Dinli DL-801 Service Manual
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Dinli DL-801 Service Manual

270 cc quad
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Summary of Contents for Dinli DL-801

  • 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 (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. (8) High-Flash Point Solvent A high-Flash point solvent is recommended to reduce fire danger.
  • 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. 13G6500xxx) VEHICLE IDENTIFICATION (ex. RKWAJ74C45Txxxxxx) 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 DL-801 Engine 4-stroke, DOHC ψ72.7 x 63.0 mm Bore and stroke Compression ratio 12.0 Displacement 261.5 cm Coolant system Liquid cooled 1:1 water/anti-freeze[ethylene glycol(containing corrosion inhibitors Coolant for aluminum engines and radiators)]...
  • Page 14 GENERAL INFORMATION CHASSIS Frame Steel Overall length 1682 mm Overall width 1060 mm Overall height 1082 mm Seat height 810 mm Wheel base 1176 mm Front tire 21 x 7 – 10 Rear tire 20 x 11 – 9 Recommended cold tire pressure (front/rear) 30kpa/ 30kpa Turning radius (Inner Radius of Tire) 1650...

  • 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 Service Limit 25~40 mm - - - Wheel Alignment: Toe-in 2WD Tires: AT 21×7-10 25N Standard tire: Front - - - MAXXIS M-971-1, Tubeless AT 20×11-9 38N Rear - - - MAXXIS M-972-2, Tubeless Tire air pressure (when cold): Front 35 kPa (0.35 kgf/cm ,5.0psi) - - -...

  • 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. 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. [B] step Pedal Position [C] Standard: 49.8 ~ 54.8 mm above footrest If it i s correct, adjust the brake pedal position. ★...

  • Page 36: Caliper Removal

    BRAKE 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. ●Unscrew the banjo bolt and remove the brake hose from the caliper.

  • Page 37: Rear Brake Pads Removal

    BRAKE Rear Brake Pads Removal ●Remove the caliper (see Caliper Removal) ●Remove the Cir-clip [A] and bolt [B] ●Remove: Anti-rattle Spring [C] Brake Pads [D] 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: Steering

    SUSPENSION/STEERING Steering Stem Removal ●Remove: Speedometer Bracket Bolts [A] Speedometer Bracket [B] Handlebar Holder Bolts [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] Washer [G] CAUTION...

  • Page 45: Steering Stem Installation

    SUSPENSION/STEERING Steering Stem Installation ●Lubricate the steering stem clamp, grease seals, (see Steering Lubrication). ●Install the grease seals [A] facing the end [B] 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 46: 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 47: 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 48: 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 49: 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 50 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 Carrier Removal-------------------------------------------------------------------------------------5-3 Rear Fender Removal-------------------------------------------------------------------------------------5-4 Rear Fender Installation-----------------------------------------------------------------------------------5-4 Radiator Removal------------------------------------------------------------------------------------------5-5 Foot Steps-------------------------------------------------------------------------------------------------------5-5 Foot Steps Removal---------------------------------------------------------------------------------------5-5 Headlight Holder-----------------------------------------------------------------------------------------------5-6 Headlight Holder Removal-------------------------------------------------------------------------------5-6 【5-1】...

  • Page 51: 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 [A] under the brace [B] on the frame, and put the stoppers [C] into the holes on the frame.

  • Page 52: Front And Rear Fenders

    FRAME Front and Rear Fenders Front Fender Removal ● Remove: Handlebar Cover [A] (see Handlebar Removal) Handlebar [B] Fuel Tank Cap ● Remove: Front Fender Screws [A]*2 Front Fender Bolts [B]*2 [C]*6 Front Fender Front Fender Installation ● Please reverse the Removal steps to install. Rear Carrier Removal ●...

  • Page 53: Rear Fender Removal

    FRAME Rear Fender Removal ● Remove: Air Cleaner Cover [A] Air Cleaner [B] ● Remove: Battery [A] CDI Unit [B] Fuse [C] Starter Relay [D] Rear Fender Bolts [E] Rear Fender Bracket [F] Rear Fender Rear Fender Installation ● Please reverse the Removal steps to install. 【5-4】...

