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SERVICE MANUAL DL700 HY700 A700

1. e Remove the dowel pins 1 and cylinder head gasket 2 e Remove the cam chain guide 3 e Remove the cylinder nuts 4 e Remove the cylinder 5 NOTE Be careful not to drop the dowel pins into the crankcase e Remove the dowel pins 1 and the gasket 2 e Remove the piston by removing the piston pin circlip 1 NOTE Place a clean rag under the piston so as not to drop the piston pin circlip into the crankcase 6 13 DINLS ENGINE Engine Bottom Side e Remove the oil filter with the special tool e Remove the water pump cover 1 e Remove the starter cup nut with a suitable bar 1 e Remove the starter cup 2 Remove the left crankcase cover 3 e Remove the dowel pins 4 and gasket 5 6 14 e Remove the starter re
2. ENGINE e Install the spacer NOTE When inserting the spacer press down the movable drive face plate so as not to cause the rollers to come out of position Movable driven face disassembly e Hold the movable driven face assembly with the special tool loosen the movable driven face ring nut with the special tools J N WARNING Do not remove the movable driven face ring nut before attaching the clutch spring compressor Ring Nut Socket Wrench e Attach the special tool to the movable driven face assembly and compress the movable driven face assembly by turning in the special tool handle NOTE Make sure to insert the flange of the special tool into the spring plate hole e Remove the movable driven face ring nut ANNANIN E Since a high spring force applies to the movable driven face care must be used so as not to cause the movable driven face to come off abruptly e Loosen the special tool handle slowly and remove the special tool e Remove the spring plate 1 and spring 2 e Remove the spring seat 3 6 43 DINLI C DINLS ENGINE
3. 8 12 InSPeCtlON orn nnn nnn nnn nn nnn nn nnn nnn nnn nnn nnn nnn nnn nn nnn nn nnn nnn 8 13 Ignition System 8 16 Troubleshooting 8 16 Spark Plug Removal Installation 8 17 Spark Plug Cleaning Inspection 8 17 Spark Plug Gap 8 18 Ignition Coil Removal 8 18 Ignition Coil Installation 8 18 Ignition Coil Inspection 8 18 CDI Output Test 8 19 Starter Relay Inspection 8 19 Main Relay Inspection 8 20 Transfer selecting system
4. 4 38 Removal 4 39 nspection 4 40 Installation 4 40 Shift Rod 4 4 Installation 4 4 Shift Rod Adjustment 4 42 4 1 INES suspENSION STEERING DRIVE SHAFT I Front Suspension Construction Front shock absorber Hex socket bolt 2pcs 25 Spacer e tower crm 16 ex water r at 65 25 Cape crap 7 Upper scam 17 _Hecwasberfacebot a7 Caypecilip S cenere i Hex washerfacebott 25 Spacer 2p gt Doae row angular bearing 19 Hex washer fac bolt Gp 4 2 SUSPENSION STEERING DRIVE SHAFT Removal and Disassembly e Remove the front wheels tires See Wheels Tires chapter e Remove the front fender and the footboard See Body chapter e Remove the front wheel hubs with brake discs See brake chapter e Remove the front brake calipers and hang it free e Remove the driver shaft
5. 3 12 Removal 3 12 Installation 3 13 Inspector n ne n nnn nnn nnn nnn nnn nnn nnn nnn nnn nnn nnn nnn nnn nnn nnn nnnn 3 13 Brake DisC 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 nspection 3 17 Replacement
6. 4 24 Inspection and Reassembly 4 24 Installation 4 26 SLC CLIN 8 nnn nnn nnn nn nnn nnn nn nn nn nnn nn nn nnn nnn 4 27 Construction 4 27 Removal and Disassembly 4 28 nspection 4 30 Reassembly and Installation 4 32 Toe Out Adjustment 4 34 Hand lebar 4 35 Construction 4 35 Removal 4 36 Installation 4 37 Indicator T M Lever 4 38 Construction
7. 8 31 Wiring Diagram 8 32 8 2 ELECTRICAL SYSTEM oe OINLI Specifications Standard Battery Capacity 12 V 20Ah Alternator type Three Phase AC Charging voltage Regulator rectifier output DC 14 15 V Alternator no load output voltage AC 65 V and more at 5000 rpm 0 49 Q l Y2 Y3 Charge Coil Stator Y3 Y1 0 49 Q Y Ground co Pulser Coil 110 15 P Primary 0 2 15 nition 1 al Secondary 6 3 KQ 20 At20 Nominal Output 0 7 kW Starter motor Gap _ 0708 Spark plug ap mm _ Reduction Ratio _ 28 283 8 3 ODINLI lt 7 ELECTRICAL SYSTEM Parts Location a O Bo Starter Circuit Relay H Regulator Rectifier CDI Unit Gear Position Indicator Flash Relay Starter Motor Position 2 Relay x 2WD 4WD Diff 4WD Actuator 8 4 ELECTRICAL SYSTEM oe OINLI r head a High Low Beam Switch g Ignition Switch Hazard Lights Switch H ees Plug po a ng D Indicator Switch Temperature Sensor E Diff 4WD Confirm Button rs Speed Sensor Staten 8 5 OINLI lt J 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 w
8. 7 12 nspection 7 12 Installation 7 13 Water Pump 7 14 Removal and Disassembly 7 14 Reassembly 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 DINLI COOLING AND LUBRICATION SYSTEM lt 9 Engine Coolant e At the time of manufacture
9. 6 22 ENGINE EE 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 e Check for wear and damage on Cam Sprocket gear teeth e Check for wear and damage on decompression related parts e 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 ODINLI C 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 NOHO Do not attempt to disassemble the 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 the camshaft installed in place e Use the plastigauge A to read the clearance at the widest portion Oil clearance at cam journal portion 0 150 mm NOTE Install camshaft journal holders to their original positio
10. 10 13 Electrical 10 17 Battery n nn nnn nnn nnn nn nnn nnn nnn nnn nnn nnn nnn nnn nnn nn nnn nnn nnn nn nnn 10 18 special Tools 10 20 Tightening Torque 10 21 EN QIN C nnn nnn nnn nnn nnn nnn nnn nnn nnn nnn nnn nnn nn nnn nnn nn nnn nnn nnn 10 21 ChassiS 10 22 Cooling SystemM 10 23 Tightening Torque Chart 10 24 Service Data 10 25 10 1 DINLI APPENDIX DP ma 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
11. 4 10 Rear Suspension 4 11 Construction 4 11 Removal 4 12 Inspection and Disassembly 4 13 Reassembly and Installation 4 15 spring Pre Load Adjustment 4 17 Rear Stabilizer Removal 4 18 Rear Stabilizer Installation 4 19 Front Propeller Shaft 4 20 Removal and Disassembly 4 20 Inspection and Reassembly 4 21 Installation 4 23 Rear Propeller Shatft 4 24 Removal
12. 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 Removal 3 6 Installation 3 7 Caliper 3 8 Front Caliper Removal 3 8 Rear Caliper Removal 3 8 Parking Brake Caliper Removal 3 8 Caliper Installation 3 9 Caliper Inspection 3 10 Brake Pade
13. ODINLI lt J ENGINE Transmission Disassembly e Disassemble the transmission as shown SAAN 37 KV Ze Lg a a Ca F a F AO a 01 ball bearing 2pcs 13 Spacer 25 Reverse shaft 37 Spacer 2pcs Reverse driven gear Fork 2pcs High T M gear Space 6 48 ENGINE Reassembly e Assemble the transmission gear in the reverse order of disassembly Pay attention to the following points NOTE Always use new snap rings NOTE 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 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 DINLI lt _7 DINEI 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 Visual checking Main Shaft and Counter Shaft Assy e After disassembling check for wear an
14. CAUTION o It is necessary to put the oil seals and needle bearing in order Follow the arrow mark to place the components to its position o When installing the needle bearing it must install from the other side make sure that the mark side is face to the engine 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 DINLS ENGINE e Install the bearings with the special tool e Install the generator stator assy The harness of the sensor must be fastened to prevent for hitting the stator 6 52 ENGINE es REASSEMBLY e Please reverse the disassembly steps to reassembly Pay attention to the following points NOTE E engine oil to each running and sliding part before reassembling CAUTION _ keep the drive belt drive face and driven face away from any greasy matter Engine Bottom Side e Install the crankshaft into crankcase Pp AUTION o Never fit the crankshaft into the crankcase by striking it with a plastic mallet Install the crank balancer shafts 1 e Install the transmission gear shaft assembly in a certain order main input shaft 1 output shaft 2 counter sha
15. 6 2 Engine Installation 6 8 Engine Disassembly 6 10 Engine Top Side 6 10 Engine Bottom Side 6 14 nspection 6 23 Camshaft and Cylinder Head 6 23 Cam Chain Tensionet 6 32 Cam Chain Guide 6 32 Cylinder 6 32 Timing Gear 6 34 PisSton 6 35 Connecting Rod 6 37 Clutch 6 38 Oil Galle
16. 2 6 Removyal 2 6 Installation 2 6 INSPeCtlON no name nn nnn nnn nnn nnn nnn nnn nnn nnn nnn nnn nnn nnn nnn naan 2 8 Hub 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 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 capaci
17. Tightening Torque Exhaust Pipe Nut 23 N m 2 3 kgf m 16 5 lb ft Muffler mounting bolt 23 N m 2 3 kgf m 16 5 lb ft Muffler assembly connected bolt 23 N m 2 3 kgf m 16 5 lb ft 9 4 PERIODIC MAINTENANCE ___ PIINLI CI 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 to specification if necessary Remove the front fender e Remove the cylinder head cover Remove the recoil starter 1 e Remove the valve timing inspection plug 2 e Turn the crankshaft to bring the TDC line A on the starter clutch to the flange B e Read the valve clearance at all the valves with the special tool 4 e If the clearance is out of specification adjust the clearance Thickness Gauge 7 we Valve Clearance When cold A 0 1 0 2 mm x aW 0 2 0 3 mm Ti Ana 9 5 DINLI PERIODIC MAINTENANCE Valve Clearance Adjustment e The clearance is adjusted by replac
18. 9 28 Shift Rod 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 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 C mmr 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
19. 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 lb ft e Make sure the cable harness and brake hose are routing properly CAUTION When installing the handlebar Align the brake reservoir on the horizontal direction is necessary 4 37 INES suspENSION STEERING DRIVE SHAFT Indicator T M Lever Construction G me o aa 7 Henin nck Ops Indicator T M level Indicator T M level bracket Tie rod end 2pcs a mmeone iz Speer pay anf evaa 5 fepping screw pay 18 Washer sy anf CN 6 Hex washer fae bot 14 Hexwatertacbok epo 22 we E ws O o s a a 4 38 SUSPENSION STEERING DRIVE SHAFT 99INELI CI 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 INES suspENSION STEERING DRIVE SHAFT Inspection e Inspect the shift lever assembly for wear or da
20. 3 17 Foot Brake 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 OINLI lt 7 BRAKE Construction 2 Fron Brake Assy 8 17 Hex Socket Bt epo 30 Rear rake Disc Sf meran is Gaertner Master Cylinder Assy 2a Hose r roor 20 Spang waster ap oo taking ase a Hex SocketBok pe a Washer pcs Braking How gt exagonal Flange Bot p 22 Sing Waster apoy 35 Bring Howe io Feapona Fange Blt ps 23 _Washer ps __ s6 _Comnecor spo naneco aa ir ae 2 Hexagonal Flange Bolt 2pcs 25 Spacer 2pcs Torsion Spring Hexagonal Flange Bolt 2pcs E Type Circlip Ps fas fas 9 25 29 18 3 2 srar _ DINLI 1 Brake Fluid N WARNING When working with the disc brake observe the precautions listed below 1 Never re
21. Throttle Cable Play 3 3 8 mm o After adjusting the throttle cable play tighten the locknut 1 Carburetor Inspect every 1000 km 50 hours 3 months and every 2000 km 100 hours 6 months thereafter e Inspect the carburetor for dirt or mud e If any dirt or mud is found clean it Idle Adjustment e To adjust the idle allow the engine to reach operating temperature 70 C 158 F e Adjust the idle speed to maintain at 1300 rpm turning the adjuster clockwise to increase idle speed or counterclockwise to decrease idle speed 9 11 DINLI PERIODIC MAINTENANCE Carburetor Limiting Device CAUTION The carburetor has a limiting device which has limit the horsepower of the engine to prevent damage Engine Oil and Oil Filter Replace initially at 200 km 10 hours 1 month and every 2000 km 100 hours 6 months thereafter e The oil should be changed while the engine is warm Oil filter replacement at the above intervals should be done together with the engine oil change Engine Oil Replacement e Place an oil pan under the drain plug 1 and then drain out the engine oil by removing the engine oil drain plug 1 and engine oil filler cap 2 e Tigh
22. 1 8 Engine Oil For Other Countries 1 8 Front Differential Gear Oil 1 8 Rear Gear Final Box Oil 1 8 Brake Fluid 1 9 Engine Coolant 1 9 Water For Mixing 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 UINELS GENERAL INFORMATION lt _F 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 ph
23. Bearing remover set CAUTION The removed mechanical seal must be replaced with a new one e Place a rag over the water pump e Remove the oil seal using a suitable bar CAUTION The removed oil seal must be replaced with a new one e Remove the needle bearing from the front side as shown e Visually inspect the oil seal for damage with particular attention given to the lip e Inspect the needle bearing for wear or damage replace it if the damages have been found e Replace the oil seal that shows indications of leakage e Visually inspect the water pump cover for damage e Replace the water pump cover if necessary 7 15 NINES COOLING AND LUBRICATION SYSTEM 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 COOLING AND LUBRICATION SYSTEM _ _9INLI CI e Install the new mechanical seal using the special tool NOTE On the new mechanical seal the sealer A has been applied e Apply GREASE to the impeller shaft e Ins
24. 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 DINLI PERIODIC MAINTENANCE CVT Water Draining Inspection e If the inside of the CVT had been accumulates with water draining the water to keep CVT from damage or danger is necessary e Remove the CVT drainage bolt to drain the water that from the CVT Drive Belt Inspect every 1000 km 50 hours 3 months Replace every 2000 km 100 hours 6 months Removal Remove the right body decoration See Body chapter e Remove the right footboard Remove the footrest 1 e Remove the CVT cover 1 and gasket 9 18 PERIODIC MAINTENANCE ___ PIINLI lt a Remove the movable drive face cover 1 e Remove the dowel pins e Remove the movable drive face by removing its bolt 2 e Remove the movable driven face with belt by removing movable driven face bolt 3 Remove the drive belt 4 from the movable driven face Inspection e Inspect the drive belt for wear or damage If any cracks or
25. 8 21 INS PeCtlON oon nnn nnn nnn nnn nnn nnn nn nnn nnn nnn nnn nn nnn nnn nnn nn nnn nn 8 21 Combination Meter 8 22 Description 8 22 Functions and Operating Procedure 8 23 Removal and Installation 8 26 nspection 8 26 Lighting System 8 29 Headlight Bulb and Assembly Replacement 8 29 Taillight Bulb and Assembly Replacement 8 29 Indicator Bulb and Assembly Replacement 8 29 8 1 DINEI ELECTRICAL SYSTEM FUSES 8 30 Main Fuse Removal 8 30 Fuse nspection 8 30 Switches
26. DINEI ENGINE e Install the spring seat by aligning the holes e Install the spring and the spring plate by aligning the spring ends with the holes e Compress the spring with the special tool e Tighten the movable driven face ring nut temporarily e Remove the special tool from the movable driven face assembly e Tighten the movable driven face ring nut to the specified torque with the special tool Tightening Torque 100 N m 10 0 kgf m 72 0 lb ft Ring Nut Socket Wrench 6 46 ENGINE LN Drive Belt Inspection ODINLI C e Check that the drive belt is free from any greasy substance e Inspect the contact surface of the drive belt for cracks or damage 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 CAUTION If grease or oil is present on the surface of the drive belt the belt thoroughly Vernier Calipers Oil Pump 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 CAUTION o Do not attempt to disassembly the oil pump assembly o The oil pump is available only as an assembly 6 47
