Dinli DMX 450 Owner's Manual
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Dinli DMX 450 Owner's Manual

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I. PREFACE
Dear Dinli Quad Users:
Before the delivery of each new vehicle from Dinli factory, the fuel in carburetor is drained off to ensure the
excellent performance and safety of the vehicle. Therefore, when first starting a new vehicle, it is normal to take
20~30 seconds. The quality of each Dinli Quad is guaranteed. Study this manual thoroughly and enjoy your riding
Dinli Quad.
!
WARNING
STOP! If you have the impression that four wheels give you the stability of a car, you are wrong. If you
have the impression that a quad is simple to drive and similar to those other vehicles, that you are
wrong. The risks involved are at least equal to those faced when riding a motorcycle.
1

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  • Page 1: Preface

    Dear Dinli Quad Users: Before the delivery of each new vehicle from Dinli factory, the fuel in carburetor is drained off to ensure the excellent performance and safety of the vehicle. Therefore, when first starting a new vehicle, it is normal to take 20~30 seconds.
  • Page 2 OWNER’S MANUAL POTENTIAL HAZARD Given the realities of sport quads and/or the limits of your own riding abilities you may lose control. The limits are impossible to be specific about because of the variation in terrain and rider ability are nearly unlimited.
  • Page 3 Experienced Riders Only All Dinli quads are high performance, sport and/or competition machines and should only be operated by licensed competition riders in excellent physical condition. Operators should be well-trained and experienced in the operation of high performance competition vehicles.
  • Page 4 If you have any comments or suggestions about this Owner's Manual, we'd appreciate hearing from you. Please send to: DIN LI METAL INDUSTRIAL CO., LTD. NO.51, Industrial 9th Rd., Tali City, Taichung 412 Taiwan, R.O.C. Tel: 886 (04) 2491-7666 Fax: 886 (04) 2491-7166 E-mail: globalservice@dinli.com.tw...
  • Page 5 All information in this Owner's Manual is based upon the latest product data and specifications available at the time of printing. Dinli Metal Industrial Co., Ltd. reserves the right to make product changes and improvements which may affect illustrations, photographs and explanations contained in this Owner's Manual. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, (electronic mechanical photocopying, recoding or otherwise), without the prior written permission of Dinli Metal Industrial Co., Ltd.

  • Page 6: Introduction

    II. INTRODUCTION Dear Users: Congratulations on your purchase of DINLI ATV. It represents the result of many years of Dinli experience in the production of fine machines. You can now appreciate our craftsmanship and reliability of the masterpieces. SAFTY ALTERTS FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.
  • Page 7 Messages with the Safety Alert Symbol ● Pay special attention to all messages preceded by the Safety Alert Symbol. It means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED DANGER Indicates that severe personal injury or DEATH will result if instructions are not followed. WARNING Indicates a potential hazard that could result in serious injury or death.

  • Page 8: Important Safety Message

    OWNER’S MANUAL III. IMPORTANT SAFETY MESSAGE ● A QUAD IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. ● A quad handles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and driving on hills or over obstacles, if you fail to take proper precautions.
  • Page 9 13. Never operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the quad on such terrain. Always be especially cautious on these kinds of terrain. 14. Always follow proper procedures for turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed.
  • Page 10 OWNER’S MANUAL 22. Never operate a quad in fast flowing water or in water deeper than that specified in this manual. Remember that wet brakes may have reduced stopping ability. Test you brakes after leaving water. If necessary, apply those several times to let friction dry out the linings.

  • Page 11: Table Of Contents

    IV. CONTENTS I. PREFACE--------------------------------------------------------------------------------------------------------------------------------------1 II. INTRODUCTION ----------------------------------------------------------------------------------------------------------------------------6 III. IMPORTANT SAFETY MESSAGE ----------------------------------------------------------------------------------------------------8 IV. CONTENTS --------------------------------------------------------------------------------------------------------------------------------11 1. LOCATION OF THE WARNING AND SPECIFICATION LABELS------------------------------------------------------------15 2. MACHINE IDENTIFICATION------------------------------------------------------------------------------------------------------------18 2-1 Vehicle Identification Number (VIN)-----------------------------------------------------------------------------------------19 2-2 Engine Serial Number----------------------------------------------------------------------------------------------------------20 2-3 Key ID number-------------------------------------------------------------------------------------------------------------------21 3. PARTS AND CONTROL FUNCTIONS-----------------------------------------------------------------------------------------------22 3-1 Seat---------------------------------------------------------------------------------------------------------------------------------25 3-2 Main Switch-----------------------------------------------------------------------------------------------------------------------28 3-3 Headlights-------------------------------------------------------------------------------------------------------------------------30...
  • Page 12 OWNER’S MANUAL 3-15 Fuel Valve -----------------------------------------------------------------------------------------------------------------------44 3-16 Speedometer -------------------------------------------------------------------------------------------------------------------45 3-17 Fuel Tank ------------------------------------------------------------------------------------------------------------------------47 3-18 Handlebar Assembly ---------------------------------------------------------------------------------------------------------47 3-19 Clutch Lever (manual) -------------------------------------------------------------------------------------------------------50 4. SAFE OPERATION------------------------------------------------------------------------------------------------------------------------51 4-1 Ride Sensibly---------------------------------------------------------------------------------------------------------------------52 4-2 Crossing Through Shallow Water--------------------------------------------------------------------------------------------53 4-3 Turning-----------------------------------------------------------------------------------------------------------------------------54 4-4 Riding Down Slope--------------------------------------------------------------------------------------------------------------55 4-5 Climbing Hill-----------------------------------------------------------------------------------------------------------------------57 4-6 Modifications----------------------------------------------------------------------------------------------------------------------59 5.
  • Page 13 7. MAINTENANCE & ADJUSTMENT----------------------------------------------------------------------------------------------------71 7-1 Work safely------------------------------------------------------------------------------------------------------------------------72 7-2 Maintenance schedule---------------------------------------------------------------------------------------------------------78 7-3 Air Filter----------------------------------------------------------------------------------------------------------------------------80 7-4 Frame, Subframe, Swingarm-------------------------------------------------------------------------------------------------81 7-5 Fuel ---------------------------------------------------------------------------------------------------------------------------------84 7-6 Engine Oil--------------------------------------------------------------------------------------------------------------------------87 7-7 Engine Cooling System -------------------------------------------------------------------------------------------------------92 7-8 Brakes -----------------------------------------------------------------------------------------------------------------------------96 7-9 Electrical -------------------------------------------------------------------------------------------------------------------------103 7-10 Air --------------------------------------------------------------------------------------------------------------------------------115 7-11 Exhaust-------------------------------------------------------------------------------------------------------------------------114 7-12 Suspension--------------------------------------------------------------------------------------------------------------------115 7-13 Wheels--------------------------------------------------------------------------------------------------------------------------116 7-14 Tires------------------------------------------------------------------------------------------------------------------------------119 7-15 Vehicle Immersion -----------------------------------------------------------------------------------------------------------122...
  • Page 14 OWNER’S MANUAL 13. QUAD LIMITED WARRANTY-------------------------------------------------------------------------------------------------------137 13-1 WARRANTY CONDITIONS-----------------------------------------------------------------------------------------------137 13-2 WARRANTY PERIOD-------------------------------------------------------------------------------------------------------137 13-3 WARRANTY TRANSFER--------------------------------------------------------------------------------------------------137 13-4 WARRANTY EXCLUSION-------------------------------------------------------------------------------------------------137 13-5 COMPETITION MODEL EXCLUSION----------------------------------------------------------------------------------137 13-6 PARTS AND LABOR COVERED BY WARRANTY------------------------------------------------------------------138 13-7 PARTS AND LABOR NOT COVERED BY WARRANTY-----------------------------------------------------------138 13-8 WARRANTY LIMITATION--------------------------------------------------------------------------------------------------140 14.

