Dinli DL702 Service Manual
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Dinli DL702 Service Manual

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FOREWORD/INDEX
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Summary of Contents for Dinli DL702

  • Page 1 FOREWORD/INDEX 【0-0】...
  • Page 2 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 3 ● 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 4 FOREWORD/INDEX Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices. 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.
  • Page 5 FOREWORD/INDEX CHAPTER INDEX CHAPTER 1 GENERAL CHAPTER 2 WHEELS/TIRES CHAPTER 3 BRAKE CHAPTER 4 SUSPENSION CHAPTER 5 FRAME CHAPTER 6 ENGINE CHAPTER 7 ELECTRICAL CHAPTER 8 APPENDIX 【0-4】...
  • Page 6 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 7: Before Servicing

    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. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts.
  • Page 8 GENERAL INFORMATION seems especially difficult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use an impact driver for screws (particularly for the removing screws held by non-permanent locking agent) in order to avoid damaging the screw heads.
  • Page 9 GENERAL INFORMATION any cir-clips, retaining rings, and cotter pins with new ones, as removal weakens and deforms them, they could become detached while the quad is driven, leading to a major problem. (15) Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the sliding surfaces have an adequate lubrication film.

  • Page 10: Model Identifications

    GENERAL INFORMATION Model Identification Engine serial number Vehicle identification number ENGINE SERIAL NUMBER (Ex. 15M18XXXXX) VEHICLE IDENTIFICATION (ex. RFWAK85CX6Txxxxxx) Whenever corresponding with DINLI about a particular issue, the engine number and serial number are important for vehicle identification. 【1-5】...

  • Page 11: General Specifications

    GENERAL INFORMATION General Specification NOTE: Specifications subject to change without notice. Model DL702 Engine 4-stroke, DOHC Bore and stroke 102mm x 85 mm Compression ratio 10.0:1 Displacement 694.6 cc Coolant system Liquid cooled 1:2 water/anti-freeze [ethylene glycol(containing corrosion Coolant inhibitors for aluminum engines and radiators)], Quantity = 3...
  • Page 12 GENERAL INFORMATION CHASSIS Frame Steel Overall length 2208 mm Overall width 1129 mm Overall height 1120 mm Seat height 916 mm Wheel base 1305 mm Front tire 25 x 8 – 12 Rear tire 25 x 10 – 12 Recommended cold tire pressure (front/rear) 35kpa/ 30kpa (5.0psi/ 4.4psi) Turning radius 6.5m...

  • Page 13: Periodic Maintenance Chart

    Steering assembly (fasteners, operation) General Lubrication ▲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 14: 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-----------------------------------------------------------------------------2-5 Wheel (Rim) Replacement--------------------------------------------------------------------------2-6 Tires-----------------------------------------------------------------------------------------------------------2-6 Tires Removal----------------------------------------------------------------------------------------2-6 Tires Installation-------------------------------------------------------------------------------------2-7 Tires Inspection--------------------------------------------------------------------------------------2-8 Front Hub---------------------------------------------------------------------------------------------------2-8 Front Hub Removal---------------------------------------------------------------------------------2-8 Front Hub Installation------------------------------------------------------------------------------2-9 Front Hub Disassembly/Assembly-------------------------------------------------------------2-9 Rear Hub---------------------------------------------------------------------------------------------------2-9...

  • Page 15: Specifications

    WHEELS/TIRES Specifications Item Standard Wheel Alignment: Toe-in 11~40 mm Tires: Standard tire: Front AT 25×8-12 MAXXIS M915, Tubeless Rear AT 25×10-12 MAXXIS M916, Tubeless Tire air pressure (when cold): Front 35 kPa (0.35 kgf/cm , 5.0 psi) Rear 30 kPa (0.31 kgf/cm , 4.4 psi) Vehicle Maximum load-capacity 250 KG...

  • Page 16: 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 toe-in is incorrect, the...

  • Page 17: Toe-In Inspection

    WHEELS/TIRES ● Repeat the straight edge 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 ●...

  • Page 18: Wheels (Rims)

    WHEELS/TIRES Wheels (Rims) Wheel Removal ● Support the vehicle on a stand or the jack so that the wheels are off the ground. ● Loosen the wheel nuts [A] ● Take off the wheel nuts and remove the wheel. Wheel Installation ●...