27. 7 7 Cooling Fan 7 8 nspection 7 8 Removal 7 8 Remounting 7 8 Cooling Fan Thermo Switch 7 9 Removal 7 9 Inspector nn nnn nnn nnn nnn nn nnn nnn nnn nnn nnn nnn nnn nnn nn nnn 7 9 Installation 7 9 ECT Sensor 7 10 Removal 7 10 nspection 7 10 Installation 7 11 Thermostat 7 12 Removal
28. CAUTION Immediately wash away any brake fluid that spills Rear Caliper Removal e Remove the rear wheel see Wheels Tires chapter e Loosen the banjo bolt at the brake hose lower end and tighten it loosely e Remove the caliper mounting bolts and detach the caliper from the disc e Remove the banjo bolt and remove the brake hose from the caliper CAUTION Immediately wash away any brake fluid that spills Parking Brake Caliper Removal e Remove the rear wheel See Wheels Tires chapter e Remove the rear caliper e Remove the brake disc mounting bolts 3 8 e Remove the circlip 1 and pull out the disc and the 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 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
29. 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 STEERING DRIVE SHAFT DINLI CI e Remove the cotter pin and steering shaft lower nut and washer CAUTION Replace the removed cotter pin with a new one ko joe e Remove the steering shaft bracket bolts e Remove the steering shaft brackets spacers oil seals and plate e Remove the steering shaft CAUTION Replace the removed oil seals with new ones e Remove the seal cover 1 pin 2 bush bearing 3 and washer 4 CAUTION Replace the removed seal cover with a new one 4 29 DINLI 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 e Inspect the seal covers 1 pin 2 and bush bearing 3 for wear or damage If any damages are found replace them with new ones Tie Rod e Inspec
30. CAUTION Replace the removed snap ring with a new one 4 20 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 damages are found replace it with a new one 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 the axle shaft and wheel spindle as shown o Wash the disassembled parts except for the boots After washing completely dry the parts using compressed air o Clean the boots with a cloth CAUTION o Wash all parts before installation clean the inside and outside of the boots with a cloth o Do not wash the boots in any commercially available degreaser such as gasoline or kerosene Washing in a degreaser causes deterioration of the boots ODINLI I 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 e Install the cage 1 on the shaft CAUTION Install the cage with the large diameter side facing the shaft end A Large Diameter B Small Diameter 4 21 DINLI SUSPENSION STEERING DRIVE SHAFT e Install the new snap ring e Apply GREASE to the entire surface o
31. e Remove the pins and rollers e Remove the movable driven face O ring and Oil seal e Inspect the lip 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 e Install the oil seal with the special tool 6 44 Movable driven face spring e Measure the spring free length with the vernier caliper e If the length is shorter than the service limit replace the spring with a new one Movable driven face spring free length 150 0 mm 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 stepped wear or discoloration caused by burning If any damages are found replace the movable driven face with a new one 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 To prevent damaging the oil seal lip from during installation slide the lip using a 0 1 mm steel sheet as a guide 6 45
32. e When installing the shift lever rod adjust the tie rod length to the properly position e Tighten the rear gear box mounting nuts to the specified torque Tightening Torque 50N m 5 0 kgf m 36 0 lb ft e Apply THREAD LOCK to the nuts X e Tighten the front differential gear mounting nuts to the specified torque Tightening Torque 50N m 5 0 kgf m 36 0 lb ft oO e Apply THREAD LOCK to the nuts i 6 8 e Apply THREAD LOCK to the foot board bracket bolts 1 and tighten them to the specified torque Tightening Torque 55N m 5 5 kgf m 40 0 lb ft e Install the new gasket and tighten the muffler bolts and exhaust pipe nuts to the specified torque Tightening Torque 23N m 2 3 kgf m 16 5 lb ft 6 9 ODINLI lt 7 ENGINE Engine Disassembly Engine Top Side e Remove the spark plug e Remove the start motor Remove water hoses 1 and 2 3 A Vila e Remove the water union e Remove the recoil starter
33. 7 22 COOLING AND LUBRICATION SYSTEM _ __9NLI lt _ 7 23 ELECTRICAL SYSTEM oe OINLI ELECTRICAL SYSTEM Table of Contents Specitications 8 3 Parts Location 8 4 Precautions 8 6 Electrical Wiring 8 8 Wiring Inspection 8 8 Battery 8 9 Battery Removal 8 9 Battery Installation 8 9 Battery Charging 8 9 Charging Procedures 8 10 Battery Test Charging 8 10 Charging System 8 12 Troubleshooting
34. e Apply a small amount of MOLYBDENUM OIL SOLUTION to the piston pin e Install the piston and piston pin NOTE When installing the piston the arrow mark on the piston head is 3 located to the exhaust side e Place a clean rag over the crankcase e Install the circlip CAUTION When turning the crankshaft pull the cam chain upward or the chain will be caught between the crankcase and the cam drive sprocket e Fit the dowel pins 1 and the new gasket 2 CAUTION Use a new gasket to prevent gas leakage 6 64 ENGINE ODINLI I e Hold each piston ring with properly position insert the piston into the cylinder Piston Ring Clip e Tighten the cylinder base nuts CAUTION When installing the cylinder and cylinder head pull the cam chain upward or the chain will be caught between the crankcase and cam drive sprocket e Install the cam chain guide 1 e Fit the dowel pins 2 and new cylinder head gasket 3 CAUTION Use a new gasket to prevent gas leakage e Install the cylinder head e 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 lb ft Final 37 N m 3 7kef m 27 0 lb ft e Tig
35. C Luggage Compartment Luggage Compartment Removal Installation e Remove the air cleaner by removing its box and bolts Remove the battery e Remove the electrical relays and units e 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 zopy POOO 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 BODY EE Protector Protector Removal Installation ODINLI C e Remove the front 1 engine 2 and rear protector 3 by removing its bolts e Install the protector by installing their bolts 5 17 ENGINE ge EPUIWES _ ENGINE Table of Contents Removal and Installation 6 2 Engine Removal
36. o To protect Earth s natural resources properly dispose of used vehicle and parts 1 5 DINLE I GENERAL INFORMATION DINLI DL 702 Right Side Left Side e Difference between photograph and actual vehicle may exist depending on the markets 1 6 GENERAL INFORMATION oe s4 NLI Model Identification Engine serial number Vehicle identification number ENGINE SERIAL NUMBER Ex 15M18XXXXX VEHICLE IDENTIFICATION ex RFWAK85CX6Txxxxxx Whenever corresponding with DINLI about a particular issue the engine number and serial number are important for vehicle identification 1 7 UINELS GENERAL INFORMATION Fuel Oil and Engine Coolant Recommendation Fuel For USA and Canada e Use only unleaded gasoline of at least 87 pump octane R 2 M 2 or 95 octane or higher rated by the 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 1OW 40 If SAE 10W 40 oil is not available select an alternative according to the following chart Engine Oil For O
37. 140 2 140 5 No groove at any Clutch shoe part Clutch engagement rpm 1800 2000 rpm Pe Clutch lock up rpm 3800 4200 rpm Pe Drive Train Unit mm Senda reductonato Base yams TC O Rear 3 600 36 10 es CT Final reduction ratio Drive belt width 34 3 3 3 3 Movable driven face spring 158 0 150 0 free length Shift fork to groove clearance 0 10 0 27 560 567 Shift fork groove width Reverse Reverse 5 40 5 50 Shift fork thickness Front differential gear oil type Hypoid gear oil SAE 80W 90 API grade GL 5 OoOo S o o Rear drive gear oil type Hypoid gear oil SAE 80W 90 API grade GL 5 o Front differential gear oil capacity 150 ml o Rear gear box oil capacity 310 ml o 10 27 DINLI APPENDIX Thermostat Radiator Fan Coolant Unit mm Thermostat valve opening 80 84 176 183 temperature ECT sensor resistance ee ee ee ee Radiator cap valve opening 110 140 kPa operating temperature Approx 86 187 a 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 1600 ml Engine coolant Carburetor Idle rpm 1300 100 rpm 10 28 APPENDIX ae LI Electrical l Unit mm Standard Specification Note Spark plug 0 17 0 23 Q Terminal Ground Ignition coil resistance 5 0 7 6 kQ
38. Dial gauge 1 100 mm 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 K 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 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 BRAKE DINLI C A DINLI 2p 4x Pressure Valve e Remove the brake hose banjo bolts 1 and remove the pressure valve mounting bolts 2 CAUTION Brake fluid quickly
39. Engine Overcools e Defective cooling fan thermo switch e Extremely cold weather e Defective thermostat 10 9 APPENDIX DINLI C LL DINLI APPENDIX Transmission Gear Shifting Faulty 1 Doesn t go 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 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 10 APPENDIX eae Drive Train CVT Operation Faulty 1 Belt slipping e Belt 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
40. 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 or weak e Camshaft bearing worn e Rocker arm worn e Worn tappet or cam surface 10 7 APPENDIX DINLI C EEE OINLI lt 7 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 8 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
41. e Tighten the rear stabilizer joint bolt nut Tightening Torque 34 N m 3 4 kgf m 24 5 lb ft 4 16 SUSPENSION STEERING DRIVE 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 C DINLI SUSPENSION STEERING DRIVE SHAFT Rear Stabilizer Removal e Remove the rear wheel e Remove the rear stabilizer joint bolt nut e Remove the rear stabilizer bracket bolts e Remove the rear stabilizer bar Inspection Rear Stabilizer Bar e Inspect the stabilizer for damage If any damages are found replace the rear stabilizer bar with a new one Stabilizer Bracket Bushing e Inspect the stabilizer bracket for damage If any damage are found replace the stabilizer bracket with a new one e Inspect the plastic bushing for wear or other damage If any
42. sez LAHI SIHL SAS GO LAAGH BTE SET 92 07 420 OF 0 SoU gg 07490 03 07 35 90 90 190 bid Cid a DEO 00 6b 0790 rlo olo 600 900 orc JAg ie SS ja Toer Gre zz JOVI E100 Foo 000 Wu SONWHWS19 Ladd i z 3 i aes eee z 4 Osans vay UFE SE L i a i ari laim aa LULL a AZISWIKS INSSSudq XX SO00S1S ON WIHS Ladd LISAIVWH XS SIS VLNOILOS 148 WIHS LAddY 1 9 8 PERIODIC MAINTENANCE 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 CR6E i e Check to see if there are carbon deposits on the 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 Wire Gauge e Check the condition of the 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 CAUTION 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 fi
43. sopr _ DINLI NN 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 A 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 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 N WARNING Ay OE Gasoline is highly flammable and explosive Keep heat spark and flame away 5 9 DINLI zopy POOO e Remove the fuel tank by removing its bolts Front Fender Installation e Please reverse the Removal steps to install 5 10 sopr _ DINLI Rear Fender Construction I etter gt Haseena i Taieacer ao Right foot board Hex washer face bolt 4pcs e i s tatoaydewraion ii sew poy
44. EE 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 o D x 2 e E x 2 left amp right 5 3 DINLI zopy C ma 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 5 4 sopr _ DINLI Front and Rear Fenders Front Fender Construction vey ii i AA Vi ay h i l 4 is T ATT OY 2 Front fender decoration 11 Hook 20 Hex insert lock nut 6 Front tender undercover 15 Hox washer fae bot epay 2a Spins 8 17 Handlebar holder cover Hex washer face bolt 2pcs 26 Tapping screw 8pcs 2 ove compartment cover 36 Machine screw ps 5 5 DINLI zopy Front Fender Removal Maintenance Compartment e Remove the front rack See 5 3 e Remove front fender decoration B by ins
45. 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 sheave 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 CVT 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 DINLI C DINLI APPENDIX 2 Front or rear final gear case noise e Insufficient lubricant e Incorrect oil Front final gear case e Bevel gear bearings worn e Bevel gears worn or chipped e Bevel 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 Bevel gears maladjusted 10 12 Chassis Break Doesn t Hold or insufficient brake power 1 Front brake e Air in the brake line e Brake 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 Bra
46. 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 lb 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 lt 7 BRAKE Rear Disc Installation e The disc must be installed with the marked side B facing toward front 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 lb ft e After installing the discs check the disc runout see Disc Runout Completely clean off any grease that has gotten on either side of the disc with a high flash point solvent Inspection Disc Wear e Measure the thickness of each disc at the point A where it has worn the most Replace the disc if has worn past the service limit B Measuring Area Front Disc Thickness Siete Rear Disc Thickness 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
47. the display changes between clock hour tachometer and temperature INRIA NING To avoid riding with only one hand do not operate the buttons while riding Odometer e Displays the total distance travelled Trip meter e Displays the distance travelled since the trip meter was last reset NOTE The trip meters A and B can be 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 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 8 25 ODINLI C DINEI ELECTRICAL SYSTEM o Select the correct hour by pressing the MODE button e Decide the hours by pressing the SET button Removal and Installation 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 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 rever
48. 19 Hee menaco ped Rightbody decoration 12 Fane bol pa 20 Hex washer face bol epe e apogo ial Neap 28 Reesor bracket epe r cmgones Ys Raber washer apoy 23 Tapping sew pes ef cipta ie ipepo at Refetor pa 5 11 DINLI zopy 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 sopr _ DINLI 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 zopy o 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 lb ft Rear Fender Installation e Please reverse the Removal steps to install 5 14 sopr _ DINLI
49. 2 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 N m 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 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 e 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 the 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
50. 2 e Remove the dowel pins 1 e Remove the O ring e Remove the one way clutch 6 20 ENGINE a LI Remove the clutch shoe nut CAUTION The clutch shoe nut has left hand threads e Remove the clutch shoe with the special tool D001 Rotor Holding Tool e Remove the right crankcase bolts M6 amp M8 o Loosen the crankcase bolts diagonally with the smaller sizes first o There have two more bolts at the left crankcase it is necessary to remove them for remove the right crankcase e Separate the right crankcase with the special tool NOTE o The crankshaft must remain in the left crankcase half e Remove the dowel pins 2 6 21 DINLS 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 the 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 Remove the crank balance shafts 1 e Remove the crankshaft
