 to the stopper Hook the return spring end A gt 4 un un 0 gt z O Q O un z oO Q un oO bD 4 4 4 Q o Locate gearshift cam in neutral position Align the gearshift cam pin with the cam driven gear hole e Reassemble the gearshift shaft e Install the gearshift by aligning the punched mark with the center of the cam driven gear 6 61 un CU 5 S 2 bD bb 50 N Ke oD T m E Z E s Y E 8 CS gt 2 5 E bp g 5 E 5 2 2 e 2 2 5 5 2 5 5 e 2 gt a 9 6 621 7 ENGINE e Use the suitable bar 1 to install the starter cup 2 e Tighten the starter cup to the specified torque 0 Ib 19 m Tightening Torque 26 N m 2 6 kgf e Apply GREASE to the gasket CAUTION oD oO
85. th 1 09 9 9 9 9 99999999999999999999999999999 999999999999 9999 9X Oq x Oq Oq x Oq x Oq Oq Oq x x OO Oq Rotate pump by hand and check that it moves smoothly If it does not move smoothly replace the oil pump assembly CAUTION un un 5 lt un un 5 gt pe ilable only as an assembly 15 il pump 7 20 COOLING AND LUBRICATION SYSTEM ___ lt Engine Lubrication System Chart OIL PAN FILTEF k kk ku OIL FILTER ip COPPER PLUG j m _ SD Bede CRANKCASE INTAKE CAMSHAFT EXHAUST CAMSHAFT BEARING LEFT JOURNAL LEFT JOURNAL CYLINDER HEAD SHA COUNTER INTAKE EXHAUST p it dith u E WA Y CONNECTING ROD CLUTCH END BEARING 2
86. the brake lever e Check the fluid level in the reservoir often replenishing it as necessary o If the fluid in the reservoir runs completely out any time during fluid change air will enter the line and the system must be bled e Repeat this operation until fresh brake fluid comes out into the plastic hose or the color of the fluid change e Close the bleed valve in clockwise direction WARNING Do not mix two brand of fluid Change the brake fluid in the brake line completely if the fluid must be refilled but the type and brand of the brake fluid that is already in the reservoir are unidentified 3 4 srake _ DINLI Tighten the bleed valve to the specified torque Tightening Torque 5 5 N m 0 55 kg m 4 0 Apply the brake lever forcefully for a few second and check for fluid leakage around the fittings J N WARNING If the brake lever has a soft or spongy feeling when it is applied there might be air in the brake line or the brake may be defective Since it is dangerous to operate the vehicle under such condition bleed the air from the brake line immediately Brake Line Air Bleeding Bleed the air whenever brake parts are replaced or reassembled Remove the reservoir and fill the reservoir with new brake fluid Slowly pump the brake lever several times until no air bubbles can be seen rising up through the fluid from the hose at the bottom of th
87. the caliper C 4 CAUTION un 4 gt TEN O gt gt z un oO 2 0 i 5 4 it loosely from the disc e Loosen the banjo bolt A at the brake hose lower end and tighten caliper e Unscrew the banjo bolt and remove the brake hose D from the e Unscrew the caliper mounting bolts B loosely the disc e Remove the caliper mounting bolts and detach the caliper from caliper e Loosen the banjo bolt at the brake hose lower end and tighten it e Remove the banjo bolt and remove the brake hose from the e Remove the rear wheel see Wheels Tires chapter Rear Caliper Removal CAUTION E ss un 4 gt TEN O gt oO 2 0 5 Remove rear wheel See Wheels Tires chapter Parking Brake Caliper Removal e Remove the brake disc mounting bolts e Remove the rear caliper 3 8 e Remove circlip 1 and pull out disc and caliper then detach the caliper from the disc e Remove the wire rope bolt 2 and detach the wire rope from the caliper Caliper Installation Front Brake e Install the caliper 1 and brake hose 2 o Replace the washers that are on each side of hose fitting with new ones e Tighten the caliper mounting bolts 3 and the brake hose banjo bolt
88. the engine to prevent damage 11 Filter Engine Oil and O Ini Replace tially at 200 km 10 hours 1 month and every Q e Q gt imd a 4 N replacement at the above intervals should be done together with the engine oil change Place an oil pan under the drain plug 1 and then drain out the oil should be changed while the engine is warm Oil filter Engine Oil Replacement and engine engine oil by removing engine oil drain plug 1 torque and then pour the new oil through the oil filler hole oil filler cap 2 e Tighten the drain plug with the new washer to the specified Tightening Torque 19 N m 1 9 kgf m 14 0 Ib ft of oil Use engine oil that meets the API service classifications SF or SG and that has a viscosity rating of SAE 10W 40 e Tighten the oil filler cap 2 speed e Turn off the engine and wait about three minutes and then check e When performing an oil change the engine will hold about 3 3 L e Start the engine and allow it to run for a few minutes at idling 7 the oil level on dipstick 3 If the level is below upper line add oil to that level The vehicle must be placed on level ground for accurate measurement 9 12 Oil Filter Replacement e Drain the engine oil e Remove the front fender e Remove the oil filter 1 with the spe
89. un 0 910 gt Y 0 a ta un bD i 0 0 un 4 Q QO un found replace it with a new one gt bD 2 un 0 Q a un bD 5 0 0 un Q QO un damages are found replace them with new ones 4 30 SUSPENSION S TEERING DRIVE SHAFT Steering Shaft Bush Bearing e Inspect the steering shaft bush bearing 1 for wear and damage If any damages are found replace it with new one e Inspect the steering shaft seal cover for any scratches or other damage If any damages are found replace the shaft seal cover with new ones e Inspect the steering bush bearing 1 and pin 2 for any scratches or other damage If any damages are found replace them with ones 4 31 INES SUSPENSION STEERING DRIVE SHAFT Reassembly and Installation e Reassemble and install the steering in the reverse order of removal and disassembly Pay attention to the following points Steering Shaft e Apply GREASE to the seal cover 1 before installing the steering shaft e Install the seal cover 1 to the steering shaft e Apply GREASE to the steering shaft bracket and oil seals before installing the steering shaft bracket
90. water hoses 1 and 2 e Remove the water union il starter e Remove the reco 6 10 DINLI ENGINE 94940 4 0 4 4 4 4 4 41444 n gt bD z Remove e Remove cylinder head cover ing the TDC line A on the starter clutch to the index mark B of the crankcase e Turn the crankshaft to br iston is at TDC of compression SG At above conditio stroke and also the engraved marks C on the camshafts are ing surface of the cylinder head cover parallel with the mat e Remove the camshaft cover bolts 1 and camshaft cover 4 bD un gt D gt un 0 gt Q da un z oO Q c 0 un 5 un ea wrench diagonally 6 11 EINE I ENGINE sy O gt Q Me 4 gn un O 5 5 H gt 0 m E 5 us 42 gt 4 5 5 c E 75 o uu 1 O aP E 8 5 s s 2 55 Q E E v i NE 9 o Qc 3 3 8 a E x x CA di e 6 When loosening cylinder head bolts loosen each bolt little by Be careful not to drop the spacer 4 into the crankcase Loosen the cylinder nuts gt oD
91. 0 ml 1 10 27 DINLI APPENDIX Thermostat Radiator Fan Coolant Unit mm Item Standard Specification Note Thermostat valve opening 80 84 176 183 temperature Thermostat valve lift Over 7 0mm at 95 C 60 C 140 F Approx 0 704 kQ ECT sensor resistance 90 C 194 F Approx 0 261 120 C 248 0 111 Radiator valve opening 110 140 pressure 1 1 1 4 kgf cm 15 6 19 9 psi Cooling fan thermo switch OFF to ON Approx 96 C 205 F operating temperature ON to OFF Approx 86 C 187 Use an antifreeze coolant compatible with aluminum radiator mixed with distilled water Engine coolant type only at the ratio of 1 2 water anti freeze ethylene glycol Engine coolant Carburetor Idle rpm 1300 100 rpm 10 28 APPENDIX L Electrical Unit mm ze NGKCRE CR6E Spark plug 0 7 0 8 Spark performance Over 8 at 1 atm Primary 0 17 0 23 0 Terminal Ground Ignition coil resistance Secondary 5 0 7 6 Plug cap Terminal 200 250 DCV mE Alternator coil resistance 01 100 Alternator no load voltage 65 V AC and more at 5000 rpm When engine is cold SC designation GS GTX20L BS Dattery Capacity 12 20Ah Headlight EC amp LO Power source source 10A Fuse size 15A Wattage Unit W Headlight Taillight 21 5 Transfer indicator light En
92. 5 01 0005 02 0006 Vernier Calipers Valve Lifter Attachment Valve Lifter Rotor Remover Piston Ring Clamp Micrometer Oil Pressure Gauge Bearing Remover Set Connecting Rod Stopper Thickness Gauge Ring Nut Socket Wrench Ring Nut Socket Wrench 10 20 APPENDIX P L Tightening Torque Engine 0 Cylinder head cover bolt Cylinder head bolt M6 11 1 1 8 0 Cylinder head bolt M10 1 0 7 0 Camshaft journal holder bolt 10 Crankcase bolt Movable driven face bolt 110 maneno 9 9 6 10 21 lt APPENDIX Chassis Handlebar clamp bolt Um sw _ Front A arm mounting nut be _ ome Front shock absorber mounting bolt upper 7 s ne m5 _ s mr aa Front brake mounting bolt ss 25 Bowbaemeeroldermemugtok 9 09 Rear shock absorber mounting nut upper and lower sbs T Rear Aarn mouningtalinutupperandiowey _ Front differential gear oil drain plug m L s L s s o 5 10 22 APPENDIX P L EE Cooling System Cooling fan mounting bolt 10 23 lt APPENDIX Tightening Torque Chart e For other
93. 8 Caliper Installation 3 9 Caliper Inspection 3 10 Brake Pad 3 12 Removal 3 12 Installation 3 13 Inspection T q 3 15 Brake 3 14 Disc Cleaning 3 14 Front Disc Removal 3 14 Rear Disc Removal 3 15 Front Disc Installation 3 15 Rear Disc Installation 3 16 nspection 3 16 Brake Hose and Pressure Valve 3 17
94. 9 5 79 E gt o2 Y o lt 55 vo S E a JE S em X 60 o wo gt p DE 23 5 S Se ae Jm Q 5 5 8 nee Des bD 8 lt 5 E E R 585 lt lt 8 9 0 6 66 ENGINE DINLI Due to special valve train mechanism aligning of the three Rooi of tooth elements the punched mark embossed line and the gear tooth RN E odd root on the cam drive idle gear sprocket can occur once every While y PRAE E xri other rotation of crankshaft CAUTION If the punched mark A does not align the embossed line B turn the crankshaft 360 1 turn to bring the line on the generator CORRECT rotor to the index mark on the crankcase again and reinstall the cam drive idle gear sprocket to the correct position as shown e Tighten the cam drive idle gear sprocket shaft to the specified torque Tightening Torque 41 N m 4 1 kgf m 29 5 Ib ft e Install the cam chain tensioner and tighten the mounting bolts to the specified torque Tightening Torque 10 N m 1 0 kgf m 7 0 Ib ft e Install the new O ring CAUTION Use the new O ring to prevent oil leakage NINININI NINININI NINININI NINININI NINI NINININI NINININI NINI NINININI NINININI NININI
95. DRIVE SHAFT _ 7 lt SUSPENSION amp STEERING amp DRIVE SHAFT Table of Contents Front 5uspension 4 2 Construction 4 2 Removal and Disassembly 4 3 4 5 Reassembly Installation 4 8 Spring Pre Load Adjustment 4 10 Rear Suspension T 4 11 Construction 4 11 4 12 Inspection Disassembly 4 13 Reassembly and Installation 4 15 Spring Pre Load Adjustment 4 17 Rear Stabilizer Removal 4 18 Rear Stabilizer Installation
96. FOREWORD INDEX 0 0 DINLI FOREWORD INDEX DINLI 700 cc Service Manual All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Dinli Metal Industrial Co Ltd No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously See your dealer for the latest information on product improvements incorporated after this publication All information contained in this publication is based on the latest product information available at the time of publication Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts COPYRIGHT DINLI METAL INDUSTRIAL LTD 2008 0 1 DINLI FOREWORD INDEX Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop A basic knowledge of mechanics the proper use of tools and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily In order to
97. I EY Luggage Compartment Luggage Compartment Removal Installation e Remove the air cleaner by removing its box and bolts e Remove the battery e Remove the electrical relays and units Remove the fuel tank decoration See 5 9 e Remove the seat hook wire rope See 5 9 Remove the rear fender See 5 12 e Remove the intake pipe clamp e Remove the luggage compartment by removing its bolts e Install the luggage compartment in the reverse order of removal 5 15 DINLI CC rr Drainage Plug Inspection e Check the drainage plug and the compartments for accumulating water e If the water had been accumulated drain the water and clean the compartments 5 16 Q 92929 1 SOSOOSSOSOOSS e QC Yam Q COS 2554 SSOOSSOOSOOSS Q P QQ 2 and rear protector 3 by their bolts engine ts bolts Protector Removal Installation removing i Remove the front 1 e Install the protector by installing Protector 5 17 ENGINE q EE ENGINE Table of Contents Removal and Installation 6 2 Engine Removal 6 2 Engine Installation
98. Inspect the radiator for damage and engine coolant leakage If any damages are found replace it with a new one Radiator Hoses Inspect every 2000 km 100 hours 6 months e Inspect the radiator hoses for damage and engine coolant leakage If any damages are found replace them with new ones 9 17 Q i INES PERIODIC MAINTENANCE Inspection ining CVT Water Dra e If the de of the CVT had been accumulates with water 11151 15 the water to keep from damage or danger ining dra necessary lt z O lt lt lt 2 2 lt R 5 bD 5 gt gt O lt 55 925555922220 AS AS AS AS AS AS AS AS AS AS AS AS XQ T Oq Oq Oq OY OY OY Replace every 2000 100 hours 6 months E Ke 3 o c b 4 e v gt gt e Remove right body decoration See Body chapter Drive Belt Removal e Remove the right footboard e Remove the footrest 1 4 un oN gt lt gt Ke O gt
99. L Ke 4 ke N 9 LO C LO Q oO gt H Vernier Calipers Thickness of Shift Fork e Measure the thickness of Shift Fork with micrometer Thickness of Shift Fork 540 550 mm 540 550 mm H 5 e ge om 5 gt 6 50 DINLI ENGINE Generator Cover bly Disassem e Remove the generator stator assy th the special tool ings wi Remove the bear 15 not ing removal lt AE T 6 5 S necessary e Remove oil seals CAUTION der ing 5 0 un 4 0 un 4 5 Q O gt un un 0 Q 4 un om ts position t must install from the i Follow the arrow mark to place the components to o When install ine ing 1 ing the needle bear make sure that the mark side is face to the eng 7 other s e Install the water pump and its cover See Water Pump Reassembly and Installation Reassembly e Install the oil seals with the special tool 6 51 DINLI lt ENGINE e Install the bearings with the special tool e Install the generator stator assy
100. N STEERING DRIVE SHAFT e Remove the shock absorber lower mounting bolts nuts and the upper A arm washer face bolts nuts e Remove the upper A arms 1 Remove the lower A arm washer face bolts nuts Remove the lower A arms 2 e Remove the shock absorber upper mounting bolts nuts Remove the shock absorbers 4 4 DINLI SUSPENSION STEERING DRIVE SHAFT Inspection Front shock absorber e Inspect the shock absorbers for oil leakage or damage If any damages are found replace it with a new one Knuckle End e Inspect the knuckle end boots for wear or damage If any replace it with a new one 7 damages are found e Remove the snap ring 1 th the special tools i e Remove the knuckle ends w Installer Set ing Bear Front Fork Installer Hammer A arm z a ci aP bD c c aP c lt aP lt aP replace it with a new one Drive Shaft Protector gt TN bD 2 Q Q da un Ke 4 Q Q un damages found replace it with a new one 4 5 INES SUSPENSION STEERING DRIVE SHAFT Brake Disc Cover e Inspect the brake disc covers
101. NI NINININI N SISS e Install cam chain tensioner cap bolt Click sound is heard when the cam chain tensioner cap bolt is installed e Tighten the cam chain tensioner cap bolt to the specified torque Tightening Torque 7 N m 0 7 kgf m 5 0 Ib ft CAUTION After installing the cam chain tensioner check to be sure that the adjuster works properly by checking the slack of cam chain 6 67 I ENGINE m 1 Tightening Torque 10 N m 1 0 kgf m 7 0 Ib ft 5 2 T Q un A 4 aP c c 4 4 c a E O Q c bD T Q un oO Q Q 4 4 correctly MOLYBDENUM OIL SOLUTION to their journals and cam faces e Apply MOLYBDENUM OIL SOLUTION to the camshaft journal holders the mating surface of the cylinder head cover e Align the line A on the starter clutch with the index mark B on e The camshaft are identified by the engraved letters e Defore replacing the camshafts on cylinder head apply e Tighten the camshaft journal holder bolts to the specified torque e Measure the valve clearance again to prevent incorrect value e Align the engraved lines C on the camshaft so it is parallel with e Pour engine oil in each oil pocket in the cylinder head e Install the dowel pins e Ch
102. P 2854 gt E E 55 5 655 5 5365 E 2 2 22 amp 5 b 9 g 5 5 5 3 15 D lt gt 558 gt gt lt 5 gt vnn 5 oa 8 9 c 3 88 v a x x 6 5 x SoS p U e e e A A Ul e ickness Gauge Th 6 25 EINE I ENGINE Valve Stem runout e Remove carbon deposits ePlace on the V block e Measure the runout by means of dial gauge e If the result is out of specifications replace with new Valve 3 5 g ES gt Service Limit Dial Gauge 1 100 mm ic Stand V block set 100mm Magnet Valve head radial runout e Place the dial gauge at right angles to the valve head face and measure the valve head radial runout e If it measures more than limit replace valve 3 5 gt H gt Un Dial Gauge 1 100 mm Magnetic Stand V block set 100mm Valve face wear e Inspect each valve for wear of its seating face Replace any valve with an abnormally worn face e Measure the thickness and if it measures less than the limit replace the valve Service Limit of Valve head thickness ipers Vernier Cal 6 26