  • Page 19: Wheel (Rim) Replacement

    WHEELS/TIRES Wheel (Rim) Replacement ● Remove the wheel (see Wheel Removal) ● Disassemble the tire from the rim (see Tire Removal). ○ Remove the air valve and discard it. CAUTION: Replace the air valve whenever the tire is replaced. Do not reuse the air valve.

  • Page 20: Tires Installation

    WHEELS/TIRES Tire Installation ● Inspect the rim (see Wheel (Rim) Inspection). ● Replace the air valve with a new one. CAUTION: Replace the air valve whenever the tire is replaced. Do not reuse the air valve. ● Check the tire for wear and damage (see Tire Inspection) ●...

  • Page 21: Tires Inspection

    WHEELS/TIRES ● Check the tire pressure using an air pressure gauge. Tire Air Pressure (when cold) Front: 35 kPa (5.0 psi) Rear: 30 kPa (4.4 psi) ● Install the wheel (see Wheel Installation). ● Wipe off the soap and water solution on the tire and dry the tire before operation.

  • Page 22: Front Hub Disassembly/Assembly

    WHEELS/TIRES Front Hub Disassembly/Assembly ● Don not press the hub bolts out. If any hub bolt [A] is damaged, replace the hub [B] and bolts as a unit. Rear Hub Rear Hub Installation ● Grease the axle spindle. ● Apply non-permanent locking agent: Rear Axle Nuts ●...
  • Page 23 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 Bleeding------------------------------------------------------------------------------3-4 Master Cylinder----------------------------------------------------------------------------------------------3-5 Master Cylinder Removal----------------------------------------------------------------------------3-5 Master Cylinder Installation-------------------------------------------------------------------------3-5 Calipers---------------------------------------------------------------------------------------------------------3-5 Front Caliper Removal--------------------------------------------------------------------------------3-5 Rear Caliper Removal---------------------------------------------------------------------------------3-6 Caliper Installation------------------------------------------------------------------------------------3-6 Brake Pads-----------------------------------------------------------------------------------------------------3-7 Brake Pads Removal-----------------------------------------------------------------------------------3-7 Brake Pads Installation--------------------------------------------------------------------------------3-7 Brake Pads Wear Inspection-------------------------------------------------------------------------3-7...

  • Page 24: 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 25: Brake Fluid Level Inspection

    BRAKE Brake Fluid Level Inspection ● Position the reservoir horizontal, and check the fluid level in the reservoir. If the fluid level is lower than the lower level line, check for fluid leakage of the brake line, and add the fluid as follow. ○...

  • Page 26: Brake Line Air Bleeding

    BRAKE ● 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 check for fluid leakage around the fittings. WARNING If the brake lever has a soft or "spongy feeling" when it is applied, there might be air in the brake line or the brake may be defective.

  • Page 27: Master Cylinder

    BRAKE Master Cylinder Master Cylinder Removal ●Removal: Brake Hose Banjo Bolt [B] Master Cylinder Clamp Bolts [A] Master Cylinder CAUTION Brake fluid quickly ruins painted surface; any spilled fluid should be completely washed away immediately. Master Cylinder Installation ● The master cylinder clamp must be installed with the "UP" mark [C] upwards.

  • Page 28: Rear Caliper Removal

    BRAKE NOTE ○If the caliper is to be disassembled after removal and if compressed air is not available, disassemble the caliper before the brake hose is removed (see Caliper Disassembly). Rear Caliper Removal ●Remove the rear wheel (see Wheels/Tires chapter). ●Remove the exhaust pipe.

  • Page 29: Brake Pads

    BRAKE Brake Pads Brake Pad Removal ● Remove the wheels (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. ●...

  • Page 30: Front Brake Disc Removal

    BRAKE Front Brake Disc Removal ● Remove: Front Hub (see Wheels/Tires chapter) Brake Disc Mounting Bolts [A] Brake Disc [B] Rear Brake Disc Removal ● Remove the rear caliper (see Rear Caliper Removal) and Parking Brake Caliper, unscrew the banjo bolt and remove the brake hose from the caliper.