  • Page 54: Radiator Removal

    FRAME Radiator Removal ● Remove: Water Tube [A], [B] and [C] Connector [D] Fan Connector Radiator Bolts [E] *2 Radiator ● Remove: Radiator Cover Bolts [A]*4 Radiator Protector [B] Radiator Installation ● Please reverse the Removal steps to install. Foot Steps Removal ●...

  • Page 55: Headlight Holder

    FRAME Headlight Holder Removal ● Remove: Handlebar (see Handlebar Removal) Front Fender (see Front Fender Removal) Headlight Holder Screw [A] Headlight Bolts and Screw [B] Headlight Holder 【5-6】...
  • Page 56 ENGINE Engine Table of Contents ENGINE REMOVAL-----------------------------------------------------------------------------------------6-2 CYLINDER HEAD/VALVES-------------------------------------------------------------------------------6-6 SERVICE INFORMATION----------------------------------------------------------------------------6-6 CYLINDER HEAD COVER---------------------------------------------------------------------------6-7 CAMSHAFT/CAMSHAFT HOLDER----------------------------------------------------------------6-7 CYLINDER HEAD------------------------------------------------------------------------------------6-11 CYLINDER/PISTON----------------------------------------------------------------------------------------6-14 SERVICE INFORMATION--------------------------------------------------------------------------6-14 CYLINDER/PISTON----------------------------------------------------------------------------------6-15 DRIVE AND DRIVEN PULLEYS------------------------------------------------------------------------6-20 SERVICE INFORMATION--------------------------------------------------------------------------6-20 LEFT CRANKCASE COVER------------------------------------------------------------------------6-21 DRIVE PULLEY---------------------------------------------------------------------------------------6-22 CLUTCH/DRIVEN PULLEY------------------------------------------------------------------------6-24 FINAL REDUCTION/TRANSMISSION SYSTEM----------------------------------------------------6-25 SERVICE INFORMATION--------------------------------------------------------------------------6-25 TRANSMISSION CASE COVER-------------------------------------------------------------------6-26 TRANSMISSION--------------------------------------------------------------------------------------6-28 CRANKCASE/CRANKSHAFT/BALANCE SHAFT--------------------------------------------------6-33...

  • Page 57: Engine Removal

    ENGINE ENGINE REMOVAL ● Drain engine oil and transmission oil. ● Remove frame covers (Refer to the “Frame” chapter). ● Remove the carburetor. ● Remove the Exhaust Pipe. Torque Value: Engine Oil Drain Plug 1.5kgf-m Exhaust Pipe Nut 1.8 – 2.2kgf-m ●...
  • Page 58 ENGINE ● Disconnect the speedometer cable. ● Remove the three bolts at the drive sprocket cover and then remove the drive sprocket cover. ● Remove the two bolts on the drive sprocket. ● Remove the drive sprocket and washer. ● Slide the rubber sleeve back to expose the starter motor wire nut.
  • Page 59 ENGINE Remove the A.C.Generator, pulser and gear change switch couplers. ● Disconnect the spark plug cap. ● Unscrew the clamp and then disconnect the outlet hose from the left crankcase cover. ● Unscrew the clamp and then disconnect the inlet hose from the left crankcase cover.
  • Page 60 ENGINE ● Remove the three bolts and nuts for remove the left and right engine brackets. ● Remove the engine assembly to the left side of the machine. 【6-5】...

  • Page 62: Cylinder Head Cover

    ENGINE CYLINDER HEAD COVER REMOVAL ● Remove the four bolts at the cylinder head cover and then remove the cylinder head cover. INSTALLATION ● Install a new cylinder head cover O-ring and install the cylinder head cover. ● Install and tighten the cylinder head cover bolts. Torque: 0.8_ 1.2kgf-m NOTE: Be sure to install the O-ring into the groove properly.
  • Page 63 ENGINE ● Remove the four camshaft holder nuts and washers. NOTE: Diagonally loosen the cylinder head nuts in 2 or 3 times. ● Remove the camshaft holder and dowel pins. ● Remove the camshaft gear from the cam chain and remove the camshaft.
  • Page 64 ENGINE CAMSHAFT HOLDER INSPECTION ● Inspect the camshaft holder for wear or damage. ● Inspect the rocker arm shaft for blue discoloration or grooves. ● If any defects are found, replace the rocker arm shaft with a new one and then inspect lubrication system. ●...

