Dinli DL-901 Service Manual
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Dinli DL-901 Service Manual

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Summary of Contents for Dinli DL-901

  • Page 2 FOREWORD/INDEX 【0-0】...
  • Page 3 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.

  • Page 4: How To Use This Manual

    ● Follow the Periodic Maintenance Chart in the Service Manual. ● Be alert for problems and non-scheduled maintenance. ● Use proper tools and genuine DINLI vehicle parts. Genuine parts provided as spare parts are listed in the Parts Catalog. ● Follow the procedures in this manual carefully. Don’t take shortcuts.
  • Page 5 FOREWORD/INDEX △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.
  • Page 6 FOREWORD/INDEX CHAPTER INDEX CHAPTER1 GENERAL CHAPTER2 WHEELS/TIRES CHAPTER3 BRAKE CHAPTER4 SUSPENSION CHAPTER5 FRAME CHAPTER6 ENGINE CHAPTER7 ELECTRICAL CHAPTER8 APPENDIX 【0-4】...
  • Page 7 FOREWORD/INDEX 【0-5】...
  • Page 8 GENERAL INFORMATION GENERAL INFORMATION Table of Contents Before Servicing------------------------------------------------------------------------------------------------1-2 Model Identifications----------------------------------------------------------------------------------------- 1-5 General Specifications-----------------------------------------------------------------------------------------1-6 Periodic Maintenance Chart----------------------------------------------------------------------------------1-8 【1-1】...

  • Page 9: General Information

    GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a quad, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.
  • Page 10 GENERAL INFORMATION 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 turning it over.
  • Page 11 GENERAL INFORMATION (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;...

  • Page 12: Model Identification

    GENERAL INFORMATION Model Identification Engine serial number Vehicle identification number ENGINE SERIAL NUMBER (Ex. EW450SR00100000xxx) VEHICLE IDENTIFICATION (ex. RFWAK85CX6Txxxxxx) Whenever corresponding with DINLI about a particular issues, the engine number and serial number are important for vehicle identification. 【1-5】...

  • Page 13: General Specifications

    GENERAL INFORMATION General Specification NOTE: Specifications subject to change without notice. Model DL901 Engine 4-stroke, DOHC Bore and stroke 94mm x 64.6 mm Compression ratio 11.6:1 Displacement 448 cc Coolant system Liquid cooled 1:1 water/anti-freeze[ethylene glycol(containing corrosion inhibitors Coolant for aluminum engines and radiators)] Starting system Electric Carburetor...
  • Page 14 GENERAL INFORMATION CHASSIS Frame Steel Overall length 183 cm Overall width 109 cm Overall height 115 cm Seat height 85 cm Wheel base 1250 mm Front tire 21 x 7 – 10 Rear tire 20 x 11 – 9 Recommended cold tire pressure (front/rear) 35kpa/ 35kpa Turning radius 2.0m...

  • Page 15: Periodic Maintenance Chart

    TIE ROD ENDS ★ ▲DINLI dealer service suggested that servicing owners should have the proper tools, service data, and be mechanically qualified. ○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.

  • Page 16: Table Of Contents

    WHEELS/TIRES Wheels/Tires Table of Contents Specifications---------------------------------------------------------------------------------------------------2-2 Wheel Alignment-----------------------------------------------------------------------------------------------2-3 Steering Centering Inspection----------------------------------------------------------------------------2-3 Steering Centering Adjustment--------------------------------------------------------------------------2-3 Toe-in Inspection-------------------------------------------------------------------------------------------2-4 Toe-in Adjustment-----------------------------------------------------------------------------------------2-4 Wheels (Rims)--------------------------------------------------------------------------------------------------2-5 Wheel Removal--------------------------------------------------------------------------------------------2-5 Wheel Installation-----------------------------------------------------------------------------------------2-5 Wheel (Rim) Inspection-----------------------------------------------------------------------------------2-6 Wheel (Rim) Replacement-------------------------------------------------------------------------------2-6 Tires--------------------------------------------------------------------------------------------------------------2-6 Tires Removal--------------------------------------------------------------------------------------------2-6 Tires Installation------------------------------------------------------------------------------------------2-7 Tires Inspection-------------------------------------------------------------------------------------------2-8 Front Hub--------------------------------------------------------------------------------------------------------2-9 Front Hub Removal--------------------------------------------------------------------------------------2-9 Front Hub Installation-----------------------------------------------------------------------------------2-9 Rear Hub-------------------------------------------------------------------------------------------------------2-10 Real Hub Installation-----------------------------------------------------------------------------------2-10...

  • Page 17: Specifications

    WHEELS/TIRES Specifications Item Standard 25~40 mm Wheel Alignment: Toe-in 2WD Tires: AT 21×7-10 Standard tire: Front KENDA K300F-002, Tubeless AT 20×11-9 Rear KENDA K300-004, Tubeless Tire air pressure (when cold): Front 35 kPa (0.35 kgf/cm , 5.0 psi) Rear 35 kPa (0.35 kgf/cm , 5.0 psi) Maximum tire air pressure 250 kPa (2.5 kgf/cm...

  • Page 18: Wheel Alignment

    WHEELS/TIRES Wheel Alignment Toe-in is the amount that the front wheels are closer together in front than at the rear at the axle height. When there is toe-in, the distance A (Rear) is the greater than B (Front) as shown. The purpose of toe-in is to prevent the front wheels from getting out of parallel at any time, and to prevent any slipping or scuffing action between the tires and the ground, if ton-in is...

  • Page 19: Toe-In Inspection

    WHEELS/TIRES ●Repeat the straightedge procedure on the other side of the vehicle, now the front wheels are parallel to each other and to the center line of the vehicle. ●Go on to the Toe-in Inspection procedure. Toe-in Inspection ●Support the vehicle on a stand or the jack so that the front wheels are off the ground.