  • Page 31: Disc Runout

    BRAKE Front Disc Thickness Standard: 3.5mm Service Limit: Rear Disc Thickness Standard: 4 mm Service Limit: 3.5mm 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. ●...

  • Page 32: Foot Brake

    BRAKE Foot Brake Brake Pedal Position Inspection ●Check that the brake pedal [A] is in the correct position as shown. Pedal Position [C] Standard: 72 ~ 80 mm above footrest If it is correct, adjust the brake pedal position. Brake Pedal Position Adjustment ●...

  • Page 33: 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]. ●Loosen the master cylinder mounting bolts [D]. CAUTION Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely washed away immediately.
  • Page 34 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 Preload Adjustment ------------------------------------------------------4-3 Suspension Arms---------------------------------------------------------------------------------------------4-3 Suspension Arm Removal----------------------------------------------------------------------------4-3 Suspension Arm Installation------------------------------------------------------------------------4-3...

  • Page 35: Shock Absorbers

    SUSPENSION/STEERING Shock Absorbers Front Shock Absorber Removal ● While supporting the vehicle up with a 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]. ●...

  • Page 36: Suspension Arms

    SUSPENSION/STEERING Suspension Arms 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 ●...

  • Page 37: Steering

    SUSPENSION/STEERING Steering Steering Stem Removal ● Remove: Handlebar Holder Bolts ×2 Handlebar Holder Cover Upper Handlebar Clamp bolts [A] ×4 Upper Handlebar Clamp Handlebar (see Handlebar Removal) Oil Tank Cover(see Frame Chapter) Instrument Panel ● Remove: Steering Clamp Bolts [A] Steering Clamp Support Plate [B] Steering Clamp [C] Tie-Rod End Nuts [D]...

  • Page 38: Steering Knuckle Removal

    SUSPENSION/STEERING ● Tighten: Torque – Bottom End Nut: 29 N-m (3.0 kgf-m, 22 ft-lb) Bearing Housing Bolts: 20 N-m (2.0 kgf-m, 14.5 ft-lb) Clamp Allen Bolts: 25 N-m (2.5 kgf-m, 18.0 ft-lb) Tie-Rod End Nuts: 47 N-m (4.8 kgf-m, 35 ft-lb) ●...

  • Page 39: Tie-Rod Installation

    SUSPENSION/STEERING Tie-Rod Installation ● The right and left tie-rods are identical. ● Install the tie-rod with the flattened area [A] located inboard. ● Tighten: Torque - Tie-Rod End Nuts: 47 N-m (4.8 kgf-m, 35 ft-lb) ● Inspect the toe-in if necessary Tie-Rod End Removal ●...

  • Page 40: Steering Stem Warp

    SUSPENSION/STEERING If the steering lubrication does not remedy the problem, inspect the steering stem warp, steering stem clamps, and tie-rod bearings. If you feel looseness, or if the steering rattles as it turns, check the tightness of the steering bolts and nuts. ●...

  • Page 41: Handlebar

    SUSPENSION/STEERING Handlebar Handlebar Removal ● Remove: Throttle Switch Front Brake Master Cylinder Left Lever Switch Housing Right Lever Switch 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 42: Differential Gear Oil Replacement