  • Page 15: Location Of The Warning And Specification Labels

    ● If any label is missing, worn, damaged, or becomes unreadable, be sure to replace it. Dinli offers replacement labels at no charge. A label's number is printed in the lower right corner of the label and here parts number in the manual. Contact an authorized Dinli dealer for replacements.
  • Page 16 OWNER’S MANUAL...
  • Page 17 Do not consume alcohol, Always stop the vehicle drugs or cigarettes before or completely before changing during operating the ATV from forward into reverse or vice versa. Failure to do so may harm the gear box. Maximum Vehicle Load: Operating this ATV if you are 200kg, (441 lbs) under the age of 16 Includes weight of operator,...

  • Page 18: Machine Identification

    OWNER’S MANUAL 2. MACHINE IDENTIFICATION NOTE: Your vehicle may differ from those shown in the illustrations in this manual. Record your vehicle's identification numbers in the spaces provided. Keep another record of the numbers in a safe place; you may need them for parts, service information, or theft recovery. Your vehicle's ID numbers identify it from others of the same model type.

  • Page 19: Vehicle Identification Number (Vin)

    2-1 VEHICLE IDENTIFICATION NUMBER (VIN) The vehicle identification number (VIN) is etched / stamped into the right side of frame. The VIN also appears on a temporary factory applied adhesive label on the front frame 1. Etched vehicle identification number 2.

  • Page 20: Engine Serial Number

    OWNER’S MANUAL 2-2 ENGINE SERIAL NUMBER The engine serial number is etched / stamped into the left crankcase of the engine. 1. Engine serial number Write your number here...

  • Page 21: Key Id Number

    2-3 KEY ID NUMBER Key identification numbers are etched / stamped into key tag. NOTE: Keep your spare key in a safe place in case you lose the primary key. 1. Primary key 2. Spare key 3. Tag (With Key ID number) Write your number here...

  • Page 22: Parts And Control Functions

    OWNER’S MANUAL 3. PARTS AND CONTROL FUNCTIONS NOTE: Your vehicle may differ slightly from those shown in the illustrations in this manual. 1. Clutch lever 4. Rear brake lever 2. Main switch 5. Throttle lever 3. Parking brake lock 6. Parking brake lever...
  • Page 23 1. Rear mirror 8. Oil tank 15. Starter motor 2. Headlight assembly 9. Shift lever 16. Footpeg & Footboard 3. Fuel pump 10. Front wheel 17. Rear wheel 4. Coolant recovery bottle 11. Seat 5. Radiator 12. Air filter(under seat) 6.
  • Page 24 OWNER’S MANUAL 18. Speedometer & Indicator lights 20. Tail light (stop light) 19. Handlebar assembly 21. Rear turn signal lights Start switch 22. Rear shock absorber Hazard switch 23. Front turn signal lights Horn button 24. Handle grips Lights switch 25.

  • Page 25: Seat

    3-1. SEAT The entire length of the seat is required so that you can shift body weight / position while riding to maintain vehicle control and stability. Make sure the seat is in good condition and fastened securely before you ride. 1.
  • Page 26 OWNER’S MANUAL 3. To install the seat, align the receiver on the seat with the catch on the frame and put the stoppers in the holes. 4. Press down gently on the middle of the seat and slide the seat forward onto the catch of frame. If correctly aligned, the rear seat pegs will slip easily.
  • Page 27 WARNING POTENTIAL HAZARD Loose, damaged, or improperly installed seat WHAT CAN HAPPEN The seat can shift or come off while you are riding causing you to lose control of the vehicle, you can be severely injured or death. HOW TO AVOID THE HAZARD Always make sure the seat is locked into position on the mounts and secured properly with the retention bolt, Never ride the quad with a damaged seat.