  • Page 20: Wheels (Rims)

    WHEELS/TIRES ●Check the toe-in. ●Tighten: Torque - Tie-Rod Adjusting Sleeve Locknuts: 33 N-m (3.4 kgf-m, 45 ft-lb) ●Test ride the vehicle. Wheels (Rims) Wheel Removal ●Loosen the wheel nuts [A] ●Support the vehicle on a stand or the jack so that the wheels are off the ground.

  • Page 21: Wheel (Rim) Inspection

    WHEELS/TIRES Wheel (Rim) Inspection ●Examine both sides of the rim for dents [A]. If the rim is dented, replace it. ●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 Wheel (Rim) Replacement ●Remove the wheel (see Wheel Removal)

  • Page 22: Tires Installation

    WHEELS/TIRES CAUTION Do not lubricate the tire beads and rim flanges with engine oil or petroleum distillates because they will deteriorate the tire. ●Remove the tire from the rim using a suitable commercially available tire changer. NOTE ○The tires cannot be removed with hand tools because they fit the rims tightly.

  • Page 23: Tires Inspection

    WHEELS/TIRES ●Support the wheel rim [A] on a suitable stand [B] to prevent the tire from slipping off. ●Inflate the tire until the tire beads seat on the rim. Maximum Tire Air Pressure ( to seat beads when cold ) Front and Rear: 250kpa (2.5 kgf-cm , 36 psi ) △WARNING...

  • Page 24: Front Hub

    WHEELS/TIRES Front Hub Removal ●Remove the cotter pin [A] and loosen the axle nut [B]. ●Remove the wheel (see Wheel Removal). ●Remove the caliper by taking off the mounting bolts [C], and let the caliper hang free. ●Remove the axle nut and pull off the front hub brake disc. ●Separate the brake disc from the front hub.

  • Page 25: Rear Hub

    WHEELS/TIRES Rear Hub Rear Hub Installation ●Grease the axle spindle. ●Apply non-permanent locking agent: Rear Axle Nuts [A] ●Tighten: Torque - Rear Axle Nut: 265 N-m (27.0 kgf-m, 195ft-lb) ●Insert a new cotter pin [B] and bend it over the nut. Rear Hub Disassembly/Assembly ●Do not press the hub bolts [A] out.
  • Page 26 BRAKE Brake Table of Contents Brake Fluid-----------------------------------------------------------------------------------------------------3-2 Brake Fluid Recommendation-------------------------------------------------------------------------3-2 Brake Fluid Level Inspection--------------------------------------------------------------------------3-3 Brake Fluid Change-------------------------------------------------------------------------------------3-3 Brake Line Air Breeding-------------------------------------------------------------------------------3-4 Master Cylinder-----------------------------------------------------------------------------------------------3-5 Master Cylinder Removal------------------------------------------------------------------------------3-5 Master Cylinder Installation---------------------------------------------------------------------------3-5 Calipers---------------------------------------------------------------------------------------------------------3-6 Calipers Removal----------------------------------------------------------------------------------------3-6 Calipers Installation-------------------------------------------------------------------------------------3-6 Brake Pads------------------------------------------------------------------------------------------------------3-7 Brake Pads Removal------------------------------------------------------------------------------------3-7 Brake Pads Installation----------------------------------------------------------------------------------3-7 Brake Pads Wear Inspection----------------------------------------------------------------------------3-7 Brake Discs-----------------------------------------------------------------------------------------------------3-8 Disc Cleaning---------------------------------------------------------------------------------------------3-8...

  • Page 27: Brake Fluid

    BRAKE Brake Fluid WARNING △ When working with the disc brake, observe the precautions listed below. 1.Never reuse old brake fluid. 2.Do not use fluid from a container that has been left unsealed or that has or that has been open for a long time.

  • Page 28: Brake Fluid Level Inspection

    BRAKE Brake Fluid Level Inspection ●Position the reservoir horizontal, and check that the fluid level in the reservoir is higher than the lower level line [B]. 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.

  • Page 29: Brake Line Air Breeding

    BRAKE △ 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. ●Tighten: Torque - Bleed Valve: 5.4 N-m (0.55 kg-m, 48 in-lb) ●Apply the brake lever forcefully for a few second, and...

  • Page 30: Master Cylinder

    BRAKE NOTE ○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. ○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.

  • Page 31: Calipers Removal

    BRAKE WARNING △ Do not attempt to drive the vehicle until a full brake level is obtained by pumping the brake level until the pads are against each dis. The brakes will not function on the first application of the level if this is not done. Caliper Removal ●Removal the front wheel (see Wheels/Tires chapter).

  • Page 32: Brake Pads Removal

    BRAKE Brake Pad Removal ●Remove the front wheel (see Wheels/Tires chapter). ●Remove the caliper (see Caliper Removal) ●Push the anti-rattle spring [A], remove the pads [B] [C]. Brake Pad Installation ●Push the caliper piston in by hand as far as it will go. ●Be sure that the anti-rattle spring is in place.

  • Page 33: Brake Discs

    BRAKE Disc Cleaning 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. WARNING △ These cleaning fluids are usually highly flammable and harmful if breathed for prolonged periods.

  • Page 34: Disc Runout

    BRAKE Disc Runout ●Jack up the vehicle so that the wheels are off the ground. ●Remove the front wheels and turn the handlebar fully to one side. ●Set up a dial gauge against the disc [A], and measure the disc runout. If the runout exceeds the service limit, replace the disc.

  • Page 35: Brake Pedal Position Inspection

    BRAKE Brake Pedal Position Inspection ●Check that the brake pedal [A] is in the correct position as shown. Pedal Position [C] Standard: 41 ~ 46 mm above footrest If it is correct, adjust the brake pedal position. ★ Brake Pedal Position Adjustment ●Remove the brake pedal (see Brake Pedal Removal).