    SUSPENSION/STEERING ● Tighten the oil level plug [1] and oil filter plug [2] to the specified torque. Differential Gear Oil Replacement ● Place the vehicle on level ground. ● Remove the front under protector. ● Place an oil pan below the differential gear case. ●...
  • Page 43 SUSPENSION/STEERING ● Drain oil by removing the oil drain plug [3], oil filter plug [2] and oil level plug [1]. ● Tighten the oil drain plug [3] to the specified torque and pour fresh oil through the oil filter hole until it overflows from the oil level hole.
  • Page 44 FRAME FRAME Table of Contents Seat---------------------------------------------------------------------------------------------------------------5-2 Seat Removal----------------------------------------------------------------------------------------------5-2 Seat Installation------------------------------------------------------------------------------------------5-2 Front and Rear Fenders-------------------------------------------------------------------------------------5-2 Front Fender Removal----------------------------------------------------------------------------------5-2 Front Fender Installation-------------------------------------------------------------------------------5-4 Rear Fender Removal-----------------------------------------------------------------------------------5-4 Rear Fender Installation--------------------------------------------------------------------------------5-4 Radiator Removal----------------------------------------------------------------------------------------5-4 Radiator Installation ------------------------------------------------------------------------------------5-5 Foot Board Removal------------------------------------------------------------------------------------5-5 Headlight Assembly Removal------------------------------------------------------------------------5-5 【5-1】...
  • Page 45 FRAME Seat Seat Removal ● To remove seat [A], insert the key to the main switch. ● Push inward the key and turn it counter-clockwise to seat open position [B]. ● Lift the seat front slightly, pull it toward the front and remove the seat.
  • Page 46 FRAME ● Remove front fender decoration [B] by inserting the opening stick into the hole [A] to open it. ● Remove the maintenance compartment ● Remove headlight by unscrewing the screws [C]×6 ● Remove headlight shade by unscrew the screws [D]×6 ●...
  • Page 47 FRAME ● Remove Left and Right Fender. Front Fender Installation ● Please reverse the Removal steps to install. Rear Fender Removal ● Remove: Seat Rear rack ● Remove: Pan head Screw [A]×6 (attach to luggage compartment) Pan head Screw [B]×3 (attach to luggage compartment) Machine Screw [C] ×6 (right×3, left×3, attach to footboard) Rear Fender Installation ●...
  • Page 48 FRAME Tube Clip and Water Hose ×2 [A] Cooling fan switch [B] Cooler bracket bolts ×4 Cooler bracket Radiator Protector Bolts ×4 Radiator Protector Reservoir water hose [C] Reservoir tank bolt ×2 Reservoir tank Radiator Installation ● Please reverse the Removal steps to install. Foot Board Removal ●...
  • Page 49 ENGINE Engine Table of Contents Removal and Installation ----------------------------------------------------------------------------------6-2 Engine Removal----------------------------------------------------------------------------------------6-2 Engine Installation---------------------------------------------------------------------------------------6-5 Engine Disassembly ----------------------------------------------------------------------------------------6-5 Engine Top Side------------------------------------------------------------------------------------------6-5 Engine Bottom Side-------------------------------------------------------------------------------------6-9 Inspection ----------------------------------------------------------------------------------------------------6-15 Camshaft and Cylinder Head-----------------------------------------------------------------------6-15 Cam Chain Tensioner---------------------------------------------------------------------------------6-19 Cam Chain Guide--------------------------------------------------------------------------------------6-19 Cylinder--------------------------------------------------------------------------------------------------6-19 Timing Gear--------------------------------------------------------------------------------------------6-19 Piston------------------------------------------------------------------------------------------------------6-20 Connecting Rod-----------------------------------------------------------------------------------------6-21 Clutch-----------------------------------------------------------------------------------------------------6-22 Movable Drive Face and Driven Face-------------------------------------------------------------6-23 Drive Belt-------------------------------------------------------------------------------------------------6-25...

  • Page 50: Removal And Installation

    ENGINE Removal and Installation Engine Removal ● Thoroughly clean the ATV engine and chassis. ● Clean work area. ● Drain coolant and engine oil. ● Remove the seat. ● Remove the side fenders. ● Remove the rear propeller shaft. ● Disconnect the battery lead wires CAUTION When disconnecting the battery lead wires, be sure to disconnect the ○,...
  • Page 51 ENGINE ● Remove Stator assembly coupler [1] and Speed Sensor coupler [2]. ● Remove Tie rod end of lever assembly rod. ● Remove Shift lever assembly [3]. ● Remove air tube [4]. ● Remove Starter Motor assembly coupler [1] and Gear shift indicator coupler [2].
  • Page 52 ENGINE ● Remove the Intake duct. ● Remove the Ignition coil. ● Remove the Exhaust pipe bolts. ● Remove the muffler. ● Remove the right foot board. ● Remove the right foot board bracket bolts [1]. ● Remove the right foot board bracket. 【6-4】...