  • Page 28: Main Switch

    OWNER’S MANUAL 3-2. MAIN SWITCH The main switch is located between the handlebars. Always remove the key from the switch to help prevent unauthorized vehicle use or theft. Ignition switch (key shown inserted) & Switch positions...
  • Page 29 Functions of the respective switch position are as follows: Key position Function The engine and lighting cannot be operated. “OFF” Turning the main switch to the “OFF” position, Removal will stop a running engine. With the brake lever pulled in, the engine started using the switch.

  • Page 30: Headlights

    OWNER’S MANUAL 3-3. HEADLIGHT Turn the main switch to the “ ” position to activate the headlights. Test for the proper operation of the headlights before operating the vehicle. Headlight...

  • Page 31: Taillight

    3-4. TAILLIGHT Turn the main switch to the “ ” position to activate the taillight. Make sure it works before every ride. Taillight...

  • Page 32: Front Break Lever

    OWNER’S MANUAL 3-5. FRONT BRAKE LEVEL The front brake lever is located on the right side of the handlebar. Pull it toward the handlebar to apply the front brakes. Pull the lever harder to increase braking force. Before each ride, make sure the front breaks are operating properly and can provide braking force when needed.

  • Page 33: Parking Brake

    3-6. PARKING BRAKE The parking brake is applied with a button switch on the parking brake lever. When the parking brake is applied (locked), the front brakes temporarily prevent the vehicle from rolling. Be sure to read the warning about using the parking brake! Parking brake button...
  • Page 34 OWNER’S MANUAL WARNING POTENTIAL HAZARD (s) 1. Quad rolling away 2. Riding with the parking brake applied. WHAT CAN HAPPEN 1. A potential decline in fluid pressure can decrease the applied braking force allowing the quad to begin to roll. 2.

  • Page 35: Foot Brake Pedal

    3-7. FOOT BRAKE PEDAL The foot brake pedal is located on the right side of the vehicle. When treaded, braking force is applied to the four wheels. Make sure the foot brake is operating properly before you ride. Roll the vehicle forward and back and press the pedal to confirm that braking force is applied to the brake disc. Foot brake pedal...

  • Page 36: Footpegs & Footboard

    OWNER’S MANUAL 3-8. FOOTPEGS & FOOTBOARD When riding always keep your feet on the footpegs. Always check the condition of the footpegs and footboard before every ride. Make sure that they are fastened securely to the vehicle. The footpegs' teeth should be in good condition (not smooth or worn excessively). The footboard should be free of any packed soils and they should not be cracked, broken, or damaged in any way.

  • Page 37: Shift Lever

    3-9. SHIFT LEVER The shift lever is located on the left side of the engine in front of the left footpeg. The vehicle has five forward and one reverse gears (Reverse, 1-down, “NEUTRAL”4-UP). Place the vehicle on a lever surface. Before every ride, make sure the shift lever operates properly and shifts through the entire range of gears with the engine turned off;...

  • Page 38: Fuel Tank Cap

    OWNER’S MANUAL 3-10. FUEL TANK CAP Make sure the fuel cap is tightly secured before every ride. Turn the fuel cap counterclockwise to remove it and clockwise to tighten it. Always make sure the breather hose is routed from the cap properly Fuel cap Breather hose...

  • Page 39: Handle Grips

    Inspect both (left and right) handlebar grips before every ride. Make sure they are firmly attached and do not twist on the handlebar. Inspect the grips for wear, tears, or other damage. Replace the grips with a new set if damage is found. Contact an authorized Dinli dealer for a replacement set. Handle grip (right)

  • Page 40: Throttle Lever

    OWNER’S MANUAL 3-12. THROTTLE LEVER The throttle lever is located on the right side of the handlebar. When pushed, the engine speed will increase. When released, engine speed will decrease-the lever spring pressure should return the lever to the set idle (engine) speed. Check for proper operation and specified free play of the throttle before every ride.
  • Page 41 WARNING POTENTIAL HAZARD (s) Improper adjustment of the speed limiter and throttle. WHAT CAN HAPPEN The throttle cable could be damaged. Improper throttle operation could result. You could lose control, have an accident or be injured. HOW TO AVOID THE HAZARD Do not turn the speed adjuster out more than 15 mm.

  • Page 42: Fuse

    OWNER’S MANUAL 3-13. FUSE The main electrical fuse is under the seat. Always replace the fuse with one of the specified rating. 1. 20A 2. 25A...

  • Page 43: Locking Steering

    3-14. LOCKING STEERING The lock insert is on the steering shaft underneath the front fender. Sitting on the vehicle, turn the steering handlebar right to end and turn the key clockwise, the steering handlebar is locked. The key can be taken out. Turn the key to left, the steering handlebar is released automatically.

  • Page 44: Fuel Valve

    OWNER’S MANUAL 3-15. FUEL VALVE The three way fuel valve is on the left side of the vehicle, which control the fuel from the fuel tank to the carburetor OFF: With the lever in this position, ON: With the lever in this position, RES: This indicates reserve.

  • Page 45: Speedometer

    3-16. SPEEDOMETER ※ Press the left button and then press the right button to interchange KM(MPH) for MPH(KM) on the speedometer.
  • Page 46 This indicator light will come on when the vehicle running mileage reach to 1000km, please have the vehicle for regular maintenance. See page141. ● Water temperature light When the main switch in “ON” if the light comes on automatically, you must stop the vehicle immediately and contact an authorized Dinli dealer.