51. 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 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 e Mistimed valves e Starter motor cranks too slowly 10 3 DINLI lt _7 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
52. 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 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 9 DINLI 2p 4x 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 lb ft e Replace the circlips 1 with new ones e Tighten the wire rope bolt 2 Caliper Inspection e Inspect the brake caliper for any scratches or other damage if any damages are found replace the caliper with a new one e If any rubber parts have been removed from the caliper replace them with new ones 3 10 srar _
53. D004 Vacuum Pump Gauge Valve Spring e Measure the free length of Valve Spring e Check the force required to compress the spring e If the result is not correct replace the spring Service Limit of Valve spring free length IN amp EX Service Limit of Valve spring free length IN amp EX 19 0 21 4 kgf 36 50mm Vernier Calipers 6 29 DINEI ENGINE Valve Reassembly 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 MOLYBDENUM OIL SOLUTION to their stems without any break CAUTION When inserting each valve take care not to damage the lip of the oil seal e Install the valve spring with the small pitch portion 1 facing cylinder head 2 Large pitch portion 3 Upward e Install the valve spring and spring retainer with special tool CAUTION Be sure to restore each spring and valve to their original positions D005_01 Valve Lifter Attachment D005 _02 Valve Lifter e Install the tappets 1 and shims 2 to their original position Apply engine oil to the shim and tappet before fitting them Aa E When seating the shim be sur
54. Degrease the movable drive face assembly Use nonflammable cleaning solvent to wipe off oily and greasy matter and make its surfaces completely dry 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 lb 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 DINLS ENGINE Install the movable drive face cover 1 e Install the new gasket and clutch cover e Tighten the clutch cover bolts to the specified torque Tightening Torque 9 N m 0 9 kgf m 6 5 lb ft e Install the pin e Install the balancer shaft drive gear e Install the cam chain drive gear with the special tool The cam chain is installed at the lower position of the drive gear e Install the keys 1 6 58 e Install the crank balancer driven gears 1 and water pump drive gear 2 NOTE Align the punched marks as shown NOTE Pay attention to the direction of the water pump drive gear and oil pump drive gear e
55. 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 Inspection 9 18 Drive Belt 9 18 Brakes 9 22 Brake Fluid 9 24 Brake Hoses 9 25 ires 9 26 DIEETIN 8 sena 9 27 SUSpenS OnS
56. Pour new engine oil 7 19 OINLI C DINLE I cooLinG AND LUBRICATION SYSTEM Oil Sump Filter NOTE When installing the oil sump filter always use the new one to keep oil clean And the thinner side is face to the CVT Oil Pump e Rotate the oil pump by hand and check that it moves smoothly If it does not move smoothly replace the oil pump assembly CAUTION o Do not attempt to disassemble the oil pump assembly o The oil pump is available only as an assembly 7 20 COOLING AND LUBRICATION SYSTEM _ __9NELI CI Engine Lubrication System Chart OIL PAN OIL SUMP FILTER RELIEF VALVE OIL PUMP OIL FILTER MAIN GALLERY COPPER PLUG CYLINDER RIGHT CRANKCASE p l CYLINDER HEAD prid H i CRANKCASE INTAKE CAMSHAFT EXHAUST CAMSHAFT sano tauen RIGHT BEARING LEFT JOURNAL LEFT JOURNAL COUNTER INTAKE EXHAUST SHAFT RIGHT CRANKSHAFT CAMSHAFT CAMSHAFT 4 4 a J b LIS CAMSHAFT CAMSHAFT OIL JET OIL JET RIGHT JOURNAL RIGHT JOURNAL a 5 i 5 b 4b ae ddy didy didy aonni ONE WAY CONNECTING ROD LEFT CAM FACE CAM FACE CLUTCH BIG END BEARING CRANKSHAFT amp TAPPET amp TAPPET b n p n 4 bb as rt b LIS bby ddy diky LLIS CYLINDER WALL STARTER amp PISTON GEAR BEARING E3 amp ad a ddy d b 7 21 NINES COOLING AND LUBRICATION SYSTEM Engine Lubrication System
57. Radiator Removal e Remove the front fender e Remove the left foot board e Drain engine coolant by removing the drain plug e Remove the right headlight M 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 y 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 _ _9INLI Radiator Inspection and Cleaning PAAR AYALA AE ee cor ee ee ae PPA j AF b E A o F foi if 1 ij Y a i s e Road dirt or trash stuck to the fins must be removed ENESA E EATA iT a Fa r w Pi 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 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 Pour engine coolant e Bleed air from the co
58. 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 5 430 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 ring which is visualized seat width must fit the specification Valve Seat Width 0 9 mm 1 1 mm Valve Lapper Set 6 27 ODINLI lt 7 ENGINE Initial Seat Cut e Using the 45 cutter descale and clean up the seat with one or two turns e Inspection the seat see Valve Seat Width If the seat is pitted or burned additional seat conditioning with the 45 cutter is required NOTE Cut only the minimum amount necessary from the seat to prevent the possibility of the tappet shim replacement e If the contact area is too high on the v
59. a tightening 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 a 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 oe s4 NLI NN 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 tu
60. 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 8 29 ODINLI C DINEI ELECTRICAL SYSTEM Fuses Main Fuse Removal e Remove the seat see Frame chapter e Remove the fuse case cap A and take out the fuse B Fuse Inspection e Inspect the fuse element If it is blown out replace the 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
61. connectors one by one so as to locate the position of trouble 8 13 DINLI lt _7 OINLI lt 7 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 15V e Turn off the ignition switch to stop the engine and remove the seat e Remove the battery stay 1 e Measure the DC voltage between the 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 d
62. damages are found replace it with a new one 9 19 DINLI PERIODIC MAINTENANCE Installation e Install the drive belt in the reverse order of removal Pay attention to the following points o 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 driven face should be thoroughly cleaned Movable Driven Face Spring Compressor o 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 Pull the center area of upper and lower belt lines to be close to each other to prevent the belt from expanding e Tighten the movable driven face bolt to the specified torque with the special tool Tightening Torque 110 N m 11 0 kgf m 79 5 lb ft 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 PERIODIC MAINTENANCE ___ PIINLI CI 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 lb ft Turn the fixed drive face until the belt is seated in and both the dri
63. first and then the negative cable Battery Charging NIN ANNE 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 No 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 on battery package for preparation and filling with battery electrolyte 2 Never interfere with the sealed state of the battery 3 Check the charging conditions with a voltmeter Normal charging voltage should be 12 8V 4 This battery may be installed only if replaces a similar sealed ___ at0 40 C 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 eyes or clothing 100 75 50 25 Os Ba M Battety charged condition Normal Charge 1 8A 5 10 hrs Fast Charge 18A 0 5 hrs 8 9 DINEI ELECTRICAL SYSTEM New Battery Use of conventional lead acid batteries is not recommended Battery type GS G
64. 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 N 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 e Tighten the bleed valve to the specified torque Tightening Torque 5 5 N m 0 55 kg m 4 0 lb ft e Apply the brake lever forcefully for a few second and check for fluid leakage around the fittings 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 e Bleed the air whenever brake parts are replaced or reassembled e Remove the reservoir cap and fill the reservoir with new brake fluid e 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
65. follows It also precedes the text of a NOTE 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 FOREWORD INDEX D IN LI CHAPTER INDEX CHAPTER 1 GENERAL INFORMATION CHAPTER 2 WHEELS TIRES CHAPTER 3 BRAKE CHAPTER 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 oe s4 NLI nN GENERAL INFORMATION Table of Contents Betore Servicing 1 2 General Precautions 1 5 DINLI DL 702 1 6 Model Identifications 1 7 Fuel Oil and Engine Coolant Recommendation 1 8 Fuel For USA and Canada 1 8 Fuel For Other Countries 1 8 Engine Oil For USA
66. in the reverse order of removal Pay attention to the following points o Tighten the brake disc mounting bolts A to the specified torque oe Tightening Torque 25 N m 2 5 kgf m 18 0 Ib ft a t o Apply GREASE to the hub spline j 4 o Tighten the axle nut to the specified torque O Tightening Torque 110 N m 11 0 kgf m 79 5 1b ft y a ee o Insert the new cotter pin and bent it over the nut Rear Hub Removal Remove the wheel See wheel Removal e Remove the cotter pin 1 CAUTION Replace the removed cotter pin with a new one e Remove the axle nut 2 with washer and pull off the rear hub Rear Hub Inspection e Inspect the rear hub bolts A for wear or damage If any damages are found replace the damaged bolts with new ones 2 10 WHEELS TIRES oe 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 Ib ft o Insert the new cotter pin and bent it over the nut 2 11 srar _ DINLI _ BRAKE Table of Contents Construction 3 2 Brake Fluid
67. 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 lb ft e Pour the specified engine coolant into the reservoir tank 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 PERIODIC MAINTENANCE ___ 2QIINLI CCI e Install the 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 Inspect the radiator for damage and engine coolant leakage If any damages are found replace it with a new one
68. lower bolt nut e Remove the rear shock absorber gt e Remove the rear knuckle mounting bolts nuts and remove the rear knuckle 4 12 SUSPENSION STEERING DRIVE SHAFT DINLI CI 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 Inspection and Disassembly Rear Shock Absorber e Inspect the shock absorber for oil leakage or damage If any damages are found replace the rear shock absorber with a new one Bushing e Inspect the rubber bushing shock absorber suspension arm for wear or other damage If any damages are found replace the bushing with a new 4 13 DINLI 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 e Remove the rear knuckle oil seal with a suitable bar CAUTION Replace the removed oil seal with a new one e Hub Bearing e Inspect the inner
69. m 7 0 lb ft e Install the 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 TAM WARNING Be sure to adjust the spring pre load on the both shock absorbers equally 4 10 SUSPENSION STEERING DRIVE SHAFT 299INELI CI Rear Suspension Construction NYS WA fe UK N 5 Rear shock absorber 14 Hex washer face bolt 23 C type circlip 6 Double row angular bearing 15 Hex washerfacebok 2a Gens vave e one a7 Hex waserfacebot 26 Spacers of Olsa sf 8 Insert lock nut 7pcs 4 11 INES suspENSION STEERING DRIVE SHAFT Removal Remove the rear wheel e Remove the exhaust pipe e Remove the driver shaft protector e Remove the cotter pin and rear hub nut e Remove the rear wheel hub CAUTION Replace the removed cotter pin with a new one e Remove the rear stabilizer joint
70. measure the valve head radial runout e If it measures more than the limit replace the valve Service Limit Of Valve head radial runout IN amp EX 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 ey a e Measure the thickness and if it measures less than the limit replace the valve Service Limit of Valve head thickness IN amp EX Vernier Calipers 6 26 ENGINE Es LI Valve stem deflection e Lift the valve about 8 mm from the valve seat Measure the valve F stem deflection in two directions perpendicular to each other by positioning the dial gauge whether the valve or the guide should be replaces with a new one l KON yo Service Limit of Valve stem deflection 2 ose off a H IN amp EX j D Dial Gauge 1 100 mm e If the deflection measured exceeds the limit then determine ff n x yE ICED A lt p Magnetic Stand Valve stem wear e If the valve stem is worn down to the limit as measured with a 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
71. 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 stem because they will deteriorate the rubber e Mount the tire on the new rim see Tire Installation e Inflate the tire to the specified pressure 2 5 ODINLI I DINEI WHEELS TIRES Tire Removal e Remove the wheel e Unscrew the valve core A to deflate the tire e Dismount the bead from the rim completely as shown Tire Bead Breaker N WARNING When dismounting the bead from the rim it is necessary to deflate the tire to prevent burst e Separate the tire from the rim using a tire bead breaker and rim protector CAUTION When using the tire bead breaker do not scratch or hit the sealing portion hump of the wheel or it may cause air leakage Installation e Inspect the rim see Wheel Rim Inspection e Replace the air valve with a new one CAUTION Replace the air valve whenever the tire is replaced Do not reuse the air valve e Check the tire for wear and damage see Tire Inspection 2 6 WHEELS TIRES e Lubricate the tire beads and rim flanges with a soap and water N WARNING Do not use the lubricant other than a water and soap solution or water to lubricate the tire beads and rim because it may cause tire separation Check t
72. 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 the CVT cover NOTE Be careful about the size of the bolts M6 amp M8 it is necessary to put them in the original position 6 55 DINLS ENGINE e Install the pin e Install the gear position indicator 1 e Install the fixed drive face Degrease the fixed drive face Use nonflammable cleaning solvent to wipe off oily or greasy matter and make its surfaces completely 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 driven 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 Pull the center area of upper and lower belt lines to be close to each other to prevent the belt from expanding 6 56 e Tighten the movable driven face bolt to the specified torque with the special tool Tightening Torque 110 N m 11 0 kgf m 79 5 lb ft e Install the movable drive face assembly
73. protector e Remove the cotter pins and tie rod end nuts CAUTION Remove the removed cotter pins with new ones e Remove the front brake disc covers e Remove the cotter pins and knuckle end nuts CAUTION Remove the removed cotter pins with new ones e Remove the steering knuckle 4 3 ODINLI C INES suspENSION 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 e Remove the lower A arm washer face bolts nuts Remove the lower A arms 2 e Remove the shock absorber upper mounting bolts nuts e Remove the shock absorbers 4 4 SUSPENSION STEERING DRIVE SHAFT ____299INLI CI 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 AT Knuckle End e Inspect the knuckle end boots for wear or damage If any damages are found replace it with a new one Remove the snap ring 1 e Remove the knuckle ends with the special tools Bearing Installer Set Front Fork Installer Hammer A arm e Inspect the A arm for wear or damage If any damage are found replace it with a new one Drive Shaft Protector e Inspect the driver shaft protector for wear or damage If any damages are found replace it with a new one 4 5 DINES suspENSION STEERING DRIVE SHAFT Bra