  • Page 53: Engine Installation

    ENGINE ● Remove the foot brake pedal. ● Remove the front differential mounting bolts/nuts ● Slide the front differential assy forward. ● Remove the front propeller shaft spring. ● Remove the engine mounting bolts/nuts. ● Remove the engine from the right side. Engine Installation Remount the engine in the reverse order of engine removal.
  • Page 54 ENGINE ● Remove the start motor. ● Remove water hoses [1] and [2]. ● Remove the recoil starter. ● Remove Timing screen cover. ● Remove cylinder head cover. 【6-6】...
  • Page 55 ENGINE ● Turn the crankshaft to bring the “TDC” line [A] on the starter clutch to the index mark [B] of the crankcase. NOTE At the above condition, the piston is at TDC of compression stroke and also the engraved marks [C] on the camshafts are parallel with the mating surface of the cylinder head cover.
  • Page 56 ENGINE ● Remove the cam driver gear [1] by removing the shaft cover [2], shaft [3] and the spacer [4]. NOTE Be careful not to drop the spacer [4] into the crankcase. ● Remove the cylinder head bolts (M6) [5]. NOTE Loosen the cylinder nuts.
  • Page 57 ENGINE ● Remove the dowel pins and the gasket. NOTE Be careful not to drop the dowel pins into the crankcase. ● Remove the piston by removing the piston pin circlip [1]. NOTE Place a clean rag under the piston so as not to drop the piston pin circlip into the crankcase.
  • Page 58 ENGINE ● Remove the dowel pins [4] and gasket [5]. ● Remove the generator rotor bolt. ● Install the special tool to the crankshaft end. ● Remove the generator rotor with the special tool. ● Remove the key [2]. ● Remove the starter driven gear [3]. 【6-10】...
  • Page 59 ENGINE ● Remove the cam chain tensioner bolt [1], cam chain tensioner [2]. ● Remove the cam chain [1]. ● Remove the snap ring [1]. NOTE Be careful not to drop the snap ring [1] into the crankcase. ● Remove the oil pump drive chain [2] and oil pump driven gear [3]. ●...
  • Page 60 ENGINE ● Remove the movable drive face [2] by removing the bolt. ● Remove the movable driven face assembly by removing the bolt. ● Remove the drive belt. ● Remove the fixed drive face. ● Remove the front and rear output connectors. ●...
  • Page 61 ENGINE ● Remove the gear shift indicator [1]. ● Remove the clutch housing [1]. ● Remove the O ring. ● Remove the clutch shoe nut. ● Remove the one clutch shoe with the special tool. 【6-13】...
  • Page 62 ENGINE ● Remove the output shaft [2]. ● Remove the right crank case bolts. NOTE Loosen the crankcase bolts diagonally with the smaller sizes first. ● Remove the right crank with special tool. NOTE * The crankcase separator plate is parallel with the end face of the crankcase.

  • Page 63: Inspection

    ENGINE ● Remove the gearshift fork shaft. ● Remove the gearshift forks [4]. ● Remove the gearshift cam drum [5]. ● Remove the seminal gear [6]. ● Remove the countershaft assembly [7]. ● Remove the input main shaft [8]. ● Remove the final shaft T/M assembly [9]. ●...
  • Page 64 ENGINE Camshaft journal wear Determine whether or not each journal is worn down to the limit by measuring the oil clearance with the camshaft installed in place. Use the plastigauge [A] to read the clearance at the widest portion. Oil clearance at cam journal portion Service Limit 0.150 mm NOTE...
  • Page 65 ENGINE Cylinder head distortion ● Clean and remove carbon deposits from the surface. Never damage the surface when cleaning. ● Place straight edge on the surface, and check with thickness gauge. ● If the result is out of specifications, replace with new Cylinder Head.
  • Page 66 ENGINE Valve stem wear ● If the valve stem is worn down to the limit, as measured with a micrometer, where the clearance is found to be in excess of the limit indicated, replace the valve; if the stem is within the limit, then replace the guide.

  • Page 67: Cam Chain Tensioner

    ENGINE CAM CHAIN TENSIONER Inspection Check the push rod slides smoothly when releasing stopper. If it does not slide smoothly, replace the cam chain tensioner with a new one. CAM CHAIN GUIDE Inspection Check the contacting surface of the cam chain guide for wear and damage.