  • Page 47: Fuel Tank

    3-17. FUEL TANK Fuel tank capacity is 12 liter including 0.8 liter in the reserve supply. Automotive gasoline with octane no.95 or higher may be used. After refueling, be sure to tighten the tank cap firmly. Do not refuel right after the engine has been running and is still hot. It is recommended to check the fuel level before you begin to ride 3-18.
  • Page 48 OWNER’S MANUAL 3-18-1. LIGHT PUSH BUTTON Push the switch to the “ ” position to switch on the low beam and the taillight. Push the switch to the “ ” position to switch on the high beam and the taillight. 3-18-2.
  • Page 49 3-18-4. HAZARD SWITCH “ ” At this position, the front and rear light and the turn signal lights blink together. “●” At this position, all light will be turned out at the time. CAUTION Turn on this switch when parking or there is special condition. After the hazard switch is turned on, it will not rest.

  • Page 50: Clutch Lever (Manual)

    OWNER’S MANUAL 3-19. CLUTCH LEVER (MANUAL) The clutch lever is located on the left side of the handlebar. Pull in the clutch lever (quickly) to disengage the clutch, and release the lever (slowly) to engage the clutch. Check the condition and proper operation of the clutch lever and cable before every ride.

  • Page 51: Safe Operation

    Crashing the quad. WHAT CAN HAPPEN Dinli ATVs are high-performance machine only by operators who already have substantial skill and operating experience. Operating without substantial skill and operating experience increases the risk that you could lose control of the vehicle becoming severely injured or killed in a resulting accident.

  • Page 52: Ride Sensibly

    They should then regularly practice the skills learned in the course and the operating techniques described in this Owner’s manual. For more information about the training course, contact an authorized Dinli dealer. Riding your machine requires skills acquired through practice over a period of time.

  • Page 53: Crossing Through Shallow Water

    4-2. CROSSING THROUGH SHALLOW WATER The quad can be used to cross slow moving shallow water up to a maximum of 52 cm (20.5”) in depth. Never attempt to ride any quad in deep or fast moving water, such as river or streams. You could quickly lose control and become caught in water currents.

  • Page 54: Turning

    OWNER’S MANUAL 4-3. TURNING It is essential that this skill shall be learned at first at low speed. The ride must learn to move his weight and control the throttle to allow the rear tires to get the turn. When turning, the wheel on the outside of the turn must travel a wider radius and thus a greater distance than the inside wheel.

  • Page 55: Riding Down Slope

    4-4. RIDING DOWN SLOPE When riding down slope, shift your weight back as far as possible with your arm straight. Choose a low gear to allow the engine to do most of braking for you. Improper braking may lead to a loss of traction and vehicle control resulting in an accident.
  • Page 56 OWNER’S MANUAL NOTE: A special technique is required when braking as you go down a slope. Always check the terrain carefully before descending any slope. Shift your weight backward. Never travel down a slope at high speed. Avoid traveling down a slope at an angle that would cause the vehicle to lean sharply to one side. Go straight down the slope when possible.

  • Page 57: Climbing Hill

    4-5 CLIMBING HILL Climbing hills is an advanced technique. Before attempting to climb difficult hills, practice on flat round and then smaller hills to build experience. Never attempt a hill or slope beyond your skill level and evaluate all hills and slopes carefully to avoid terrain that may cause the quad to overturn.
  • Page 58 OWNER’S MANUAL NOTE: Always check the terrain carefully before ascending any hill. Shift your weight forward. Never operate the quad on hill steeper than 25° Never climb hill with excessively slippery or loose surface. Keep both feet on the footrests, maintain steady and controlled throttle openings.

  • Page 59: Modifications

    Never modify this quad through improper installation or use of accessories. All parts and accessories added to this vehicle should be genuine DINLI or equivalent components designed for use on this quad and should be installed and used according to approved instructions. If you have question,...

  • Page 60: Per-Ride Inspection

    Always inspect this quad before you operate it. Always follow the inspection and maintenance procedures found in this Owner’s Manual. Have your vehicle serviced by an authorized Dinli dealer every 20 hours of operation, and per 1,000 Km riding. When reading this manual, remember: WARNING Indicates a potential hazard that COULD result in serious injury or death.

  • Page 61: Pre-Ride Checklist

    Proper operation, condition lever freeplay 40, 41, 86 107, 108, Battery Check connections 134 – 136 ※If you have any doubt, not understanding or difficulty in inspection or adjustment with this quad, we suggest to contact the nearby service point or a Dinli’s dealer.

  • Page 62: Operation

    HOW TO AVOID THE HAZARD Read the owner’s manual carefully and be sure you understand everything in it before operating the vehicle. If you don’t understand something, ask a Dinli dealer. General Starting Tips CAUTION Only hold the start switch for 2-3 seconds at a time.

  • Page 63: Cold Starting

    6-1. COLD STARTING 1. Make sure the vehicle is on level ground and the transmission is in NEUTRAL. 2. Lock the parking brake and make sure the fuel valve is on. 3. Turn the main switch to the “ON” position 4.

  • Page 64: Starting A Warm Engine

    OWNER’S MANUAL 6. Press and hold the engine start switch for no more than 2 to 3 seconds at a time. If the engine “pops” or seems to backfire you're holding the throttle open too much. 1 mm is a very fine lever movement. Back the lever off, wait briefly, and re-try.

  • Page 65: Break

    6-3. BREAK-IN The brake-in period is critical to the long term life and reliability of the engine. The break-in period for the engine is at least 1 hour. When operating during this period be sure to observe the following cautions: ●...
  • Page 66 OWNER’S MANUAL 3. After riding the vehicle, clean it thoroughly and allow it to dry. Then inspect the entire vehicle for damage or loose fasteners. 4. Repair or tighten any damaged or loose components and lubricate the vehicle. 5. If the vehicle is damaged, it is recommended that you put tape over the main switch to remind you to not start the vehicle.

