Dinli DL-702 2008 Offroad Vehicle Manuals

Dinli DL-702 2008 Offroad Vehicle Manuals

Manuals and User Guides for Dinli DL-702 2008 Offroad Vehicle. We have 1 Dinli DL-702 2008 Offroad Vehicle manual available for free PDF download: Service Manual

Dinli DL-702 2008 Service Manual

Dinli DL-702 2008 Service Manual (306 pages)

Brand: Dinli | Category: Offroad Vehicle | Size: 19.6 MB

Table of Contents

General Information General Information

6
- Table of Contents
  6
- Before Servicing
  7
- General Precautions
  10
- Dinli
  11
- Model Identifications
  12
- Fuel, Oil and Engine Coolant Recommendation
  13
- Fuel (for USA and Canada)
  13
- Fuel (for Other Countries)
  13
- Engine Oil (for USA)
  13
- Engine Oil (for Other Countries)
  13
- Front Differential Gear Oil
  13
- Rear Gear (Final) Box Oil
  13
- Brake Fluid
  14
- Engine Coolant
  14
- Water for Mixing
  14
- Anti-Freeze/Engine Coolant
  14
- Liquid Amount of Water/Engine Coolant
  14
- Break-In Procedures
  15
- Information Labels
  16
- General Specifications
  17
Wheels/Tires Wheels/Tires

20
- Specifications
  21
- Construction
  22
- Installation
  23
- Removal
  23
- Wheel (Rim)
  23
- Inspection
  24
- Replacement
  24
- Installation
  25
- Removal
  25
- Tire
  25
- Inspection
  27
- Front Hub Inspection
  28
- Front Hub Removal
  28
- Hub
  28
- Front Hub Installation
  29
- Rear Hub Inspection
  29
- Rear Hub Removal
  29
- Rear Hub Installation
  30
Brake

31
- Construction
  32
- Brake Fluid
  33
- Brake Fluid Recommendation
  33
- Brake Fluid Change
  34
- Brake Fluid Level Inspection
  34
- Brake Line Air Bleeding
  35
- Master Cylinder
  36
- Removal
  36
- Installation
  37
- Caliper
  38
- Front Caliper Removal
  38
- Parking Brake Caliper Removal
  38
- Rear Caliper Removal
  38
- Caliper Installation
  39
- Caliper Inspection
  40
- Brake Pad
  42
- Removal
  42
- Inspection
  43
- Installation
  43
- Brake Disc
  44
- Disc Cleaning
  44
- Front Disc Removal
  44
- Front Disc Installation
  45
- Rear Disc Removal
  45
- Rear Disc Installation
  46
- Brake Hose and Pressure Valve
  47
- Inspection
  47
- Replacement
  47
- Brake Pedal Inspection
  49
- Brake Pedal Position Adjustment
  49
- Foot Brake
  49
- Brake Pedal Installation
  50
- Brake Pedal Removal
  50
- Master Cylinder Removal
  50
- Master Cylinder Installation
  51
Suspension ＆ Steering ＆ Drive Shaft

52
- Construction
  53
  - Protector
    53
- Front Suspension
  53
- Removal and Disassembly
  54
- Inspection
  56
- Reassembly and Installation
  59
- Spring Pre-Load Adjustment
  61
- Construction
  62
- Rear Suspension
  62
- Removal
  63
- Inspection and Disassembly
  64
- Reassembly and Installation
  66
- Spring Pre-Load Adjustment
  68
- Rear Stabilizer Removal
  69
- Rear Stabilizer Installation
  70
- Front Propeller Shaft
  71
- Removal and Disassembly
  71
- Inspection and Reassembly
  72
- Installation
  74
- Inspection and Reassembly
  75
- Rear Propeller Shaft
  75
- Removal
  75
- Installation
  77
- Construction
  78
- Steering
  78
- Removal and Disassembly
  79
- Inspection
  81
- Reassembly and Installation
  83
- Toe-Out Adjustment
  85
- Construction
  86
- Handlebar
  86
- Hex Socket Bolt (4Pcs)
  86
- Removal
  87
- Installation
  88
- Construction
  89
- Indicator T/M Lever
  89
- Removal
  90
- Inspection
  91
- Installation
  91
- Installation
  92
- Shift Rod
  92
- Shift Rod Adjustment
  93
Table of Contents

94
- Installation
  95
- Removal
  95
- Seat
  95
- Front and Rear Racks
  96
- Front and Rear Racks Removal
  96
- Front and Rear Racks Installation
  97
- Front and Rear Fenders
  98
- Front Fender Construction
  98
- Hexagonal Flange Bolt
  98
- Front Fender Removal
  99
- Front Fender Installation
  103
- Bolt (4Pcs)
  104
- Rear Fender Construction
  104
- Rear Fender Removal
  105
- Rear Fender Installation
  107
- Luggage Compartment
  108
- Luggage Compartment Removal/Installation
  108
- Drainage Plug Inspection
  109
- Protector
  110
- Protector Removal/Installation
  110
Engine