74. race play of the hub bearing by hand while it is in the rear knuckle e Rotate the inner race by hand to inspect for abnormal noise and smooth rotation If there is anything unusual replace the bearing with a new one Remove the hub bearing circlip 1 4 14 SUSPENSION STEERING DRIVE SHAFT 299INELI CI e Remove the hub bearing from the direction that arrow marks Reassembly and Installation e Reassemble and install the rear suspension in the reverse order of removal and disassembly Pay attention to the following points 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 e Install the rear knuckle oil seal with the special tool 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 gt i 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 a
75. reservoir side and bleed the air off at the reservoir 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 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 e Repeat this operation until no bubbles comes out the brake fluid reservoir e 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 e Tighten the bleed valve to the specified torque Tightening Torque 5 5 N m 0 55 kg m 4 0 lb ft e Apply the brake lever forcefully for a few seconds and check for fluid leakage around the fittings 3 5 BRAKE ODINLI C EE DINLI 2p 4x aa Master Cylinder Removal e Place a rag underneath the brake hose union bolt on the master cylinder to catch any split fluid Remove the brake hose union bolt and disconnect the brake hose B e Remove the master cylinder by taking off its clamp bolts A CAUTION Brake
76. 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 srar _ DINLI Oooo Foot Brake Brake Pedal Inspection Brake Pedal Position e Check that the brake pedal A is in the correct position as shown Pedal Position B Standard 72 80 mm above footrest xX If it is correct adjust the brake pedal position Brake Pedal Free Play e Check the brake pedal free play A o Depress the brake pedal lightly by hand until the brake is applied If the free play is incorrect adjust it Pedal Free Play Brake Pedal Position Adjustment e Remove the brake pedal see Brake Pedal Removal e Loosen the locknut A and turn the nut B until pedal is correctly positioned e Tighten the locknut A 3 19 DINLI 2p 4x Brake Pedal Removal Remove the brake pedal by removing the master cylinder locknut A circlip B and pin C e Pulling 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 cyli
77. 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 fluids batteries and tires
78. 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 ml 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 lb 9 14 PERIODIC MAINTENANCE ___ 2IINLI CI Rear Driver Gear Oil 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 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 filler plug 2 to the specified torque Rear Driver Gear Oil Replacement e Place the vehicle on level ground e 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 re
79. specified fuse rating for that circuit Installation of a fuse with a higher rating may cause damage to wiring and components 8 30 ELECTRICAL SYSTEM oe OINLI EEE Switches e Measure each switch for continuity using a multi circuit tester If any abnormality is found replace the respective switch assemblies with new ones Multi Circuit Tester Set Indicator Swatch O Wire Color B Black W B White with Black tracer Br Brown W Bu White with Blue tracer Bu Blue W R White with Red tracer G Green Y B Yellow with Black tracer Gr Gray Y R Yellow with Red tracer 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 8 31 DINEI ELECTRICAL SYSTEM Wiring Diagram LAMP LAM SOCKET railed Sine RELAY Cal Coy HAZARD TAMP SENSOR FLAS TAr l l TT E H it H e et 2 a afo at o eee eS d f iiil 4 Chit pen HIT Y A PEE AS WE e e i i T T EE e A E iaaii ii ee oes i TAILLIGHTR TAILLIGHTL FUEL LEVEL LICENC 2WD amp 4WD MHIR 8 32 ELECTRICAL SYSTEM oe DINLI Wiring Diagram eae es TE IR sti LIGHTR DOR OoOo A t2 10W e TURN LIGHT L 12v 10W E LAMP 8 33 DINEI ELECTRICAL SYSTEM Fag is igang ine i i ind IE a H pirti ei bait eme i ie
80. 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 C Clean R Replace L Lubricate l Inspect Verify Clean Adjust Lubricate Replace if necessary A E a E a e A A A T T e a A a a a SWITCHES engine stop start tether ignition Regular Maintenance Internal Replace every four years Replace every 6000 km Replace every two years Replace every year Replace every two years BRAKE SYSTEM cables discs pads hosed etc NUTS BOLTS AND FASTENERS WHEELS TIRES pressure condition wear STEERING ASSEMBLY fasteners operation GENERAL LUBRICATION A DINLI dealer service suggested servicing owners should have the proper tools service data and be mechanically qualified Replace every 10000 km O Operational safety involved The service should be performed by a DINLI dealer Service more frequently if operation in dusty sandy or snowy area or conditions 9 2 PERIODIC MAINTENANCE ___ PIINLI CI Maintenance and Tune Up Procedures e this section describes the servicing procedures for the items mentioned in the 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 w
81. 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 56C 69 F Anti freeze density Freezing point 20 2 4007 60 55 67 F CAUTION o Use a high quality ethylene glycol base anti freeze mixed with distilled water Do not mix an alcohol base anti freeze and different brands of anti freeze A O o Do not use a radiator anti leak additive 32 0 e 66 7 Engine coolant including reserve tank capacity For instance 94 70 40 40 Freezing point 3 20 40 60 80 100 Density 5 TAN WARNING o You can be injured by scalding fluid or steam if you open the Engine coolant density freezing point curve radiator cap when the engine is hot After the engine cools wrap a thick cloth around cap and carefully remove the cap CF C 302 150 by turning it a quarter turn to allow pressure to escape and then turn the cap all the way off 284 140 o The engine must be cool before servicing the cooling system o Coolant is harmful amp 266 130 If it comes in contact with skin or eyes flush with water 248 120 EE Gauge pressure If sw
82. 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 the axle shaft and wheel spindle as shown o Wash the disassembled parts except for the boots After washing completely dry the parts using compressed air o Clean the boots with a cloth CAUTION o Wash all parts before installation clean the inside and outside of the boots with a cloth o Do not wash the boots in any commercially available degreaser such as gasoline or kerosene Washing in a degreaser causes deterioration of the boots 4 24 SUSPENSION STEERING DRIVE SHAFT DINLI CI 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 e Install the cage 1 on the shaft CAUTION Install the cage with the large diameter side facing the shaft end A Large Diameter B Small Diameter e Install the new snap ring e Apply GREASE to the entire surface of the cage and the inside of the outer race NOTE The tube of joint grease is included in the wheel side boot set or wheel side joint assembly of spare parts 4 25 INES suspENSION ST
83. 4 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 8 12 MOVABLE COIL TYPE 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 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 terminal 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 ON position when measuring current When checking for excessive current leakage remove the couplers and
84. 6 10 e Remove Timing screen cover e Remove cylinder head cover e Turn the crankshaft to bring the TDC line A on the starter clutch to the index mark B of the crankcase A At the above condition the piston is at TDC of compression stroke and also the engraved marks C on the camshafts are parallel with the mating surface of the cylinder head cover Remove the camshaft cover bolts 1 and camshaft cover NOON E Be sure to loosen the camshaft cover bolts evenly by shifting the r 4 pz e wrench diagonally S gt 2 eal O 6 11 DINLS ENGINE e Remove the pins and camshafts Be careful not to drop the pins into the crankcase NOTE Remove the cam chain tensioner bolt 1 e Remove the cam chain tensioner 2 e Remove the cam driver gear 1 by removing the shaft cover 2 shaft 3 and the spacer 4 NOTE Be careful not to drop the spacer 4 into the crankcase e Remove the cylinder head bolts M6 1 NOJS Loosen the cylinder nuts e Remove the cylinder head bolts M10 2 and washers NOTE When loosening the cylinder head bolts loosen each bolt little by little diagonally e Remove the cylinder head 6 12
85. 9 DINLI C OINLI lt 7 APPENDIX Special Tools D001 D002 Rotor Holding Tool Compression Gauge Set Oil Filter Wrench Vacuum Pump Gauge D005_01 D005_02 D006 i 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 ea LI a Tightening Torque Engine Cam chain tensioner adjuster bolt M6 10 1 0 7 0 Crankcase bolt M8 26 Clutch shoe nut Morean e as a Morasano O o o e o l Exhaust pipe nut Maeron a o a Engineoildminpg l o a l poenom e f a f Front arive ferenta gear cse mounting 0 O so OO 360 r S S E S E Crank balancer drive gear bolt 36 0 10 21 OINLI lt 7 APPENDIX Chassis Steering knuckle end nut upper and lower Tie rod end nut Tie rod locknut 10 22 APPENDIX Lae LI EEE Cooling System Thermostat cover bolt 10 23 OINLI lt 7 APPENDIX Tightening Torque Chart e For other nuts and bolts not listed in the preceding page refer to this chart Bolt Diameter Conventional or 4 marked bolt on ess os 8 13 1 3 9 5 23 23 ay ATE iI mrmr an TA m T of A i wK a Conventional bolt 4 marked bolt 7 marked bolt 10 24 APPENDIX ae LI Service Data Valve Valve Guide Unit mm wp w o EX 33 0
86. ANCE Clutch Lock Up Inspection e Perform this inspection to determine if the clutch is engaging fully and not 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 e 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 ae LI _ APPENDIX Table of Contents Troubleshooting Guide 2 EN QIN C nn nn nnn nn nnn nnn nnn nnn nnn nnn nnn nnn nnn nnn nnn nn nnn nn nnmn nn 10 2 Radiator Cooling System 10 9 ransmission 10 10 Drive rain 10 11 ChassiS
87. Apply THREAD LOCK to the oil pump mounting bolts e Install the pin 1 NOJN Be careful not to drop the washer and pin into the crankcase e Install the oil pump drive gear 1 and oil pump driven gear with chain 2 NOTE Both gears have to be installed at the same time 6 59 Outside OINLI lt 7 ENGINE e Install the snap ring and washer NOTE Be careful not to drop the snap ring into the crankcase e Apply THREAD LOCK to the balancer driven gear bolts e Hold the crank balancer drive gear with the special tool and tighten the crank balancer shaft driven gear bolts to the specified torque Tightening Torque 50 N m 5 0 kgf m 36 0 lb ft e Install the cam chain guide e Tighten the cam chain guide bolt to the specified torque Tightening Torque 23 N m 2 3 kgf m 16 5 lb ft e Install the starter driven gear 1 e Install the key 2 o Degrease the tapered portion of the generator rotor assembly and also the crankshaft Use nonflammable cleaning solvent to wipe off the 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 e Install the generator rotor assembly CAUTION Make sure that the one way clutch on the crankshaft rotor is fitted into the generator rotor properl
88. 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 high e CDI unit trouble 10 4 APPENDIX NN Poor Running or No Power at High Speed 1 Firing incorrect e Spark plug dirty broken or maladjusted e Spark plug cap or Spark plugs cable trouble e Spark plug cap shorted or not in good contact e Spark plug incorrect e Pickup coil trouble e 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 Piston 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 DIN
89. DINLI 3 11 Brake Pad Removal e Remove the wheels see Wheels Tires chapter Front Brake e 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 the anti rattle spring Rear Brake e Remove the rear caliper See Caliper Removal e Push the plate A remove the pads B Remove the anti rattle spring Parking Brake e Remove the rear caliper See Caliper Removal e Remove the parking brake caliper See Caliper Removal e Remove the pins A that attach the caliper and the brake pads then remove the pads B 3 12 srar _ DINLI Installation e Push the caliper piston in by hand as far as it will go e Be 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 specified 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 ch
90. EERING DRIVE SHAFT 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 boot 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 Installation e Install the rear propeller shaft in the reverse order of removal 4 26 SUSPENSION STEERING DRIVE SHAFT DINLI CI Steering Construction Pa Seng Teroa osy e s Bashtening ia Coterpin pe Steering shaft bracket 2pcs 9 Oilseal 2pc 5 Spring washer 4pcs Pin Washer apes 5 Seal cover 2pcs 11 Castle nut 17 Washer S spacer pen Cat ut GP 4 27 INES suspENSION STEERING DRIVE SHAFT Removal and Disassembly e Remove the front fender e Remove the front wheels tires 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 A e Remove the handlebar e Remove the cotter pins and tie rod end nuts
91. FOREWORD INDEX DINLI nN DINLI lt 7 SERVICE MANUAL DL700 HY700 A700 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 CCOPYRIGHT DINLI METAL INDUSTRIAL CO LTD 2008 0 1 FOREWORD INDEX D IN LI s 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
92. IL SOLUTION to the camshaft journal S olders NOTE l Before installing the camshaft check that the tappets are installed correctly e Tighten the camshaft journal holder bolts to the specified torque Tightening Torque 10 N m 1 0 kgf m 7 0 lb ft e Measure the valve clearance again to prevent incorrect value e Align the engraved lines A on the camshaft so it is parallel with the mating surface of the cylinder head cover e Check the valve clearance e Pour engine oil in each oil pocket in the cylinder head 6 68 e Install the new gasket 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 l e Tighten the head cover bolts to the specified two step torque sequentially Tightening Torque Initial 10 N m 1 0 kgf m 7 0 lb ft Final 14 N m 1 4 kgf m 10 0 Ib ft NOTE Apply engine oil to the both side of head cover washer before installing the 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 lb 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 NOHO Use a new O ring to prevent engine coolant leakage e Apply engine coolant to the O
93. LI C 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 fully 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 Piston noise e Cylinder piston clearance excessive
94. Pa 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 WHEELS TIRES oe OINLI Hub Front Hub Removal e Remove the wheel see Wheel Removal Remove the cotter pin CAUTION Replace the removed cotter pin with a new one e Remove the caliper by taking off the mounting bolts A and let the 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 Front Hub Inspection e Inspect the front hub bolts A for wear or damage If any damages are found replace the damaged bolts with new ones 2 9 B gt DINLI WHEELS TIRES Front Hub Installation e Install the front hub