  • Page 36: Brake Pedal Installation

    BRAKE Brake Pedal Installation ●Please reverse the Removal steps to install the brake pedal. Caliper Removal ●Removal the Rear wheel (see Wheels/Tires chapter). ●Loose the banjo bolt [A] at the brake hose lower end, and tighten it loosely. ●Unscrew the caliper mounting bolts [B], and detach the caliper from the disc.

  • Page 37: Rear Brake Pads Removal

    BRAKE Rear Brake Pads Removal ●Remove the caliper (see Caliper Removal) ●Remove: Anti-rattle Spring [C] Brake Pads [B] Brake Pad Installation ●Check the lining thickness (see Brake Pad Wear Inspection). ●Push the caliper piston in by hand as far as it will go. ●Be sure that the anti-rattle spring is in place.

  • Page 38: Master Cylinder Removal

    BRAKE Master Cylinder Removal ●Remove the master cylinder joint [A] and the banjo bolt [B] at the brake hose lower end, and tighten it loosely. ●Remove the brake hose [C]. ●Loose the master cylinder mounting bolts [D]. CAUTION Brake fluid quickly ruins painted surface; any spilled fluid should be completely washed away immediately.

  • Page 39: Brake Disc Removal

    BRAKE Brake Disc Removal ●Remove the rear caliper, unscrew the banjo bolt and remove the brake hose from the caliper. ●Loose the brake disc mounting bolts [A] and nut [B]. ●Support the vehicle. ●Remove the rear wheel (see Wheel Removal). ●Remove the disc.
  • Page 40 SUSPENSION/STEERING Suspension & Steering Table of Contents Shock Absorbers------------------------------------------------------------------------------------------------4-2 Front Shock Absorber Removal------------------------------------------------------------------------4-2 Front Shock Absorber Installation---------------------------------------------------------------------4-2 Front Shock Absorber Inspection----------------------------------------------------------------------4-2 Front Shock Absorber Preload Adjustment-----------------------------------------------------------4-2 Rear Shock Absorber Removal-------------------------------------------------------------------------4-2 Rear Shock Absorber Installation----------------------------------------------------------------------4-2 Rear Shock Absorber Scrapping-----------------------------------------------------------------------4-3 Suspension Arms-----------------------------------------------------------------------------------------------4-3 Suspension Arm Removal-------------------------------------------------------------------------------4-3 Suspension Arm Installation----------------------------------------------------------------------------4-3 Suspension Arm Disassembly--------------------------------------------------------------------------4-3...

  • Page 41: Front Shock Absorber Removal

    SUSPENSION/STEERING Front Shock Absorber Removal ●While supporting the vehicle to up with the jack. ●Remove: Front Shock Absorber Mounting Bolt and Nut [A] Front Shock Absorber [B] Front Shock Absorber Installation ●Insert the shock absorber into the bracket [C]. ●Tighten: Torque - Mounting Bolts and Nuts: 47 N-m (4.8 kgf-m, 35 ft-lb) ●While supporting the vehicle to down with the jack.

  • Page 42: Suspension Arm Removal

    SUSPENSION/STEERING Rear Shock Absorber Preload Adjustment ●See the Front Shock Absorber Preload Adjustment Suspension Arm Removal ●Remove: Front Wheel (see Wheels/Tires chapter) Front Hub (see Wheels/Tires chapter) Cotter Pin, Nut and Bolt [A] Tie-Rod End [B] Front Shock Absorber Mounting Bolts [C] Suspension Arm Pivot Bolts [D] Suspension Arm Installation ●Tighten:...

  • Page 43: Suspension Arm Assembly

    SUSPENSION/STEERING Suspension Arm Assembly ●When installing the rubber bushing into the arm, lubricate the outer surface of the bushings with a soap and water solution. CAUTION Do not lubricate the rubber bushings with engine oil or petroleum distillates because they will deteriorate the rubbers.

  • Page 44: Swingarm Bearing Installation

    SUSPENSION/STEERING Swingarm Bearing Installation ●Lubricate the swingarm bearing before installation (see swingarm bearing Lubrication). ●Use the bearing driver set to press in the tapered roller bearing outer races and grease seals. Swingarm Bearing Inspection ●Move the swingarm up and down to check for abnormal friction, and push and pull it back and forth to check for bearing play.

  • Page 45: Steering

    SUSPENSION/STEERING Steering Stem Removal ●Remove: Speedometer Cover Bolts [A] Speedometer Cover [B] Handlebar Holder Bolts *4 [C] Handlebar [D] Front Cover (see Frame Chapter) ●Remove: Steering Clamp Bolts [A] Steering Clamp Support Plate [B] Steering Clamp [C] Tie-Rod End Nuts [D] Steering Stem Cotter Pin [E] and Nut [F] CAUTION Do not loosen the locknut at the ends of the tie-rod...

  • Page 46: Steering Stem Installation

    SUSPENSION/STEERING Steering Stem Installation ●Lubricate the steering stem clamp, grease seals, (See Steering Lubrication). ●Install the grease seals [B] facing the end [A] rearward to prevent the entry of dirt. ●Install the steering stem clamps on both grease seals fit into the groves on the steering stem clamps [C].

  • Page 47: Steering Knuckle Installation

    SUSPENSION/STEERING Steering Knuckle Installation ●Clean the sealing surface [A] and the hole [B]. ●Grease the sealing surface. ●Tighten: Torque – Suspension Arm Pivot Bolts: 88 N-m (9.0 kgf-m, 65 ft-lb) Steering Knuckle Joint Nut: 42 N-m (4.3 kgf-m, 35 ft-lb) Front Shock Absorber Clamp Nut: 52 N-m (5.3 kgf-m, 38 ft-.lb) Tie-Rod End Nut: 47 N-m (4.8 kgf-m, 35 ft-lb)

  • Page 48: Tie-Rod End Installation

    SUSPENSION/STEERING CAUTION Do not remove the grease seal. It is packed with grease. Tie-Rod End Installation ●Install the tie-rod ends so that the tie-rod has the correct length [A], and the both visible thread length [B] make equal. Tie-Rod Length Standard: 385 mm ●Tighten: Torque –...