103. Q 4 bD Eu Q Q c 4 e E gt gt Q e Remove front and rear rack and fender e Remove the water hoses 6 2 DINLI ENGINE e Remove Oil pressure gauge coupler 1 and Coolant Temperature sensor coupler 2 Remove the air cleaner box Remove the carburetor Remove fuel feeding hoses 6 3 EINE I ENGINE e Remove Stator assembly coupler 1 and Speed Sensor coupler 2 e Remove Tie rod end of lever assembly rod e Remove Shift lever assembly 3 e Remove PCV Positive Crankcase Ventilation tube 4 5 un Q 5 lt z un un 2 Un gt x coupler 2 e Remove Regulator Rectifier coupler 1 t speed sensor coupler 2 e Disconnec T 5 E g lt 5 gt lt gt z x e Remove Intake duct 6 4 DINLI 0471111111 SS XX XXX 5 ENGINE ht foot board 15 un 0 Q 2
104. STEM e Just when the water temperature reaches specified value the e Keep on heating the water to raise its temperature thermostat valve should have lifted A by at least 7 0mm 0 gt oO un Over 7 0mm at 95 Over 0 28 in at 203 F Standard e A thermostat failing to satisfy either of the two requirements start to open temperature and valve lift must be replaced e Install the thermostat in the reverse order of removal e Apply engine coolant to the rubber seal on the thermostat Installation Q 5 un 0 Q oO oO un 4 4 lt 0 gt ES bD 20 e After installing the thermostat be sure to add engine coolant e Tighten the thermostat cover bolts to the specified torque htening Torque 10 N m 1 0 kgf m 7 0 Ib ft Tig 7 13 DINLI COOLING AND LUBRICATION SYSTEM lt Water Pump Removal and Disassembly e Remove the left mud guard e Drain engine coolant e Drain engine oil e Remove the water hoses e Remove the water pump cover 1 Before draining engine coolant inspect engine coolant leakage between the water pump and crankcase If engine oil is leaking visually inspect the oil seal and O ring If engine coolant is leaking visually inspect the mechanical seal and seal ring CAUTION In order t
105. Standard tire AT 25x8 12 MAXXIS M915 Tubeless AT 25x10 12 MAXXIS M916 Tubeless Tire air pressure when cold Front 35 kPa 0 35 kgf cm 5 1 psi Rear 35 kPa 0 35 kgf cm 5 1 psi Maximum tire bead seat pressure Front 250 kPa 2 5 kgf cm 36 psi Rear 250 kPa 2 5 kgf cm 36 psi Vehicle Maximum load capacity 250 KG 2 2 WHEELS TIRES oe OINLI Construction I e veeo Jo me cenge ime Ls s m Em Name EJ 5 Insert Bolt 16pcs Tire n 43 5 2 3 Rim Valve 4 OINLI WHEELS TIRES Wheel Rim Removal e Loosen the wheel nuts A for just one turn e Support the vehicle on a stand or the jack so that the wheels are off the ground e Take off the wheel nuts and remove the wheel Installation Check the tire rotation mark A the tire and install the wheel accordingly 2 O gt 2 un D lt c lt lt Ke the tire sidewall 201029202929 0292 lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt
106. UTION Check the thread size and reach when replacing the spark plug If the reach is too short carbon will be deposited on the screw portion of the spark plug hole and engine damage may result CAUTION To avoid damaging the cylinder head threads first tighten the spark plug by hand and then tighten it to the specified torque using the spark plug wrench e Insert the spark plug and tighten it to the cylinder head by hand and then tighten it to the specified torque Tightening Torque 14 N m 1 4 kgf m 10 1 Ib ft 9 9 INES PERIODIC MAINTENANCE m we er iz Ne 5 Mer iz c gt gt e Remove muffler end cover 1 Spark Arrester from the muffler e Clean the spark arrester pipe 2 by non e Extract the spark arrester pipe 2 ic brush If synthet necessary blow debris from the arrester with compressed air m M er vu 4 c gt gt id 2 Replace every four years e Reinstall the spark arrester pipe 2 e Inspect the fuel feed hose for damage and fuel leakage If any Fuel Line damages are found replace it with a new one 9 10 DINLI PERIODIC MAINTENANCE Throttle Cable Play tially at 200 km 10 hours 1 month and every
107. UTION Use the new O rings to prevent engine coolant and engine leakage NOTE o Apply engine coolant to the O ring 1 e Install the water pump cover 1 and tighten its mounting bolts to the specified torque Tightening Torque 10 N m 1 0 kgf m 7 0 Ib ft e Connect the radiator hoses e engine coolant 7 18 COOLING AND LUBRICATION SYSTEM Lubrication System Oil Pressure e Check the engine oil pressure periodically Oil Pressure Above 15 kPa 0 15 2 0 psi See Periodic Maintenance Oil Filter e Drain the engine oil e Remove the left inner fender e Remove the oil filter 1 with the special tool e Apply slightly of engine oil to the gasket of the new oil filter before installation e Install the new oil filter to the engine Turn it by hand until you feel that the oil filter gasket has contacted the oil filter mounting surface Then tighten the oil filter two full turns with the special tool D003 Oil filter wrench NOTE To properly tighten the oil filter use the special tool Never tighten the oil filter by hand e Pour new engine oil 7 19 DINLI DINLI COOLING AND LUBRICATION SYSTEM c lt un 5 gt 43 5 un s K 5 Oil Sump Filter de is face to the CVT Inner SI keep oil clean And the
108. VE SHAFT Spring Pre Load Adjustment e After installing the rear shock absorbers adjust the spring pre load e The spring adjusting sleeve on shock absorber has 5 positions so that the spring can be adjusted for different terrain and loading conditions If the spring action feels too soft or too stiff adjust it in accordance with the following photograph e Turn the adjusting sleeve on shock absorber to the desired position with the wrench N WARNING Be sure to adjust the spring pre load on the both shock absorbers equally 4 17 DINLI DINLI SUSPENSION STEERING DRIVE SHAFT ilizer Removal Rear Stab Remove the rear wheel Remove the rear stabilizer joint bolt nut Remove the rear stabilizer bracket bolts Remove the rear stabilizer bar Inspection Rear Stabilizer Bar Inspect the stabilizer for damage If any damages found replace the rear stabilizer bar with a new one ing izer Bracket Bush l Stabi Inspect the stabilizer bracket for damage If any damage are found replace the stabilizer bracket with a new one Inspect the plastic bushing for wear or other damage If any ith a new one ing wi damages are found replace the bush ink izer L Stabil un bD gt bD oO 2 kaw B a un 4 Q QO un
109. ake pedal not properly adjusted e Pad over worn or worn unevenly e Disc worn unevenly or scored e Oil grease on pads and disc e Dirt water between pads and disc e Brake system overheated e Pressure valve trouble Excessive Brake Lever Stroke e Air in hydraulic system e Insufficient brake fluid e Improper quality of brake fluid 10 131 APPENDIX OINLI EEE DINLI APPENDIX Noisy Brake e Foreign material adhesion on pad surface e Tilted pad e Damaged wheel hub bearings e Foreign material in brake fluid e Pad installed incorrectly e Pad surface glazed e Disc or pads worn or warped e Clogged return port of master cylinder e Caliper trouble Leakage of Brake Fluid e Insufficient tightening of connection joints e Cracked hose e Worn piston and or cup Brake Drags e Rusty part e Insufficient brake lever or brake pedal pivot lubrication Shock absorption unsatisfactory 1 Too hard e Tire air pressure too high e Shock absorber maladjusted e Worn upper or lower A arm and related bushing 2 Too soft e Shock absorber oil leaking e Shock absorber spring weak e Tire air pressure too low e Shock absorber maladjusted Noisy Suspension e Loose nuts or bolts on suspension e Worn A arms and related bushings 10 14 APPENDIX TN Handing and or stability Unsatisfactory 1 Handlebar hard to turn e Tire air pressure too low e Steering shaft bearing damage
110. al and the battery lead wire with the multi circuit tester If the reading exceeds the specified value leakage is evident Multi Circuit Tester Set Tester knob indication Current DCA 20 mA Battery current leak Under 14 mA CAUTION o Because the current leak might be large turn the tester to high range first to avoid tester damage o Do not turn the ignition switch to the position when measuring current When checking for excessive current leakage remove the couplers and connectors one by one so as to locate the position of trouble 7 13 DINLI gt DIMNE ELECTRICAL SYSTEM Regulator Rectifier Inspection e Check the battery condition see Battery section e Warm up the engine to obtain actual alternator operating conditions e Check that the ignition switch is turned off and connect the multi circuit tester to the battery terminal e Start the engine and note the voltage readings at various engines speeds with the headlight turned on and then turned off The readings should show nearly battery voltage when the engine speed is low and as the engine speed rises the readings should also rise But they must be kept under the specified voltage Regulator Rectifier Output Voltage Tester Range Reading 25 V DC Battery Battery 14 15 V e Turn off ignition switch to stop engine and remove seat e Remove the battery stay 1 e Measure the DC v
111. andlebar Align the brake reservoir on the horizontal direction is necessary 4 37 INES 1 sPENSION STEERING DRIVE SHAFT Indicator T M Lever Construction ___ __ gt Tapping screw 4pcs Washer 3pcs Net 7 e A 4 38 SUSPENSION STEERING DRIVE SHAFT _ 7 lt gt Removal e Remove the indicator T M lever knob 1 indicator level tapping screws 2 and mounting bolts 3 e Loosen the bolt 1 and remove the tie rod end 2 e Remove the T M lever assembly 4 39 DINLI SUSPENSION STEERING DRIVE SHAFT Inspection e Inspect the shift lever assembly for wear or damage If any damages are found replace it with a new one Installation e Install the indicator T M lever in the reverse order of removal Pay attention to the following points e Apply GREASE to level shaft e Install the T M lever assembly to the frame bracket e Apply THREAD LOCK to lever assembly mounting bolts e Install the tie rod end 1 e Tighten the bolt 2 4 40 SUSPENSION S TEERING DRIVE SHAFT Shift Rod Installation e Before removing lever assembly keep tie rod end 1 in the N position e Install the tie rod end 1 on its shaft NOTE When installin
112. ap is capable of holding that pressure for at least 10 seconds e Replace the cap if it is found not to satisfy either of these two requirements Radiator Cap Valve Opening Pressure 110 140 kPa 1 1 14 kgf cm 15 6 19 9 psi 7 6 DINLI COOLING AND LUBRICATION SYSTEM ion tor Hose Inspect Radia iator hose found in a cracked condition or flattened must leakage from the connecting section should be corrected by Remove the front grill upper cover be replaced Remove the left headlight Remove the left inner fender Remove the left side cover rad proper tightening 1 5 N m htening Torque Cooling hose clamp Tig 0 15 kgf m 1 0 Ib ft 7 7 COOLING AND LUBRICATION SYSTEM ing Fan Cool Inspection e Disconnect the cooling fan motor lead wire coupler 1 e Test the cooling fan motor for load current with an ammeter connected as shown in the illustration e The voltmeter is for making sure that the battery 2 applies 12 With the motor with electric motor fan running at full speed ammeter 4 should be indicating not volts to the motor 3 more than 5 3 amperes e If the fan motor does not turn replace the cooling fan assembly with a new one it is not necessary to remove the a un 9 gt O Q 5 5 lt
113. apter e Remove the fuse case cap and take out the fuse Fuse Inspection e Inspect the fuse element If itis blown out replace fuse Before replacing a blow fuse always check the amperage in the affected circuit If the amperage is equal to or greater than the fuse rating check the wiring and related components for a short circuit CAUTION When replacing a fuse be sure the new fuse matches the specified fuse rating for that circuit Installation of a fuse with a higher rating may cause damage to wiring and components 7 30 Switches e Measure each switch for continuity using a multi circuit tester If ELECTRICAL SYSTEM any abnormality is found replace the respective switch assemblies with new ones Multi Circuit Tester Set Indicator Switch 1 iigh Loa Heam Seatch 3 Wire Color B Black Br Brown Bu Blue G Green Gr Gray Light G Light Green O Orange P Pink R Red W White B Y Black with Yellow tracer Br B Brown with Black tracer G R Green with Red tracer G W Green with White tracer W B White with Black tracer W Bu White with Blue tracer W R White with Red tracer Y B Yellow with Black tracer Y R Yellow with Red tracer 7 31 DINEI ELECTRICAL SYSTEM Wiring Diagram Version I zi umm LAMP SOCKET SOURCE FUSE RELAY CDLI CE 2 HAZARD TAMPSENSOR PLAS mellem 19 LI
114. bD 4 gt 4 x e Remove high voltage cable e Remove the Exhaust pipe bolts e Remove the muffler e Remove the right foot board bracket e Remove the foot brake pedal e Remove ther 6 5 DINEI ENGINE 2 5 bD 5 gum 5 O T D lt Mas lt gt ide front differential assy forward e S e Remove the front propeller shaft spring e Remove the front propeller shaft e Remove the rear gear box bolts nuts 6 6 DINLI ENGINE Slide the rear gear box assy backward e Remove the rear propeller shaft spring e Remove the rear propeller shaft d 5 un oD t e Remove the engine moun e Remove the engine from the right side 6 7 EINE I ENGINE Remount the engine in the reverse order of engine removal e Tighten the engine mounting nuts to the specified torque Pay attention to the following points Engine Installation Tightening Torque 60N m 6 0 kgf m 43 5 Ib ft bD c p 5 lt lt un 2 ud gt un 5 T un 5 4 Q E Tighten rear gear box mounting nuts to specified torque 0 kgf m 36 0 Ib
115. bring it into the specified range 9 27 DINLI gt DINLE PERIODIC MAINTENANCE Suspensions 6 months 3 uz 2 4 e N E O gt Q Q aP e Support the vehicle with a jack and wooden blocks e Remove the front and rear wheels e Inspect the A arm and bushing for scratches wear or damage If any damages are found replace them with new ones See Suspension chapter e Inspect the front and rear shock absorbers for oil leakage or replace them with new ones 7 damage If any damages are found See Suspension chapter ift Rod Sh e Check the position of the gearshift lever shift the lever to position and check if the lever moves smoothly as shown in the figure e If the lever can not move successfully measure the tie rod length and adjust the tie rod to the proper position e Adjust the tie rod in two positions as shown in the figure Be careful not to separate the rod from the joint by turning the Q 3 5 9 281 PERIODIC MAINTENANCE CAUTION lt lt un hem ic 5 bD em lt un lt to standard or it will cause transmission gears to wear or damage Reverse Shifting Switch De
116. cial tool e Apply engine oil lightly to the gasket of the new oil filter before installation e Install the new oil filter to the engine Turn it by hand until you feel that the oil filter gasket has contacted the oil filter mounting surface Then tighten the oil filter two full turns with the special tool D003 Oil Filter Wrench NOTE To properly tighten the oil filter use the special Never tighten the oil filter by hand e Pour the new engine oil through the oil filler hole When performing the oil filter change the engine will hold about 3 3 L of oil e Check the oil level e Add new engine oil and check the oil level Engine Oil Capacity Oil change Engine overhaul CAUTION ONLY USE A DINLI OIL FILTER Other manufacture s oil filters may differ in thread specifications thread diameter and pitch filtering performance and durability which may lead to engine damage or oil leaks 9 13 INES PERIODIC MAINTENANCE Differential Gear Oil Inspection Inspect every 2000 km 100 hours 6 months Replace every two years e Place the vehicle on level ground e Remove the oil level plug 1 and oil filler plug 2 and inspect the oil level If the oil level is below the level hole add fresh oil until oil flows from the level hole e Tighten the oil level plug 1 and oil filter plug 2 to the specified torque Differential Gear Oil Replacement e Place the vehicle on level ground
117. cified torque Tightening Torque 18N m 1 8kg m 13 0ft Ib WARNING Do not attempt to drive the vehicle until a full brake lever is obtained by pumping the brake lever until the pads are against each disc The brakes will not function on the first application of the lever if this is not done After replacing the brake pads pump the brake lever a few times to check for proper brake operation and then check the brake fluid level Inspection e Check the lining thickness A of the pads in each caliper If the lining thickness of either pad is less than the service limit B replace both pads in the caliper as a set Pad Lining Thickness 3 13 DINLI pp x7 Brake Disc Disc Cleaning e Poor braking can be caused by oil on a disc Oil on a disc must be cleaned off with an oil cleaning fluid such as trichloroethylene or acetone Z Z lt lt 2 Q z lt D 3 un 3 un m bD amp oO lt un harmful if breathed for prolonged periods Be sure to heed the fluid manufacturer s warnings Front Brake Disc Removal e Remove the front wheel see Wheel Removal e Remove the front brake caliper 0 0 0 00 XX e Remove the front hub by removing its cott