  • Page 67: Manual Shift

    6-4. MANUAL SHIFT 6-4-1. FORWARD The gear shift pedal is located in front of the left footpeg. One full stroke of the pedal shift the transmission to the next gear in the shifting sequence. The pedal automatically returns to a horizontal position when released. To upshift to a higher gear, place the toe of your boot under the gear shift pedal and raise the pedal one full stroke.
  • Page 68 OWNER’S MANUAL WARNING POTENTIAL HAZARD Shift without releasing the throttle and disengaging the clutch. WHAT CAN HAPPEN Could cause loss of control or vehicle overturn. HOW TO AVOID THE HAZARD Always release the throttle and fully squeeze the clutch lever while shifting gears. NOTE: Always allow a cold engine to warm up before shift gears.
  • Page 69 8. Use the same procedure to change gear pattern as recommended: Gear Speed Recommended for shifting gear After start Approach 30km/h Approach 50km/h Approach 65km/h Approach 75km/h 9. To slow or stop the quad, release the throttle lever and apply the brakes smoothly and evenly. As the vehicle slows and engine RPM decreases, disengage the clutch and shift to a lower gear.
  • Page 70 OWNER’S MANUAL 6-4.2 REVERSE SWITCH The reverse switch is located in front of right fender. Make sure the machine is at the “1 ” gear, lift up the “REVERSE” lever and set down the shift lever. Simultaneously Release the “reverse” lever and clutch lever to engage the “REVERSE” gear. The “R” indicator lights on.

  • Page 71: Maintenance & Adjustment

    Your Ability If you do not feel comfortable or in any way doubt your own abilities to perform a procedure described in this manual, don't attempt it; have an authorized Dinli dealer perform the servicing...

  • Page 72: Work Safely

    OWNER’S MANUAL 7-1. WORK SAFELY Make sure you read and understand the warnings at the beginning of this section. Carbon Monoxide DANGER POTENTIAL HAZARD Running the engine indoors. Breathing exhausts gases. WHAT CAN HAPPEN Running the engine indoors will expose you to dangerous exhaust gases.
  • Page 73 Hot Components WARNING POTENTIAL HAZARD Hot components (e.g., engine, radiator, hoses, bulbs, exhaust, brakes) WHAT CAN HAPPEN The engine and other vehicle systems operate at extremely high temperatures. HOW TO AVOID THE HAZARD Wait for the engine and vehicle systems to cool completely before starting any work.
  • Page 74 OWNER’S MANUAL Gasoline WARNING POTENTIAL HAZARD Improper care when handling fuel. WHAT CAN HAPPEN Fuel is highly flammable; spilling it can cause a fire or explosion. HOW TO AVOID THE HAZARD Be sure the fuel cap is closed securely. Work in a well-ventilated area which is free of sources that could ignite any spilled fuel accidentally (e.g.
  • Page 75 Protect Your Eyes WARNING POTENTIAL HAZARD Blindness, eye injury WHAT CAN HAPPEN Anytime you work on the vehicle there is a potential that an accident involving a foreign object, vehicle component part, fluid, tool, or other maintenance related item can result in severe injury to your eyes. HOW TO AVOID THE HAZARD Always wear safety glasses when working.
  • Page 76 OWNER’S MANUAL Moving parts WARNING POTENTIAL HAZARD Losing a finger, hand or limb or entanglement WHAT CAN HAPPEN Moving parts can catch your clothing, fingers or hand resulting in severe injury. HOW TO AVOID THE HAZARD Never perform maintenance procedures with the engine running.
  • Page 77 Fluids WARNING POTENTIAL HAZARD Vehicle fluids (e.g., engine oil, brake fluid, coolant) WHAT CAN HAPPEN The fluids in your vehicle are hazardous substances. Contact with your skin or eyes you can result in serious injury or irritation. If swallowed, death can result. HOW TO AVOID THE HAZARD Wear hand protecti9on and safety glasses when working with vehicle fluids.

  • Page 78: Maintenance Schedule

    ＊ ENGINE OIL FILTER (s) ▲DINLI dealer service suggested 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 79 TIE ROD ENDS ★ ▲DINLI dealer service suggested 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 80: Air Filter

    OWNER’S MANUAL 7-3. AIR FELTER NOTE: The air filter is located under the seat Do not operate with the air filter removed. You can seriously damage the engine. 1. Cover of air filter 2. Cogs x 4 3. Clip...

  • Page 81: Frame, Subframe, Swingarm

    If you have crashed or rolled your quad, there could be damage hidden from your view, DO NOT ride a quad with any crack, even a small one. It must be carefully inspected by an authorized DINLI dealer before it is used again.
  • Page 82 HOW TO AVOID THE HAZARD Contact an authorized DINLI dealer for servicing if either the frame, subframe or swingarm is damaged; never try to repain the frame, subframe, swingarm or other components.
  • Page 83 1. Frame 2. Rear shock strut 3. Subframe 4. Swingarm 5. Engine rail/skid plate 6. Bumper...

  • Page 84: Fuel

    OWNER’S MANUAL 7-5. FUEL Always use clean high quality unleaded gasoline. (Octane 95 above is recommended) WARNING POTENTIAL HAZARD Over filling the fuel tank. WHAT CAN HAPPEN Fuel expands due to heat (e.g., engine, sun) and may overflow if the tank is overfilled, resulting in a fire.
  • Page 85 The idle speed adjustment screw is located on the carburetor body. It is accessible from the left side of the vehicle. A special diagnostic tool is necessary to read (display) the engine rpm. For this reason, idle adjust should be left to a DINLI service technician. 1. To adjust the idle, allow the engine to reach operating Temperature 158℉...
  • Page 86 If the proper adjustment cannot be obtained or the throttle lever does not operate properly, the cable end at the throttle body can be adjusted; however, access to it is difficult and should be left to a qualified service technician. See your DINLI dealer for servicing.