  • Page 49: Steering Lubrication

    SUSPENSION/STEERING Steering Lubrication ●Lubricate the steering stem clamps. ○Remove the steering stem (see Steering Stem Removal). ○Wipe all the old grease off the steering stem, and clamps, and out of the grease seals. ○Apply grease to the steering stem [A], grease seal lips and mating surface [B] of the clamp, and pack the grooves [C] in the clamp with grease.

  • Page 50: Handlebar

    SUSPENSION/STEERING Handlebar Removal ●Remove: Throttle Switch (see Steering Stem Removal) Front Brake Master Cylinder Left-hand Switch Housing Handlebar Cover Screw Handlebar Cover ●Remove: Handlebar Holder Bolts [A] Handlebar Holders [B] Handlebar [C] Handlebar Installation ●Install the handlebar so that the angle of the handlebar matches the angle of the steering stem as shown.
  • Page 51 SUSPENSION/STEERING NOTE: 【4-12】...
  • Page 52 FRAME Frame Table of Contents Seat---------------------------------------------------------------------------------------------------------------5-2 Seat Removal-----------------------------------------------------------------------------------------------5-2 Seat Installation--------------------------------------------------------------------------------------------5-2 Front and Rear Fenders----------------------------------------------------------------------------------------5-3 Front Cover Removal-------------------------------------------------------------------------------------5-3 Front Fender Removal------------------------------------------------------------------------------------5-3 Front Fender Installation----------------------------------------------------------------------------------5-3 Rear Fender Removal-------------------------------------------------------------------------------------5-4 Rear Fender Installation-----------------------------------------------------------------------------------5-4 Radiator Removal------------------------------------------------------------------------------------------5-5 Foot Steps-------------------------------------------------------------------------------------------------------5-6 Foot Steps Removal---------------------------------------------------------------------------------------5-6 【5-1】...

  • Page 53: Seat

    FRAME Seat Seat Removal ● To remove the seat [A] by pulling the seat latch lever [B] up and then pulling the seat up to the rear. Seat Installation ● Slip the seat hook [B] under seat; and put the stoppers [C] into the holes on the rear fender.

  • Page 54: Front And Rear Fenders

    FRAME Front and Rear Fenders Front Cover Removal ● Remove: Headlight Assy. [A] Handlebar [B] Fuel Tank Cap ● Front Cover : Screws [C]*2 [D]*2 [E]*6 Bolts [A]*2 [B]*2 Front Fender Removal ● Remove: Front Left Fender Bracket Screws [A]*4 Front Left Fender Bracket Front Left Fender Screw [B]*4 Front Left Fender...

  • Page 55: Rear Fender Removal

    FRAME Rear Fender Removal ● Remove: Air Intake Duct [C] Rear Fender Bracket Bolts [A]*6 Rear Fender Bracket Screw [B]*4 Rear Fender Installation ● Please reverse the Removal steps to install. 【5-4】...

  • Page 56: Radiator Removal

    FRAME Radiator Removal ● Remove: Side Cover Screw [A] Side Cover [B] Water Tube [C] [D] [E] Connector [F] [G] Cooler Bolts *2 [H] Cooler [I] ● Remove: Radiator Cover Bolts [A] Radiator Protector [B] Radiator Installation ● Please reverse the Removal steps to install. 【5-5】...

  • Page 57: Foot Steps Removal

    FRAME Foot Steps Removal ● Remove: Step Bracket Bolts [A] [B] Step Screw*4 [C] and Bolts*2 [D] Step Bracket [E] Step [F] Headlight Assy Removal ● Remove: Handlebar (see Handlebar Removal) Front Cover (see Front Cover Removal) Headlight Holder Bolts [A] Headlight Screws [B] Headlight Base 【5-6】...
  • Page 58 ENGINE Engine Table of Contents Removal and Installation -------------------------------------------------------------------------------------6-2 Inspection -------------------------------------------------------------------------------------------------------6-7 Reassembly ---------------------------------------------------------------------------------------------------6-15 Attachment (1) Special Tool ---------------------------------------------------------------------------------------6-32 (2) Timing Chain -------------------------------------------------------------------------------------6-33 (3) Matrix Table --------------------------------------------------------------------------------------6-34 (4) Tightening Torque table -------------------------------------------------------------------------6-35 (5) Tightening Torque chart -------------------------------------------------------------------------6-40 (6) Service Data ---------------------------------------------------------------------------------------6-45 (7) Adhesive, Sealant and Oil application ---------------------------------------------------------6-47 (8) Periodic Maintenance Schedule ----------------------------------------------------------------6-48 (9) Specifications -------------------------------------------------------------------------------------6-49...

  • Page 59: Removal And Installation

    ENGINE Removal and Installation ● Thoroughly clean the ATV engine and chassis. ● Clean work area. ● Drain coolant and engine oil. Disassembly Set the engine assembly onto Special Tool; Engine Base Plate AY. ● Take out Cover CP (Drive Chain) and Plate (Drive Chain). ●...
  • Page 60 ENGINE MAG Cover CP. Note: Adopt tray or clothes (waste) to prevent oil pollution. ● Remove Reduction Gear 1, Shaft 1, Reduction Gear 2, Shaft ● Make sure their original positions for reassembling. ● Remove Oil Filter Cover and take out Oil Filter CP, O-ring and Spring (Filter).
  • Page 61 ENGINE Oil Pump ● Take out Snap Ring and Oil Pump Gear. ● Remove bolts and take out Oil Pump Case. ● Take out Oil Pump; feed Pump, Scavenging Pump and Oil Pump Shaft etc. ● Take out Shift Shaft CP along with washer. Note: Fit the washer onto the Shaft, not to lose it.
  • Page 62 ENGINE MAGNETO ASSY ● Remove flange nut. ● Take out Magneto Assy along with Starter Gear, Needle Bearing and Spacer, by means of Special Tool; MAG Remover. THERMOSTAT ● Remove bolts and take out Thermostat Cover and Thermostat. WATER PUMP ●...
  • Page 63 ENGINE CRANKCASE ● Remove bolt on the clutch side. ● Remove bolts on the MAG side. ● Take out the crankcase from Special Tool; Engine Base Plate AY and set it with the clutch side facing up on the plastic containers.