118. cotter pin with a new one e Remove the steering shaft bracket bolts spacers oil seals and plate e Remove the steering shaft brackets e Remove the steering shaft CAUTION 2 2 un 5 O gt G lt Q Q 2 ing 3 and washer 2 bush bear pin 4 e Remove seal cover 1 CAUTION 2 c gt Q T 4 un 5 gt Ker lt Q Q 4 29 INES SUSPENSION STEERING DRIVE SHAFT Inspection e Inspect the handlebar clamp for wear or damage If any damages are found replace the clamp with a new one Seal Cover and Bush Bearing oO 2 bD 5 un 5 5 5 Q un 0 gt Q 0 un 4 4 Q QO un damage If any damages found replace them with new ones e Rod Ti e Inspect the tie rod for distortion or damage If any damages are found replace it with a new one Ti e Rod End D Ner 4 45 0 0 gt Ke 4 un un un O Ke 4 Q un abnormalities replace them with new ones Steering Shaft and Bracket
119. d e Steering shaft bearing lubrication inadequate e Steering shaft bent e Damaged steering knuckle joint e Damage tie rod end e Improper front wheel alignment 2 Handlebar shakes or excessively vibrates e Defective or incorrect tires e Unequally inflated tires e Loose front wheel hub nuts e Worn or loose tie rod ends e Damaged or worn A arms and related bushings e Wheel rim warped e Front axle runout excessive e Wheel bearing worn e Handlebar clamp loose e Loose chassis nuts and bolts 3 Handlebar pulls to one side e Frame bent e Improper front wheel alignment e Worn front wheel hub bearings e Suspension arm bent or twisted e Steering shaft bent e Front or rear tire air pressure unbalanced e Front shock absorber unbalanced Shocks Felt In The Steering e High tire pressure e Worn steering linkage connection e Loose suspension system bolts Tires Rapidly or Unevenly Wear e Worn or loose front wheel hub bearings e Improper front wheel alignment 10 151 OINLI DINLI APPENDIX Wobbly Rear Wheel e Distorted wheel rims e Damage or worn rear wheel hub bearings e Defective or incorrect tires e Loose nuts or bolts on rear suspensions e Loose rear wheel hub nuts e Improper rear brake adjustment e Rear shock absorber leaks oil e Loosen rear stabilizer mounting bolts Other Noise e Shock absorber damaged e Bracket nut bolt etc not properly mounted
120. d ts poin e Install the hub bearings with the special tool il seal with the special tool ing knuckle o e Install the steer e The oil seal which has faces to the front hub can be installed by hand e Install the knuckle end boots to the upper and lower A arm with ial tool the spec 1 ings e Install the snap r 4 8 e Install knuckles to upper A arms by installing bolts e Apply THREAD LOCK to the A arm washer face nut and then tighten the nut to the specified torque Tightening Torque Upper 60 N m 6 0 kgf m 43 5 Ib ft Lower 60 N m 6 0 kgf m 43 5 Ib ft e Tighten the shock absorber mounting lower bolt nut 1 to the specified torque Tightening Torque 60 N m 6 0 kgf m 43 5 Ib ft e Tighten the shock absorber mounting upper bolt nut 2 to the specified torque Tightening Torque 60 N m 6 0 kgf m 43 5 Ib ft e Tighten the knuckle end nut upper and lower to the specified torque Tightening Torque 29 N m 2 9 kgf m 21 0 Ib ft e Install the new cotter pins to the nuts 4 9 DINLI SUSPENSION STEERING DRIVE SHAFT lt e Tighten rod end nut to the specified torque Tightening Torque 29 N m 2 9 kgf m 21 0 Ib ft e Install the new cotter pins to the nuts e Apply THREAD to front brake disk cover mounting bolts and then tighten them securely Tightening Torque 10 N m 1 0 kgf m 7 0 Ib ft e Install the
121. d to inspect for abnormal noise ing If there is anything unusual replace the bear smooth rotation th a new one WI v om ircl ing Remove hub bear 4 14 DINLI SUSPENSION STEERING DRIVE SHAFT e Remove the hub bearing from the direction that arrow marks lon Reassembly and Installat e Reassemble and install the rear suspension in the reverse order of ts ing poin removal and disassembly Pay attention to the follow e Apply GREASE to the hub bearings and the lips of the oil seals before installing them e Install the hub bearings with the special tool y Q O un 4 4 4 un O Q 5 4 Ner un 4 15 INES SUSPENSION STEERING DRIVE SHAFT e Tighten the suspension arm nuts to the specified torque Tightening Torque 60 N m 6 0 kgf m 43 5 lb ft Upper amp Lower e Tighten rear knuckle bolt nut to the specified torque Tightening Torque 60 N m 6 0 kgf m 43 5 lb ft e Apply THREAD LOCK to the rear shock absorber mounting bolts and then tighten the nut to the specified torque Tightening Torque 60 N m 6 0 kgf m 43 5 lb ft Upper amp Lower e Tighten the rear stabilizer joint bolt nut Tightening Torque 34 N m 3 4 kgf m 24 5 lb ft 4 16 SUSPENSION S TEERING DRI
122. de elower sidera 4 Q lt 2 lt Q M ar 6D T c located to exhaust side piston pin e Apply a small amount of MOLYBDENUM OIL SOLUTION to the e Install the piston and piston pin e Place a clean rag over the crankcase Install the circlip CAUTION chain will be caught between the crankcase and the cam drive Nen 2 5 5 Ke lt Q lt E Q 22 Ka un lt e m bD 5 5 sprocket and the new gasket 2 has to be matched with same level cylinder e Fit the dowel pins 1 e 3 35 and 6 33 A Piston has to be matched with A cylinder B Piston has to be matched with B cylinder see 6 CAUTION bD oO oO 2 un oO bD gt e gt D un bD 4 4 un 6 64 ENGINE e Hold each piston ring with properly position insert the piston into the cylinder ing Clip Piston R e Tighten the cylinder base nuts CAUTION lt Mer Q d lt p Q T 5 un 5 O O
123. ducting accurate electrical system tests o The electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them o To prevent damage to electrical parts do not disconnect the battery leads or any other electrical connections when the ignition switch is on or while the engine is running o Because of the large amount of current never keep pushing the starter button when the starter motor not have to turn over or the current may burn out the starter motor windings o Do not use a illumination bulb rated for other than the voltage or wattage specified in the wiring diagram as the handle cover could be warped by excessive heat radiated from the bulb CAUTION Take care not to short the leads that are directly connected to the battery positive terminal to the chassis ground 7 6 ELECTRICAL SYSTEM DINLI hl o Troubles may involve one or in some cases all items Never replace a defective part without determining what CAUSED the failure If the failure was caused by some other item or items they too must be repaired or replaced or the new replacement will soon fail again o Make sure all connectors in the circuit are clean and tight and examine wires for signs of burning fraying etc poor wires and bad connections will affect electrical system operation o Measure coil and winding resistance when the part is cold at room tempe
124. e 1 9 5 Spark Plug 9 9 Spark Arrester 9 10 Fuel Line 9 10 Throttle Cable Play 9 11 Carburetor 9 11 Engine Oil and Oil Filter 9 12 Differential Gear Oil Inspection 9 14 Differential Gear Oil Replacement 9 14 Rear Driver Gear Oil 9 15 Engine Coolant 9 16 Radiator 9 17 Radiator Hoses 9 17 CVT Water Draining
125. e Fluid N WARNING When working with the disc brake observe the precautions listed below 1 Never reuse old brake fluid 2 Do not use fluid from a container that has been left unsealed or that has or that has been open for a long time 3 Do not mix two different brands of fluid for use in the brake This lowers the brake fluid boiling point and could cause the brake to be ineffective It may also cause the rubber brake parts to deteriorate 4 Don t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid 5 Don t change the fluid in the rain or when a strong wind is blowing 6 Except for the disc pads and disc use brake fluid isopropyl alcohol or ethyl alcohol for cleaning brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause deterioration of the rubber parts Oil spilled on any parts will be difficult to wash off completely and will eventually deteriorate the rubber used in the disc brake 7 When handing the disc pads or disc be careful that no disc brake fluid or any oil gets on them Clean off any fluid or oil that inadvertently gets on the pads or disc with a high flash point solvent Replace the pads with new ones if they cannot be cleaned satisfactorily 8 Brake fluid quickly ruins painted surface any spilled fluid should be completely washed away immediately 9 If any of the brake line f
126. e discs Completely clean off any grease that has gotten on either side of the disc with a high flash point solvent Inspection Disc Wear where it has e Measure thickness of each disc the point worn the most Replace the disc if has worn past the service limit Measuring Area b Front Disc Thickness 0 Q gt 0 Rear Disc Thickness Service Limit Micrometer 0 25 mm Disc Runout e Jack up the vehicle so that the wheels are off the ground e Remove the front wheels and turn the handlebar fully to one side e Set up a dial gauge against the disc A and measure the disc runout If the runout exceeds the service limit replace the disc Disc Runout 0 3 mm Service Limit ial gauge 1 100 mm D Magnetic stand 3 16 Brake Hose and Pressure Valve Inspection Brake Hose e The high pressure inside the brake line can cause fluid to leak or the hose to burst if the line is not properly maintained Bend and twist the brake hose while examining it Replace it if any cracks or bulges are noticed Pressure Valve e Inspect the pressure valve for leakage if any leakage has been found replace the pressure valve with a new one Replacement Brake Hose e Pump the brake fluid out of the line as explained in the Brake Fluid Change e Remove the banjo bolts at both ends of the brake hose and pull the hose off the
127. e ends of the leads o Set the tester to the x 1 O range and read the tester the tester does not read 0 the lead is defective Replace the lead or the wiring harness B if necessary Multi Circuit Tester Set 7 8 ELECTRICAL SYSTEM q Battery Removal e Disconnect the battery negative cable Black first and then the positive cable red e Take out the battery Battery Installation e Connect the positive cable first and then the negative cable Battery Charging Keep the battery away from sparks and open flames during charging since the battery gives off an explosive gas mixture of hydrogen and oxygen When using a battery charger connect the battery to the charger before turning on the charger This procedure prevents sparks at the battery terminals which could ignite any battery gases The battery is a maintenance free design and construction Use of conventional lead acid batteries is not recommended electrolyte or refilling water is required Because this battery is a completely sealed type abuse of the battery can cause an explosion Please adhere to the following points 1 Follow the instructions shown battery package for preparation and filling with battery electrolyte 2 Never interfere with the sealed state of the battery 3 Check charging conditions with a voltmeter Normal charging voltage should be 12 8V 4 This battery may be i
128. e of Contents Engine Coolant n T T 7 2 Cooling Circuit T TT 7 3 Cooling Circuit Inspection 7 3 Radiator and 7 4 Radiator Removal 7 4 Radiator Inspection and Cleaning 7 5 Radiator Remounting 7 5 Radiator Reservoir Tank 7 6 Radiator Cap Inspection 7 6 Radiator Hose Inspection 7 7 Cooling 7 8 nspection 7 8 Removal 7 8 Remounting 7 8 Cooling Fan Thermo Switch 7 9
129. e reservoir This bleeds the air from the master cylinder and the brake line NOTE oTap the brake hose lightly going from the caliper to the reservoir side and bleed the air off at the reservoir Attach a clear plastic hose to the bleed valve on the caliper run the other end of the hose into a container Bleed the brake line and the caliper as follows o Hold the brake lever applied B o Quickly open and close the bleed valve o Release the brake lever A Repeat this operation until no bubbles comes out the brake fluid reservoir The fluid level must be checked several times during the bleeding operation and replenished as necessary o If the fluid in the reservoir runs completely out any time during bleeding the bleeding operation must be done over again from the beginning since air will have entered the line o If the brake level action still feels soft or spongy tap the brake hose from bottom to top and air will rise up to part of the hose Slowly pump the brake level in the same manner as above Tighten the bleed valve to the specified torque Tightening Torque 5 5 N m 0 55 kg m 4 0 Apply the brake lever forcefully for a few seconds and check for fluid leakage around the fittings 3 5 DINLI E Master Cylinder Removal e Place rag underneath the brake hose union bolt on the master cylinder to catch any split fluid Remove the brake hose union b
130. e the speed sensor with a new one The highest voltage reading in this test will be the same as that of battery 12 V 7 28 ELECTRICAL SYSTEM Lighting System Headlight Bulb and Assembly Replacement e Remove Headlight Unit A Bulb Holder B e Slide back the dust protection and remove the bulb from the headlight unit o Turn the holder counterclockwise and pull it out e De sure the socket is clean e Insert the new bulb by aligning the tang with the notch in the headlight unit CAUTION If you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure e Push the holder in turn it clockwise and release it it should lock in position e Fit the dust cover completely Taillight Bulb and Assembly Replacement e Remove Taillight Bracket Screw 3 A Taillight Unit e Insert the new bulb CAUTION If you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure Indicator Bulb and Assembly Replacement e Remove Indicator Screw B e Insert the new bulb CAUTION If you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure 7 29 DINLI OINLI lt ELECTRICAL SYSTEM Fuses Main Fuse Removal e Remove the seat see Frame ch
131. e water pump and then drain the engine coolant by removing the drain plug 5 A N WARNING o Do not open the radiator cap when the engine is hot as you may be injured by escaping hot liquid or vapor o Engine coolant may be harmful if swallowed or if it comes in contact with the skin or eyes If engine coolant gets into the eyes or contacts the skin flush the eyes or wash the skin thoroughly with plenty of water If engine coolant is swallowed induce vomiting and call a physician immediately e Flush the radiator with fresh water if necessary e Tighten the drain plug 5 to the specified torque Tightening Torque 13 N m 1 3 kgf m 9 5 Ib ft e Pour the specified engine coolant into the reservoir tank CAUTION Use and antifreeze designed for aluminum radiators mixed with distilled water only Water antifreeze mixture ratio 50 50 33 67 NOTE For engine coolant information refer to page 7 2 9 16 e Install radiator cap 1 securely e After warming up and cooling down the engine add the specified engine coolant until the level is between the upper and lower lines on the engine coolant reservoir tank CAUTION Repeat the above procedure several times and make sure the radiator is filled with engine coolant to the upper line of the engine coolant reservoir tank Engine coolant capacity including reservoir 1950 ml Radiator Inspect every 1000 km 50 hours 3 months e
132. easure runout with dial gauge e Set on the V 5 c 5 x 0 Q gt E 52 219 3 Q w om A3 ux N Q w gt 6 37 EINE I ENGINE Clutch Clutch Shoe cracks uneven wear and heat 7 discoloration Also check depth of grooves the clutch e Inspect the clutch shoe for chips shoe replace the shoe as a 7 If there is no groove at any part of shoe set FEE O N e N e O e lt O N gt w 5 O N The clutch e Inspect the condition of the inner clutch wheel surface for scuffs Clutch Wheel scratches cracks or uneven wear e If any damages are found replace the clutch wheel with a new one e Install the starter clutch in the proper direction e Remove the starter clutch securing bolts Starter Clutch gt O G gt gt un 2 Q gt z bp T 5 O 4 gt 2 O O lt a 5 4 O lt 5 N outer ring groove 2 and faces to the rotor
133. eck the valve clearance 6 68 DINLI ENGINE e Install the new gasket to the cylinder head cover eApply BOND to the cam end caps of the gasket as shown CAUTION bD oO oO RS gt Q O O un oO bD 4 4 Ke 4 4 un Tighten head cover bolts to specified two step torque sequentially itial 10 N m 1 0 kgf m 7 0 Ib ft Final 14 N m 1 4 kgf m 10 0 Ib ft Tightening Torque In Ner un 2 gt Q O n gt bD E O lt installing head cover bolts e Tighten the valve timing inspection plug to the specified torque Tightening Torque 23 N m 2 3 kgf m 16 5 Ib ft e Apply a small quantity of THREAD LOCK to the bolts e Install the recoil starter e Install the new O ring to the water union CAUTION bD O O lt S bD gt i T O un e Apply engine coolant to the O ring e Install the water union 6 69 ENGINE 2 0 un 4 4 oO un 6 70 COOLING AND LUBRICATION SYSTEM ___ lt COOLING amp LUBRICATION SYSTEM Tabl