  • Page 66: Cylinder Head

    ENGINE CYLINDER HEAD REMOVE ● Remove the camshaft. (Refer to the “Camshaft Remove” section ) ● Remove the carburetor and exhaust muffler.. ● Remove the two bolts and then remove the carburetor intake manifold as show. ● Remove the clip to disconnect the thermostat (Remember to drain the water in the hoses first) ●...
  • Page 67 ENGINE VALVE /VALVE GUIDE INSPECTION ● Inspect each valve for bending, burning, scratches or abnormal stem wear. If any defects are found, replace the valve with a new one. Check valve movement in the guide. ● Measure each valve stem O.D. ●...
  • Page 68 ENGINE ASSEMBLY ● Install the valve spring seats and oil seal. NOTE: Be sure to install new oil seal. ● Lubricate each valve with engine oil and insert the valves into the valve guides. ● Install the valve springs and retainers. ●...

  • Page 69: Cylinder/Piston

    ENGINE CYLINDER/PISTON SERVICE INFORMATION GENERAL INSTRUCTIONS The cylinder and piston can be serviced with the engine installed in the frame. After disassembly, clean the removed parts and dry them with compressed air before inspection. SPECIFICATIONS Standard (mm) Service Limit (mm) ψ72.70 –...

  • Page 70: Cylinder/Piston

    ENGINE CYLINDER/PISTON REMOVAL ● Remove the cylinder head. (Refer to “Cylinder Head/Valves”) ● Remove the two dowel pins, cylinder head gasket and cam chain guide. ● Disconnect the water hose. ● Remove the cylinder ● Remove the cylinder gasket and dowel pins. ●...
  • Page 71 ENGINE INSPECTION ● Inspect the piston, piston pin and piston rings. ● Remove the piston rings. NOTE: Take care not to damage or break the piston rings during removal. ● Clean carbon deposits from the piston ring grooves. ● Inspect the piston wall for wear/scratches/damage. If any defects are found, replace the piston with a new one.
  • Page 72 ENGINE ● Measure the piston pin O.D. Service Limit: ψ17.06mm replace if below ● Measure the piston O.D. NOTE: Take measurement at 10mm from the bottom and 90 to the piston pin hole. Service Limit: ψ72.60mm replace if below ● Measure the piston-to-piston pin clearance. Service Limit: 0.025mm replace if over CYLINDER INSPECTION ●...
  • Page 73 ENGINE PISTON RING INSTALLATION ● Install the piston rings onto the piston. ● Apply engine oil to each piston ring. NOTE: Be careful not to damage or break the piston and piston rings. All rings should be installed with the markings facing up. After installing the rings, they should rotate freely without sticking.
  • Page 74 ENGINE PISTON INSTALLATION ● Remove any gasket material from the crankcase surface. NOTE: Be careful not to drop foreign matters into the crankcase. ● Install the piston, piston pin and a new piston pin clip. NOTE: Position the piston “IN” mark on the intake valve side. Place a clean shop towel in the crankcase to keep the piston pin clip from falling into the crankcase.

  • Page 75: Drive And Driven Pulleys

    ENGINE DRIVE AND DRIVEN PULLEYS SERVICE INFORMATION GENERAL INSTRUCTIONS The drive pulley, clutch and driven pulley can be serviced with the engine installed in the frame. Avoid getting grease and oil on the drive belt and pulley faces. Remove any oil or grease from them to minimize the slipping of drive belt and drive pulley.

  • Page 76: Left Crankcase Cover

    ENGINE LEFT CRANKCASE COVER REMOVAL ● Loosen the drive belt air inlet and outlet hose band screws and disconnect them from the left crankcase cover. ● Remove the left crankcase cover bolts and left crankcase cover. ● Remove the gasket and dowel pins. INSPECTION ●...

  • Page 77: Drive Pulley

    ENGINE DRIVE PULLEY REMOVAL ● Remove the left crankcase cover. (Refer to the “LEFT CRANKCASE COVER REMOVAL” section) ● Hold the drive pulley using a universal holder and remove the drive face nut and washer. ● Remove the drive pulley. ●...
  • Page 78 ENGINE ● Measure the movable drive face bushing I.D. Service Limit: ψ27.06mm replace if over ASSEMBLY ● Install the weight rollers into the movable drive face. ● Install the ramp plate. ● Check the drive pulley collar for wear or damage. ●...