95. Plug cap Terminal CDI output voltage 200 250 DCV Alternator coil resistance 0 1 1 00 Alternator no load voltage 65 V AC and more at 5000 rpm When engine is cold Type designation GS GTX20L BS Battery Capacity 12 V 20Ah Headlight 10A HI amp LO Fuse size Speedometer light Engine coolant temperature LED indicator light Differential lock indicator light LCD 10 29 DINLI APPENDIX Brake Wheel Unit mm C roepane ew a O as O C Fontasse OOOO O T C raean OOOO O T ate discranout ont Rea OOOO O T er Brake lever play Brake fluid type DOT 4 pe Steering angle 30 Right amp Left pe Turning radius Tire Unit mm Cold inflation tire pressure 35 kPa 0 35 kgf cm 5 0 psi Solo riding 35 kPa 0 35 kgf cm 5 0 psi pe Tire size Cia a a Suspension P Unit mm Front shock absorber 5 positions spring adjustor Rear shock absorber 5 positions spring adjustor 10 30 APPENDIX ea LI es Fuel Oil 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 Engine
96. 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 2p 4x 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 Z N WARNING Change the fluid in the brake line completely if the fluid must be refilled but the type and brand of the fluid that is already in 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 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 the brake lever A e Check the fluid level in the reservoir often replenishing it as necessary o If the
97. TX20L 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 Turn the charger off or unplug it then disconnect it from the battery 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 sudde
98. aking poor contact e Load excessive e g bulb of excessive wattage e Ignition switch trouble e Regulator rectifier trouble e g shorted circuited or punctured regulator rectifier e Alternator 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 nN Battery Runs Down Quickly e Trouble in charging system e Cell plates have lost much of their active material as a 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 1
99. al o Set the tester to the x 20 kQ 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 Q Ignition coil resistance Primary 0 17 0 23Q Terminal Ground Secondary 5 0 7 6kQ Spark plug cap terminal 8 18 ELECTRICAL SYSTEM 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 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 indication Resistance Q Starter relay resistance 3 5Q 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 v
100. allowed accidentally induce vomiting and call physician 230 110 immediately Keep it away from children 10 20 30 40 50 60 Density Engine coolant density boiling point curve 7 2 COOLING AND LUBRICATION SYSTEM _ __9NLI CI Cooling Circuit RESERVOIR ENGINE COOLANT TANK THERMOSTAT CYLINDER HEAD TEMPERATURE i SWITCH CYLINDER BYPASS COOLING FAN THERMO SWITCH o RADIATOR 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 TAN WARNING Do not remove the radiator cap when the engine is hot e Give a pressure of about 180kpa 1 8kgf cm 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 or part 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 NINES COOLING AND LUBRICATION SYSTEM Radiator and Hoses
101. alve 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 or too low use the 75 cutter to narrow and raise the contact area e If the contact area is too low or too narrow use the 45 cutter to raise and widen the contact area After cutting the 30 and 75 angles it is possible that the valve seat 45 is less than the correct width 6 28 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 Do not use lapping compound after the final cut is made The finished valve seat should have a velvety smooth finish but not a highly polished or shiny finish This will provide a soft surface for the final seating of the valve which will occur during the first few seconds of engine operation e Clean and assemble the head and valve components Use the vacuum pump gauge to cover intake and exhaust ports and check for leaks If any leaks occur inspect the valve seat and face for burrs or other things that could prevent the valve from sealing NOTE After servicing the valve seats be sure to check the valve clearance after the cylinder head has been reinstalled
102. ank See Body chapter e Connect the tachometer onto the spark plug high voltage cable e Remove the cooling duct 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 DINLI PERIODIC MAINTENANCE EE a 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 eradually 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 DINLI PERIODIC MAINTEN
103. attery lead wire first e Remove front and rear rack and fender e Remove the water hoses 6 2 e Remove Oil pressure gauge coupler 1 and Coolant Temperature sensor coupler 2 e Remove the air cleaner box e Remove the carburetor e Remove fuel feeding hoses 6 3 ODINLI lt J 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 Remove PCV Positive Crankcase Ventilation tube 4 e Remove Starter Motor assembly coupler 1 and Gear shift indicator coupler 2 e Remove Regulator Rectifier coupler 1 e Remove the CVT ducts Breather and outlet e Remove the Intake duct 6 4 LIA we e Remove the high
104. cation of their chapters Each chapter in turn has its own 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 ONL FOREWORDANDEX GEE 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
105. clamp 1 5 N m 0 15 kgf m 1 0 lb ft 7 7 DINLI COOLING AND LUBRICATION SYSTEM C mmr Cooling Fan 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 volts to the motor 3 With the motor with electric motor fan running at full speed the ammeter 4 should be indicating not more than 5 3 amperes e If the fan motor does not turn replace the cooling fan assembly with a new one NOTE When making above test it is not necessary to remove the cooling fan Removal e Remove the radiator e Remove the cooling fan mounting bolts and collars Remounting e Install the cooling fan in the reverse order of removal e Tighten the cooling fan mounting bolts to the specified torque Tightening Torque 5 N m 0 5 kgf m 3 60 lb ft 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 te
106. contacting or operating e Starter button not contacting e Wiring open or shorted e gnition switch trouble 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 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 NN 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 Pilot 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 cap 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
107. ction 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 lb ft e Make sure the cable harness and brake hose are routing properly r t Forward 4 33 INES suspENSION STEERING DRIVE SHAFT Toe Out Adjustment e Adjust the toe out as follows e Place the vehicle on level ground and set the handlebars straight e Make sure all the tires are inflated to the standard pressure 1 2 2 1 e Place 75 kg 165 lbs weight on the seat 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 quem i 1 w e Right angie B A Tie out 90 deg B A Tie ou opa the right or left until the toe out is within the specified range La i Toe out e Temporarily tighten the four locknuts e Check that the distance C and D are equal as sho
108. cycle motorcycle engine oil SAE 10W 40 grade API SF or higher Unleaded Octane 95 or higher 45 1 12 GENERAL INFORMATION oe v4 NLI s CHASSIS Frame Steel Ground clearance unloaded Water crossing maximum depth Loading limit Incl rider cargo etc 2 speed forward with reverse Gearshift pattern Front suspension Independent double A arm coil spring oil damped Front brake Dual hydraulic disc 1 13 UINELS GENERAL INFORMATION AT 25 x 8 12 tubeless AT 25 x 10 12 tubeless 1 14 WHEELS TIRES oo OINLI Oo o o WHEELS TIRES Table of Contents Specifications 2 2 Construction 2 3 Wheel Rim 2 4 Removal 2 4 Installation 2 4 nspection 2 5 Replacement 2 5 ire
109. d damage on dig clutch portion gears and spline portions e If any wear and damage had found replace with new one Gearshift Fork To Groove Clearance e Measure the gear fork to groove clearance by using the thickness gauge e If the clearance exceeds the limits replace the fork or its gear or both Shift for to groove clearance Standard 0 10 0 27 mm 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 Width of Shift Fork groove 5 60 5 67 mm Standard 5 60 5 67 mm Vernier Calipers Thickness of Shift Fork e Measure the thickness of Shift Fork with micrometer Thickness of Shift Fork 5 40 5 50 mm Standard 5 40 5 50 mm Vernier Calipers 6 50 ENGINE LE Generator Cover ODINLI C Disassembly e Remove the generator stator assy Fs j DW e Remove the bearings with the special tool NOTE If there is no abnormal noise than the bearing removal is not necessary e Remove the oil seals O
110. damages are found replace the bushing with a new one Stabilizer Link e Inspect the stabilizer joint for wear or damage If any damages are found replace the stabilizer joint with a new one 4 18 SUSPENSION STEERING DRIVE SHAFT 299INELI CI 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 lb ft 4 19 INES suspENSION STEERING DRIVE SHAFT Front Propeller Shaft Removal and Disassembly e 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 NOTE If it is difficult to remove the front drive shaft by hand use the special tools Sliding Hammer e Remove the boot bands of the differential side joint double offset joint CAUTION Replace the removed boot bands with new ones e Slide the boot toward the center of the front propeller shaft and remove the stopper ring from the outer race CAUTION Replace the removed stopper ring with a new one e Separate the outer race from the front drive shaft e Wipe off any grease and remove the snap ring
111. duction gear and gearshift shaft e Remove the gearshift shaft 1 Ee 5 e Remove the gearshift cam driven gear 2 by removing its bolts 7 eS e Remove the generator rotor bolt Rotor Mounting Socket Wrench e Install the special tool to the crankshaft end D006 Rotor Remover Remove the generator rotor with the special tool 6 15 ODINLI lt J ENGINE e Remove the key 2 e Remove the starter driven gear 3 3 e Remove the cam chain guide bolt 1 cam chain guide 2 e Remove the cam chain 3 e Remove the balancer shaft driven gear bolts with the special tool Stopper Plate e Remove the oil pump driven gear NORTON The oil pump drive gear and the oil pump driven gear must removed at the same time e Remove the snap ring 1 iN 4 4 NOTE j Be careful not to drop the snap ring 1 into the crankcase 1 e Remove the oil pump drive chain 2 and oil pump driven gear 3 3 gt 6 16 Remove the oil pump bolts and the oil pump e Remove the balancer shaft driven gears 1 e Remove
112. e aluminum radiator Anti Freeze Engine Coolant e 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 e 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 e 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 UINELS 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 o Keep to these break in engine speed limits Break in engine speeds Initial 500 km Less than 1 2 throttle o Upon reachin
113. e the figure printed surface faces Lo z the tappet mS OS NIRS 6 30 Valve Clearance Adjustment s e Measure the clearance between the valve and the camshaft e If the value is not correct use the tappets 1 to adjust the valve clearance Valve Clearance IN 0 1 0 2 mm 0 2 0 3 mm Thickness Gauge Intake Pipe e Remove the intake pipe 1 e Apply GREASE to the O ring CAUTION Use the new O ring to prevent air from sucking through joint 6 31 DINLS ENGINE e Apply THREAD LOCK to the intake pipe bolts Water Bypass Union and Oil Pressure Gauge e Remove the oil pressure gauge 1 and water bypass union 2 e Apply THREAD LOCK to the oil pressure gauge e Apply THREAD LOCK to the thread part of water bypass union and tighten it to the specified torque Tightening Torque 14 N m 1 4 kgf m 10 0 lb ft Thermostat Remove the thermostat cover 1 e Remove the thermostat 1 Cam Chain Tensioner Inspecti
114. each roller and their sliding surface for wear or damage If Front Side any damages are found replace the rollers as a set eo NOTE ee xe e se e wo U Oil seal e Inspect the lip of the oil seal for wear or damage If any damages are found replace the oil seal with a new one i 6 41 DINLS ENGINE e Remove the oil seal Movable and fixed drive face e Inspect each drive faces for any abnormal conditions such as stepped wear or discoloration caused by burning If any damages 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 CAUTION o Wipe off any excess grease thoroughly o Take care not to apply grease to the contact surface of the drive belt e Position the eight rollers 1 on the movable drive face e Mount on the dampers 2 on the movable drive face plate e Position the movable drive face plate 3 on the movable drive face NOTE When installing the roller set make sure the roller s front side is faces to the right in clockwise direction 6 42
115. ear to the starter clutch e Check that the starter driven gear is in the opposite direction of the arrow mark A on the rotor while holding the 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 e Install the bearing with the special tool Oil Gallery Copper Plug e Inspect the copper plug and its O ring If any damages has found in the O ring replace it with a new one CAUTION If the O ring does not changed even if the damages are found the oil pressure will be too low to run and may turns on the oil pressure indicator 6 39 DINLS ENGINE Movable Drive Face and Driven Face oe Fined ae fa a w Oil seal 2pcs Movable drive plate FI Hexagonal flange bolt 14 Movable drive face ae Pin 4pcs 5 Hexagonal flange bolt 15 Roller set 8pcs 25 Ring 4pcs 6 Hexagonal flange bolt Slide piece 4pcs Movable driven sheet Hexagonal flange bolt Movable driven holder Es Dowel pin 2pcs 18 Movable drive spacer 28 Movable driven face Spacer 19 Gearshift shaft assy 29 Fixed driven face 6 40 ENGINE LI _ E Movable drive face disassembly Remove the spacer e Remove the movable drive face plate 1 and rollers 2 Roller and sliding surface e Inspect
116. eck 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 Service Limit 2mm 3 13 DINEI grace i 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 N WARNING These cleaning fluids are usually highly flammable and 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 e Remove the front hub by removing its cotter pin and axle nut e Remove the brake disc mounting bolts A e Remove the brake disc B 3 14 srar _ DINLI 1 A Rear Brake Disc Removal 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 A e Remove the rear gear box bolts and slide the gear box backward e Remove the disc Front Disc Installation
117. eel 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 or tightened e Damaged or worn front wheel hub bearings e Insufficiently lubricated 10 16 APPENDIX OoOo 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 Too 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 4WD 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 DINLI C OINLI lt 7 APPENDIX g Battery Battery Discharged e Battery faulty e g plates sulfated shorted through Sedimentation electrolyte level too low e Battery lead wires m
118. efective or the alternator output is insufficient for the loads check the alternator and th if regulator rectifier to determine which part is defective a aT NOTE When making this test be sure that the battery is in fully charged condition Multi Circuit Tester Set Tester knob indication Voltage DCV 8 14 ELECTRICAL SYSTEM oe OINLI 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 Q Alternator coil resistance 0 1 1 0Q 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 engine 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 8 15 DINEI ELECTRICAL SYSTEM Igniti