134. enerally damages seals Oil or grease seals should be pressed into place using a suitable driver applying a force uniformly to the end of seal until the face of the seal is even with the end of the hole unless instructed otherwise When pressing in an oil or grease seal which has manufacturer s marks press it in with the marks facing out 14 Cir clip Retaining Ring and Cotter Pin When installing cir clips and retaining rings take care to compress or expand them only enough to install them and no more Install the cir clip with its chamfered side facing load side as well Replace any cir clips retaining rings and cotter pins with new ones as removal weakens and deforms them 1 3 22INL lt GENERALINFORMATION they could become detached while the quad is driven leading to a major problem 15 Lubrication Engine wear is generally at its maximum while the engine is warming up and before all sliding surfaces have an adequate lubrication film During assembly make sure to apply oil to any sliding surface or bearing that has been cleaned Old grease or dirty oil could have lost its lubrication quality and may contain forging particles that act as abrasives therefore make sure to wipe it off and apply fresh grease oil Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended 16 Direction of Engine Rotation To r
135. ening sequence is given in this Service Manual make sure to follow the sequence When installing a part with several bolts nuts or screws start them all in their holes and tighten them to a snug fit thus ensuring that the part has been installed in its proper location Then tighten them to the specified torque in the tightening sequence and method indicated If tightening sequence instructions are not given tighten them evenly in a cross pattern Conversely to remove pat first loosen all the bolts nuts or screws that are retaining the part a 1 4 turn before removing them Torque When torque values are given in this Service Manual use them Either too little or too much torque may lead to serious damage Use a good quality reliable torque wrench Force Common sense should dictate how much force is necessary in assembly and disassembly If a part seems especially difficult to remove or install stop and examine what may be causing the problem 1 2 GENERAL INFORMATION Z INLI em Whenever tapping is necessary tap lightly using a wooden or plastic faced mallet Use an impact driver for screws particularly for the removing screws held by non permanent locking agent in order to avoid damaging the screw heads 7 Edges Watch for sharp edges as they could cause injury through careless handing especially during major engine disassembly and assembly Use a clean piece of thick cloth when lifting the engine or turnin
136. er pin and axle nut e Remove the brake disc mounting bolts e Remove the brake disc B 3 14 srake _ DINLI Rear Brake Disc Removal e Remove the rear wheel see Wheel Removal e Remove the rear caliper see Rear Caliper Removal and Parking Brake Caliper unscrew the banjo bolt and remove the brake hose from the caliper e Loosen the brake disc mounting bolts e Remove the rear gear box bolts and slide the gear box backward e Remove the disc Front Disc Installation e The disc must be installed with the marked side A facing toward the steering knuckle e Apply non permanent locking agent Disc Mounting Bolts e Tighten the disc mounting bolts to the specified torque Tightening Torque 25 N m 2 5 kg m 18 0 Ib ft e After installing the discs check the disc runout Completely clean off any grease that has gotten on either side of the disc with a high flash point solvent 3 15 DINLI E Rear Disc Installation front 2 gt bD Q 22 n 5 lt 2 T un 5 lt e Apply non permanent locking agent Disc Mounting Bolts e Tighten the disc mounting bolts to the specified torque 25 N m 2 5 kg m 18 0 Ib ft ing Torque Tighten check the disc runout see Disc Runout e After installing th
137. essure Kgf cnv 5 0 me os Vehicle Load Capacity Limit 250 kg 551 Ib CAUTION To minimize the possibility of tire damage from over inflation we strongly recommended that a manual type air pump be used rather than a high pressure air compressor as found in service stations When filling air into the tires never exceed 70kPa 0 7 kgf cnv 10 psi CAUTION The standard tire fitted on this vehicle is an AT25x8 12 for the front and a AT25x10 12 for the rear The use of tires other than those specified may cause instability It is highly recommended to use the specified tires 9 26 PERIODIC MAINTENANCE Steering Inspect initially at 200 km 10 hours 1 month and every 200 km 10 hours 1 month thereafter e Steering system should be adjusted properly for smooth manipulation of the handlebars and safe running Toe Out e Place the vehicle on level ground e Make sure the tire pressure for right and left tires is the same and set to the proper specification e Set the front wheels in the straight position e Place a load of 75 kg 165 Ibs on the seat e Measure the distances A and B between the front wheels Subtract the measurement of B from that of A to find the toe out If the toe out is not within specification adjust the tie rod to the right or left until the toe out is within the specified range B A Toe out e If the toe out is out of specification
138. fluids batteries and tires o To protect Earth s natural resources properly dispose of used vehicle and parts 1 5 GENERAL INFORMATION DINLI DL 702 Right Side Left Side e Difference between photograph and actual vehicle may exist depending on the markets 1 6 22INL GENERAL INFORMATION Model Identification Engine serial number Vehicle identification number ENGINE SERIAL NUMBER Ex 15M18XXXXX RFWAK85CX6Txxxxxx VEHICLE IDENTIFICATION ex ber and serial number are lar issue the engine num Whenever corresponding with DINLI about a part ication tant for vehicle identif impor 1 7 22INL lt GENERALINFORMATION Fuel Engine Coolant Recommendation Fuel For USA and Canada e Use only unleaded gasoline of at least 87 pump octane R 2 2 or 95 octane or higher rated by Research Method e Gasoline containing MTBE Methyl Tertiary Butyl Ether less than 10 ethanol or less than 5 methanol with appropriate cosolvents and corrosion inhibitor is permissible Fuel For Other Countries e Gasoline used should be graded 95 octane Research Method or higher An unleaded gasoline is recommended Engine Oil For USA e Dinli recommends the oil which is rated SF or SG under the API American Petroleum Institute service classification The recommended viscosity is SAE 10W 40 If SAE 10W 40 oil is not available
139. for dent or damage If any damages are found replace it with a new one Bushing bD z 5 O 2 T un bD un D 5 lt O replace them with new ones any damages are found Oil Seal e Inspect the Oil seal lips for wear or damage If any damages are found replace them with new ones e Remove the steering knuckle oil seals by using the appropriate bar CAUTION v zs ae Q un 6 5 gt gt c 4 6 DINLI SUSPENSION STEERING DRIVE SHAFT Hub Bearing e Inspect the inner race play of the hub bearings by hand while they are in the steering knuckles e Rotate the inner races by hand to inspect for abnormal noise and smooth rotation If there is anything unusual replace the bearing with a new one z z un 4 5 bD 5 Q Q 4 Ke Q O 42 0 5 un 0 gt Remove circlip e Remove hub bearings from the direction that arrow marks 4 7 INES cu sPENSION STEERING DRIVE SHAFT Reassembly and Installation e Reassemble and install the front suspension in the reverse order ing Pay attention to the followi y isassembl of removal and
140. ft e Apply THREAD LOCK to the nuts Tightening Torque 50N m 5 Tightening Torque 50N m 5 0 kgf m 36 0 Ib ft e Apply THREAD LOCK to the nuts e Tighten the front differential gear mounting nuts to the specified torque 6 8 ENGINE Tightening Torque 55N m 5 5 kgf m 40 0 Ib ft hten them to the specified torque 15 t e Apply THREAD LOCK to the foot board bracket bolts 1 and 1 un 5 A X O 5 z Ke 4 0 4 4 un oO bD z 4 4 un ts to specified torque pipe nu Torque 23N m 2 3 kgf m 16 5 Ib ft Tightening 555955555522 ATA AT 6 9 DINEI ENGINE Engine Disassembly 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 Engine Top Side e Remove the spark plug e Remove the start motor e Remove
141. g it Over 8 High Flash Point Solvent A high Flash point solvent is recommended to reduce fire danger A commercial solvent commonly available in North America is standard solvent generic name Always follow manufacturer and container directions regarding the use of any solvent 9 Gasket O Ring Replace a gasket or an O ring with a new part when disassembling Remove any foreign matter from the mating surface of the gasket or O ring to ensure a perfectly smooth surface to prevent oil or compression leaks 10 Liquid Gasket Locking Agent Clean and prepare surfaces where liquid gasket or non permanent locking agent will be used Apply them sparingly Excessive amount may block engine oil passages and cause serious damage 11 Press When using a press or driver to install a part such as a wheel bearing apply a small amount of oil to the area where the two parts come in contact to ensure a smooth fit 12 Ball Bearing and Needle Bearing Do not remove a ball bearing or a needle bearing unless it is absolutely necessary Replace any ball or needle bearings that were removed with new ones Install bearings with the manufacturer and size marks facing out applying pressure evenly with a suitable driver Apply force only to the end of the race that contacts the press fit portion and press it evenly over the base component 13 Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones as removal g
142. g the tie rod end align the tie rod end s grooves with the spline of the shaft e Tighten the bolt 2 securely CAUTION Make sure the installation position of the gear selection arm is accurate 4 41 INES SUSPENSION STEERING DRIVE SHAFT Shift Rod Adjustment e Check the position of the gearshift lever shift the lever to the N position and check if the lever moves smoothly as shown in the figure e If the lever can not move successfully measure the tie rod length and adjust the tie rod to the proper position e Adjust the tie rod in two positions as shown in the figure turning the gt 2 4 0 un C 5 0 oO Q rod too much CAUTION o Adjust the tie rod length immediately if it does not conform to the standard or it will cause the transmission gears to wear or damage 4 42 opy __ DINLI BODY Table of Contents 5 2 5 2 Installation 5 2 Front and Rear Racks
143. gh e CDI unit trouble 10 4 APPENDIX OOOO Poor Running or No Power at High Speed 1 Firing incorrect Spark plug dirty broken or maladjusted Spark plug or Spark plugs cable trouble Spark plug cap shorted or not in good contact Spark plug incorrect Pickup coil trouble CDI unit trouble e Ignition coil trouble 2 Fuel air mixture incorrect e Main jet clogged or wrong size e Jet needle or needle jet worn e Bleed holes of air bleed pipe or needle jet clogged e Fuel level too high or too low e Air cleaner clogged poorly sealed or missing e Water or foreign matter in fuel e Carburetor holder loose e Air cleaner duct loose e Fuel tank air vent obstructed e Return fuel pump clogged e Fuel line clogged 3 Compression low e Spark plug loose e Cylinder head not sufficiently tightened down e Loss of valve clearance e Cylinder piston worn e l iston rings bad worn weak broken or sticking e Piston ring groove clearance excessive e Cylinder head gasket damaged e Cylinder head distorted e Valve spring broken or weak e Valve not seating properly valve bent worn or carbon accumulation on the seating surface 10 5 OINLI DINLI APPENDIX 4 Knocking e Carbon built up in combustion chamber e Fuel poor quality or incorrect e Spark plug incorrect e CDI unit trouble e Engine overheating 5 Miscellaneous e Throttle valve won t full
144. gine coolant temperature indicator 10 291 ODINLI APPENDIX Brake Wheel Unit mm Foot brake pedal height 72 80 l Front brake disc thickness Brake lever play Brake fluid type DOT 4 Tire Unit mm Turning radius Cold inflation tire pressure Front 35 kPa 0 35 kgf cm 5 0 ps 00 000 rer mer _ O Tire size arao a me s Suspension Unit mm Front shock absorber 5 positions spring adjustor Rear shock absorber 5 positions spring adjustor 10 30 APPENDIX L EEE Fuel Use only unleaded gasoline of at least 87 pump octane R 2 M 2 or 95 octane or higher rated by the Research Method Gasoline containing MTBE Methyl Tertiary USA and Canada Butyl Ether less than 10 ethanol or less than Fuel type 5 methanol with appropriate cosolvents and corrosion inhibitor is permissible Gasoline used should be graded 95 octane Research Method or higher An unleaded The others gasoline is recommended Fuel tank capacity Engine oil type SAE 10W 40 SF or SG Engine oil capacity 10 31
145. gt a 4 0 un 5 oO Q 0 0 un e Mount the tire on the new rim see Tire Installation e Inflate the tire to the specified pressure 2 5 DINEI WHEELS TIRES Tire Removal Remove the wheel Unscrew the valve A to deflate the tire Dismount the bead from the rim completely as shown Tire Bead Breaker O gt un un lt 2 E UO 7 p M d7 8 E o 5 bD 4A E 5 O E deflate tire to prevent burst e Separate the tire from the rim using a tire bead breaker and rim protector CAUTION sealing portion hump of the wheel or it may cause air leakage 4 4 Q un 0 oO 5 oO 0 0 D 4 bD 5 un 5 4 Installat e Inspect the rim see Wheel Rim Inspection e Replace the air valve with a new one CAUTION Q O at gt 2 gt i Q reuse air valve e Check the tire for wear and damage see Tire Inspection 2 6 e Lubricate tire beads rim flanges with a soap and water N WARNING Do not use the lubricant other t
146. h and the column thermometer with a pan Installation e Install the new O ring 1 e Tighten the cooling fan thermo switch to the specified torque Tightening Torque 25 N m 2 5kgf m 18 0 Ib ft e Pour engine coolant e Install the headlight 7 9 DINLI amp JINIL I COOLING AND LUBRICATION SYSTEM ECT Sensor Removal e Remove the left side cover e Disconnect the ECT sensor coupler 1 e Place a rag under the ECT sensor and remove the ECT sensor Inspection e Check the ECT sensor by testing it at the bench as shown in the figure Connect the ECT sensor 1 to a circuit tester and place it in the water 2 contained in a pan which is placed on a stove e Heat the water to raise its temperature slowly and read the column thermometer 3 and the ohmmeter e If the ECT sensor ohmic value does not change in the proportion indicated replace it with a new one Temperature Sensor Specification 60 C 140 0 704 90 194 0 261 120 248 Approx 0 111 e If the resistance is noted to show infinity or too much different resistance value replace the ECT sensor with a new one CAUTION o Take special care when handling the ECT sensor It may cause damage if it gets a sharp impact o Do not contact the ECT sensor and the column thermometer with a pan 7 10 COOLING AND LUBRICATION SYSTEM ___ x 4 Insta
147. han a water and soap solution or water to lubricate the tire beads and rim because it may cause tire separation e Check the tire rotation mark A on the tire and install the tire on the rim accordingly o The tires should be installed on the rims so that each air valve is toward outside of the vehicle o The direction of the tire rotation is shown by an arrow on the tire sidewall e Lubricate the tire beads again and center the tire on the rim e Mount the tire on the rim by using the tire changer e Inflate the tire until the tire beads seat on the rim N WARNING Do not inflate the tire to more than the maximum tire air pressure Over inflation can explode the tire with possibility of injury and loss of line CAUTION The standard tire fitted on this vehicle is AT25x8 12 for the front and AT25x10 12 for the rear The use of tires other than the standard may cause instability It is highly recommended to use the specified tire e Check to see that rim lines A on both sides of the tire are parallel with the rim flanges the rim lines and the rim flanges are not paralleled deflate the tire lubricate the sealing surfaces again and re inflate the tire e After the beads are properly seated check for air leaks o Apply a soap and water solution around the tire bead and check for bubbles e Deflate the tire to the specified pressure 2 7 DINEI WHEELS TIRES Check the tire pressu
148. ied If the free play is incorrect adjust it Pedal Free Play Standard 2 2 0 5 mm Brake Pedal Position Adjustment e Remove the brake pedal see Brake Pedal Removal e Loosen the locknut A and turn nut B until pedal is correctly positioned e Tighten the locknut 3 19 DINLI Brake Pedal Removal e Remove the brake pedal by removing the master cylinder locknut A circlip B and pin C ePulling down the springs where circled remove the brake pedal Brake Pedal Installation e Reverse the Removal steps to install the brake pedal Master Cylinder Removal e Remove the master cylinder joint A and the banjo bolt B at the brake hose lower end and tighten it loosely Remove the brake hose e Loosen the master cylinder mounting bolts D CAUTION Brake fluid quickly ruins painted surfaces any spilled fluid should be completely washed away immediately e Remove the clamps A hose B and reservoir C 3 20 Master Cylinder Installation e Usea new flat washer on each side of the brake hose fitting and tighten the banjo bolt to the specified torque Tightening Torque 25N m 2 5kg m 18 0ft Ib e Check the fluid level A in the brake reservoir e Bleed the brake line after master cylinder installation see Brake Line Air Bleeding e Check the brake for good braking power and no fluid leakage 3 21 SUSPENSION STEERING
149. ine Oil For Other Countries 1 8 Front Differential Gear Ojil 1 8 Rear Gear Final Box Oil 1 8 Brake 1 9 Engine 1 1 9 Water For 1 9 Anti Freeze Engine Coolant 1 9 Liquid Amount of Water Engine Coolant 1 9 Break In Procedures 1 10 Information Labels 1 11 General Specifications 1 12 1 1 NINES GENERAL INFORMATION lt Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a quad read the precautions given below To facilitate actual operations notes illustrations photographs