  • Page 64: Inspection

    ENGINE INSPECTION CYLINDER HEAD Disassembling Note: Identify the original position of disassembled parts, with marking as necessary. Place them in order on the clean table. ● Remove Valve lifter and adjusting pad. ● While depressing Valve Spring with exclusive tool (Valve spring compressor), take out Colette.
  • Page 65 ENGINE INTAKE & EXHAUST VALVE Valve Stem runout ● Remove carbon deposits. Place on the V-block. ● Measure the runout by means of dial gauge. ● If the result is out of specifications, replace with new Valve. Valve Stem runout Service Limit 0.03 mm Outer diameter (OD) of Valve Stem...
  • Page 66 ENGINE Valve Spring free length ● Measure the free length of inner and outer Valve Spring. ● If the result is out of specifications, replace with Spring as a set. Service Limit of free length 38.0 mm 39.9 mm CAMSHAFT Cam profile height ●...
  • Page 67 ENGINE Visual Checking ● Check for ware and damage on Cam Sprocket gear teeth. ● Check for ware and damage on decompression related parts. ● Check if decompression would be operated smoothly. ● If any parts would be damaged or worn, replace with new Camshaft Assy.
  • Page 68 ENGINE Clearance between Piston and Cylinder ● Clearance is Cylinder ID minus Piston OD. Clearance between Piston and Cylinder Service Limit 0.100 mm ID of Piston hole for Pin ● Clean Piston hole for Pin. ● Measure ID in the up and down direction and the right angle direction with dial caliper gauge.

  • Page 69: Piston Rings

    ENGINE PISTON RINGS Clearance between Piston Ring and groove ● Remove carbon deposits from Rings and grooves. ● Measure the clearance between Piston Ring and groove, by holding the Ring upwards in the groove, with thickness gauge. Service Limit of clearance 0.15 mm Second 0.15 mm...

  • Page 70: Timing Chain

    ENGINE TIMING CHAIN Chain Pitch ● Check for ware, damage and roller fallout. ● Place Chain on the flat table and pull with the 4.53 kg force and then measure the length of 20 pitches. Timing Chain Pitch (20 pitches) Service Limit 13.7 mm STARTER GEAR/ONE-WAY CLUTCH...
  • Page 71 ENGINE TRANSMISSION Visual checking – Shift Fork and Drum ● Check for ware and damage. ● If any ware on the Fork craw portion, replace with new one. Visual checking – Main Shaft and Counter Shaft Assy. ● After disassembling, check for ware and damage on dug clutch portion, gears and spline portions.