  • Page 68: Timing Gear

    ENGINE TIMING GEAR Timing gear adjust ● Remove the Cylinder head cover and camshaft. ● Remove the Recoil starter. ● Leave the Starter cup on the left crankcase. ● Use tool to adjust the Start cup to align the TDC line [A] with the index mark [B] of the crankcase to make the piston to the highest position.

  • Page 69: Piston

    ENGINE PISTON Piston Diameter ● Check for ware and damage on the sliding surface. ● Measure OD of Piston at the position shown in the picture. If the measurement is less than the limit, replace the piston. Piston OD Service limit 101.880 mm Piston Rings Clearance between Piston Ring and groove...

  • Page 70: Connecting Rod

    ENGINE Piston pin and pin bore ID of Piston hole for Pin ● Clean Piston hole for Pin. ● Measure ID in the up and down direction and the right angle direction with dial caliper gauge. ID of Piston hole for Pin Service limit 23.030 mm Piston Pin OD...

  • Page 71: Clutch

    ENGINE CLUTCH Clutch Shoe ● Inspect the clutch shoe for chips, cracks, uneven wear, and heat discoloration. Also, check the depth of the grooves on the clutch shoe. ● If there is no groove at any part of the shoe, replace the shoe as a set.

  • Page 72: Movable Drive Face And Driven Face

    ENGINE MOVABLE DRIVE FACE AND DRIVEN FACE Movable drive face disassembly ● Remove the spacer. ● Remove the movable drive face plate and rollers. Roller and sliding surface ● Inspect each roller and their sliding surface for wear or damage. If any damages are found, replace the rollers as a set.
  • Page 73 ENGINE Movable driven face disassembly ● Hold the movable driven face assembly with the special tools and vise, loosen the movable driven face ring nut with the special tools. WARNING Do not remove the movable driven face ring nut before attaching the clutch spring compressor.

  • Page 74: Drive Belt

    ENGINE Reassembly ● Install the new O-rings. ● Apply grease to the oil seal lips and movable driven face inside grease groove. ● Apply grease to the O-rings and pin grooves. ● Install the rollers and pins. CAUTION To prevent damaging the oil seal lip from during installation, slide the lip using a 0.1 mm steel sheet as a guide.

  • Page 75: Transmission

    ENGINE TRANSMISSION Visual checking – Shift Fork and Drum ● Check for ware and damage. ● If any ware on the Fork craw portion, replace with new one. Visual checking – Main Shaft and Counter Shaft Assy. ● After disassembling, check for ware and damage on dug clutch portion, gears and spline portions.
  • Page 76 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 CDI Output Test----------------------------------------------------------------------------------------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...

  • Page 77: Specifications

    ELECTRICAL SYSTEM Specifications Item Standard Battery Capacity 12 V ; 18A/h Alternator type Three-phase AC Charging voltage (Regulator/rectifier output) 14~15 V Alternator output voltage DC14V-23A @ 3000 rpm Y1-Y2 0.52 Ω Y2-Y/R 0.49 Ω Charge Coil Y/R-Y1 0.49 Ω Stator Y-Ground ∞...

  • Page 78: Parts Location

    ELECTRICAL SYSTEM Parts Location High/Low Beam Switch [A] Hazard Lights Switch [B] Horn Switch [C] Indicator Switch [D] Ignition Switch [E] Starter Button [F] Battery [A] Starter Circuit Relay [B] CDI Unit [C] Indicator Relay [D] Position Light Relay [E] Ignition Coil [F] Spark Plug [G] Cylinder head Cover...
  • Page 79 ELECTRICAL SYSTEM Regulator/Rectifier [H] Magneto CP [A] Starter Motor [B] Horn [C] Temperature Sensor[D] 【7-4】...

  • Page 80: 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 81: 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 82: Battery

    ELECTRICAL SYSTEM 3. Check the charging conditions with a voltmeter (Normal charging voltage should be 12.8V) 4. This battery may be installed only if replaces a similar sealed type battery. 5. Keep away from high temperature of fire. 6. In the case of an accident sulfuric acid may escape. Avoid contact with skin, eyes or clothing.