119. er Installation 5 10 Rear Fender Construction 5 11 Rear Fender Removal 5 12 Rear Fender Installation 5 14 Luggage Compartment 5 15 Luggage Compartment Removal Installation 5 15 Drainage Plug Inspection 5 16 Protector 5 17 Protector Removal Installation 5 17 5 1 DINLI zopy Seat Seat Removal e To remove seat A insert the key to the main switch e Push inward the key and turn it counter clockwise to seat open position B e Lift the seat front slightly pull it toward the front and remove the seat Seat Installation e Align the catch A at the back of the seat with the receiver B on the frame e Slip the seat hook C under seat into lock D e Push the front of the seat until you hear the click sound to lock the seat 5 2 sopr _ DINLI
120. er rotation of crankshaft nn ia n Hara 4 CAUTION a or If the punched mark A does not align the embossed line B ga ka ISB Aid 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 lb 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 lb ft e Install the new O ring NOHO Use the new O ring to prevent oil leakage e Install the cam chain tensioner cap bolt NOTE 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 lb 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 DINLS ENGINE e Align the line A on the starter clutch with the index mark B on the crankcase e Install the dowel pins Om g e The camshaft are identified by the engraved letters pS e Before replacing the camshafts on cylinder head apply D ia MOLYBDENUM OIL SOLUTION to their journals and cam faces PEP aa MOLYBDENUM O
121. erting 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 A j e E x 2 left amp right attach to the body decoration e Remove the lead wire of the accessory socket F 5 6 sopr _ 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 o B x5 e C x 6 left amp right attach to the front fender Front Fender Under Cover e Remove the indicator bulb A See Electrical System 5 7 DINLI zopy e Remove the under cover of front fender by unscrew the screws B x4 Front Fender Left amp Right e Remove the 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 o A x 6 left amp right attach to the footboard o B x 6 left amp right attach to the body decoration 5 8
122. et 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 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 E 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 8 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 B Odometer a Tripmeter Tripmeter e 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 km h e With each press of the SET button
123. f the cage and the inside of t the outer race on Wheel side Differential side NOTE The tube of joint grease is included in the wheel side boot set or 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 Locate the opening of the stopper ring 1 so that the opening is not lined up with a ball 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 DINLI SUSPENSITON STEERING DRIVE SHAFT lt lt Installation e Install the front propeller shaft in the reverse order of removal 4 23 DINLI SUSPENSION STEERING DRIVE SHAFT Rear Propeller Shaft Removal e Remove the rear wheel e Remove the rear suspension e Hold the in board joint 1 of the rear propeller shaft and tug the propeller shaft horizontally Inspection and Reassembly e Inspect the boots for wear or damage If any damages are found replace them with new ones e Inspect the stopper ring snap ring and boot bands for
124. fluid quickly ruins painted surface any spilled fluid should be completely washed away immediately Remove the brake lever 1 3 6 srar _ DINLI 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 a 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 ZN 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 2p 4x Caliper Front Caliper Removal e Remove the front wheel see Wheels Tires chapter e Loosen the banjo bolt A at the brake hose lower end and tighten it loosely e Unscrew the caliper mounting bolts B and detach the caliper C from the disc e Unscrew the banjo bolt and remove the brake hose D from the caliper
125. ft 3 and reverse idle gear assembly 4 e Install the spacer 5 e Install the gearshift forks 6 53 DINLI lt _7 DINLS 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 connecting 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 Tightening torque M6 10 N m 1 0 kgf m 7 0 lb ft M8 26 N m 2 6 kgf m 19 0 lb ft NOTE Tighten the crankcase bolts diagonally with the bigger size first 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 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 NOTE The clutch shoe nut has left hand threads Tightening Torque 150 N m 15 0 kgf m 108 5 lb ft e Apply MOLYBDENUM OIL to the inside of the
126. g 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 s4 NLI Information Labels ATSI Aibemtioni Fine m o i ee os ee ay i a ten E D Gha a ie Sr en ae oe a SS Always stop the vehicle completely before changing from forward to reverse or VICE versa Failure ta do so can be hazardous Do not consume alcohol drugs or cigarettes before or during operating the AT Maximum Wehicle Load 250kg 551 lbs Includes weight of operator cargo and accessories Mever load over 250kg or may cause loss of control Never operate this ATW if you are Under age 16 Ciperating this ATY if you are under the age af 1b Increases your chance or severe injury or death Read the Owners Manual before riding the vehicle Always wear protective clothing when driving your AT 1 11 IINELS GENERAL INFORMATION General Specification NOTE Specifications subject to change without notice ENGINE Model Engine Number of cylinders Bore and stroke Compression ratio Displacement Air cleaner Coolant system Cooling device operating temperature Starter system Carburetor Idle speed Lubrication system Lubricant Gasoline Note Permissible operating temperature 10 1 2 water anti freeze ethylene glycol containing corrosion inhibitors for aluminum engines and radiators 4
127. g free end gap with a thickness gauge Service Limit of Piston Ring free end gap Vernier Calipers 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 Top ring Second ring Thickness Gauge Piston pin and pin bore ID of Piston hole for Pin e Clean Piston hole for Pin e Measure ID in the up and down direction and the right angle direction with dial caliper gauge ID of Piston hole for Pin 23 030 mm Dial Gauge 1 1000 mm 1mm Small Bore Gauge 18 35 mm Piston Pin OD e Check for wear and damage on the sliding surface e Measure OD at total 3 positions both ends and middle position in the X and Y direction Piston Pin OD 22 980 mm Micrometer 0 25 mm 6 36 ENGINE aaa Lr Connecting Rod 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 Dial Calipers 10 34 mm Connecting rod deflection 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 Connecting Rod deflection Magnetic Stand Dial Gauge 1 100 mm V block Set 100 mm Side clearance at large end of Connecting Rod e Measure the side clea
128. gasket j CAUTION Use the new gasket to prevent oil leakage e Install the water pump cover 1 q e Install the oil filter with the special tool D003 Oil Filter 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 After placing the spacer fit the two side rails NOTE INCORRECT Side designations top and bottom are not applied to the spacer L S A A and side rails Those can be positioned each either way I E E INNON When installing the spacer be careful not to allow its two ends to STS AeA a overlap in the groove 3 Sor CORRECT 6 63 DINLS ENGINE e Install the second ring and first ring e Second ring has letter RN marked on the side and the first ring First Ring has the letter 1R marked on the side Be sure to bring the marked 4R side to the top when fitting it to the piston RN econd Ring 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 rigg SPS a aaia i Gl NOTE The spacer can be inserted into either first ring side or the second ring side elower sid NOP
129. he front hub can be installed by hand e Install the knuckle end boots to the upper and lower A arm with the special tool e Install the snap rings 1 4 8 SUSPENSION STEERING DRIVE SHAFT ___299INELI lt _ e Install the knuckles to the upper A arms by installing the 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 lb ft Lower 60 N m 6 0 kgf m 43 5 lb 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 lb 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 lb 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 lb ft e Install the new cotter pins to the nuts 4 9 INES suspENSION STEERING DRIVE SHAFT e Tighten the tie rod end nut to the specified torque Tightening Torque 29 N m 2 9 kgf m 21 0 lb ft e Install the new cotter pins to the nuts e Apply THREAD LOCK to the front brake disk cover mounting bolts and then tighten them securely Tightening Torque 10 N m 1 0 kgf
130. he 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 NOTE 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 B If 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 DINLI lt ODINLI G WHEELS TIRES e Check the tire pressure using an air pressure gauge Tire Air Pressure when cold Front 35 kPa 5 0 psi Rear 35 k
131. hten the cylinder head bolts M6 2 to the specified torque Tightening Torque 11 N m 1 1 kgf m 8 0 lb ft 6 65 DINLS ENGINE Apply engine oil to the both side of washer and thread portion of the bolts before installing the cylinder head bolts e Align the line A on the generator rotor with the index mark B on the crankcase A e Install the cam drive idle gear sprocket with cam drive chain onto the cylinder head e Align the punched mark on the cam drive idle gear sprocket with the embossed line on the cylinder head e Install the cam drive idle gear sprocket shaft 1 copper washer 2 and shim 3 CAUTION When checking the positions remove the cam chain slack at the cam chain guide side by holding the cam drive idle gear sprocket by hand 6 66 ENGINE LI Due to special valve train mechanism aligning of the three Roat of tooth elements the punched mark embossed line and the gear tooth i vor a ee root on the cam drive idle gear sprocket can occur once every pi at Fal Tt Hating AN ey pain oth
132. il pedal is correctly positioned e Tighten the nut A e Make sure to tighten the nut A securely 9 22 PERIODIC MAINTENANCE e Check the brake pedal free play A o Depress the brake pedal lightly by hand until the brake is applied If the free play is incorrect adjust it Pedal Free Play Brake Lever e After adjusting the brake pedal check the brake lever play 1 The brake lever play 1 as measured at the lever holder should be between 6 8 mm when the lever is lightly pulled in towards the erip If adjustment is necessary slacken the cable by loosening the locknut 2 and screwing the adjusters 3 on the brake lever holder all the way in Brake Lever Play 1 Standard 6 8mm e after adjusting the play check that the wheels roll freely without 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 ODINLI lt DINLI 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 TAN WARNING o The brake system of this vehicle is filled with a g
133. ill 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 conducting 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 ignit
134. ing the existing tappet shim by a thicker or thinner one e Remove the 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 the shim as illustrated Select a 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 NOTE 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 s
135. ion e Make the mark C on the Timing chain driver gear to the highest position Meanwhile the mark on the opposite side the Timing C chain driver gear is also aligned with the mark position D e Assemble the camshafts by aligning the engraved marks E with the mating surface of the cylinder head cover 6 34 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 101 880 mm Micrometer 100 125 mm Piston Rings Clearance between Piston Ring and groove e Measure the clearance between Piston Ring and groove by holding the Ring upwards in the groove with thickness gauge e If any of the clearances exceeds the limit replace both piston and piston rings Service Limit of clearance 0 180 mm 0 150 mm Piton ring groove width 1 21 1 23 mm Standard 1 21 1 23 mm Oil 2 01 2 03 mm Piton ring thickness 1 17 1 19 mm Standard 1 17 1 19 mm Thickness Gauge Micrometer 0 25 mm 6 35 ODINLI lt J ENGINE Piston Ring Free End Gap and Piston Ring End Gap e Measure the Piston Rin
136. ion 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 8 6 ELECTRICAL SYSTEM 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 temperature o Be careful not to drop the part with a semi conductor built in such as a CDI unit o Properly use the 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
137. its bolts to the specified torque Tightening Torque 22 N m 2 2 kgf m 15 9 lb ft 8 21 DINLI lt _7 DINEI 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 Mode Button 2 Coolant Temperature Indicator 9 4WD Differential Lock Indicator Pa eseon pa eoe High Beam Indicator Position Light 8 22 ELECTRICAL SYSTEM oe OINLI Functions and Operating Procedure Functions 1 Engine Oil 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 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 Hazard Light Indicator This indicator lights up and blinks when the 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 Indicator Light When the indicator switch is operated this indicator light will b
138. k nut 24 5 9 30 PERIODIC MAINTENANCE _ _ QIINLI CI eat Sr A DINLI PERIODIC MAINTENANCE General Lubrication Lubricate every 1000 km 50 hours 3months e Proper lubrication is important for smooth operation and long life of each working part of the vehicle e Major lubrication points are indicates below Front A arm grease valve E3 Brake pedal a 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 ___ PIINLI 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 goe
139. ke Disc Cover e Inspect the brake disc covers for dent or damage If any damages are found replace it with a new one Bushing e Inspect the rubber bushings A arm for wear or other damage If any damages are found replace them with new ones 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 Remove the removed oil seals with new ones 4 6 SUSPENSION STEERING DRIVE SHAFT DINLI CI 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 NOTE Make sure to check each bearing in the same manner Remove the circlip e Remove the hub bearings from the direction that the arrow marks 4 7 DINLI SUSPENSION STEERING DRIVE SHAFT Reassembly and Installation e Reassemble and install the front suspension in the reverse order of removal and disassembly Pay attention to the following points e Install the hub bearings with the special tool e Install the steering knuckle oil seal with the special tool e The oil seal which has faces to t
140. ke pedal not properly adjusted 2 Rear Brake e Air in the brake line e Brake fluid leakage e Brake fluid deteriorated e Primary or secondary cup trouble e Master cylinder scratched inside e Brake 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 13 APPENDIX DINLI lt _7 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 bolt