150. ine and keep it running at 5000 rpm e Measure the voltage between three lead wires with the multi circuit tester e If the tester indicates under the specified value replace the alternator with a new one Multi Circuit Tester Set Tester knob indication Voltage ACV Alternator no load performance 65 V and more at 5000 rpm When engine is cold 7 15 DIMNE ELECTRICAL SYSTEM Ignition System Mam sw ACG ud 6 ING Coil N WARNING The ignition system produces extremely high voltage Do not touch the spark plug ignition coil or spark plug lead while the engine is running or you could receive a severe electrical shock CAUTION Do not disconnect the battery leads or any other electrical connections when the ignition switch is on or while the engine is running This is to prevent CDI unit damage Do not install the battery backwards The negative side is grounded This is to prevent damage to the diodes and CDI unit Use the standard regulator rectifier or the CDI unit will be damaged Troubleshooting No spark or poor spark o Check that the transmission is in neutral o Check that the fuse is not blown and the battery is fully charged before diagnosing Step1 Check the ignition system couplers for poor connections Is there connection in the ignition system couplers YES Move to Step 2 NO Poor connection of couplers 7 16 ELECTRICAL SYSTEM C OINLI Step2 Inspect the
151. ing which is visualized seat width must fit the specification Valve Seat Width 0 9 mm 1 1 mm Valve Lapper Set 6 27 burned additional seat conditioning with the 45 cutter is EINE I ENGINE required turns e Inspection the seat see Valve Seat Width If the seat is pitted or e Using the 45 cutter descale and clean up the seat with one or two Initial Seat Cut Q 4 45 a 5 2E 4 Q Am CE os og 9 gt 0 9 5 S EE 5 9 v EE 5b a e If the contact area is too high the valve or if it is too wide use the 30 60 cutters to lower and narrow the contact area e If the contact area is too wide too low use the 75 cutter to narrow and raise the contact area cutter to w use the 45 e If the contact area is too low or too narro raise and widen the contact area and 75 angles it is possible that the valve After cutting the 307 E Q D Q un e un 6 28 DINLI ENGINE e After the desired seat position and width is achieved use the 45 cutter slightly to clean up any burrs caused by the previous cutting operation CAUTION finished valve seat should have a velvety smooth finish but
152. ing rod big end and the gears e Apply BOND to the mating surface of the right crankcase e Tighten the crankcase bolts a little at a time to equalize the pressure until the specified torque M6 10 N m 1 0 kgf m 7 0 Ib ft 8 26 N m 2 6 kgf m 19 0 Ib ft ightening torque T 45 un 0 un 0 bD 4 4 2 225 T c bD s un 0 un oO Q Q 4 c 0 20 e After the crankcase bolts have been tightened check if the each shaft rotates smoothly If a large resistance is felt to rotation try to free the shafts by tapping them with a plastic mallet 6 54 DINLI ENGINE e Install the collar 1 and the drive bevel gear 2 e Install the output shaft 1 e Apply THREAD LOCK to the clutch shoe nut e Install the clutch shoe assembly and tighten the clutch shoe nut to the specified torque wn 5 un Ta 5 un Q Ke ft m 108 5 Tightening Torque 150 N m 15 0 kgf e Apply MOLYBDENUM OIL to the inside of the one way clutch e Install the one way clutch with facing the mark A outside e Install the new gasket and the plate 1 and CVT cover gt oO un un 0 Q un gt 5 2 un
153. ion Resistance Starter relay resistance 3 50 e Apply 12 V to A and B terminals and check for continuity between the positive and negative terminals with the multi circuit tester If the starter relay clicks and continuity is found the relay is OK Multi Circuit Tester Set Tester knob indication Continuity test CAUTION Do not apply battery voltage to the starter relay for five seconds and more since the relay coil may overheat and get damaged 7 19 DIMNE ELECTRICAL SYSTEM QE Main Relay Inspection e Remove the seat e Remove the fuse box cover e Remove the main relay 1 e First check the insulation between 1 and 4 terminals with the tester Then apply 12 V to terminals 2 and 3 and check the continuity between 1 and 4 If there is no continuity replace the main relay with a new one Multi Circuit Tester Set Tester knob indication Continuity test 7 20 ELECTRICAL SYSTEM C OINLI Transfer Selecting System Inspection e Remove the front rack and fender e Probe the terminals and check the voltage changing between the connected terminals when shifting the transfer selecting switch e The voltage must maintain at 12 V if the voltage does not conform to the standard check the continuity of each lead wire or replace the actuator assembly with a new one Multi Circuit Tester Set Tester knob indication Voltage DCV Q Q 92900010100 p SpE
154. istance which the vehicle has been ridden e Trip meter The 2 Trip meter can be reset and recorded two kinds of distance For example Trip A can register the trip distance and Trip B can record the distance between adding fuels Press more than 2 seconds to reset the Trip to 0 13 Clock Hour Tacho Temp Meter This display has four functions Clock Hour Tacho and Temp meter To change the display press Set button shortly e Clock Display the time in 12 hour To set the clock change to Clock mode and press Set button more than 2 seconds The display starts to blink Press Mode to change minute and hour Press Set to adjust e Hour amp The hour meter indicates the total time that the vehicle is used e Tacho Meter Tacho meter displays the engine RPM e Temp This shows the engine temperature 14 Fuel Meter The fuel meter shows the remaining amount of fuel in the fuel tank It displays 8 segments when the fuel tank is full The bottom segment blinks when the fuel level drops Please add fuel when the fuel alert comes on Operating Procedure Initial Display e When the ignition switch is set to ON all LCD light up for two seconds NOTE o Since the clock resets to 1 00 it will need to be readjusted 7 24 ELECTRICAL SYSTEM Change the Display Mode e With each press of the MODE button the display changes between odometer trip meter A and trip meter B as shown Odometer Tripmeter
155. ition thee 6 42 DINLI ENGINE e Install the spacer When inserting the spacer press down the movable drive face plate so as not to cause the rollers to come out of position e Hold movable driven face assembly with special tool loosen aP Q gt D O a Q 4 Q aP 5 gt a AH 7 2 2 5 E 5 9 5 90 2 E z 4 8 3 Ol Q 4 8 5 gt v 5 BU gt Y S 2c O gt 5 5 5 Z 4 5 Mos gt gt z Attach the special tool to the movable driven face assembly in the ing by turn compress the movable driven face assembly special tool handle bD 5 un 4 5 O E Q O un Ke 4 TN 0 oD un 5 0 5 un 0 gt olate hole e Remove the movable driven face ring nut e Loosen the special tool handle slowly and remove the special tool e Remove the spring plate 1 and spring 2 Remove spring seat 3 6 43 EINE I ENGINE d rollers e Remove the pins an Q O r gt E O gt x 1 seal 1 ring
156. ittings or the bleed valve is opened at any time the AIR MUST BE BLED FROM THE BRAKE LINE Brake Fluid Recommendation Use DOT 3 or 4 as a brake fluid when pouring the brake fluid mixed them up is not available If there have no sign for indicates the suitable fluid use the greater one such as DOT 4 3 3 DINLI lt BRAKE Brake Fluid Level Inspection e Position the reservoir horizontal and check the fluid level in the reservoir If the fluid level is lower than the lower level line check for fluid leakage of the brake line and add the fluid as follow o Removal the reservoir cap and fill the reservoir to the upper level line A in the reservoir with the same type and brand of the fluid that is already in the reservoir And then install the reservoir cap WARNING Change the fluid in the brake line completely if the fluid must refilled but the type and brand of the fluid that is already the reservoir are unidentified e Tighten the reservoir cap screws to the specified torque Tightening Torque 1 5 N m 0 15 kg m 13 in Ib Brake Fluid Change e Remove the reservoir cap and the rubber cap on the bleed valve e Attach a clear plastic hose to the bleed valve on the caliper and run the other end of the hose into a container e Fill the reservoir with new brake fluid e Change the brake fluid as follows o Open the bleed valve in counterclockwise o Squeeze the brake lever B o Release
157. kage before riding Air Bleeding the Brake Fluid Circuit e Air trapped in the brake fluid circuit acts like a cushion absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full braking performance of the brake caliper The presence of air is indicated by sponginess of the brake lever and also by lack of braking force e Considering the danger to which such trapped air exposes the machine and rider it is essential that after installing the brake and restoring the brake system to the normal condition the brake fluid circuit be purged of air in the following manner o Remove the reservoir cap and fill the reservoir with new brake fluid o Slowly pump the brake lever several times until no air bubbles can be seen rising up through the fluid from the hose at the bottom of the reservoir This bleeds the air from the master cylinder and the brake line NOTE oTap the brake hose lightly going from the caliper to the reservoir side and bleed the air off at the reservoir 9 24 PERIODIC MAINTENANCE SJJ AFE 7 lh 607 o Attach a clear plastic hose to the bleed valve and run the other end of the hose into a container o Bleed the brake line and the caliper as follows o Hold the brake level applied B o Quickly open and close the bleed valve o Release the brake lever e Repeat this operation until no bubbles comes out the brake fluid re
158. l e Remove the rear stab gt Remove the rear shock absorber 4 EJ e Remove the rear knuckle mounting bolts nuts and remove the rear knuckle 4 12 22INL SUSPENSION S TEERING DRIVE SHAFT e Remove the upper arm 1 by removing the washer face bolt nut e Remove the lower arm 2 by removing the washer face bolt nuts isassembly ion and D Rear Shock Absorber Inspect e Inspect the shock absorber for oil leakage or damage If any D D amp c lt 5 d 5 Bushing shock absorber suspension arm for ing e Inspect the rubber bush wear or other damage If any damages are found replace the bushing with a new 4 13 INES SUSPENSION STEERING DRIVE SHAFT Oil Seal e Inspect the Oil seal for wear or damage If any damages are found replace the oil seal with a new one CAUTION il seal with a new one 5 gt D 5 x e Remove rear knuckle oil seal with a suitable bar Hub Bearing e Inspect the inner race play of the hub bearing by hand while it is the rear knuckle Rotate inner race by han
159. leaned Compressor ing Movable Driven Face Spr o The other way 15 using the same size bolts which at least 70 mm long to install the drive belt e Install the movable driven face assembly CAUTION 0 un Q un 4 Q 5 4 0 0 Q 4 4 5 each other to prevent belt from expanding e Tighten the movable driven face bolt to the specified torque with the special tool 0 kgf m 79 5 Ib ft 110 N m 11 Torque ightening T e Install the movable drive face assembly Degrease the movable drive face assembly Use nonflammable cleaning solvent to wipe off oily and greasy matter and make its surfaces completely dry 9 20 DINLI PERIODIC MAINTENANCE e Install the collar and movable drive face bolt Be careful about the direction of the collar e Tighten the movable drive face bolt to the specified torque with Tightening Torque 85 N m 8 5 kgf m 62 0 lb ft the special tool Turn the fixed drive face until the belt is seated in and both the drive and driven faces will move together smoothly without e Install the dowel pins e Install the movable drive face cover 1 9 21 INES PERIODIC MAINTENANCE Brakes Inspect initially at 200 km 10 hours 1 month and every 200 km 10 hours 1 month thereafter
160. llation e Install the ECT sensor in the reverse order of removal e Tighten the ECT sensor to the specified torque Tightening Torque 20 N m 2 0 kgf m 14 44 lb ft CAUTION Take special care when handling the ECT sensor It may cause damage if it gets a sharp impact e engine coolant 7 11 COOLING AND LUBRICATION SYSTEM Thermostat Removal Remove the left side cover e Drain engine coolant e Place a rag under the thermostat cover Remove the thermostat cover 1 Remove the thermostat 2 Inspection e Inspect the thermostat pellet for signs of cracking e Test the thermostat at the bench for control action in the following manner 0 oO z 4 4 5 oO un Mes 4 4 0 un bD 0 0 0 bD 4 un un un as shown in the illustration Note that contained in a beake immersed thermostat is in suspension by placing the beaker on a stove 2 and observe rising temperature thermometer 3 o Heat the water 1 e Read the thermometer just when opening the thermostat This which is the temperature level at which the thermostat reading valve begins to open should satisty the standard value Thermostat Valve Opening Temperature 80 84 C 176 183 F Standard 7 12 COOLING AND LUBRICATION SY
161. long life of each working part of the vehicle e Major lubrication points are indicates below Steering shaft holder Drive shaft joint spline Brake lever holder and throttle lever 6 Front grease valve Brake pedal Rear A arm grease valve Propeller shaft joint spline Drive belt cover bearing inner race o Before lubricating each part remove any rust and wipe off any grease oil dirt or grime o Lubricate exposed parts which are subject to rust with a rust preventative spray especially whenever the vehicle has been operated under wet or rainy conditions 9 32 PERIODIC MAINTENANCE Compression Pressure Check e The compression pressure reading of a cylinder is a good indicator of its internal condition e The decision to overhaul the cylinder is often based on the results of a compression test Periodic maintenance records kept at your dealership should include compression readings for each maintenance service Automatic decompression actuated Low compression pressure can indicate any of the following conditions o Excessively worn cylinder walls o Worn piston or piston rings o Piston ring stuck in grooves o Poor valve seating o Ruptured or otherwise defective cylinder head gasket NOTE When the compression pressure goes below specification check the engine for conditions listed above Compression Test Procedure o Before testing the engine for co
162. lug it then disconnect it from the battery e Check battery condition If the battery condition indicates that is not fully charged additional charging time is necessary Battery Test Charging e If the battery is suspected of being defective sulfated or unable to take a charge consult the table e To test charge a battery perform the ordinary charging procedure and monitor the battery voltage and other signs as mentioned below If the battery voltage suddenly jumps to over 13 V just after the start of charging the plates are probably sulfated A good battery will rise to 12 V immediately and then gradually go up to 12 5 or13 V in about 30 min to an hour after the start of charging 7 10 ELECTRICAL SYSTEM C OINLI e If there does not appear to be enough sediment in a cell to short the plates but that cell has a very low specific gravity after the battery is fully charged the trouble may be that there is not enough acid in that one cell In this case only sulfuric acid solution may be added to correct the specific gravity If a fully charged battery doesn t lose its charge after 2 to 7 days or if the specific gravity drops markedly the battery is defective The self discharge rate of a good battery is only about 176 per day 7 11 DIMNE ELECTRICAL SYSTEM Charging System M COIL 12W MOVABLE Battery COL Troubleshooting battery runs down quickly
163. ly Water other than distilled water can corrode and clog the aluminum radiator Anti Freeze Engine Coolant The engine coolant performs as a corrosion and rust inhibitor as well as anti freeze Therefore the engine coolant should be used at all times even though the atmospheric temperature in your area does not go down to freezing point Dinli recommends the use of engine coolant is compatible with an aluminum radiator Liquid Amount of Water Engine Coolant Solution capacity total Approx 1950 ml For engine coolant mixture information refer to cooling system section in page 7 2 CAUTION Mixing of anti freeze engine coolant should be limited to 70 Mixing beyond it would reduce its efficiency If the anti freeze engine coolant mixing ratio is below 50 rust inhabiting performance is greatly reduced Be sure to mix it above 50 even though the atmospheric temperature does not go down to the freezing point 1 9 NINES GENERAL INFORMATION Break In Procedures e During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to Break In before subjecting the engine to maximum stresses The future performance and reliability of the engine depends on the care and restraint exercised during its early life The general rules are as follows Keep to these break in engine speed limits Break in engine s