  • Page 87: Engine Oil

    7-6. ENGINE OIL Engine oil is a significant factor in the service life and performance of the engine. Change the engine oil in accordance with the maintenance schedule. See “Maintenance & Adjustment” starting on page78. Service more frequently under severe conditions. 7-6-1.
  • Page 88 OWNER’S MANUAL 1. To check the level, start the engine and allow to run for 1 minute at idle speed, then turn off the engine. 2. Remove the dipstick. Full 1. Engine oil dipstick 2. Markings 3. Wipe the dipstick with a clean rag and screw back in completely. Then remove and inspect the level on the stick. The oil level should be between the markings on the dipstick.
  • Page 89 7-6-2. CHANGING ENGINE OIL Always change the oil at the intervals outlined in the “MAINTENANCE SCHEDULE” see page78. Perform a break-in oil change after one hour of operation, or after the first tank of fuel, whichever comes first, change the oil more frequently on vehicles subjected to severe use.
  • Page 90 OWNER’S MANUAL 3. Allow the oil to drain completely. 4. Replace the sealing washer and reinstall the plug & torque to 19 Nm. NOTE: The sealing surfaces on drain plugs, and crankcase should be clean and free of burrs, nicks or scratches.
  • Page 91 6. Allow the oil to drain completely. 7. Replace the sealing washer and reinstall the plug & torque to 19 Nm. 8. Place shop towels beneath the oil filter. 9. Remove the three cover bolts and remove the cover. 10. Pull out the oil filter. 11.

  • Page 92: Engine Cooling System

    OWNER’S MANUAL 7-6-3. OIL PUMP PRIMING This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected. 1. Clamp or pinch off the vent line approximately 2” from the oil tank. 2.
  • Page 93 1. Coolant bottle 2. Bleed hose NOTE: The coolant system on your vehicle is the self bleed type and the hose should be visible.
  • Page 94 OWNER’S MANUAL 7-7-2. CHECKING THE COOLANT LEVEL 1. Make sure the engine and radiator are completely cold. 2. Observe the coolant level in the recovery bottle without opening the cap. The level should be between “FULL” and “ADD” mark “FULL” & “ADD” mark FULL 7-7-3.
  • Page 95 7-7-4. CHANGING THE COOLANT 1. Make sure the coolant system is completely cold and you are wearing safety glasses and protective rubber gloves. Have a few clean rags handy to wipe up any spills. 2. Remove the clip. 3. Remove coolant recovery bottle tube to allow coolant to drain completely. Reinstall the tube and clip. 4.

  • Page 96: Brakes

    You should feel firm resistance when braking. As with the foot brakes, force applied to the pedal should be forward to the front and rear discs preventing the vehicle from rolling. If the foot brake operates improperly have a DINLI dealer inspect the system. 4. Inspect the rear brake pads for wear.
  • Page 97 7-8-2. BRAKE FLUID WARNING POTENTIAL HAZARD Using contaminated brake fluid, using brake fluid other than DOT4, mixing brake fluid types. WHAT CAN HAPPEN Brake performance can be reduced or brakes can fail resulting in a serious accident. HOW TO AVOID THE HAZARD Use only DOT4 brake fluid from a sealed container.
  • Page 98 OWNER’S MANUAL 7-8-3. HAND BRAKE 1. To check the hand brake system, place vehicle on a level surface and level the handlebars. 2. Inspect the fluid level through the inspection window in the master cylinder reservoir. The fluid should be above the “LOWER” make on reservoir body. Add fluid if necessary. 3.
  • Page 99 5. Add the recommended brake fluid from a sealed container until the fluid level is above the “LOWER” mark on the reservoir body. 6. Reinstall the diaphragm, cover, and cover screws. NOTE: The hand brake master cylinder reservoir is located on the left side of the vehicle handlebar. Make sure the vehicle is on a level surface and the reservoir itself is level when checking.
  • Page 100 OWNER’S MANUAL 7-8-4. FOOT BRAKE 1. To check the foot brake fluid level, place vehicle on a level surface and make sure the reservoir itself is level. The fluid level should be above the “MIN” mark. Add if necessary. 2. To add, clean the cap and surrounding area thoroughly before opening. Pour the specified brake fluid from a clean container until it reaches over the “MIN”...
  • Page 101 7-8-5. PARKING BRAKE When parking, squeeze each hand brake lever. While doing this, press the parking brake button on each handlebar brake set. This will result in locking the brake lever. Make sure that the brake lever is locked to ensure that the ATV will remain safely immobile while parked.
  • Page 102 OWNER’S MANUAL WARNING POTENTIAL HAZARD Riding with improperly operating brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD Check the brake cable for kinks or signs of wear that could cause sticking or failure. Lubricate the brake cable with a available cable lubricant to prevent premature wear or corrosion.