141. leed the air off at the reservoir 9 24 PERIODIC MAINTENANCE o Attach a clear plastic hose to the bleed valve on the caliper 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 A e Repeat this operation until no bubbles comes out the brake fluid reservoir 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 in lb 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 e Check the brake hoses for leakage cracks wear and damage If any damages are found replace the brake hoses with new ones 9 25 DINLI lt _7 DINLI 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 co
142. ling the spark plug make sure to tighten the spark plug to the specified torque Tightening Torque 14 N m 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 8 17 DINEI 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 ignition coil e Measure the primary winding resistance as follows o Connect the tester between the coil terminals o Set the tester to the x 1Q 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 termin
143. link and the buzzer will sound High beam indicator light This indicator lights up when the light switch is switched to high beam and will go out when switched to low beam ia Er This light comes on when the ignition switch is turned on Position Light Mode button Press this button to switch the display between ODO TRIP A TRIP B Meter JD 4WD Differential Lock Indicator GD RS The instrument panel shows 4D 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 4WD Lock and the 4WD Lock On button is pressed 10 Gear Position Indicator This shows the present gear and changes while shifting gears 8 23 OINLI lt J ELECTRICAL SYSTEM 11 Speedometer The 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 distance 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 res
144. lycol 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 o 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 leakage 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 b
145. mage 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 the T M lever assembly mounting bolts Q e Install the tie rod end 1 e Tighten the bolt 2 4 40 SUSPENSION STEERING DRIVE SHAFT 299INLI CI Shift Rod Installation e Before removing the T M lever assembly keep the tie rod end 1 in the N position C e Install the tie rod end 1 on its shaft NOTE When installing 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 DINLI SUSPENSION STEERING DRIVE SHAFT lt 9 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 s
146. mperatures 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 96 205 F Standard ON to OFF Approx 86 187 F 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 switch 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 lb ft e Pour engine coolant e Install the headlight 7 9 ODINLI C NINES 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 ohmme
147. n To rotate 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 All the electrical wires are either one color or two color A 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 20 Specifications Specification terms are defined as follows Standards show dimensions or performances which brand new
148. nce at each fuel level gauge float position If the resistance is incorrect replace the carburetor with a new one F Full Approx 10Q E Empty Approx 90Q Multi Circuit Tester Set Tester knob indication Resistance Q 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 e Remove the left mud guard e Disconnect speed sensor coupler 1 e Remove the speed sensor 2 by removing its mounting bolt e Connect the 12 V battery 10kQ 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 OV If the tester reading voltage does not change replace the speed sensor with a new one The highest voltage reading in this test will be the same as that of battery 12 V 8 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 Be sure the socket is
149. nder joint A and the banjo bolt B at the brake hose lower end and tighten it loosely e Remove the brake hose C 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 srar _ DINLI A Master Cylinder Installation e Use a 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 DINLI SUSPENSTON SSTEERING DRIVE SHAFT lt lt SUSPENSION amp STEERING amp DRIVE SHAFT Table of Contents Front Suspension 4 2 Construction 4 2 Removal and Disassembly 4 3 INS pecHONn eee nnn nnn nnn nnn nnn nnn nnn nnn nnn nnn nnn nnn 4 5 Reassembly and Installation 4 8 spring Pre Load Adjustment
150. nly 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 8 10 ELECTRICAL SYSTEM oe 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 1 per day 8 11 DINEI ELECTRICAL SYSTEM Charging System MOVABLE C OIL a ae L 12V Battery Troubleshooting battery runs down quickly Step1 Check accessories which use excessive amounts of electricity Are accessories being installed YES Remove accessories NO Move to Step 2 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 Step
151. ns Plastigauge 6 23 DINLS 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 lb 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 measure 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 ID of cam journal portion Standard IN amp EX 23 000 23 021 mm Small Bore Gauge 18 35 mm Dial Gauge 1 1000 mm 1 mm OD of Camshaft journal portion Standard IN amp EX 22 959 22 980 mm Micrometer Camshaft Runout e Measure the runout from using the dial gauge e Replace the camshaft if the runout exceeds the limit Service Limit Of Camshaft Runout IN amp EX Dial Gauge 1 1000 mm 10 mm Magnetic Stand V block Set 100 mm 6 24 Cylinder head e Remove tappe
152. nsequently 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 Pressure Kgf cm Front 35 0 35 5 0 Vehicle Load Capacity Limit 250 kg 551 1b 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 cm 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 Se
153. o Pass a string between flange immerse the thermostat in the water contained in a beaker as shown in the illustration Note that the immersed thermostat is in suspension o Heat the water 1 by placing the beaker on a stove 2 and observe the rising temperature on a thermometer 3 e Read the thermometer just when opening the thermostat This reading which is the temperature level at which the thermostat valve begins to open should satisfy the standard value Thermostat Valve Opening Temperature Standard 80 84 176 183 7 12 COOLING AND LUBRICATION SYSTEM _ _9INLI CI e Keep on heating the water to raise its temperature e Just when the water temperature reaches specified value the thermostat valve should have lifted A by at least 7 0mm Thermostat Valve Lift Standard Over 7 0mm at 95 Over 0 28 in at 203 e A thermostat failing to satisfy either of the two requirements start to open temperature and valve lift must be replaced Installation e Install the thermostat in the reverse order of removal e Apply engine coolant to the rubber seal on the thermostat i NOTE The jiggle valve A of the thermostat faces upside e After installing the thermostat be sure to add engine coolant e Tighten the thermostat cover bolts to the specified torque Tightening Torque 10 N m 1 0 kgf m 7 0 lb ft 7 13 NINES COOLING AND LUBRICATION SYSTEM Water Pump Removal and Disas
154. oil type SAE 10W 40 API SF or SG Engine oil capacity 10 31
155. oling circuit 7 5 NINES 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 kgf cm 15 6 19 9 psi and that with the tester held standstill the cap 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 1 4 kgf cm 15 6 19 9 psi 7 6 COOLING AND LUBRICATION SYSTEM Radiator Hose Inspection DINLI I e Remove the front grill upper cover e Remove the left headlight e Remove the left inner fender e Remove the left side cover e Any radiator hose found in a cracked condition or flattened must be replaced e Any leakage from the connecting section should be corrected by proper tightening Tightening Torque Cooling hose
156. oltage to the starter relay for five seconds and more since the relay coil may overheat and get damaged 8 19 DINLI C DINEI ELECTRICAL SYSTEM 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 8 20 ELECTRICAL SYSTEM 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 G Black C Green D Orange E Brown F Gray H White B Blue A Pink e When installing the actuator assembly tighten
157. om the joint by turning the rod too much 9 28 PERIODIC MAINTENANCE ___ QIINLI CCI 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 Reverse Shifting Switch Device 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 e The cable will pull the stopper to allow the transmissions gear shifting to the R or P position due to foot brake applied 9 29 DINLI 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 Erona am opper OO l o beon aarm ower o o l s ewe ooo d a S a d 10 Front shock absorber momning bolt nut lower i Front shock borer moninga open 0 eo as terda S l 16 Footrest mounting bolt A E E 15 Rear shock absorver outing boWnat owe 0 eo ss 19 Rear shock absorber mounting blinat wppen 0 eo es po RearA ambolinat upperandiover 0 o O so e T ans 22 Rear stabilizer lin
158. on e Rotates the stopper in clockwise and check if the push rod 1 slides smoothly when releasing stopper e If it does not slide smoothly replace the cam chain tensioner with a new one 6 32 ENGINE Ee LI _ A Cam Chain Guide Inspection e Check the contacting surface of the cam chain guide for wear and damage e If it is found to be damaged replace it with a new one Cylinder Cylinder distortion Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge taking a clearance reading at several places as indicated If the largest reading at every position of the straightedge exceeds the limit replace the cylinder Cylinder Distortion Thickness Gauge Cylinder bore e Check for damage or wear on bore surface e Measure the cylinder bore at total 6 positions top middle and bottom positions and perpendicular to each other Cylinder bore 102 000 102 020mm Cylinder Gauge Set 6 33 DINLS ENGINE Timing Gear Timing gear adjust e Remove the Cylinder head cover and camshaft e Remove the Recoil starter Sf z e Leave the Starter cup on the left crankcase e Use tool to adjust the Start cup to align the TDC line A with the index mark B of the crankcase to make the piston to the highest posit
159. on System Main sw mh INCColl 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 8 16 ELECTRICAL SYSTEM oe OINLI Step2 Inspect the spark plug Is the spark plug OK YES Move to Step 3 NO 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 instal
160. ork O 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 warm 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 anew one 9 3 DINLI PERIODIC MAINTENANCE e Reinstall the cleaned or new air cleaner in the reverse order of removal 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
161. otographs 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 or 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
162. out maintenance and repair satisfactorily In order to 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 Be 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 lo
163. 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 s4 NLI General Precautions NWARNING o Proper service and repair procedures are important for the safety of the service mechanic and the 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 If 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 the specified lubricant bond or
164. pecified two step torque sequentially and diagonally Tightening Torque Initial 10 N m Final 14 N m NOTE Apply engine oil to the both side of head cover washer before installing the head cover bolts 9 6 1 E150005 XX TAPPET SHIM SELECTION TABLE INTAKE TAPPET SHIM Ni PERIODIC MAINTENANCE ___ QIINLI p SS lh Intake Side 23mm 2 amm 280mm JUIRED EX AMPLE JWSE THIS CHART Tappet clearance js 3 00 ST MENT REC Measuretappet clearance ENGINE SCOLD ll Measure present shim size Ill Match clearance in vertical colinin with present shinv size horizontal column Present shim size Shim size to be used WT iil J A PAINE H l i Zz ia rer C3 a fale i 4 em oF al Lt i IHE Cy c3 E 1 S TE i g r a E i 5 E te ry 280 35 300 300 3 og u Pat 280 HE pE T E ke es IE ita D a 5 Faa olo o iD ED ee FH ia fo o olola o k eR Shy f c i be 2 oe I L L Tio a i bo a Lo or 5 S io in to ef ale o oo o ic TE PF Whey cE aa Ue WI eee Aaa at e 9 7 INES PERIODIC MAINTENANCE Exhaust Side HEIS LUIS tues aid KIM LOO POE A Ul SoU BIE So POLE Al WISE pashagorazis wiys LULU OP azis wys yuasald Woe fy Shaaueveers paddel Sd iW XS azis LUIYS wasaad ainseajy Oo SISNIONG a2ueleap yedderainseayy ore oo
165. rance at large end of Connecting Rod with thickness gauge Side clearance at large end Thickness Gauge Crankshaft Runout e Set on the V block and measure runout with dial gauge Crankshaft Runout Dial Gauge 1 100 mm Magnetic Stand V block Set 100 mm 6 37 DINLI C ENGINE Clutch Clutch Shoe e Inspect the clutch shoe for chips cracks uneven wear and heat discoloration Also check the depth of the grooves on the clutch shoe e If there is no groove at any part of the shoe replace the shoe as a set NOTE The clutch shoe must always be changed as a set Clutch Wheel e Inspect the condition of the inner clutch wheel surface for scuffs scratches cracks or uneven wear e If any damages are found replace the clutch wheel with a new one Starter Clutch e Remove the starter clutch securing bolts e Install the starter clutch in the proper direction o When installing the one way clutch assy onto the rotor make sure the arrow mark side 1 of the one way clutch is fit the outer ring groove 2 and faces to the rotor e Apply the engine oil to the starter clutch CAUTION If the ball bearing has fall out of the one way clutch replace the one way clutch for new one 6 38 e Apply THREAD LOCK to the bolts e Tighten the starter clutch bolts to the specified torque Tightening Torque 26 N m 2 6 kgf m 19 0 lb ft e Install the starter driven g
166. rforming 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 ODINLI C DINLI 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 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
167. ring e Install the water union 6 69 DINEI ENGINE e Install the starter motor 6 70 DINLI COOLING AND LUBRICATION SYSTEM lt lt COOLING amp LUBRICATION SYSTEM Table of Contents Engine Coolant 7 2 Cooling Circuit 7 3 Cooling Circuit Inspection 7 3 Radiator and Hoses 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
168. rning 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 remo
169. rst 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 lb ft 9 9 ODINLI C 0 7 0 8 mm DINLI PERIODIC MAINTENANCE Spark Arrester Clean every 2000 km 100 hours 6 months Remove the muffler end cover 1 e Extract the spark arrester pipe 2 from the muffler e Clean the spark arrester pipe 2 by non synthetic brush If necessary blow debris from the arrester with compressed air e Reinstall the spark arrester pipe 2 Fuel Line Inspect every 1000 km 50 hours 3 months Replace every four years e Inspect the fuel feed hose for damage and fuel leakage If any damages are found replace it with a new one 9 10 PERIODIC MAINTENANCE _ _ QIINLI CI Throttle Cable Play Inspect initially at 200 km 10 hours 1 month and every 200 km 10 hours 1 month thereafter e Adjust the throttle cable play o Loosen the locknut 1 of the throttle cable grows o Turn the adjuster 2 in or out to obtain the correct play
170. ry Copper Plug 6 39 Movable Drive Face and Driven Face 6 40 Drive Belt 6 47 Oil Pump 6 47 TransmiSss1ONn 6 48 Gearshift Fork 6 50 Generator COVer 6 51 Reassembly 6 53 Engine Bottom Side 6 53 Engine lop Side 6 62 6 1 DINLS ENGINE C T Removal and Installation Engine Removal e Thoroughly clean the ATV engine and chassis e Clean work area e Drain coolant and engine oil e Remove the seat e Remove the side fenders e Remove the rear propeller shaft e Disconnect the battery lead wires CAUTION When disconnecting the battery lead wires be sure to disconnect the O b