164. mances which brand new parts or systems have Service Limits indicate the usable limits If the measurement shows excessive wear or deteriorated performance replace the damaged parts 1 4 GENERAL INFORMATION oe v4 NLI General Precautions Proper service and repair procedures are important for safety of the service mechanic and safety and reliability of the vehicle o When 2 or more persons work together pay attention to the safety of each other o When it is necessary to run the engine indoors make sure that exhaust gas is forced outdoors o When working with toxic or flammable materials make sure that the area you work in is well ventilated and that you follow all of the material manufacturer s instructions o Never use gasoline as a cleaning solvent o To avoid getting burned do not touch the engine engine oil radiator and exhaust system until they have cooled o After servicing the fuel oil water exhaust or brake systems check all lines and fittings related to the system for leaks CAUTION o f parts replacement is necessary replace the parts with genuine parts or their equivalents o When removing parts that are to be reused keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation o Be sure to use special tools when instructed o Make sure that all parts used in reassembly are clean Lubricate them when specified o Use
165. ming T 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 of crankcase to make piston to highest 4 Mar 2 lt 5 E a a o S w 5 2 e 9 o 4 p Q o m c E gt t d a oo 9 5 SES mo v 5 2 94802 o a 2 D F ighest iver gear to h e Make the mark C on the Timing chain dr iming Meanwhile the mark on the opposite side the T position igned with the mark position D is also al iver gear dri chain the engraved marks E with ing ign the mating surface of the cylinder head cover e Assemble the camshafts by al 22INL ENGINE Piston Piston Diameter e Check for wear and damage on the sliding surface e Measure OD of Piston at the position shown in the picture If the measurement is less than the limit replace the piston Piston OD 101 880 mm Q gt 0 aP gt 125 1crome M ton Pis Recognize e top of piston was printed Pist
166. mpression pressure make sure that the cylinder head nuts are tightened to the specified torque and the valves are properly adjusted o Warm up the engine before testing o Make sure that the battery is fully charged e Remove the related parts and test the compression pressure in the following manner o Remove the spark plug o Install the compression gauge in the spark plug hole Make sure that the connection is tight o Keep the throttle lever in the fully open position Press the starter button and crank the engine for a few seconds Record the maximum gauge reading as the cylinder compression D002 Compression Gauge Set 9 33 INES PERIODIC MAINTENANCE Oil Pressure Check e Check the engine oil pressure periodically This will give a good indication of the condition of the moving parts Pressure Above 15 kPa 0 15 kgf cnv 2 0 psi e Low or high oil pressure can indicate any of the following conditions Low Oil Pressure o Clogged oil filter o Oil leakage from the oil passage o Damaged O ring o Defective oil pump o Combination of the above items High Oil Pressure o Engine oil viscosity is too high o Clogged oil Passage o Combination of the above items Oil Pressure Test Procedure e Remove the front fender See Body chapter e Remove the fuel tank See Body chapter e Connect the tachometer onto the spark plug high voltage cable e Remove the cooling duct
167. n 6 8 mm when the lever is lightly pulled in towards the locknut 2 and screwing the adjusters 3 on the brake lever e After adjusting the brake pedal check the brake lever play 1 holder all the way in Brake Lever gt am gt ea 6 8mm Standard check that the wheels roll freely without e after adjusting the play applying the brake the transmission in neutral and the wheels off the ground Readjust the brake lever if the wheel could not roll freely 9 23 INES PERIODIC MAINTENANCE Brake Fluid Inspect every 1000 km 50 hours 3 months Replace every two years e Place the handlebar straight e Check the brake fluid level by observing the lower limit line on the brake fluid reservoir e When the brake fluid level is below the lower limit line replenish with brake fluid that meets the following specification Specification and Classification DOT4 o The brake system of this vehicle is filled with a glycol based brake fluid Do not use or mix different types of fluid such as silicone based and petroleum based fluids Do not use any brake fluid taken from old used or unsealed containers Never reuse brake fluid left over from the last servicing or stored for a long period of time Brake fluid if it leaks will interfere with safe running and immediately discolor painted surfaces Check the brake hoses and hose joints for cracks and oil lea
168. n coil e Measure the primary winding resistance as follows o Connect the tester between the coil terminals o Set the tester to the x 1O range and read the tester e Measure the secondary winding resistance as follows o Remove the plug cap by turning it counterclockwise o Connect the tester between the spark plug lead and terminal o Set the tester to the x 20 range and read the tester If the multi circuit tester does not read as specified replace the coil o To install the plug cap turn it clockwise Multi Circuit Tester Set Tester knob indication Resistance Ignition coil resistance Primary 0 17 0 230 Terminal Ground Secondary 5 0 7 6kQ Spark plug cap terminal 7 18 ELECTRICAL SYSTEM _ LLLP CDI Output Test Using Peak Reading Adaptor e Measure the CDI output voltage by using the multi circuit tester Average Output w Digital Voltmeter with or without Peak Reader 200 250 DCV Multi Circuit Tester Set Starter Relay Inspection e Remove the seat e Disconnect the battery lead wire from the battery e Disconnect the starter motor lead wire battery lead wire and starter relay coupler 1 e Remove the starter relay e Measure the relay coil resistance between the terminals with the multi circuit tester If the resistance is not within the specified value replace the starter relay with a new one Multi Circuit Tester Set Tester knob indicat
169. n comprehensive Table of Contents The Periodic Maintenance Chart is located in the Periodic Maintenance chapter The chart gives a time schedule for required maintenance operations If you want spark plug information for example go to the Periodic Maintenance Chart first The chart tells you how frequently to clean and gap the plug Next use the Quick Reference Guide to locate the Electrical System chapter Then use the Table of Contents on the first page of the chapter to find the Spark Plug section 0 2 DINLI FOREWORD INDEX Whenever you see these WARNING and CAUTION symbols heed their instructions Always follow safe operating and maintenance practices N WARNING This warning symbol identifies special instructions or procedures which if not correctly followed could result in personal injury or loss of life CAUTION This caution symbol identifies special instructions or procedures which if not strictly observed could result in damage to or destruction of equipment This manual contains four more symbols in addition to WARNING and CAUTION which will help you distinguish different types of information NOTE o This note symbol indicates points of particular interest for more efficient and convenient operation e Indicates a procedural step or work to be done o Indicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a NOTE
170. nator trouble e g short circuited grounded or open alternator coil e Wiring faulty Battery Over charged e Regulator rectifier trouble e Poorly grounded regulator rectifier e Battery trouble e g internal short circuit in the battery Alternator Dose Charge But Charging Rate Is Below The Specification e Lead wires tend to get short or open circuited or loosely connected at terminals e Grounded or open circuited alternator coil e Defective regulator rectifier e Defective cell plates in the battery Unstable Charging e Lead wire insulation frayed due to vibration resulting in intermittent short circuiting e Internally short circuited alternator e Defective regulator rectifier 10 18 APPENDIX OoOo Battery Runs Down Quickly Trouble in charging system Cell plates have lost much of their active material as result of overcharging e Internal short circuit in the battery e Too low battery voltage e Too old battery e The option accessories had been installed so the load excessive Battery Sulfation e Incorrect charging rate When not in use battery should be checked at least once a month to avoid sulfation e The battery was left unused in a cold climate for too long 10 19 OINLI lt lt gt APPENDIX Special Tools 0001 0002 0003 0004 Rotor Holding Tool Compression Gauge Set Oil Filter Wrench Vacuum Pump Gauge 000
171. nstalled only if replaces a similar sealed type battery 5 Keep away from high temperature of fire 6 In the case of an accident sulfuric acid may escape Avoid contact with skin or clothing T 50 28 0 Charging Method gattety charged condition Normal Charge 1 8 5 10 hrs Fast Charge 18A 0 5 hrs 7 9 DIMNE ELECTRICAL SYSTEM Use of conventional lead acid batteries is not recommended Battery type GS GTX20L BS CAUTION NEVER attempt to add electrolyte or water to the maintenance free design and construction Doing so will damage the case and shorten the life of the battery Charging Procedure e Remove the battery see Battery Removal e Connect a charger to the battery BEFORE plugging it in or turning it on e Set the charging rate and time according to the battery condition previously determined CAUTION Always remove the battery from the vehicle for charging Do not use a high rate battery charger as is typically employed at automotive service stations unless the charger rate can be reduced to the level required Charging the battery at a rate higher than specified may ruin the battery Charging at a high rate causes excess heat which can warp the plates and cause internal shorting Higher than normal charging rates also cause the plates to shed active material Deposits will accumulate and can cause internal shorting e Turn the charger off or unp
172. o into gear e Shift arm bent or seized e Gear stuck on the shaft e Shift tie rod maladjusted e Shift tie rod damaged 2 Jumps out of gear e Shifter groove worn e Shift cam worn e Shift stopper positioning bolt spring weak or broken e Shift tie rod maladjusted e Drive shaft output shaft and or gear worn e Distorted or worn gearshift forks 3 Over shifts e Shift arm positioning bole spring weak or broken e Shift tie rod maladjusted Transmission noise e Bearing worn e Transmission gears worn or chipped e Metal chips jammed in gear teeth e Engine oil insufficient or too thin 10 101 APPENDIX _ C Y R Drive Train Operation Faulty 1 Belt slipping e dirty worn or wetted e Drive or driven pulley sheave dirty or worn e Drive pulley spring broken or weak 2 CVT engagement speed too low e Drive pulley spring broken or weak 3 CVT engagement speed too high e Belt dirty or worn e Drive or driven pulley sheave dirty or worn e Drive pulley doesn t move smoothly e Drive pulley movable sheave doesn t move smoothly e Drive or driven pulley movable sheave bush worn e Drive pulley roller worn 4 Shifting too quickly e Drive pulley spring weak e Driven pulley spring weak or incorrectly installed too loose 5 Shifting too slowly e Belt dirty or worn e Drive or driven pulley sheave dirty or worn e Drive pulley doesn t move smoothly e Drive pulley movable shea
173. o remove or disassemble the water pump it is necessary to disassemble the recoil starter 1 and engine left crankcase cover 2 e Remove the circlip 1 and water pump drive gear 2 e Remove the impeller shatt pin 3 and washer 4 7 14 DINLI COOLING AND LUBRICATION SYSTEM and impeller 6 Remove the impeller shaft 5 and the left crankcase for damage with particular attention given Also replace the seal ring if necessary to the sealing face Replace the mechanical seal that shows indications of leakage Visually inspect the mechanical seal that install in the impeller Remove the mechanical seal using the special tool Bearing remover set 2 aP E Q S Z 6 2 5 lt Er OE T C Q gt aP e Place a rag over the water pump e Remove the oil seal using a suitable bar CAUTION 2 Ke 2 Q E un 5 T Q un 6 5 gt damages have been found e Visually inspect the oil seal for damage with particular attention given to the lip e Remove the needle bearing from the front side as shown e Inspect the needle bearing for wear or damage replace it if the e Replace the oil seal that shows indications of leakage e Visually inspec
174. o specification if necessary e Remove the front fender e Remove the cylinder head cover e Remove the recoil starter 1 e Remove the valve timing inspection plug 2 e Turn crankshaft to bring the line A on the starter clutch to the flange B e Read the valve clearance at all the valves with the special tool e If the clearance is out of specification adjust the clearance Thickness Gauge Valve Clearance When cold 0 1 0 2 mm 0 2 0 3 mm 9 5 DINLI PERIODIC MAINTENANCE lt 7 Valve Clearance Adjustment QOOOOOOOOOOOOOOOOOOO LVL LL LVL LVL LVL LVL LRN LVL LVL LVL OO OO OO OO LVL LRN LVL LV LLL LVL LQ LLL QQ QQ QR Q RQ QR QQ RQ LKQ QR QV QQ RQ QR QV QQ QQ QQ QR QQ QQ VQ QR QQ QQ RK Q QQ QV QQ QQ QQ QR QQ QR QL QQ RQ clearance is adjusted by replacing existing tappet shim a thicker or thinner one Remove intake or exhaust camshaft See Engine Chapter e Remove the tappet and shim by fingers or magnetic hand e Check the figures printed on the shim These figures indicate the thickness of shim as illustrated e Select a
175. oken or sticking e Piston ring groove clearance excessive e Cylinder head gasket damaged e Cylinder head distorted e Valve spring broken or weak e Valve not seating properly valve bent worn or carbon accumulation on the seating surface e Mistimed valves e Starter motor cranks too slowly 10 3 OINLI DINLI APPENDIX Poor Running at Low Speed 1 Spark weak e Spark plug dirty broken or maladjusted e Spark plug cap or Spark plug cable trouble e Spark plug cap shorted or not in good contact e Spark plug incorrect e CDI unit trouble e Pickup coil trouble e Ignition coil trouble 2 Fuel air mixture incorrect ePilot screw and or idle adjusting screw maladjusted e Pilot jet or air passage clogged e Air cleaner clogged poorly sealed or missing e Fuel level too high or too low e Fuel tank air vent obstructed e Carburetor holder loose e Air cleaner duct loose 3 Compression low e Spark plug loose e Cylinder head not sufficiently tightened down e Loss of valve clearance e Cylinder piston worn e Piston ring bad worn weak broken or sticking e Piston ring groove clearance excessive e Cylinder head gasket damaged e Cylinder head distorted e Valve spring broken or weak e Valve not seating properly valve bent worn or carbon accumulation on the seating surface 4 Other e Carburetor vacuum piston doesn t slide smoothly e Engine oil viscosity too hi
176. olt and disconnect the brake hose B e Remove the master cylinder by taking off its clamp bolts A CAUTION any spilled fluid 7 lt 5 un 5 i Q un amp 5 gt T should be completely washed away immediately py Remove the brake lever 1 3 6 srake Installation e Install the master cylinder in the reverse order of removal Pay attention to the following points e The master cylinder clamp must be installed with the UP mark C upwards e Tighten the upper clamp bolt first and then the lower clamp bolt There will be a gap at the lower part of the clamp after tightening Tightening Torque 9 N m 0 90 kg m 6 5 Ib ft e Use new flat washer on each side of the brake hose fitting and tighten the banjo bolt Tightening Torque 25N m 2 5kg m 18 0 Ib ft e Bleed the brake line after master cylinder installation see Brake Line Air Bleeding e Check the brake for good braking power and no fluid leakage N WARNING Do not attempt to drive the vehicle until a full brake lever is obtained by pumping the brake lever until the pads are against each disc The brakes will not function on the first application of the lever if this is not done 3 7 DINLI E e Remove the front wheel see Wheels Tires chapter Front Caliper Removal Caliper and detach
177. oltage between and terminals with the multi circuit tester If the regulator rectifier output voltage is kept between the values given in the table the charging system is considered to be working normally If the output voltage is much higher than the values specified in the table the regulator rectifier is defective or the regulator rectifier leads are loose or open If the battery voltage does not rise as the engine speed increases then the regulator rectified is defective or the alternator output is insufficient for the loads check the alternator and regulator rectifier to determine which part is defective NOTE When making this test be sure that the battery is in fully charged condition Multi Circuit Tester Set Tester knob indication Voltage DCV 7 14 ELECTRICAL SYSTEM q Alternator coil resistance e Disconnect the alternator coupler 1 e Measure the resistance between the three lead wires with the multi circuit tester e If the resistance is out of specified value replace the stator with a new one Also check that the generator core is insulated properly Multi Circuit Tester Set Tester knob indication Resistance Alternator coil resistance 0 1 1 00 Y Y Q Y Grnd NOTE When making above test it is not necessary to remove the alternator Alternator no load performance e Disconnect the alternator coupler 1 e Start the eng