111
- Engine Removal
  112
- Removal and Installation
  112
- Engine Installation
  118
- Engine Disassembly
  120
- Engine Top Side
  120
- Engine Bottom Side
  124
- Camshaft and Cylinder Head
  133
- Inspection
  133
- Cam Chain Tensioner
  142
- Cam Chain Guide
  143
- Cylinder
  143
- Timing Gear
  144
- Piston
  145
- Connecting Rod
  147
- Clutch
  148
- Oil Gallery Copper Plug
  149
- Movable Drive Face and Driven Face
  150
- Drive Belt
  157
- Oil Pump
  157
- Spacer (2Pcs)
  158
- Transmission
  158
- Gearshift Fork
  160
- Generator Cover
  161
- Engine Bottom Side
  163
- Reassembly
  163
- Engine Top Side
  173
Cooling and Lubrication System Cooling ＆ Lubrication System

181
- Engine Coolant
  182
- Cooling Circuit
  183
- Cooling Circuit Inspection
  183
- Radiator and Hoses
  184
- Radiator Removal
  184
- Radiator Inspection and Cleaning
  185
- Radiator Remounting
  185
- Radiator Cap Inspection
  186
- Radiator Reservoir Tank
  186
- Radiator Hose Inspection
  187
- Cooling Fan
  188
- Inspection
  188
- Remounting
  188
- Removal
  188
- Cooling Fan Thermo-Switch
  189
- Inspection
  189
- Installation
  189
- Removal
  189
- ECT Sensor
  190
- Inspection
  190
- Removal
  190
- Installation
  191
- Inspection
  192
- Removal
  192
- Thermostat
  192
- Installation
  193
- Removal and Disassembly
  194
- Water Pump
  194
- Reassembly and Installation
  196
- Lubrication System
  199
- Oil Filter
  199
- Oil Pressure
  199
- Oil Pump
  200
- Oil Sump Filter
  200
- Engine Lubrication System Chart
  201
- Engine Lubrication System
  202
Electrical System Electrical System

204
- Specifications
  206
- Parts Location
  207
- Precautions
  209
- Electrical Wiring
  211
- Wiring Inspection
  211
- Battery
  212
- Battery Charging
  212
- Battery Installation
  212
- Battery Removal
  212
- Battery Test Charging
  213
- Charging Procedures
  213
- Charging System
  215
- Troubleshooting
  215
- Inspection
  216
- Ignition System
  219
- Troubleshooting
  219
- Spark Plug Cleaning/Inspection
  220
- Spark Plug Removal/Installation
  220
- Ignition Coil Inspection
  221
- Ignition Coil Installation
  221
- Ignition Coil Removal
  221
- Spark Plug Gap
  221
- CDI Output Test
  222
- Starter Relay Inspection
  222
- Main Relay Inspection
  223
- Inspection
  224
- Transfer Selecting System
  224
- Combination Meter
  225
- Description
  225
- Functions and Operating Procedure
  226
- Inspection
  229
- Removal and Installation
  229
- Headlight Bulb and Assembly Replacement
  232
- Indicator Bulb and Assembly Replacement
  232
- Lighting System
  232
- Taillight Bulb and Assembly Replacement
  232
- Fuse Inspection
  233
- Fuses
  233
- Main Fuse Removal
  233
- Switches
  234
- Wiring Diagram
  235
Periodic Maintenance

239
- Periodic Maintenance
  240
- Periodic Maintenance Chart
  241
- Periodic Maintenance Schedule
  241
- Air Cleaner
  242
- Maintenance and Tune-Up Procedures
  242
- Exhaust Pipe Nuts and Muffler Mounting Bolts
  243
- Valve Clearance
  244
- Spark Plug
  248
- Fuel Line
  249
- Spark Arrester
  249
- Carburetor
  250
- Throttle Cable Play
  250
- Engine Oil and Oil Filter
  251
- Differential Gear Oil Inspection
  253
- Differential Gear Oil Replacement
  253
- Rear Driver Gear Oil
  254
- Engine Coolant
  255
- Radiator
  256
- Radiator Hoses
  256
- CVT Water Draining Inspection
  257
- Drive Belt
  257
- Brakes
  261
- Brake Fluid
  263
- Brake Hoses
  264
- Tires
  265
- Steering
  266
- Shift Rod
  267
- Suspensions
  267
- Reverse Shifting Switch Device
  268
- Chassis Nuts and Bolts
  269
- General Lubrication
  271
- Compression Pressure Check
  272
- Compression Test Procedure
  272
- Oil Pressure Check
  273
- Oil Pressure Test Procedure
  273
- Initial Engagement Inspection
  274
- Clutch Lock-Up Inspection
  275
Appendix Appendix

276
- Engine
  277
- Troubleshooting Guide
  277
- Radiator (Cooling System)
  284
- Transmission
  285
- Drive Train
  286
- Chassis
  288
- Electrical
  292
- Battery
  293
- Special Tools
  295
- Engine
  296
- Tightening Torque
  296
- Cooling System
  298
- Tightening Torque Chart
  299
- Service Data
  300

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