  • Page 79: Clutch/Driven Pulley

    ENGINE CLUTCH/DRIVEN PULLEY REMOVAL ● Remove the left crankcase cover. (Refer to “LEFT CRANKCASE COVER REMOVAL”) ● Remove the drive pulley. (Refer to “DRIVE PULLEY REMOVAL” ) ● Remove the o-ring, nut, washer and clutch outer. ● Remove the clutch/driven pulley and drive belt. SUGGESTION: If the clutch/driven pulley is damaged, please replace the whole clutch/driven Assy.

  • Page 80: Final Reduction/Transmission System

    ENGINE FINAL REDUCTION/TRANSMISSION SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS The transmission system can be serviced with the engine installed in the frame.  W hen replacing the drive shaft, use a special tool to hold the bearing inner race for this operation. SPECIFICATIONS Specified Oil: GEAR OIL SAE ??# Oil Capacity:...

  • Page 81: Transmission Case Cover

    ENGINE TRANSMISSION CASE COVER REMOVAL ● Drain transmission gear oil into a clean container.(Refer to “Engine Removal” section) ● Remove drive sprocket cover and drive sprocket. (Refer to “Engine Removal” section) ● Remove the drive select lever. (Refer to “Engine Removal” section) ●...
  • Page 82 ENGINE TRANSMISSION CASE COVER DISASSEMBLY ● Remove the drive axle cir-clip. ● Remove the drive axle from the transmission case cover. ● Remove the bearing. ● Inspect the bearing for allow play in the transmission case cover or the bearing turns roughly. If any defects are found, replace the bearing with a new one.

  • Page 83: Transmission

    ENGINE ● Inspect the needle bearing for allow play in the transmission case cover or the bearing turns roughly. If any defects are found, replace the bearing with a new one. ASSEMBLY ● Install the needle bearing. ● Install the oil seal and bearing. ●...
  • Page 84 ENGINE ● Remove the stopper plug. ● Remove spring, washer and shift cam stopper. ● Remove the transmission guide bar. ● Measure the guide bar runout. Out of specification – Replace. NOTE: Do not attempt to straighten a bent guide bar. ●...
  • Page 85 ENGINE ● Inspect shift shaft gear. Damage – Replace. ● Inspect shift shaft. Damage/bends/wear – Replace. ● Remove the main axle. MAIN AXLE DISASSEMBLY ● Remove the washers, collar, primary driven gear and clutch dog. 【6-30】...
  • Page 86 ENGINE ● Remove the cir-clip and then remove the washers, reverse wheel gear and needle bearing. ● Inspect the gear teeth. Blue discoloration/pitting/wear – Replace. ● Inspect the mated dogs. Rounded edges/cracks/missing portions – Replace. ● Remove the counter axle. ●...
  • Page 87 ENGINE PRIMARY DRIVE AXLE REMOVAL ● Remove the clutch/driven pulley. (Refer to “DRIVE AND DRIVEN PULLEYS”) ● Remove the oil seal and cir-clip. ● Remove the primary drive axle. ● Inspect the bearings for allow play in the transmission case cover or the bearing turns roughly.

  • Page 88: Crankcase/Crankshaft/Balance Shaft

    ENGINE CRANKCASE/CRANKSHAFT/BALANCE SHAFT SERVICE INFORMATION GENERAL INSTRUCTIONS This section covers crankcase separation to service the crankshaft. The engine must be removed for this operation. The following parts must be removed before separating the crankcase. Cylinder head/Cylinder/piston/Drive and driven pulleys /A.C. generator/Starter clutch/Oil pump SPECIFICATIONS Item Standard (mm)