178. on has to be matched with A cylinder B Piston has to be matched with B cylinder Piston Rings Clearance between Piston Ring and groove e Measure the clearance between Piston Ring and groove by holding with thickness gauge 7 groove the Ring upwards e If any of the clearances exceeds the limit replace both piston and piston rings Q Q gt Q om gt 22 Piton ring groove width Standard 1 21 1 23 mm 121 123 mm 2 01 2 03 mm Piton ring thickness 1 17 1 19 mm 1 17 1 19 mm Thickness Gauge ter 0 25 mm Icrome M 6 35 I ENGINE e Measure Piston Ring free end gap with a thickness gauge Piston Ring Free End Gap and Piston Ring End Ga Service Limit of Piston Ring free end gap E D Q di o Q eP e i Q gt e Insert Piston Ring into the lower portion of Cylinder horizontally by using Piston e Measure the Piston Ring free end gap by using a thickness gauge Service Limit of Piston Ring end gap E pt D Q di gt 6 Q e Measure ID in the up and down direction and right angle Piston pin and pin bore ID of Piston hole for Pin e Clean Piston hole for Pin
179. oot on the outer race side and allow air to enter the boot so that the air pressure in the boot becomes the same as the atmospheric pressure at the positions indicated in the illustration A 188 198 mm 7 4 7 8 in a EH sssi BL Installation e Install the rear propeller shaft in the reverse order of removal 4 26 SUSPENSION STEERING DRIVE SHAFT _ 7 lt lt pz Steering Construction Steering shaft Plate Cotter pin Steering Tie rod assy 2sets FI Bush bearing FI Cotter pin 4pcs u Steering shaft bracket 2pcs n Oil seal 2pcs 15 Spring washer 4pcs s 14 271 DINLI SUSPENSION STEERING DRIVE SHAFT lt Removal and Disassembly e Remove the front fender e Remove front wheels tires e Remove the handlebar holder cover 1 e Remove the handlebar clamp bolts e Remove the wire rope that from the handlebar assembly See Handlebar Removal e Remove the handlebar upper clamps e Remove the handlebar e Remove the cotter pins and tie rod end nuts CAUTION Replace the removed cotter pins with new ones e Separate the tie rod ends 1 nuts 2 and 3 and tie rods 4 CAUTION The locknuts 2 have left hand threads 4 28 SUSPENSION S TEERING DRIVE SHAFT e Remove the cotter pin and steering shaft lower nut and washer CAUTION Replace the removed
180. or tightened e Damaged or worn front wheel hub bearings e Insufficiently lubricated 10 16 APPENDIX xa Electrical Spark Plug Soon Become Fouled With Carbon e Mixture too rich e Idling speed set too high e Incorrect gasoline e Dirty air cleaner Spark Plug Become Fouled Too Soon e Worn piston rings e Worn piston or cylinder e Excessive clearance of valve stems in valve guides e Worn stem oil seal Spark Plug Electrodes Overheat or Burn e Too hot spark plug e Overheated the engine e Loose spark plug e oo lean mixture Start Button Is Not Effective e Run down battery e Defective switch contacts e Brushes not seating properly on starter motor commutator e Defective starter relay starter interlock switch e Defective main fuse 2WD AWD Button Does Not Work e Wiring connections loose or disconnected e Defective actuator assembly Diff Lock Button Does Not Work e Defective diff lock switch e Wiring connections loose or disconnected e Defective actuator assembly 10 17 OINLI lt APPENDIX Battery Battery Discharged e Battery faulty e g plates sulfated shorted through Sedimentation electrolyte level too low e Battery lead wires making poor contact e Load excessive e g bulb of excessive wattage Ignition switch trouble e Regulator rectifier trouble e g shorted circuited or punctured regulator rectifier e Alter
181. otate the crankshaft manually make sure to do so in the direction of positive rotation Positive rotation is counterclockwise as viewed from the left side of the engine To carry out proper adjustment it is furthermore necessary to rotate the engine in the direction of positive rotation as well 17 Replacement Parts When there is a replacement instruction replace these parts with new ones every time they are removed Always replace these parts with new ones every time they are removed Although the previously mentioned gasket O ring ball bearing needle bearing grease seal oil seal cir clip and cotter pin have not been so designated in their respective text they are replacement parts 18 Electrical Wires the electrical wires are either one color or two color two color wire is identified first by the primary color and then the stripe color For example a yellow wire with thin red stripes is referred to as a yellow red wire it would be a red yellow wire if the colors were reversed Unless instructed otherwise electrical wires must be connected to wires of the same color 19 Inspection When parts have been disassembled visually inspect these parts for the following conditions or other damage If there is any doubt as to the condition of them replace them with new ones Color change Deterioration Seizure 20 Specifications Specification terms are defined as follows Standards show dimensions or perfor
182. outing properly 4 33 DINLI INES 1 sPENSION STEERING DRIVE SHAFT Toe Out Adjustment e Adjust the toe out as follows e Place the vehicle on level ground and set handlebars straight e Make sure all the tires are inflated to the standard pressure e Place 75 kg 165 Ibs weight on the seat e Loosen the locknuts 1 2 on each tie rod NOTE The locknuts 2 have left hand threads e Measure the distance A and B between the front wheels Subtract the measurement of B from that of A to find the toe out If the toe out is not within specification adjust the tie rod de Peg angie a 5 B Tie out JR Forward K the right or left until the toe out is within the specified range Toe out e Temporarily tighten the four locknuts e Check that the distance C and D are equal as shown If the distances are not equal adjust the tie rod to the right or left until the toe out is within specification Check the toe out again by measuring distances A and B e If the toe out is not within specification repeat the adjustment as above until the proper toe out is obtained and distances C and D become equal e After adjustment has been made tighten the four locknuts 1 to the specified torque Tightening Torque 27 N m 2 7 kgf m 20 0 Ib ft 4 34 SUSPENSION STEERING DRIVE SHAFT _ 7 lt gt Handlebar Construction
183. pa 1 8kgf cnv 25 psi and see if the system holds this pressure for 10 seconds e If the pressure should fall during this 10 second interval it means that there is a leaking point in the system In such a case inspect the entire system and replace the leaking the leaking component part J N WARNING When removing the radiator cap tester put a rag on the filler to prevent spouting of engine coolant CAUTION Do not allow the pressure to exceed the radiator cap release pressure or the radiator can be damaged 7 3 DINLI COOLING AND LUBRICATION SYSTEM lt Radiator and Hoses Radiator Removal e Remove the front fender e Drain engine coolant removing drain plug e Remove left foot board e Remove the right headlight e Disconnect the cooling fan motor lead wire coupler 1 and cooling fan thermo switch leas wire coupler 2 e Remove the front grill upper cover e Disconnect the upper and lower radiator hoses e Disconnect the siphon hose from the radiator e Remove the mounting bolts and radiator assembly 7 4 COOLING AND LUBRICATION SYSTEM ___ lt Radiator Inspection and Cleaning e Road dirt or trash stuck to the fins must be removed e Use of compressed air is recommended for this cleaning e Remove the radiator fin guard net e Fins bent down or dented can be repaired by straightening them with the blade of a small screwdriver
184. peeds Initial 500 km Less than 1 2 throttle o Upon reaching as odometer reading of 500 km you can subject the vehicle to full throttle operation for short periods of time 1 10 GENERAL INFORMATION oe Information Labels 7 s ANI zu T 4 Ti TL Always stop the vehicle completely before changing from forward to reverse or Vice versa Failure to do so can be hazardous Do not consume alcohol drugs or cigarettes before or during operating the ATV Maximum Vehicle Load 250kg 551 Ibs Includes weight of operator cargo and accessories Never load over 250kg or may cause loss of control Never operate this ATV if you are under age 16 Operating this ATV if you are under the age of 16 increases your chance or severe injury or death Read the Owner s Manual before riding the vehicle Always wear protective clothing when driving your ATV 1 11 22INL lt gt GENERALINFORMATION General Specification NOTE Specifications subject to change without notice ENGINE Model DL 702 Mild er Displacement 694 6 cc Cooling device operating temperature 1 2 water anti freeze ethylene glycol containing corrosion inhibitors for aluminum engines and radiators cycle motorcycle engine oil SAE 10W 40 grade API SF 4 Lubricant higher Note Permissible operating temperature 10
185. r Plug CAUTION 5 O QO aP gt aP bD s em un QO E bD in E oil pressure will be too low to run and may turns on the oil pressure indicator 6 39 ENGINE Movable Drive Face and Driven Face i 1 2 Cone m Ma m Le Hesagonal ange bolt 15 Movable driven ect Fw Movable drive pacer 28 Movable driven fae Spacer ue Food arven tee _ n ms 6 40 22INL ENGINE face disassembly Movable drive e Remove the spacer and rollers 2 e Remove movable drive face plate 1 Roller and sliding surface 47 om e Inspect each roller and their sliding surface for wear or damage If any damages are found replace the rollers as a set 45 0 un un 5 bD Q 0 un gt un 3 E Ke seal un bD gt bD 2 T un
186. rature Be careful not to drop the part with a semi conductor built in such as a CDI unit Properly use multi circuit tester and probes Improper use can cause damage to the vehicle and tester o If the voltage and current values are not known begin measuring in the highest range o When measuring the resistance make sure that no voltage is applied If voltage is applied the tester will be damaged o After using the tester be sure to turn the switch to the OFF position CAUTION Before using multi circuit tester read its instruction manual Multi Circuit Tester Set Color codes ME _ Bu Blue Pu Purple mos uw R Red Chocolate ic qu Light green nc 0 Y Yellow o Electrical Connectors Female Connectors A Male Connectors B 7 7 DIMNE ELECTRICAL SYSTEM ASaAiiiiiliikiiikitiiwakikikikKuuuu a a U U U U Electrical Wiring Wiring Inspection e Visually inspect the wiring for signs of burning fraying etc If any wiring is poor replace the damaged wiring e Pull each connector A apart and inspect it for corrosion dirt and damage If the connector is corroded or dirty clean it carefully If it is damaged replace it e Check the wiring for continuity o Use the wiring diagram to find the ends of the lead which is suspected of being a problem o Connect the hand tester between th
187. re the inside diameter of the camshaft journal holder and outside diameter of the camshaft journal e Replace the camshaft or the cylinder head depending upon which one exceeds the specification 23 000 23 021 mm ID of cam journal portion lt 52 2 c f LA oo bD gt Q 25 1 mm y ial Gauge 1 1000 mm D 22 959 22 980 mm O Q T m da Ke un z m Standard IN e Replace camshaft if runout exceeds limit e Measure the runout from using the dial gauge Camshaft Runout Micrometer Service Limit Of Camshaft Runout Dial Gauge 1 1000 mm 10 mm Magnetic Stand V block Set 100 mm 6 24 ENGINE and check with thickness gauge 2 20 S E AE 555 2 E g G E gt c E 3 202050018 m sn E gt D M A 2 E T dg 4 9 S gt a gt D in c 9 Q 2 S g S D 5 p 7 c z M yo 5 5 gt 8 8 gt z o lt z 45 9 Qo E H B 5 wi 2 5 2 5
188. re using an air pressure gauge Tire Air Pressure when cold Front 35 kPa 5 0 psi Rear 35 kPa 5 0 psi e Install the wheel see Wheel Installation e Wipe off the soap and water solution on the tire and dry the tire before operation Tire Inspection e Examine the tire for damage and wear o If the tire is cut or cracked replace it o Lumps or high spots on the tread or sidewalls indicate internal damage requiring tire replacement o Remove any foreign objects from the tread After removal check for leaks with a soap and water solution o Inspect the tire tread wear when decrease to the specified value replace the tire with a new one Tire Tread Wear Service Limit 2 8 DINLI WHEELS TIRES Hub Front Hub Removal Remove the wheel see Wheel Removal e Remove the cotter pin CAUTION 2 2 Q 5 gt Q S O Q 24 ud 8 Q 4 D H SG d bp amp gt Q Q gt caliper hang free e Remove the axle nut and pull off the front hub with brake disc e Separate the brake disc by removing the brake disc mounting bolts B lon Front Hub Inspect e Inspect the front hub bolts A for wear or damage If any aP
189. reeze and different brands of anti freeze o Do not use a radiator anti leak additive e 66 7 Engine coolant including reserve tank capacity For instance N WARNING 20 40 80 100 Freazing point You can be injured by scalding fluid or steam if you open the radiator cap when the engine is hot After the engine cools wrap a thick cloth around cap and carefully remove the cap by turning it a quarter turn to allow pressure to escape and P 4 then turn the cap all the way off o The engine must be cool before servicing cooling system 284 140 o Coolant is harmful 266 130 point it comes in contact with skin or eyes flush with water 248 120 swallowed accidentally induce vomiting and call physician 230 110 immediately 212 100 Keep it away from children 10 20 40 Density 55 Engine coolant density boiling point curve 7 2 COOLING AND LUBRICATION SYSTEM ___ Cooling Circuit RESERVOIR EE ENGINE COOLANT TANK EHERMOSTAT CYLINDER HEAD TEMPERATURE BYPASS COOLING gm RADIATOR WATER PUMP Cooling Circuit Inspection e Before removing the radiator and draining the engine coolant inspect the cooling circuit for tightness e Remove the radiator cap 1 and connect the tester to the filler N WARNING Do not remove the radiator cap when the engine is hot e Give a pressure of about 180k
190. replacement shim that will provide a clearance within the specified range For the purpose of this adjustment a total of 21 sizes of tappet shim are available ranging from 2 50 to 3 50 mm in steps of 0 05 mm Fit the selected shim to the valve stem end with numbers towards tappet Be sure to check shim size with micrometer to ensure its size Refer to the tappet shim selection table for details in the following pages o Be sure to apply engine oil to tappet shim top and bottom faces o When seating the tappet shim be sure the figure printed surface faces the tappet Reinstall the camshafts in the specified manner See Engine Chapter e After replacing the tappet shim and camshafts rotate the engine so that the tappet is depressed fully This will squeeze out oil trapped between the shim and the tappet that could cause an incorrect measurement Then check the clearance again to confirm that it is within the specified range e Install the new gasket 1 to the cylinder head cover e Apply BOND to the cam end caps of the gasket as shown CAUTION Use the new gasket to prevent oil leakage e Tighten the head cover bolts to the specified two step torque sequentially and diagonally Tightening Torque Initial 10 N m Final 14 N m Apply engine oil to the both side of head cover washer before installing the head cover bolts 9 6 DINLI PERIODIC MAINTENANCE Intake Side cL 9L1
191. rm water wash away the dust from the cleaner element and replace the foam with a new one e If the element is too dirty to clean replace the whole cleaner with new one 9 3 INES PERIODIC MAINTENANCE _________ ________________________ e Reinstall the cleaned or new air cleaner in the reverse order of removal CAUTION In driving under dusty conditions clean the air cleaner element more frequently The surest way to accelerate engine wear is to operate the engine without the element or to use a worn element Make sure that the air cleaner is in good condition at all times The life of the engine depends largely on this component e Remove the drain plug 2 from the air cleaner drain hose and air cleaner box to allow any water to drain out Exhaust Pipe Nuts and Muffler Mounting Bolts e Tighten the exhaust pipe nuts 1 muffler mounting bolts 2 and the muffler assembly connected bolt 3 to the specified torque Tightening Torque Exhaust Pipe Nut 23 N m 2 3 kgf m 16 5 Ib ft Muffler mounting bolt 23 N m 2 3 kgf m 16 5 Ib ft Muffler assembly connected bolt 23 N m 2 3 kgf m 16 5 Ib ft 9 4 PERIODIC MAINTENANCE 7 lt Valve Clearance e Excessive valve clearance results in valve noise and insufficient valve clearance results in valve damage and reduced power e Check the intake and exhaust valve clearances at the interval indicated above and adjust the valve clearances t