  • Page 72: Reassembly

    ENGINE Reassembly CRANKCASE 1 ● Press-fit crankshaft into crankcase 1 by means of Special Tool; CRANK ASSY TOOL KIT. Note: Hold Connecting Rod not to strike the Crankcase mating surface while press fitting. ● Install 1/8 plug in position. Tightening Torque: 9 -15 N-m ●...
  • Page 73 ENGINE ● Install Main Shaft Assy and Counter Shaft Assy with gears engaged into Crankcase 1. Note: Pay attention not to miss washer fitting to Counter Shaft. Be sure not to damage the lip portion of oil seal by the Counter Shaft end spline.
  • Page 74 ENGINE CRANKCASE 2 ● (When replacing Bearing with new one) Install Bearing Retainer Plates. Stopper Plate for Main Shaft Bearing Tightening Torque: 12 - 14 N-m Fastener:M6 Hex bolt 1 pcs. Stopper Plate B for Shift Drum Bearing Tightening Torque: 7 – 9 N-m Fastener: M6 Hex bolt 1 pcs.
  • Page 75 ENGINE ● Cover Crankcase 2 over Crankcase 1, assemble cases by lightly and carefully tapping with hummer to fit mating surfaces properly, without decline. Note: Hold Connecting Rod to keep the position of the groove on the end surface of Balancer Shaft. ●...
  • Page 76 ENGINE ● Set the case assembly onto Special Tool; Engine Base Plate ● Apply TB #1344 to Reverse Arm Lever threads (M6), and install along with Reverse Arm Spring. Tightening Torque: 9 - 11 N-m Fastener : M8 X 12L 1 pc.
  • Page 77 ENGINE ● Apply TB #1316 to M6 Stepped bolt threads, and fix Stopper Arm CP and Spring (Stopper) with M6 Stepped bolt. Tightening Torque: 9 - 11 N-m Fastener : M6 Stepped bolt 1 pc Note: Make sure the Spring (Stopper) orientation. Assembly Oil Pump Assy.
  • Page 78 ENGINE ● Assemble Drum Shifter and related parts. Make sure the spring force and smooth operation by moving the ratchet pole with finger. ● Install Drum Shifter along with Shifter Collar and Guide Plate onto Shift Cam. Tightening Torque: 9 - 11 N-m Fastener : M6 X 20L 2 pcs.
  • Page 79 ENGINE ● Apply oil to O-ring and install Starter Motor in position. Tightening Torque: 9 - 11 N-m Fastener : M6 X 25L 2 pcs. ● Fit two Pipe Knocks and set Cylinder Gasket. Assemble and install Piston. ● Set Piston Rings into Piston grooves; - Expander Ring into Oil Ring groove - Second Ring, facing the marking upwards - Top Ring, facing the marking upwards...
  • Page 80 ENGINE ● Install Chain Guide 1 onto Cylinder. Assemble Cylinder Head as shown in the illustration (1) Seal-valve ; 4 pcs. (2) Intake Valve ; 2 pcs. (3) Exhaust Valve ; 2 pcs. (4) Valve Spring (Inner) ; 4 pcs. (5) Valve Spring (Outer) ;...
  • Page 81 ENGINE Install Cylinder Head. ● Apply oil to M11 bolts threads and washer, and then tighten them in the following procedure. [As shown in Attachment (5)] Fastener : M11 X 198L 4 pcs. ● Tighten M6 bolts. Tightening Torque: 9 - 11 N-m Fastener : M6 X 40L 2 pcs.
  • Page 82 ENGINE ● Align the markings between Crank Sprocket and marking pale of Chain. ● Apply oil to Camshafts attaching portion, and install Camshaft (IN) and (EX) with Cam Sprocket marking and marking plate of Timing Chain aligned. Note: Decompression is furnished on Camshaft (EX). Do not mixed up.
  • Page 83 ENGINE ● Take out Special Tool and install bolt with Gasket (Aluminum). Tightening Torque: 4.5 – 6 N-m Fastener : M6 X 8L 1 pc. ● Make sure of smooth operation by turning Crankshaft. ● Adjust valve clearance with thickness gauge adopted at TDC position in the following procedures;...
  • Page 84 ENGINE Install Flywheel ● Fit Spacer with the chafer side inside onto Crankshaft on the MAG side. ● Apply TB #1306 and remove oil from the taper portion of Crankshaft. ● Fit Needle Bearing and apply grease. Not to apply grease onto the taper portion.
  • Page 85 ENGINE Install Clutch Assy. ● Assemble Clutch Assy. properly after checking disassembled parts. ● Fit Distance Collar into Main Shaft, apply oil into hole and turn Collar by one-turn. ● Fit Cultch Outer CP, lock washer with the hollow surface inwards and lock nut.
  • Page 86 ENGINE Install Clutch Cover. ● Fit Spring (Filter). ● Fit Filter Cover along with Oil Filter CP and O-ring. Tightening Torque: 9 – 11 N-m Fastener : M6 X 25L 2 pcs. ● Fit Gasket (Clutch Cover) onto Crankcase after spot applying TB #1215 onto the Crankcase surface.
  • Page 87 ENGINE Install MAG Cover ● Apply grease around Shaft 1 and 2, and fit Reduction Gear 1 and 2 in position correspondingly. ● Apply grease to gears. ● Fit Stator Coil into MAG Cover. Tightening Torque: 5.5 – 6.5 N-m Fastener : M5 X 30L 3 pcs.
  • Page 88 ENGINE ★ Make sure O-ring (Head Cover) and Chain Guide 2 are furnished and fit Head Cover. Fit rubber mount and tighten bolts. Tightening Torque: 9 – 11 N-m Install Adapter with convex portion upwards. Tightening Torque: 16 – 20 N-m Fastener : M8 X 20L 2 pcs.

  • Page 89: Attachment (1) Special Tool

    ENGINE Attachment (1) Special Tool 【6-32】...
  • Page 90 ENGINE 【6-33】...

  • Page 91: Matrix Table

    ENGINE ATTACHMENT (3) Matrix Table <Intake-Adjusting Pad Selection Matrix> Existing Adjusting Pad Marking (numeral mark w/3 digits on Adjusting Pad) 145 150 155 160 162 165 167 170 172 175 180 182 185 187 190 192 195 197 200 202 205 207 210 212 215 220 225 230 Suitable Adjusting Pad Marking (numeral mark w/3 digits on Adjusting Pad) 0.00-0.04 145 150 150 155 155 160 160 152 165 167 170 172 175 177 180 182 185 187 190 192 195 197 200 202 207 212 220...
  • Page 92 ENGINE ATTACHMENT (4) Fasteners and Tightening Torque table Parts Fasteners Numbers Tightening Torque Remarks (N-m) Adapter CP Hex bolt M8 16-20 Camshaft Support Bolt M6 9-11 Chain Guide Special bolt M8 13.5-16.5 Chain Tensioner Bolt M6 9-11 Chain Tensioner (itself) Bolt M6 4.5-6 Clutch...
  • Page 93 ENGINE 【6-36】...
  • Page 94 ENGINE 【6-37】...
  • Page 95 ENGINE 【6-38】...
  • Page 96 ENGINE 【6-39】...
  • Page 97 ENGINE 【6-40】...
  • Page 98 ENGINE 【6-41】...
  • Page 99 ENGINE 【6-42】...
  • Page 100 ENGINE 【6-43】...
  • Page 101 ENGINE 【6-44】...

  • Page 102: Service Data

    ENGINE ATTACHMENT (6) Service Data Cylinder Head and Valve Items Standards Service Limit Compression Pressure (Engine cranking speed at 400 rpm) 588-618 KPa (6.0-6.3 Kgf/cm 0.150 ± 0.05 mm Valve Clearance (Cold engine) 0.270 ± 0.05 mm Warpage on cylinder head upper surface 0.05mm 42.35 –...
  • Page 103 ENGINE Cylinder and Piston Items Standards Service Limit Cylinder Inner diameter 94.000 – 94.020 mm Cylindricality 0.05 mm Roundness 0.05 mm Warpage (Upper surface) 0.05 mm Piston Outer diameter* 93.955 – 93.970 mm Piston Ring Clearance between cylinder and piston 0.030 –...