  • Page 89: Crankcase/Crankshaft/Balance Shaft

    ENGINE CRANKCASE/CRANKSHAFT/BALANCE SHAFT REMOVAL ● Remove the timing chain from right crankcase. ● Remove the left and right crankcase attaching bolts. ● Remove the right crankcase.. NOTE: Do not damage the crankcase gasket surface. ● Remove the gasket and dowel pins. ●...
  • Page 90 ENGINE ● Remove balance shaft from the left crankcase. ● Clean off all gasket material from the crankcase mating surfaces. NOTE: Avoid damaging the crankcase mating surfaces. ● Inspect the balance shaft gear teeth. Burrs/chips/roughness/wear – Replace. CRANKSHAFT INSPECTION ● Inspect the crankshaft gear teeth. Burrs/chips/roughness/wear _ Replace.
  • Page 91 ENGINE ● Measure the crankshaft run out (A). Service Limit: 0.10mm replace if over ● Measure the connecting rod big end side clearance (B). Service Limit: 0.6mm replace if over ● Measure the connecting rod big end radial clearance (C). Out of specification (0.05 mm) –...
  • Page 92 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 93: Specifications

    ELECTRICAL SYSTEM Specifications Item Standard Battery Capacity 12V ; 12Ah (10hr) Alternator type Charging voltage (Regulator/rectifier output) 14.5V ± 0.5V Alternator output voltage 244V Stator Charge Coil 0.3 – 1.0Ω Resistance Pulser Coil 110Ω ± 15% Primary 1.5 – 3.5Ω Ignition Coil Resistance Secondary 12 –...

  • Page 94: Parts Location

    ELECTRICAL SYSTEM Parts Location Light/Dimmer Switch [A] Switch [B] Indicator Switch [C] Starter Button [D] Ignition Switch [E] Horn Switch [F] Battery [A] CDI Unit [B] Fuse [C] Starter Circuit Relay [D] Indicator Relay [A] Flasher Relay [B] Ignition Coil [C] Spark Plug [D] 【7-3】...
  • Page 95 ELECTRICAL SYSTEM Regulator/Rectifier [E] Magneto CP [A] Starter Motor [B] Horn [B] Temperature Sensor[C] 【7-4】...

  • Page 96: 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 97: 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 98: 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 99: 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 100: 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 101: 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 102: 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 103: 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 104: Ignition Timing Test

    ELECTRICAL SYSTEM Ignition Timing Test ● Remove the plug to expose the timing hole [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 105: Lighting System

    ELECTRICAL SYSTEM Lighting System Headlight Bulb Replacement ● Remove: Bulb Holder Screws [A]*2 Bulb Holder Bolts [B]*2 Bulb Holder Bulb ○ Turn the holder counterclockwise and pull it out. ● Be sure the socket is clean. ● Insert the new bulb by aligning the tang with the notch in the headlight unit.

  • Page 106: Taillight Bulb Replacement

    ELECTRICAL SYSTEM Taillight Bulb Replacement ● Remove: Taillight Holder Nut [A] Taillight ● Remove: Taillight Lens Screws [B] Taillight Lens [C] ● Turn the Taillight Bulb [A] counterclockwise to Remove it. ● Insert a new bulb by turning it clockwise. 【7-15】...

  • Page 107: 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 108: Fuses

    ELECTRICAL SYSTEM Fuses Main Fuse Removal ● Remove the seat (see Frame chapter) ● Remove the fuse case cap [A] and take out the fuse [B]. Fuse Inspection ● Inspect the fuse element [A] If it is blown out, replace the fuse. Before replacing a blow ★...

  • Page 109: Wiring Diagram

    ELECTRICAL SYSTEM Wiring Diagram 【7-18】...
  • Page 110 ELECTRICAL SYSTEM Wiring Diagram 【7-19】...
  • Page 111 ELECTRICAL SYSTEM NOTE: 【7-20】...
  • Page 112 APPENDIX Appendix Table of Contents Considerations for Various Riding Conditions-------------------------------------------------------------8-2 Carburetor----------------------------------------------------------------------------------------------------8-2 Spark Plug----------------------------------------------------------------------------------------------------8-4 Fuel System--------------------------------------------------------------------------------------------------8-6 Troubleshooting Guide----------------------------------------------------------------------------------------8-7 【8-1】...

  • Page 113: 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 114 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 115: 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 116 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 117: Fuel System

    APPENDIX Fuel System WARNING Gasoline is extremely flammable and explosive under certain conditions. ● Always stop the engine and refuel outdoors or in a well ventilated area. ● Do not smoke or allow open lames or sparks in/near the area where refueling is performed or where gasoline is stored.

  • Page 118: 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 119 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 120 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 121 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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