192. s up and blinks when hazard light switch on the left handlebar assembly turns on Front and rear indicators will blink simultaneously setting Button Press button to switch the display of Clock Hour Tacho Temp Meter PS Indicator Light When indicator switch is operated this indicator will blink and the buzzer will sound a This indicator lights up when the light switch is switched to high beam and will go out when switched to low beam Position Light This light comes on when the ignition switch is turned on Mode button Press this button to switch the display between ODO TRIP A TRIP B Meter PESE AWD Differential Lock Indicator 1 The instrument panel shows when the drive switch on the right handlebar is turned to 4WD The differential lock indicator comes on when the drive switch is turned to AWD Lock and the 4WD Lock On button is pressed 10 Gear Position Indicator This shows the present gear and changes while shifting gears 7 23 DIMNE ELECTRICAL SYSTEM 11 Speedometer speedometer shows approximate vehicle speed To change between mph and km h press Set and Mode button simultaneously for more than 2 seconds The display unit of ODO TRIP meters changes at the same time 12 ODO TRIP meter This display has two functions odometer and 2 trip meters Press Mode button to change the display e Odometer The odometer registers the total d
193. select an alternative according to the following chart Engine Oil For Other Countries e Use a premium quality 4 stroke motor oil to ensure longer 207050 service life of your vehicle Use only oil which are rated e SF or SG under the API service classification The ENGINE OIL EOZ 40 l recommended viscosity is SAE 10W 40 If SAE 10W 40 motor oil is not available select an alternative according 40 to right chart Front Differential Gear Oil e Use hypoid gear oil that meets API service classification GL 5 and is rated SAE 80W 90 Rear Gear Final Box Oil e Use hypoid gear oil that meets API service classification GL 5 and is rated SAE 80W 90 1 8 GENERAL INFORMATION oe ws NLI Brake Fluid Specification and classification DOT 4 WARNING o Since the brake system of this vehicle is filled with a glycol based brake fluid by the manufacturer do not use or mix different types of fluid such as silicone based and petroleum based fluid for refilling the system otherwise serious damage will result o Do not use any brake fluid taken from old or used or unsealed containers o Never re use brake fluid left over from a previous servicing which has been stored for a long period Engine Coolant Use anti freeze engine coolant compatible with an aluminum radiator mixed with distilled water only Water For Mixing Use distilled water on
194. sembly and Installation 7 16 Lubrication System 7 18 Oil Pressure 7 18 Oil Filter 7 18 Oil Sump Filter 7 18 Oil Pump 7 19 Engine Lubrication System Chart 7 20 Engine Lubrication System 7 21 7 1 amp JINIL COOLING AND LUBRICATION SYSTEM Engine Coolant e At the time of manufacture the cooling system is filled with a 1 2 mixture of distilled water and ethylene glycol anti freeze This 1 2 mixture will provide the optimum corrosion protection and excellent heat protection and will protect the cooling system from freezing at temperature above 56 69 Anti freeze density Freezing point 50 30 22 arc carm 6096 55 C 67 CAUTION o Use a high quality ethylene glycol base anti freeze mixed with distilled water Do not mix an alcohol base anti f
195. servoir e The fluid level must be checked several times during the bleeding operation and replenished as necessary While bleeding the brake system replenish the brake fluid in the reservoir as necessary Make sure that there is always some fluid visible in the reservoir e Tighten the bleed valve to the specified torque Tightening Torque 5 5 N m 0 55 kg m 48 e Apply the brake lever forcefully for a few seconds and check for fluid leakage around the fittings CAUTION Handle brake fluid with care the fluid reacts chemically with paint plastics rubber materials etc Brake Hoses Inspect every 1000 km 50 hours 3 months Check the brake hoses for leakage cracks wear and damage If any damages are found replace the brake hoses with new ones 9 25 PERIODIC MAINTENANCE Tires Inspect every 1000 km 50 hours 3 months Tire Tread Condition e Operating the vehicle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation It is highly recommended to replace a tire when the remaining depth of the tire tread reaches the following specification Tire Depth Gauge Tire Tread Depth Tire Pressure e If the tire pressure is too high or too low steering will be adversely affected and tire wear will increase Therefore maintain the correct tire pressure for good roadability and a longer tire life Inflation Tire Pr
196. slipping e Connect a tachometer onto the spark plug high voltage cable e Start the engine e Shift the range lever to the HIGH position e Apply the front and rear brakes as firmly as possible e Fully open the throttle for a brief period and note the maximum engine speed sustained during the test cycle Lock Up Speed 3800 4200 rpm CAUTION Do not apply full power for more than 5 seconds or damage to the clutch or engine may occur If the lock up speed rpm does not coincide with the standard range inspect the following items for any abnormalities o Clutch shoe See Engine chapter o Clutch wheel See Engine chapter o Movable drive and driven face See Engine chapter 9 36 APPENDIX L EE APPENDIX Table of Contents Troubleshooting Guide 10 2 ENO IOs 10 2 Radiator Cooling System 10 9 511115510 1 10 10 Drive 10 11 Chassis Y 10 13 Electrical 10 17 Dattery nnn nnn nnn nnn nnn nnn nnn nnn nnn nnn nn 10 18 special Tools
197. spark plug Is the spark plug OK YES Move to Step 3 NO Faulty spark plug Step3 Inspect the ignition coil Is the ignition coil OK YES Open circuit in wiring harness NO e Poor connection of ignition coil e Faulty ignition coil Spark Plug Removal Installation e Remove high voltage cable A e Remove or install the spark plug B using the spark plug wrench from the vehicle right side e When installing the spark plug make sure to tighten the spark plug to the specified torque Tightening Torque 14 1 4 kgf m 10 0 lb ft Spark Plug Cleaning Inspection e Clean the spark plug preferably in a sandblasting device and then clean off any abrasive particles The plug may also be cleaned using a high flash point solvent and a wire brush or other suitable tool If the spark plug electrodes are corroded or damaged or if the insulator is cracked replace the plug Use the standard spark plug or its equivalent 7 17 DIMNE ELECTRICAL SYSTEM Spark Plug Gap e Measure the gap A with a wire type thickness gauge e If the gap is incorrect carefully bend the side electrode B with a suitable tool to obtain the correct gap Spark Plug Gap 0 7 0 8 mm Ignition Coil Removal e Remove the ignition coil by removing its bolts Ignition Coil Installation e Connect the primary winding leads to the ignition coil terminals Ignition Coil Inspection Ignition coil resistance e Remove the ignitio
198. spring broken e Recoil starter pawl not engaging 4 Engine won t turn over e Valve seizure e Rocker arm seizure e Cylinder piston seizure e Crankshaft seizure e Connecting rod small end seizure e Connecting rod big end seizure e Transmission gear or bearing seizure e Camshaft seizure e Balancer bearing seizure 5 No fuel flow e Fuel tank air vent obstructed e Return fuel pump clogged e Fuel line clogged e Float valve clogged e Fuel filter clogged 10 2 APPENDIX _64 ________ 6 Engine fuel flooded e Fuel level too high e Float valve worn or stuck open e Starting technique faulty When flooded crank the engine with the throttle fully opened to allow more air to reach the engine 7 Fuel air mixture incorrect e l ilot screw and or idle adjusting screw maladjusted e Pilot jet or air passage clogged e Air cleaner clogged poorly sealed or missing e Fuel jet clogged 8 No spark spark weak e Spark plug dirty broken or maladjusted e Spark plug or spark plug cable trouble e Spark plug cap not in good contact e Spark plug incorrect e Pickup coil trouble e CDI unit trouble e Ignition coil trouble e Battery voltage low e Wiring shorted or open e Fuse blown 9 Compression Low e Spark plug loose e Cylinder head not sufficiently tightened down e No valve clearance e Cylinder piston worn e Piston ring bad worn weak br
199. t the water pump cover for damage e Replace the water pump cover if necessary 7 15 DINLI COOLING AND LUBRICATION SYSTEM lt e Visually inspect the impeller and its shaft for damage Reassembly and Installation e Reassemble and install the water pump in the reverse order of removal and disassembly Pay attention to the following points e Install the needle bearing from the other side and make sure the mark is face to the engine e Apply a small quantity of the GREASE to the oil seal lip e Install the oil seal using the special tool NOTE The stamped mark on the oil seal faces outside 7 16 DINLI COOLING AND LUBRICATION SYSTEM OOOO 9 929 99 9 9 9 9 9 9 9 9 9 OOOO 9 9 9 9 9 9 9 9 29 9 9 9 99 9 9 9 9 9 9 9 OX E CU e Install the new mechanical seal using the special tool On the new mechanical seal the sealer A has been applied e Apply GREASE to the impeller shaft e Install the impeller shaft and the impeller to the water pump body 9 9 99 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 99 9 4 e Install the washer 1 and impeller shaft pin 2 to the impeller shaft F A 3 and circlip 4 Iven gear e Install the water pump dr 7 17 DINLI COOLING AND LUBRICATION SYSTEM lt e Install the engine left crankcase cover 1 and recoil starter 2 e Install the new O ring 1 CA
200. the specified lubricant bond or sealant o When removing the battery disconnect the negative cable first and then the positive cable o When reconnecting the battery connect the positive cable first and then the negative cable and replace the terminal cover on the positive terminal o When performing service to electrical parts if the service procedures do not require use of battery power disconnect the negative cable from the battery o When tightening the cylinder head or case bolts and nuts tighten the larger sizes first Always tighten the bolts and nuts to the specified torque o Whenever you remove oil seals gaskets packing O rings locking washers self locking nuts cotter pins circlips and certain other parts as specified be sure to replace them with new ones Also before installing these new parts be sure to remove any left over material from the mating surfaces o Never reuse a snap ring When installing a new snap ring take care not to expand the end gap larger than required to slip the snap ring over the shaft After installing a snap ring always ensure that it is completely seated in its groove and securely fitted o Use a torque wrench to tighten fasteners to the specified torque Wipe off grease and oil if a thread is smeared with them o After reassembling check parts for tightness and proper operation CAUTION o To protect the environment do not unlawfully dispose of used motor oil engine coolant and other
201. ve doesn t move smoothly e Driven pulley spring incorrectly installed too tight e Drive pulley movable sheave doesn t move smoothly Abnormal Drive Train Noise 1 noise Belt worn e Drive or driven pulley sheave worn e Drive or driven pulley movable sheave bush worn e Drive or driven pulley loose e Drive pulley slide piece worn e Drive pulley roller worn 10 11 OINLI DINLI APPENDIX s s ss 2 Front or rear final gear case noise e Insufficient lubricant e Incorrect oil Front final gear case e Devel gear bearings worn e Bevel gears worn or chipped e gears maladjusted 3 Front axle or propeller shaft noise e Front propeller shaft Constant velocity universal joint damaged Front or rear final gear case overheating e Insufficient oil e gears maladjusted 10 12 Chassis Break Doesn t Hold or insufficient brake power 1 Front brake e Air in the brake line e Drake fluid leakage e Brake fluid deteriorated e Primary or secondary cup trouble e Master cylinder scratched inside e Pad over worn or worn unevenly e Oil grease on pads and disc e Disc worn or scored e Brake system overheated e Pressure valve trouble e Brake pedal not properly adjusted 2 Rear Brake e Air in the brake line e Drake fluid leakage e Brake fluid deteriorated e Primary or secondary cup trouble e Master cylinder scratched inside e Br
202. vehicle e Immediately wipe up any brake fluid that spills CAUTION Brake fluid quickly ruins painted surfaces any spilled fluid should be completely washed away immediately e Use a new flat washer for each side of the hose fittings e Install the new brake hose in its place and tighten the banjo bolts to the specified torque Tightening Torque 25N m 2 5kg m 18 0ft Ib e After installing the brake hose bleed the brake line immediately see Brake Line Air Bleeding 3 17 DINLI gt EE DINLI E Pressure Valve e Remove the brake hose banjo bolts 1 and remove the pressure valve mounting bolts 2 CAUTION Brake fluid quickly ruins painted surfaces any spilled fluid should be completely washed away immediately e Install the pressure valve by installing the brake hose banjo bolts and pressure valve mounting bolts e Bleed the brake line see Brake Line Air Bleeding e Check the brake for good braking power no brake drag and no fluid leakage 3 18 srake Foot Brake Brake Pedal Inspection Brake Pedal Position e Check that the brake pedal A is in the correct position as shown w Pedal Position B Standard 72 80 mm above footrest 7 If it is correct adjust the brake pedal position Brake Pedal Free Play e Check the brake pedal free play o Depress the brake pedal lightly by hand until the brake is appl
203. vice e If the foot brake did not applied before shifting to the R or P position shifting to the R or P position is not available e Apply the foot brake bD un c 5 un is lt 2 T O gt un 2 lt shifting to or P position due to foot brake applied 9 29 INES PERIODIC MAINTENANCE Chassis Nuts and Bolts Tighten initially at 200 km 10 hours 1 month and every 200 km 10 hours 1month thereafter e Check that all chassis nuts and bolts are tightened to their specified torque Refer to page 9 30 for the locations of the following nuts and bolts Item kef m lb ft _ 29 B9 LreddwhWemt 79 E Font aam upper o o o o s 6 shockabsorbermouning eo ss Fon shock absorver mounting so 5 18 Rear shock absorber mounting bolt nut lower 9 5 as _ po Rear Aarmbolinat upperandiover 0 69 eedem _ 5 23 Hitch ball mounting bolt 9 30 PERIODIC MAINTENANCE J AFE 7 lt INLD PERIODIC MAINTENANCE General Lubrication Lubricate every 1000 km 50 hours 3months e Proper lubrication is important for smooth operation and
204. witch 4WD Conf Speed Sensor c 5 5 ea iff D Starter Button 7 5 DIMNE ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems Learn and observe all the rules below o Do not reverse the battery lead connections This will burn out the diodes in the electrical parts o The MF battery used in this vehicle does not require maintenance o During normal charging no hydrogen gas is produced However if the battery is overcharged hydrogen gas may be produced Therefore be sure there are no fire or spark sources nearby when charging the battery o Be sure to recharge the battery in a well ventilated and open area o Note that the charging system for the MF battery is different from that of a conventional battery Do not replace the MF battery with a conventional battery o When disconnecting terminals from the battery for disassembly or servicing be sure to connect the negative battery lead wire first o When connecting the battery lead wires be sure to connect the positive battery lead wire first o If the terminal is corroded remove the battery pour warm water over it and clean it with a wire brush o After connecting the battery apply a light coat of grease to the battery terminals o Always check battery condition before condemning other parts of an electrical system A fully charged battery is a must for con
205. y open e Carburetor vacuum piston doesn t slide smoothly e Overheating e Engine oil level too high e Engine oil viscosity too high e Balancer mechanism malfunctioning Overheating 1 Firing incorrect e Spark plug dirty broken or maladjusted e Spark plug incorrect e CDI unit trouble 2 Compression high e Carbon built up in combustion chamber 3 Engine load faulty e Engine oil level too high e Engine oil viscosity too high e Drive train trouble 4 Lubrication inadequate e Engine oil level too low e Defective oil pump or clogged oil circuit e Engine oil poor quality or incorrect 10 6 Exhaust Smokes Excessively 1 White smoke e Piston oil ring worn e Cylinder worn e Valve oil seal damaged e Valve guide worn e Cylinder head gasket damaged e Engine oil level to high 2 Black Smoke e Air cleaner clogged e Main jet too large or fallen off e Spark too weak e Incorrect fuel air mixture e Fuel level too high Abnormal Engine Noise 1 Knocking e CDI unit trouble e Carbon built up in combustion chamber e Fuel poor quality or incorrect e Spark plug incorrect e Overheating 2 l iston noise e Cylinder piston clearance excessive e Cylinder piston holes worn e Connecting rod bent e Piston pin piston holes worn e Worn piston rings or ring grooves e Combustion chamber fouled with carbon 3 Valve noise e Valve clearance incorrect e Valve spring broken

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