  • Page 104: Adhesive, Sealant And Oil Application

    ENGINE ATTACHMENT (7) Adhesive, Sealant and Oil application Adhesive or Sealant Application Adhesive or Sealant Application Crankcase 2 Mating surface to Crankcase 1 TB#1215 Clutch Cover Spotting application for keeping gasket in position MAG Cover TB#1306 Flywheel Oil removing from taper portion Shift Drum M8 Bolt Threads Stopper Arm CP...

  • Page 105: Periodic Maintenance Schedule

    ENGINE ATTACHMENT (8) Periodic Maintenance Schedule Note; The maintenance schedule indicated in the following table is based on the normal operation condition. If operated in the extremely dusty condition or in heavier loading condition, the maintenance intervals must be Shortened depending on the conditions of oil, clogging of oil filter and air cleaner elements, ware of parts and so on.

  • Page 106: Specifications

    ENGINE ATTACHMENT (9) SPECIFICATIONS DIMENSIONS LENGTH 382 mm WIDTH 458 mm HEIGHT 489 mm DRY WEIGHT 48 kg ENGINE SPECIFICATIONS TYPE 4 CYCLE DOHC GASOLINE ENGINE SINGLE CYLINDER INCLINED 20∘FROM VERTICAL CLINDER ARRANGEMENT ψ94.0 X 64.6 mm BORE X STROKE DISPLACEMENT 0.448 L COMPRESSION RATIO...
  • Page 107 ENGINE DRIVE TRAIN SPECIFICATIONS PRIMARY REDUCTION SYSTEM: TYPE GEAR REDUCTION RATIO 2880 (72/25) CLUTCH TYPE MANUAL RELEASE, MULTI PLATE (8 PLATES), WET TRANSMISSION TYPE 5SPEED, DOG CLUTCH, CONSTANT MESH GEAR RATIO, CRANKSHAFT VS OUTPUTSHAFT GEAR RATIO: 1 2.429 (34/14) 6.994 1.611 (29/18) 4.640 1.286 (27/21)
  • Page 108 ELECTRICAL SYSTEM Electrical System Table of Contents Specifications---------------------------------------------------------------------------------------------------7-2 Parts Location---------------------------------------------------------------------------------------------------7-3 Precautions------------------------------------------------------------------------------------------------------7-5 Electrical Wiring------------------------------------------------------------------------------------------------7-6 Wiring Inspection------------------------------------------------------------------------------------------7-6 Battery-----------------------------------------------------------------------------------------------------------7-7 Battery Charging-----------------------------------------------------------------------------------------7-7 Charging Procedures--------------------------------------------------------------------------------------7-8 Battery Test Charging-------------------------------------------------------------------------------------7-8 Regulator/Rectifier Output Voltage Inspection--------------------------------------------------------7-9 Alternator Inspection------------------------------------------------------------------------------------7-10 Ignition System-----------------------------------------------------------------------------------------------7-11 Spark Plug Removal/Installation-----------------------------------------------------------------------7-11 Spark Plug Cleaning/Inspection------------------------------------------------------------------------7-11 Spark Plug Gap-------------------------------------------------------------------------------------------7-11 Ignition Coil Removal-----------------------------------------------------------------------------------7-11 Ignition Coil Installation--------------------------------------------------------------------------------7-12 Ignition Coil Inspection---------------------------------------------------------------------------------7-12...

  • Page 109: Electrical System

    ELECTRICAL SYSTEM Specifications Item Standard Battery Capacity 12 V 14Ah, Alternator type Three-phase AC Charging voltage (Regulator/rectifier output) 14~15 V Alternator output voltage DC14V-13.7A @ 3000 rpm Y1-Y2 0.52 Ω Y2-Y/R 0.49 Ω Charge Coil Y/R-Y1 0.49 Ω Stator Y-Ground ∞...

  • Page 110: Parts Location

    ELECTRICAL SYSTEM Parts Location High/Low Beam Switch [A] Hazard Lights Switch [B] Horn Switch [F] Indicator Switch [D] Ignition Switch [E] Starter Button [C] Battery [A] Starter Circuit Relay [B] CDI Unit [C] Ignition Coil [D] Spark Plug [E] Indicator Relay [F] 【7-3】...
  • Page 111 ELECTRICAL SYSTEM Regulator/Rectifier [G] Magneto CP [A] Starter Motor [B] Horn [B] Temperature Sensor[C] 【7-4】...

  • Page 112: Precautions

    ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and observe all the rules below. ○ Do not reverse the battery lead connections. This will burn out the diodes in the electrical parts. ○...

  • Page 113: Electrical Wiring

    ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection ● Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. ★ ● Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully.

  • Page 114: Battery

    ELECTRICAL SYSTEM Battery Battery Charging WARNING △ 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.

  • Page 115: Battery Test Charging

    ELECTRICAL SYSTEM Charging Procedure ● Remove the battery (see Battery Removal). ● Connect a charger to the battery BEFORE plugging it in or turning it on. ● Set the charging rate and time according to the battery condition previously determined CAUTION Always remove the battery from the vehicle for charging.

  • Page 116: Regulator/Rectifier Output Voltage Inspection

    ELECTRICAL SYSTEM Regulator / Rectifier Output Voltage Inspection ● Check the battery condition (see Battery section) ● Warm up the engine to obtain actual alternator operating conditions. ● Check that the ignition switch is turned off, and connect the hand tester to the battery terminal. ●...

  • Page 117: Alternator Inspection

    ELECTRICAL SYSTEM Alternator Inspection There are three types of alternator failures: short, open (wire burned out), or loss in rotor magnetism. A short or open in one of the coil wires will result in either a low output, or no output at all.

  • Page 118: Ignition System

    ELECTRICAL SYSTEM Ignition System 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.