  • Page 103: Electrical

    The engine temperature sensor is brass, located on the left side vehicle. If the engine temperature is too high, the “high-temp” indication located on meter will light on. You should stop riding/using the vehicle immediately and have the vehicle inspected by authorized DINLI dealer. Coolant temperature sensor...
  • Page 104 If a fuse blows immediately after replacement have the electrical circuits checked by an authorized DINLI dealer. Always turn OFF the main switch when checking or replacing the fuse. Otherwise a short circuit may occur. Check the condition of the wiring harness and connectors before replacing a blown fuse.
  • Page 105 7-9-3. LIGHTING NOTE: Always wipe off a newly install bulb with alcohol-dampened clean cloth or tissue. Oils from your fingers can cause premature bulb failure. Headlight bulb replacement 1. Disconnect the headlight harness connector. 2. Loosen the screws [A] & bolts [B] from the headlight housing and remove the bulb. 3.
  • Page 106 OWNER’S MANUAL Taillight bulb replacement Remove the taillight cover by loosen the bolts. Push and turn the bulb mount counterclockwise to remove it from the housing 1. Pull the bulb out from mount and install a new bulb. 2. Push the new bulb into mount and turn clockwise to reinstall it. 3.
  • Page 107 7-9-4. BATTERY All models use a sealed type battery therefore they do not require any maintenance other than routine charging such as during storage and cleaning. Always have the battery serviced by an authorized DINLI dealer. CAUTION Never attempt to add water to a maintenance-free battery.
  • Page 108 OWNER’S MANUAL Keep battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels.
  • Page 109 7-9-5. SPARK PLUG Use NGK DCPR8E sparks. Proper electrode gap is 0.8~0.9 mm Spark plug torque is 250 kgf-cm. CAUTION Using non-recommended spark plugs may result in serious engine damage and may void your emission-related warranty. Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds.
  • Page 110 OWNER’S MANUAL Wet Fouled The insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. General causes of fouling are excessive oil, use of non-recommended oil, improper use of the choke, or incorrect carburetion adjustments.
  • Page 111 5. Lightly coat the threads with a suitable anti-seize compound; this will allow for easier plug removal in the future. 6. Install the spark plug into the cylinder head and tighten to the specified torque. 7. Reinstall removed components...

  • Page 112: Air

    OWNER’S MANUAL 7-10. AIR Air filter element cleaning The air filter is located under the seat WARNING POTENTIAL HAZARD Fire or explosion, filter damage WHAT CAN HAPPEN Using gasoline or other low flash point solvents to clean the air filter can result in a fire or explosion. HOW TO AVOID THE HAZARD Use a non-flammable (high-flash point) solvent to clean the air filter elements CAUTION...
  • Page 113 1. Remove the seat. 2. Release the filter retaining clip and remove it. 3. Push away the cog to remove the filter cover. 4. Remove the air filter from the air filter base plate. (1) Air filter foam 5. Clean filter element with an air filter specific cleaning solvent. Rinse the element in warm water and allow drying. 6.

  • Page 114: Exhaust

    OWNER’S MANUAL 7-11. EXHAUST Spark arrester cleaning The spark arrester must be purged of carbon build up at the intervals specified in the maintenance schedule of this Owner’s Manual. (1) Screw (2) Spark arrester 1. Move the vehicle to a suitable outdoor location. Place the vehicle on a level surface, shift the transmission into NEUTRAL and apply the parking brake.

  • Page 115: Suspension

    Uneven adjustment will result in pool handing and/or loss of vehicle stability. You can lose control of the quad and suffer severe injury or death in a resulting accident. HOW TO AVOID THE HAZARD Contact DINLI’s dealer or the other professional maintenance station to make adjustment when required. CAUTION Do not turn the adjusters beyond the fully closed position (fully seated).

  • Page 116: Wheels

    OWNER’S MANUAL 7-13. WHEELS WARNING POTENTIAL HAZARD (1) Damaged cotter pins (or re-using cotter pins) (2) Riding on damaged wheel rims WHAT CAN HAPPEN (1) A damaged cotter pin can become dislodged allowing the hub nut and wheel to come off suddenly causing you to lose control.
  • Page 117 Excessive freeplay could be caused by worn or damaged A-arm bushings, damaged or worn wheel bearings, incorrectly adjusted or loose tie rod ends, or other damage in the steering assembly. Contact an authorized DINLI dealer and have the conditions corrected. Lateral Freeplay Inspection...
  • Page 118 OWNER’S MANUAL 4. Make sure the wheel axle nut cotter pins on each wheel are in good condition before every ride. Make sure the pin is not broken or damaged. It should have both tabs (or legs) and they should be bent properly. (1) Cotter pin...

  • Page 119: Tires

    7-14. TIRES The air pressure within the tires affects the quad's handing and stability. Check the air pressure and maintain the recommended tire pressure in each tire before every ride. Ordinary automotive tire pressure gauges are not capable of accurately reading the pressure in your quad tires. WARNING POTENTIAL HAZARD (1) Uneven or improper tire pressure...
  • Page 120 OWNER’S MANUAL The tire listed below has been homologation approved for this vehicle; other tires combinations are not recommended. Homologation Front: 92.5 kg (205 lb) Max load Type Rear: 132 kg (290 lb) 21 x 7.00 – 10 25N ☆☆ Tubeless Front tires 20 x 11.00 –...
  • Page 121 7-14-2. WEAR LIMIT 1. The pressure should be checked when the tires are cold before running the vehicle. 2. Tire pressure must be equal on both sides. 3. Never set tire pressure below minimum. 4. Higher pressure may cause the tire to burst. Inflate tires very slowly and carefully. Fast inflation could cause the tire to burst.

  • Page 122: Vehicle Immersion

    OWNER’S MANUAL 7-15. VEHICLE IMMERSION If your quad has been submerged or overturned in water deeper than the footpeg level, it’s critical to dry it promptly and properly before starting the engine. CAUTION Do not start the engine after a quad has been in water that exceeds the recommended depth. Tow or trailer the quad to your dealer for service.

  • Page 123: Cleaning

    8. CLEANING Regular cleaning helps to maintain appearance and contributes to overall performance if the quad keeping it free of damaging dirt, soils, and grime. ● When cleaning, avoid harsh detergents and chemical solvents. ● Use an ordinary garden hose and only enough water pressure to do the job. ●...
  • Page 124 OWNER’S MANUAL Before you start cleaning the quad take the following precautions: ● Make sure the vehicle is completely cool before cleaning it. ● Thoroughly dry the vehicle after washing it. ● Cover the rear muffler opening, brake lever and pedals, start and stop switch, throttle with plastic bags secure with strong rubber bands.