171. s below specification check the engine for conditions listed above Compression Test Procedure o Before testing the engine for compression 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 o 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 DINLI 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 Oil Pressure Above 15 kPa 0 15 kgf cm 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 t
172. s on suspension e Worn A arms and related bushings 10 14 APPENDIX OoOo Handing and or stability Unsatisfactory 1 Handlebar hard to turn e Tire air pressure too low e Steering shaft bearing damaged 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 15 DINLI lt 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 wh
173. se 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 8 26 ELECTRICAL SYSTEM Engine Coolant Temperature Meter and Indicator e Disconnect the ECT sensor coupler 1 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 Resistance A LED B Water temperature Over 0 2 kO a Approx 110 Approx 0 11 kQ 120 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 ODINLI Belowillo 12 00 2 0 7 70 38 420 43 0 99 730 pomza 8 27 OINLI lt J ELECTRICAL SYSTEM Fuel Gauge e Measure the resista
174. sembly e Remove the left mud guard e Drain engine coolant e Drain engine oil 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 to 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 shaft pin 3 and washer 4 7 14 COOLING AND LUBRICATION SYSTEM _ _9INLI CI e Remove the impeller shaft 5 and impeller 6 e Visually inspect the mechanical seal that install in the impeller and the left crankcase for damage with particular attention given to the sealing face e Replace the mechanical seal that shows indications of leakage Also replace the seal ring if necessary e Remove the mechanical seal using the special tool
175. 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 the multi circuit tester read its instruction manual Multi Circuit Tester Set o Color codes Bo Black G _ Green P Pink DG Dark green O Orange Y Yellow o Electrical Connectors Female Connectors A Male Connectors B 8 7 ODINLI lt DINEI ELECTRICAL SYSTEM 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 the ends of the leads o Set the tester to the x 1 Q range and read the tester If the tester does not read 0 Q the lead is defective Replace the lead or the wiring harness B if necessary Multi Circuit Tester Set 8 8 ELECTRICAL SYSTEM oe OINLI Battery Battery Removal e Disconnect the battery negative cable Black first and then the positive cable red o Take out the battery Battery Installation e Connect the positive cable
176. t the front wheels in the straight position e Place a load of 75 kg 165 Ibs on the seat Forward e Measure the distances A and B between the front wheels B 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 bring it into the specified range 9 27 OINLI I DINLI PERIODIC MAINTENANCE C mmm Suspensions Inspect every 2000 km 100 hours 6 months 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 damage If any damages are found replace them with new ones See Suspension chapter Shift Rod 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 i NOTE Be careful not to separate the rod fr
177. t the tie rod for distortion or damage If any damages are found replace it with a new one Tie Rod End e Inspect the tie rod ends and boots for smooth movement If there are any abnormalities replace them with new ones Steering Shaft and Bracket e Inspect the steering shaft for distortion or bends If any damages are found replace it with a new one e Inspect the steering shaft brackets for wear or damage If any damages are found replace them with new ones 4 30 SUSPENSION STEERING DRIVE SHAFT INL CI 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 s
178. tall the impeller shaft and the impeller to the water pump body e Install the washer 1 and impeller shaft pin 2 to the impeller shaft e Install the water pump driven gear 3 and circlip 4 7 17 DINLE I CooLING AND LUBRICATION SYSTEM e Install the engine left crankcase cover 1 and recoil starter 2 e Install the new O ring 1 CAUTION Use the new O rings to prevent engine coolant and engine oil 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 lb ft e Connect the radiator hoses e Pour engine coolant 7 18 COOLING AND LUBRICATION SYSTEM Lubrication System Oil Pressure e Check the engine oil pressure periodically Above 15 kPa 0 15 kgf cm 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 To properly tighten the oil filter use the special tool Never tighten the oil filter by hand e
179. teering shaft bracket and oil seals before installing the steering shaft bracket 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 Ib ft NOTE Make sure that the wiring harness cables and brake routing are proper CAUTION To prevent the entry of dirt the oil seal end must face 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 pin into the steering shaft Tie Rod e Tighten the tie rod end nuts to the specified torque Tightening Torque 29 N m 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 STEERING DRIVE SHAFT DINLI C 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 dire
180. ten the drain plug with the new washer to the specified torque and then pour the new oil through the oil filler hole Tightening Torque 19 N m 1 9 kgf m 14 0 lb ft e When performing an oil change the engine will hold about 3 3 L 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 e Start the engine and allow it to run for a few minutes at idling speed e Turn off the engine and wait about three minutes and then check the oil level on the 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 PERIODIC MAINTENANCE Oil Filter Replacement e Drain the engine oil e Remove the front fender e Remove the oil filter 1 with the special 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 pe
181. ter e If the ECT sensor ohmic value does not change in the proportion indicated replace it with a new one Temperature Sensor Specification Temperature Standard Resistance 60 140 Approx 0 704 kO 90 194 Approx 0 261 kO 120 248 Approx 0 111 kQ 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 _ __9INLI A Installation 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 Pour engine coolant 7 11 DINLI COOLING AND LUBRICATION SYSTEM lt 9 Thermostat Removal Remove the left side cover e Drain engine coolant e Place a rag under the thermostat cover e Remove the thermostat cover 1 e 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
182. the water pump drive gear 2 e Remove the keys 1 Remove the cam chain drive gear with the special tools Bearing Remover Set e Remove the pin and crank balancer drive gear 6 17 DINLS ENGINE e Remove the CVT cover 1 and gasket Remove the movable drive face cover 1 e Remove the dowel pins e Remove the movable drive face 2 by removing the bolt e Remove the movable driven face assembly by removing the bolt e Remove the drive belt 6 18 e Remove the fixed drive face e Remove the front and rear output connectors e Remove the plate 1 CVT inner cover 2 and gasket NOTE Be careful about the size of the bolts M6 amp M8 it is necessary to put them in the original position e Remove the gear position indicator 1 e Remove the pin e Remove the clutch housing shaft 1 6 19 DINLS ENGINE e Remove the output shaft 2 Remove the collar 1 e Remove the drive bevel gear
183. ther Countries e Use a premium quality 4 stroke motor oil to ensure longer Ej ff 20W 50 service life of your vehicle Use only oil which are rated ae i SF or SG under the API service classification The ENGINE OIL lm i aas recommended viscosity is SAE 10W 40 If SAE 10W 40 motor oil is not available select an alternative according C 30 20 10 0 10 20 30 40 TEMP F 22 4 l4 32 50 68 86 104 to the right chart Front Differential Gear Oil e Use hypoid gear oil that meets the API service classification GL 5 and is rated SAE 80W 90 Rear Gear Final Box Oil e Use hypoid gear oil that meets the API service classification GL 5 and is rated SAE 80W 90 1 8 GENERAL INFORMATION oe s4 NLI Brake Fluid e Specification and classification DOT 4 J N 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 e Use an anti freeze engine coolant compatible with an aluminum radiator mixed with distilled water only Water For Mixing e Use distilled water only Water other than distilled water can corrode and clog th
184. ts 1 and shims 2 e Use special tools compress the Valve Spring and remove the valve keeper e Remove the spring retainer and valve spring D005_01 Valve Lifter Attachment D005_02 Valve Lifter Pull out the valve 3 from the combustion chamber side e Remove oil seals 1 and spring seats 2 NOTE Do not reuse the removed oil seals Cylinder head distortion e Clean and remove carbon deposits from the surface Never damage the surface when cleaning e Place straightedge on the surface and check with thickness gauge e If the result is out of specifications replace with new Cylinder Head Cylinder Head Distortion Thickness Gauge 6 25 DINLS ENGINE Ca LL 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 Valve Stem runout Dial Gauge 1 100 mm Magnetic Stand V block set 100mm Valve head radial runout e Place the dial gauge at right angles to the valve head face and
185. ty 250 KG 2 2 WHEELS TIRES oo OINLI Construction Front Wheel Hub EJ Castle Nut 4pcs Rim Rear Wheel Hub 8 Cotter Pin 4pcs Rim FHSC 8pcs 9 Spring Washer 4pcs Name Plate 4pcs Item N m kgf m lb ft 2 3 DINEI 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 on the tire and install the wheel accordingly NOTE o The direction of the tire rotation is shown by an arrow on the tire sidewall Position the wheel so that the air valve B is toward the 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 lb ft 2 4 WHEELS TIRES Inspection Examine both sides of the rim for dents A If the rim is dented replace it e If the tire is removed inspect the 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 Replace the air valve whenever the tire is replaced Do not reuse the air valve e Install a new air valve in the new rim
186. uccessfully 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 NOTE l Be careful not to separate the rod from the joint by turning the 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 szopy _ DINLI i g BODY Table of Contents Seat 5 2 Removal 5 2 Installation 5 2 Front and Rear Racks 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 Fend
187. use 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 fittings or the bleed valve is opened at any time the AIR MUST BE BLED FROM THE BRAKE LINE Brake Fluid
188. val generally 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 ODINLI lt J GENERAL INFORMATION l 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 the 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 or 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 Rotatio
189. ve and driven faces will move together smoothly without slip e Install the dowel pins e Install the movable drive face cover 1 9 21 DINLI PERIODIC MAINTENANCE Brakes Inspect initially at 200 km 10 hours 1 month and every 200 km 10 hours 1 month thereafter Front Brake Pad e 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 e 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 x If it is incorrect adjust the brake pedal position NOTE l First adjust the brake pedal and then adjust the brake lever sith i Pe a e Loosen the nut A and turn the bracket B unt
190. voltage cable e Remove the Exhaust pipe bolts e Remove the muffler e Remove the right foot board e Remove the right foot board bracket bolts 1 e Remove the right foot board bracket e Remove the foot brake pedal 6 5 DINLS ENGINE e Remove the front differential mounting bolts nuts e Slide the front differential assy forward e Remove the front propeller shaft spring e Remove the front propeller shaft e Remove the rear gear box bolts nuts 6 6 e Slide the rear gear box assy backward e Remove the rear propeller shaft spring e Remove the rear propeller shaft e Remove the engine mounting bolts nuts e Remove the engine from the right side 6 7 ENGINE ODINLI lt DINLS ENGINE Engine Installation Remount the engine in the reverse order of engine removal Pay attention to the following points e Tighten the engine mounting nuts to the specified torque Tightening Torque 60N m 6 0 kgf m 43 5 lb ft
191. wn 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 lb ft 4 34 SUSPENSION STEERING DRIVE SHAFT DINLI CI Handlebar Construction IO ae O e aeea y Bl chokecae s Rearview minor o niom Upper handlebar camp 09 9 RearView minore ia Handlebar owith 4 35 INES suspENSION STEERING DRIVE SHAFT Removal Remove the handlebar holder cover 1 Remove the brake hose e Remove the brake master cylinder assembly See Brake chapter Remove the throttle wire e Remove the right switch assembly e Remove the choke cable by removing its cap 1 e Remove the parking brake cable 2 e Remove the left lever assembly 3 by removing its screws 4 4 36 SUSPENSION STEERING DRIVE SHAFT DINLI lt _ e Remove the handlebar clamp bolts A d e Remove the upper clamps e Remove the handlebar
192. x ow clearance EX 0 030 0 057 Pan aos sp Valve stem O D ex so sas Valve diam Valve spring free length 190 214 N 19 0 21 4 kgf 41 8 Valve spring tension 47 2 lbs at length 36 5 mm Camshaft Cylinder Head Unit mm IN 36 400 36 500 36 150 mae E 35 350 35 450 35 100 Camshaft journal oil clearance IN amp EX 0 020 0 062 0 150 10 25 OINLI lt 7 APPENDIX Cylinder Piston Piston Ring Unit mm Compression pressure Approx 950 kPa 9 5 kgf cm 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 Piston diam 101 880 Cylinder distortion Piston ring free end gap Measure at 15 mm from the skirt end 0 05 2nd Approx 11 70 8 7 1 21 1 23 Piston ring end gap Piston ring to groove clearance Ist 1 30 1 32 Piston ring groove width 2nd 1 21 1 23 Oil 2 01 2 03 Ist 1 17 1 19 2nd 1 17 1 19 Piston pin bore I D 23 002 23 008 23 030 Piston pin O D 22 992 23 000 22 980 Piston ring thickness Connecting Rod Crankshaft Unit mm Conrod small end I D 23 002 23 008 23 035 Conrod big end side clearance 0 35 0 60 Conrod big end width 24 95 25 00 pe Crank web to web width 72 95 73 05 10 26 APPENDIX ea LI a Clutch Unit mm Clutch wheel I D 140 0
193. y ll foun nian fal M wa A o te aad H et Ws Of TE jm LIRI oh Bid i t i l H iR IE IgE aie 8 34 OINLI ELECTRICAL SYSTEM oe ay NOTE r 8 35 DINLI PERIODIC MAINTENANCE EE aa 4 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 Valve Clearance 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
194. y there had to have a small amount of clearance between the rotor and the starter driven gear e Tighten the generator rotor nut to the specified torque Tightening Torque 160 N m 16 0 kgf m 115 lb 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 Hook the return spring end A to the stopper o Check the gearshift cam stopper moves smoothly o Locate the gearshift cam in the neutral position NOTE 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 DINLS ENGINE e Install the starter reduction gear and gearshift shaft e Install the dowel pins 1 and new gasket 2 e Install the copper plug and its O ring e Install the generator cover e Install the starter cup NOTE Fit the pin to the starter cup hole 6 62 ENGINE ae LI ms e Use the suitable bar 1 to install the starter cup 2 e Tighten the starter cup to the specified torque Tightening Torque 26 N m 2 6 kgf m 19 0 lb ft e Apply GREASE to the

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