  • Page 83: Battery Test Charging

    ELECTRICAL SYSTEM Battery Test Charging ● If the battery is suspected of being defective, sulfated, or unable to take a charge, consult the table. ● To test charge a battery, perform the ordinary charging procedure and monitor the battery voltage and other signs as mentioned below.

  • Page 84: Alternator Inspection

    ELECTRICAL SYSTEM If the battery voltage does not rise as the engine speed increases, then the regulator/rectified is defective or the alternator output is insufficient for the loads, check the alternator and regulator/rectifier to determine which part is defective. Alternator Inspection There are three types of alternator failures: short, open (wire burned out), or loss in rotor magnetism.

  • Page 85: Spark Plug Removal/Installation

    ELECTRICAL SYSTEM Spark Plug Removal/Installation ● Remove Ignition Coil [A] ● Remove or install the spark plug [B] using the spark plug wrench from the vehicle right side. Torque - Spark Plug: 14 N-m (1.4 kgf-m, 10.0 ft-lb) Spark Plug Cleaning/ Inspection ●...

  • Page 86: Cdi Unit Inspection

    ELECTRICAL SYSTEM ○ Remove the plug cap by turning it counterclockwise. ○ Connect the tester between the spark plug lead and terminal. ○ Set the tester to the × 1 kΩ range, and read the tester. If the hand tester does not read as specified, replace the coil. ○...

  • Page 87: Taillight Bulb Replacement

    ELECTRICAL SYSTEM ● Be sure the socket is clean. ● Insert the new bulb by aligning the tang with the notch in the headlight unit. ● Push the holder in, turn it clockwise, and release it, it should lock in position. ●...

  • Page 88: Wiring Diagram

    ELECTRICAL SYSTEM Wiring Diagram 【7-13】...
  • Page 89 ELECTRICAL SYSTEM Wiring Diagram 【7-14】...
  • Page 90 ELECTRICAL SYSTEM NOTE: 【7-15】...
  • Page 91 APPENDIX Appendix Table of Contents Considerations for Various Riding Conditions-------------------------------------------------------8-2 Carburetor-------------------------------------------------------------------------------------------------8-2 Fuel System-------------------------------------------------------------------------------------------------8-3 Spark Plug--------------------------------------------------------------------------------------------------8-4 Clutch Adjustment----------------------------------------------------------------------------------------8-6 Troubleshooting Guide-------------------------------------------------------------------------------------8-7 【8-1】...

  • Page 92: 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 93: Fuel System

    APPENDIX 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. NOTE Adjusting the idle speed affects throttle cable freeplay and electronic throttle control (ETC) adjustment.

  • Page 94: 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 95 APPENDIX CAUTION If the spark plug is replaced with a type other than the standard plug, make certain the replacement plug has the same thread pitch and reach (length of threaded portion) and the same insulator type (regular type or projected type) as the standard plug.

  • Page 96: Troubleshooting Guide

    APPENDIX Troubleshooting Guide CAUTION This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. Engine Doesn’t Start, Starting Difficulty: Ignition coil trouble Starter motor not rotating: Battery voltage low...
  • Page 97 APPENDIX Engine oil viscosity too high Main jet clogged Brake dragging Fuel level too low CDI unit trouble Carburetor holder loose Front or rear final gear case oil viscosity too high Air cleaner poorly sealed, or missing Poor Running or No Power at High Speed: Air cleaner duct loose Firing incorrect: Air cleaner clogged...
  • Page 98 APPENDIX Drive shaft, output shaft, and/or gear worn Abnormal Frame Noise: Over shifts: Shock absorber noise: Shift arm positioning bole spring weak or broken Shock absorber damaged Shift tie-rod maladjusted Disc brake noise: Abnormal Engine Noise: Pad installed incorrectly Knocking: Pad surface glazed CDI unit trouble Disc warped...
  • Page 99 APPENDIX Break Doesn’t Hold Oil, grease on lining and drum Front brake: Dirt, water between lining and drum Air in the brake line Overheated Brake fluid leakage Battery Discharged: Brake fluid deteriorated Battery faulty (e.g., plates sulfated, shorted through Primary or secondary cup trouble Sedimentation, electrolyte level too low) Master cylinder scratched inside Battery leads making poor contact...

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