  • Page 119: Ignition Coil Installation

    ELECTRICAL SYSTEM Ignition Coil Installation ● Connect the primary winding leads to the ignition coil terminals Ignition Coil Inspection ● Remove the ignition coil. ● Measure the primary winding resistance as follows: ○ Connect the tester between the coil terminals. ○...

  • Page 120: Ignition Timing Test

    ELECTRICAL SYSTEM Ignition Timing Test ● Remove the ignition inspection plug [A]. ● Attach the timing light and a tachometer in the manner prescribed by the manufacturer. ● Start the engine and aim the timing light at the timing mark on the Alternator rotor. ●...

  • Page 121: Lighting System

    ELECTRICAL SYSTEM Lighting System Headlight Bulb Replacement ● Remove: Headlight Unit. (See Frame Removal Chapter) Bulb Holder ● Slide back the dust protection , and remove the bulb from the headlight unit. ○ Turn the holder counterclockwise and pull it out. ●...

  • Page 122: Rear-View Mirror Replacement

    ELECTRICAL SYSTEM Rear-View Mirror Replacement ● Loosen the nut [A] anti-clockwise and disconnect the front indicator light wire [B] to remove the mirror. ● Reverse above procedure to assemble the new mirror. ○ Be sure to connect wiring with correct color as following chart.

  • Page 123: Wiring Diagram

    ELECTRICAL SYSTEM Wiring Diagram ON-OFF SPEEDOMETER / TRAN MAIN SWITCH INDICATOR LIGHTS SWITC Left Right High LEFT FRONT DIRECTIONAL SIGNAL RIGHT FRONT DIRECTIONAL SIGNAL HORN HEADLIGHT CLUTCH SWITCH HAND BRAKE SWITCH FROUT GROUND W/Bu Br/W STATOR 【7-16】...
  • Page 124 ELECTRICAL SYSTEM Wiring Diagram BATTERY 12V STARTER STARTER WINKER TRANS RELAY MOTOR RELAY SWITCH FUSE 20A LEFT REAR DIRECTIONAL SIGNAL RIGHT REAR DIRECTIONAL SIGNAL Bu/W HOT LAMP SWITCH FAN MOTOR Or/B FAN SWITCH TAIL LIGHT TETHER SWITCH FOOT BRAKE SWITCH REAR GROUND W/Bu...
  • Page 125 ELECTRICAL SYSTEM NOTE: 【7-18】...
  • Page 126 APPENDIX Appendix Table of Contents Considerations for Various Riding Conditions-------------------------------------------------------------8-2 Carburetor----------------------------------------------------------------------------------------------------8-2 Fuel System--------------------------------------------------------------------------------------------------8-3 Spark Plug----------------------------------------------------------------------------------------------------8-4 Clutch Adjustment------------------------------------------------------------------------------------------8-6 Troubleshooting Guide----------------------------------------------------------------------------------------8-7 【8-1】...

  • Page 127: Considerations For Various Riding Conditions

    APPENDIX Considerations for Various Riding Conditions This vehicle has been designed and manufactured to operate under a wide range of riding conditions. However, it is not feasible to anticipate all of the conditions under which this vehicle might be used. Extremes of temperature, altitude, and riding usage may make changing some carburetor parts pr the spark plug desirable to maintain the vehicle in peak operating condition.

  • Page 128: Fuel System

    APPENDIX ● Readjust idle speed to specification. Note: Always check throttle cable freeplay after adjusting idle speed and adjust if necessary. Idle Speed Adjustment ● Start engine and warm it up thoroughly. ● Adjust idle speed by turning the idle adjustment screw in (clockwise) to increase or out (counterclockwise) to decrease RPM.

  • Page 129: Spark Plug

    APPENDIX Spark Plug: The spark plug ignites the fuel and air mixture in the combustion chamber. To do this effectively and at the proper time, the correct spark plug must be kept clean and the gap adjusted. Tests have shown the plug listed in the General Information chapter to be the best plug for general use.
  • Page 130 APPENDIX The carbon on the electrodes conducts electricity, and can short the center electrode to ground by either coating the ceramic insulator or bring across the gap. Such a short will prevent an effective spark. Carbon build-up on the plug can also cause other troubles.

  • Page 131: Clutch Adjustment

    APPENDIX Clutch Adjustment Clutch Lever Freeplay ● Measure clutch lever freeplay between the perch and the lever (A). This distance should be 3~4.5mm. ● If adjustment is required, slide the clutch perch pivot boot down the clutch cable to access the clutch adjustment screw (B) and lock ring (C).

  • Page 132: Troubleshooting Guide

    APPENDIX Troubleshooting Guide NOTE ○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 Doesn’t Start, Starting Difficulty: CDI unit trouble Starter motor not rotating: Ignition coil trouble...
  • Page 133 APPENDIX Other: Fuel/air mixture incorrect: Carburetor vacuum piston doesn’t slide smoothly Main jet clogged Engine oil viscosity too high Fuel level too low Brake dragging Carburetor holder loose CDI unit trouble Air cleaner poorly sealed, or missing Front or rear final gear case oil viscosity too high Air cleaner duct loose Air cleaner clogged Poor Running or No Power at High Speed:...
  • Page 134 APPENDIX Over shifts: Abnormal Frame Noise: Shift arm positioning bole spring weak or broken Shock absorber noise: Shift tie-rod maladjusted Shock absorber damaged Abnormal Engine Noise: Disc brake noise: Knocking: Pad installed incorrectly CDI unit trouble Pad surface glazed Carbon built up in combustion chamber Disc warped Fuel poor quality or incorrect Caliper trouble...
  • Page 135 APPENDIX Break Doesn’t Hold Front brake: Air in the brake line Brake fluid leakage Brake fluid deteriorated Primary or secondary cup trouble Master cylinder scratched inside Pad over worn or worn unevenly Oil, grease on pads and disc Disc worn or warped Brake overheated Rear Brake: Brake not properly adjusted...

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