  • Page 125: Storage

    9. STORAGE When the vehicle will not be operated for an extended period of time (e.g., winter months, 45 days or more), it is necessary to perform certain procedures to guard against deterioration and make sure it is in perfect running condition when the riding season begins. 1.

  • Page 126: Transporting

    OWNER’S MANUAL 10. TRANSPORTING It is essential to transport the vehicle in a proper position. The proper position must be strong and firm to against the quad roll off the truck and trailer. WARNING POTENTIAL HAZARD Failure to properly secure the ATV. WHAT CAN HAPPEN Failure to properly secure the vehicle may cause an accident or damage to the vehicle.

  • Page 127: Troubleshooting

    Piston ring is worn or stuck cylinder is Engine turns over but will not start or is Low compression worn. hard to start. See you Dinli dealer. Low battery voltage. Charge and/or clean the battery. The terminals are loose or corroded. No spark to spark plug Inspect plug, verify switch is on.
  • Page 128 OWNER’S MANUAL Engine stop and start switches are faulty Check Solenoid faulty. Replace. Air filter clogged Clean or replace Corroded battery terminal Clean Engine starts hard when hot Fouled spark plug. Replace. Faulty solenoid. Test or replace Fuel return line blocked Inspect.
  • Page 129 Coolant bottle cap loose Tighten. Fuel deterioration. Drain, fill with fresh fuel. Worn or defective spark plug wire. See your Dinli dealer Fouled or defective spark plug Replace spark plug Engine stalls. Fuel hose clogged. Clean or replace Air filter clogged...

  • Page 130: Model Specification

    OWNER’S MANUAL 12. MODEL SPECIFICATION NOTE: Specifications subject to change without notice 12-1 ENGINE Model DMX 450 Engine 4-stroke, DOHC Bore and stroke 94 mm x 64.6mm Compression ratio 11.6 : 1 Displacement 448 cc Coolant system Liquid cooled 1:1 water/ anti-freeze [ethylene glycol(containing corrosion...
  • Page 131 1600 ± 100 rpm Engine idle speed Spark plug, standard NGK (DCPR8E) 0.8 – 0.9 mm Spark plug gap Lubrication system Dry sump Ignition system Compression pressure 130 psi Fuel filter replacement FRAM G4 164 or equivalent CAUTION Be sure to change the engine oil and clean/replace the filters in accordance with the vehicle maintenance schedule.

  • Page 132: Chassis

    OWNER’S MANUAL 12-2 CHASSIS Model DMX 450 Frame Steel Overall length 1830 mm Overall width 1090 mm Overall height 1150 mm Seat height 850 mm Wheel base 1268 mm Front tire 21x7-10 Rear tire 20x11-9 Recommended cold tire pressure 35kpa / 35kpa...
  • Page 133 Water crossing maximum depth 520 mm Front suspension travel 11” Rear suspension travel 10” Dry weight (appx KGs) Fuel tank capacity 11.5L 1/8 – 5/16 in (3-8 mm) Throttle lever freeplay Air filter Foam Brake fluid DOT4 Brake pad thickness (MIN) 1.0 mm Brake disc thickness (MIN) 3.5 mm...

  • Page 134: Battery

    OWNER’S MANUAL 12-3 BATTERY Warning notes and safety regulations for lead-acid battery. ● Read instructions carefully. ● Do not use at the places near fire. Hydrogen gas generated from battery may Cause fire and explosion. ● When using the battery, wear safety glasses and rubber gloves. Sulfuric acid may cause blindness or severe burn. ●...
  • Page 135 Battery instruction...
  • Page 136 OWNER’S MANUAL DANGER EXPLOSIVE GASES keep sparks, flames and cigarettes away. Provide adequate ventilation when charging or using batteries in an enclosed space. CHEMICAL HAZARD contains sulfuric acid. Contact with skin even through clothing. May cause severe burns. Wear a face shield and protective clothing. If electrolyte gets into your eyes, antidote: flush thoroughly with water for at least 15 minutes and call a physician immediately.

  • Page 137: Quad Limited Warranty

    13-2 WARRANTY PERIOD The warranty period for Dinli begins on the date of purchase and six (6) months from the date of purchase. 13-3 WARRANTY TRANSFER This warranty applies to the original purchaser and is not transferable 13-4 WARRANTY EXCLUSION Dinli quad used for commercial, rental, or law enforcement purposes are excluded from warranty coverage.

  • Page 138: Parts And Labor Covered By Warranty

    DINLI dealer. Covered parts used in warranty repairs will be warranted for the balance of the warranty period. Covered parts replaced under warranty become the property of DINLI...
  • Page 139 ● Maintain and operate the DINLI quad in accordance with the instructions and maintenance schedule printed in the Owner's Manual. ● Keep records and receipts of the date of purchase of the DINLI quad and all scheduled maintenance performed at the intervals specified in the Owner's Manual. This will be necessary when requesting warranty repairs to prove that the DINLI quad is within the warranty period and that required scheduled maintenance was performed.

  • Page 140: Warranty Limitation

    Dinli makes no other presentations or warranties, expressed or implied, with respect to service to owners or users or to any other person or entity. No one is authorized to assume for Dinli any warranty obligation or liability in connection with the sale of Dinli quads. Dinli owns the right to change any warranty and service policy at any time without liability to any person or entity by reason of any such change.

  • Page 141: Maintenance Record

    14. MAINTENANCE RECORD It is important to keep accurate records of maintenance service. This data is vital for referencing previous work or knowing what type of tuning was performed under certain conditions. DATE SERVICE REMARKS...

  • Page 142: Addenda

    OWNER’S MANUAL ADDENDA This section is reserved for updates, supplements, and revisions.

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